Material Bulk Processing Case Studies

Ingredient Masters offers a comprehensive Powder Process Analysis package that encompasses all facets of a powder handling operation. Our analysis details workable alternatives for expanding production capacity (without adding floorspace), reducing labor costs, shortening cycle times—or achieving other objectives. Notably, implementation can be completed in stages, or all at-once, at your option.

Biosphere Industries

“Biosphere sought to provide closed-loop food packaging systems that have minimal to no impact on the earth’s natural life cycles. Using yearly renewable raw materials, and ultra-efficient (essentially no-waste) manufacturing processes, we wanted to deliver truly earth-friendly solutions.” — Elie Helou Jr., Founder, Biosphere Industries Read case study

Insight Beverages Inc.

“Automating the process minimized cross-contamination by reducing manual labor involved in the batching process, and connecting the system to the dust collector simplified housekeeping and eliminated product waste. The system greatly improved the quality control of our products and will help us achieve Safe Quality Food certification. We're even on target to see a three-year ROI.” Gary Berg, Plant Manager, Insight Beverages Inc. Read case study

Bear Metallurgical

“It is literally everything we expected, and accomplishes all we wanted it to. In addition to eliminating handling steps that added no value, we were also able to eliminate three high-maintenance scales that required quarterly calibration. Plus, the system is robust and ‘worker-proof,’ with zero unscheduled downtime.” Dave Carey, Plant Manager, Bear Metallurgical Read case study

Prince Minerals

“We wanted to optimize the ergonomics of the operation by eliminating manual tasks, such as bag cutting, and have the cleanest possible work environment, by preventing material from becoming airborne when dispensed.” Jon Attridge, Construction Facility Manager, Prince Minerals Read case study

JTM Food Group

“Everything is done automatically now. The system records each spice batch by lot number, detailing such information as recipe ID, ingredient quantity dispensed, and batch start and stop times, so we know exactly what goes into every batch. The system also improved the accuracy of the ingredient amounts in each batch, which minimized product loss and reduced operating costs. Additionally, the system reduced housekeeping costs because the ingredients room is much cleaner.” Joe Maas, Vice President of Operations, JTM Food Group Read case study

Dinovite

“With sales of Dinovite dog (food) supplement on a tear, we purchased a 52,000 sq. ft. manufacturing plant and decided to see what Ingredient Masters could do for us in the very competitive, and highly regulated, field of canine nutrition.” Ed Lukacevic, Dinovite Read case study

Oceanside Glasstile

“We are now able to feed 4,200 pounds of material into a furnace in two minutes instead of several hours, using three hoppers instead of 14 drums.” Mike Taylor, Purchasing Manager, Oceanside Glasstile Read case study

Integrated Bakery Resources

“The savings in time between manually breaking the bags, measuring the material and verifying its weight – as opposed to simply suspending the bulk bags in the frame—has been significant. There's also a great ergonomic benefit since we've eliminated manual handling. Sales are increasing, helped in part by our ability to go from product concept to market in 30 days, if the customer circumstances are right.” Mike Lengacher, Director of Operations Integrated Bakery Resources Read case study

S.E. Rykoff & Co. (Now US Foodservice)

“Dispensing bins transfer weighed quantities of ingredients into bulk batching bags for faster handling, increased production.” James Peterson, Operations Manager | Victor Holman, Assistant Operations Manager S.E. Rykoff & Co. Read case study in English or in Chinese

Cincinnati Tyrolit

“More material is being processed, product waste has been reduced and quality has been enhanced. In addition, delays from change-outs have been eliminated, and the maintenance needed to keep the area clean has been reduced. The system is also well accepted by workers. We estimate that improvements in all of these areas is at least 10%-and greater in some areas.” Bob Hegener,Process Engineering Manager,Cincinnati Tyrolit Read case study

Calhoun Bend Mill

“We have a more consistent product, a lower ingredient cost, and reduced risk of injuries. I would say it's a safer setup. Trash dumpsters are only picked up once a week, and cleanup time has been reduced. We have a simple fail-safe system. You almost have to be brainless to not be able to operate this.” Jesse Calhoun, co-owner, Vice President and Plant Manager Calhoun Bend Mill Read case study

Uni-Ref

“Production throughput has increased 15 percent, and the plant now operates at near 90 percent capacity. Aside from the cost savings and production gains, the greatest benefit has been achieved in quality control.”Fred Daniels, Production Manager, Uni-Ref Read case study

Eli Lilly

“The new material handling system converted a labor-intense manual process into a simple automated process. The new system drastically reduced the need for the operators to manually handle materials.” Mike Svenstrup, Eli Lilly Read case study

Morganite Crucible

“In addition to increasing the plant's batching accuracy and reducing dust emission, the automated batching system has also increased production flexibility, reduced manual handling of the raw materials, and reduced labor requirements.” Dave Okamoto, Operations Manager, Morganite Crucible Read case study

Redland Brick

“The system is completely automated, so it's much more accurate and efficient than the manual batching system we used in our old plant. We can easily do the same operations in half the time with the automated system.” John Vrobel, Plant Manager, Redland Brick Read case study

Pigment Producer Stimsonite Corporation Cleans Up Minor Ingredient Batching

“I was totally satisfied with the service received from Ingredient Masters from the initial contact to installation of our system. Ingredient Masters‚ engineering crew supplied excellent drawings that allowed us to change the system from the initial design to a system custom fitted to our exact requirements. We have been happy ever since.” Bill Floor, Process Engineer, Stimsonite Corporation Read case study

Universal Specialties’ New Automated Mineral Batching System Increases Productivity and Improves Worker Safety

“We were looking for viable options to increase production while also improving our quality. Ingredient Masters' solution, an automated system, provides a more consistent product while generating more controlled data. Other advantages of our system include reduced risk of back injuries and lower raw material costs due to the bulk packaging. Our production has increased 70%, while our labor costs have decreased about 30%.” Shawn R. Elliot, Director of Research Quality Manager, Universal Specialties Read case study

Old California Food Products Manufacturer Reduced Labor Costs and Trash

“From the first day we put our bulk containers into service, my labor cost reduced by almost 25 percent in production as well as cleanup. In the first month of operation, using these bulk containers, my company surpassed the garbage reduction requirements imposed by the city of Hayward, CA. Ingredient Masters has gone beyond my expectations of quality and workability.” Ronald C. Yates, President, Old California Sour Dough Pizza Crust & Mining Company Read case study

Zedmark Increases Refractory Manufacturer's Batching Accuracy with a Bulk Bag System

“We were looking for a flexible system that would rapidly switch between formulas. Now the computer can tell which material is in which discharge station and weigh out the required amount of material. That's one of the features everyone likes. It reduces the potential for making a mistake.” Bob McCutcheon, Engineer, Zedmark Refractories Read case study

Lander, Health and Beauty Aid Manufacturer, Greatly Increases Production With Company's Bulk Bag Lifting Frames

A Binghamton, New York manufacturer of hair and skin care products, can now receive truckloads of bulk bags, rather than paper bags, and substantially reduce solid waste disposal costs. Read case study

Harris Pottery Improves Accuracy and Lowers Costs with an Automated Batching System

Harris Potter is a Midwest pottery manufacturer who built a new processing plant in the south sought more efficient ways to handle the mixing of raw materials. Read case study

Integrated Bakery Resources

“We achieved a 250% production increase, and reduced our reliance on outsourcing following installation of a 16-stage, PC/PLC-driven Ingredient Masters system. The savings in time is also significant—as is the ergonomic benefit realized by eliminating manual handling and potential injuries.” Mike Lengacher, Director of Operations, Integrated Bakery Resources Read case study

Morganite AM&T

“The system produced significant benefits in improved batch accuracy, shorter batching times (the average cycle is just five minutes—1/3 of what was required by the previous manual system) reduction of manual labor, and better housekeeping due to more effective control of fugitive dusts.” David Brown, Development Engineer, Morganite AM&T Read case study