Why consider a centralised system?
The general housekeeping of any processing company can be drastically improved with the installation of a material conveying system.
Jenco Engineered Solutions have been providing materials handling solutions to the Plastics Processing, Pharmaceutical, Food, Chemical and Water Treatment Industries for over 45 Years. Our knowledge of your industry and our Design Expertise and Manufacturing Capabilities make Jenco the natural choice to satisfy your materials handling needs.
Our continuous commitment to support customers and their requirements are demonstrated by our ability to provide the flexible manufacturing of systems and equipment to suit the customer’s needs.
Conveying trials and demonstrations can also be arranged in our test facility in Essex. With innovative and continuous development when conveying difficult materials in a range of process conditions, Jenco has become a market leader supplying leading manufacturers in the plastics, food, pharmaceutical and chemical industries.
The following are just a few valuable points which have been proven to be specific key areas within processing companies, where a material conveying system has shown not only increase in production performance and efficiency, but can also helped improve the health and safety and well being of company employees.
PRODUCTION FLOOR UTILIZATION
Valuable production floor areas previously occupied with material storage can be released for more effective use.
With new technologies available, tool changes can be achieved within 30 minutes. It is no longer feasible to consider machine mounted dryers, which dictate when a new production run could commence.
Therefore, drastic reductions in tool change times can be achieved by centralizing existing machine mounted dryers, allowing dried material to be constantly available via a manifold coupling system.
MATERIAL PRICES/BULK PURCHASE
As more material can be quickly processed and safely stored. The increase of bought material will offer an obvious price advantage.
An Central feed Material Handling System enables you to convey from beside the press or centrally.
The following are an example of the relevant cost justifications on a general basis. Additional savings that are more difficult to quantify can also be gained. And are dependent upon the existing practices carried out by the processor.
Losses due to the manual handling of materials delivered in 25kg bags, tote boxes and Octabins, can be retrieved with a saving of 2-3% of the annual material usage, when using a Material Handling System, by reducing manual involvement. For example, with an annual material bill of £500,000 a 2% saving is £10,000.
QUALITY CONTROL/QUALITY ASSURANCE
With a material conveying system operating on the basis of all materials being stored in a central area, the problem of contamination with materials being handled and stored within the moulding shop is completely eliminated. Thus the quality of mouldings is improved. Similarly, by virtue of greater efficiency being applied to materials stored in a central area and conveyed in closed loop system, the condition of the material is maintained and presented at an optimum condition to the process machine. Again, this results in improved quality of mouldings.
By elimination of manual involvement in materials handling and all responsibility for selection of grade etc., being applied to more senior personnel, any human error is drastically reduced. QC/QA originates from the material source and if this is not correct then despite the latest technology in moulds and injection moulding machines, all efforts are wasted.
In general terms the installation of a Material Handling System results in a power consumption reduction of 75%. This is achieved as only one motor is used to provide the vacuum source compared to individual motors on each hopper loader.
For example, 15 hopper loaders each having 1 kW drive motors results in a total of 15kW. A central vacuum pump of 3kW would suffice. Therefore, assuming a cost of 5p per kW/hr, the power consumption cost based on a 24 hour day, 7 day week and 52 week year would be £5,241.
By eliminating all manual handling of material with a material conveying system, direct savings can be achieved and the labour re-deployed for other tasks within the factory.
Due to all materials being confined to one storage area, the fire insurance premiums will be reduced as the fire hazard in contained. Additional precautions can be taken in respect of fireproofing the material storage and fitting fire doors.