 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." pdf file
Ed Lukacevic, Dinovite
 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." pdf file
Mike Taylor, Purchasing Manager, Oceanside Glasstile
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." pdf file
Mike Lengacher, Director of Operations
Integrated Bakery Resources
S.E. Rykoff & Co. (Now US Foodservice)
Dispensing bins transfer weighed quantities of ingredients into bulk batching bags for faster handling, increased production.
pdf file – English | pdf file – Chinese
James Peterson, Operations Manager
Victor Holman, Assistant Operations Manager
S.E. Rykoff & Co.
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." pdf file
Bob Hegener,
Process Engineering Manager
Cincinnati Tyrolit
 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." pdf file
Jesse Calhoun, co-owner,
Vice President and Plant Manager
Calhoun Bend Mill
 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."
pdf
file
Fred Daniels, Production Manager
Uni-Ref
 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." pdf file
Mike Svenstrup
Eli Lilly
 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."
pdf
file
Dave Okamoto, Operations Manager
Morganite Crucible
 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."
pdf
file
John Vrobel, Plant Manager
Redland Brick
"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
"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 percent, while our labor costs have decreased about 30 percent."
Shawn R. Elliot, Director of Research
Quality Manager
Universal Specialties
"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
"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
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.
A midwest pottery manufacturer building a new processing plant in the south sought more efficient ways to handle the mixing of raw materials.
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." pdf file
Mike Lengacher, Director of Operations
Integrated Bakery Resources
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." pdf file
David Brown, Development Engineer
Morganite AM&T
Ingredient Masters Case Studies that appeared in Powder Bulk & Engineering magazine:
Table-free Ingredient batching (pdf file)
Automated Batching Systems (pdf file)
Bulk Bag Systems (pdf file)
Minor Ingredient Batching (pdf file)
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.
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