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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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