Position: In this article, you will learn a pottery Manufacturer lowers costs and improves batching accuracy by automated Batching System.
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.
In addition, quality batching controllers is enable the batching systems work more safely and efficiently.
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 batching 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 automatic batching 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 batching system that would reduce labor requirements while improving accuracy, the batching 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 batching system that was installed has worked so well, the customer is now ready to redo his original plant with this modern solution.
