A worldwide manufacturer of friction materials was enjoying growing sales of a new product line, but the existing production equipment was a bottleneck. The existing semi-manual batching method was labor intensive, and caused variable quality. Charging the V blender was difficult, and put the operator at risk of a lifting injury. The actual blend time was very long.
After blending, an operator would hand scoop and weigh a charge of the finished material, then manually dump and level it in the die cavity of the hydraulic press. Every aspect of production was laborious, inaccurate, and un-ergonomic.
In addition to solving those process issues, the customer also wanted if possible, to avoid the considerable costs of re-arranging the existing cold presses, ovens, and hot presses. They needed the small space that was being used for the existing system, to be the same space for any new automated system.
Many vendors were able to quote a bulk bag dispenser; a dump station; a scale; or a blender. A few vendor were able to quote a system. The customer eventually found that only Applicon had the solution and the experience for their plant.
With 30 years of experience in designing compact batching and processing systems, Applicon designed a system that fit the available space, improved ergonomics and safety, provided dependable accuracy, and improved the output of blended product by three fold.
This system included|
• Eight bag/drum dump hoppers
• One 2 ton bulk bag dispenser
• One micro ingredient scale
• A loss-in-weight oil dispenser
• A rotary in line batch blender
• Portable bins and filling station
• Portable bin dispensing station
• Blended product batching