Automated Batching System for
Pottery Manufacturer Improves Accuracy
and Lowers Costs

In mid-1996 a Midwest pottery manufacturer preparing to open a new processing
plant in the South was seeking better methods to efficiently, safely and cleanly
handle mixing of raw materials to finish batches.  Disparity in paper bag weights
was a common problem for the company, so it was considering an automated
batching system to eliminate the mismatched and out-of-spec batches resulting
from the disparity.  Minimizing labor and eliminating the disposal of paper bag
waste were also major considerations.

Manual lifting and emptying of the bags was fatiguing and hazardous and
created spillage and dust.  Pieces of the bag always had the potential to fall
into the batch and clog the strainers which then had to be cleaned.

The company's product is highly specialized and requires precise measurements
of raw materials since small variations can affect the finished product.  Fifty pound
bags of raw material were found to vary by as much as 10%, making accuracy
impossible.  Manual lifting and emptying of the bags was fatiguing and hazardous
and created spillage and dust.

Pieces of the bag always had the potential to fall into the batch and clog the
strainers which then had to be cleaned.  Disposal of the empty bags created
environmental problems, and smaller bags used for ergonomic reasons were
thought too expensive.  Labor costs and training for the new plant were also
considered, as was the increasing problem of landfill regulations and cost.

The company contacted Ingredient Masters because of its knowledge and
experience in efficient handling and batching of dry ingredients.  Ingredient
Masters' knowledge of powder flow and the availability of cost-effective solutions
to the problems the ceramic manufacturer was experiencing in their current
plant were also deciding factors.

The equipment offered by Ingredient Masters was custom designed to meet
the exact requirements of the manufacturer.  Effective solutions to material
handling problems were guaranteed, and the price quoted was less than
expected, assuring a quick return on investment (under a year).  A prompt
schedule for engineering and delivery was also an attractive feature.  Delivery
was within six weeks, and installation took only a week.

The mini bulk system that was installed reduced labor cost by allowing one
person to prepare the entire batch (called the body) and by eliminating the
need to handle and dispose of paper bags.  The system also allowed batches
to be mixed with the required accuracy (within a pound or two) that could be
verified by the scale controller readout.

Using such a bulk dispenser system can cut labor costs by 12-40%,
reduce product loss from spillage by as much as 18% and reduce
disposal costs by as much as 55%.

Since the company was looking for a complete system that would reduce labor
requirements while improving accuracy, the system was set up with a single
button to weigh the ingredients, transfer them to the mixer, start the mixer,
and complete the entire batch and mix requirements.  Now the supervisor can
prepare the batch without requiring a full-time person to do it.

Since the system that was installed has worked so well, the customer is now
ready to redo his original plant with this modern solution.

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Ingredient Masters is represented by leading
experts in the powder handling industry: http://www.ingredientmasters.com/partner_profile.htm.
There are currently opportunities for qualified sales
representatives in five regions: Chicago, Atlanta, southern
California, Dallas and Denver. Email for more information.