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Improve Production Efficiency and Flexibility Using MATCON IBCs

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Improve Production Efficiency and Flexibility Using MATCON IBCs

Improve Production Efficiency and Flexibility Using MATCON IBCs
April 14
10:07 2016

A major advantage of IBCs is the ability to maximise productivity even when accommodating a widening portfolio of recipes. Total manufacturing flexibility is achieved because material is blended in the container, meaning that recipe changeovers are virtually instantaneous as there is no need to clean down. In addition, the decoupled nature of the system results in product flowing efficiently around the manufacturing process steps, keeping OEE rates high on the essential processes of Blending and Packing. The Matcon Powder Packer can efficiently fill sacks from 5-25kg straight from the IBC, and with change-out parts available, recipe changeovers are extremely rapid.

Matcon1April2016Improvements in yield reduce costs as waste from scrap or rework is diminished by using Matcon Cone Valve IBCs. The IBCs stimulate cohesive materials to flow and control free-flowing powders. Mass-flow discharge protects all blended mixes from segregation, producing a quality final product every time.

A large proportion of manufacturing costs are sustainability related in the form of energy, water usage and waste-water. The Matcon product modules are designed to reduce utility consumption. Notably, the air wash station efficiently cleans most recipes costing a fraction of that for water cleaning.

Bakery manufacturer British Bakels added a Matcon IBC System alongside their fixed mixing system to produce the high variety, low volume product lines.

Matcon2April2016This additional line has reduced cleaning time from 480 to 70 man hours, released £175,000 of cash by reducing Inventory, reduced labour costs by 25%, cut manufacturing time in half as mixes with fat are done as ‘single-stage’ mixes and enabled the company to expand their product range to meet changing consumer tastes.

Boh Tea Plantations Sdn Bhd in Malaysia maximised their throughput with only minimal investment as the small footprint of the IBC System allowed them to use available factory space without costly extensions. The modular design also allows for expansion as the company grows.

If you would like to find out more about how a Matcon IBC system can help reduce your costs, please contact them on +44 1386 769000 or email matcon_marketing@idexcorp.com.

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