Case Study: Is Automating Material Handling Worth It?
In today’s competitive manufacturing landscape, it is critical to optimise production efficiency while controlling costs. To that end, upgrading or automating material handling systems can be a gamechanger for industrial plants looking to achieve peak performance.
But with the investment required, are industrial automation systems really worth it?
MACTEX helped a leading plastic pallet manufacturer implement a comprehensive automated material handling solution with pneumatic conveyors to streamline operations.
This case study outlines the key challenges, the solutions, and the results from the project.
The Challenge: Inefficiencies in manual bulk material handling
Industry: Plastic pallet manufacturing
Product: Recycled resins
The plastic pallet manufacturing company faced considerable inefficiencies in its material handling processes. Dependence on manual operations resulted in higher operational costs, inconsistent production quality, and difficulties in maintaining overall production efficiency.
Here is a closer look at some of the key challenges faced:
Challenge #1: High labour costs
The manual handling process of recycled resins required a large workforce, significantly driving up labour expenses. This high cost diverted resources that could be better invested in advanced material handling and production enhancements.
Challenge #2: Inconsistent production quality
Frequent human errors in handling materials led to fluctuations in production quality and throughput. This inconsistency affected the final product and could potentially harm customer satisfaction, making it difficult for the company to meet quality standards.
Challenge #3: Space constraints
The need for extensive storage space for raw materials led to poor utilisation of available areas, limiting the potential for production expansion.
Challenge #4: Manual material transport
Manually transporting raw materials over a distance of 200 metres slowed down the production process. This labour-intensive method created delays and bottlenecks, hindering overall efficiency and preventing the company from meeting its production targets.
These challenges collectively prevented the company from scaling its production effectively and managing operational costs efficiently.
Facing one or more of these challenges? MACTEX offers a range of bulk material handling solutions that could help overcome these issues.
The Solution: An automated material handling system
To tackle these challenges head on, MACTEX developed a comprehensive pneumatic system tailored to streamline the company’s bulk material handling processes.
By integrating industrial automation systems and leveraging industrial engineering services, the solution aimed to enhance efficiency and cost effectiveness, while improving overall production quality.
Key components of this innovative system included:
1. A silo system with pneumatic conveyors
MACTEX helped the client install a silo-based system to automate the bulk material handling process. As an added bonus, the design of this system would also help to maximise vertical storage space and optimise the facility’s layout.
With this in place, pneumatic conveyors were used to efficiently transport materials over long distances, eliminating the need for manual transport. These advanced pneumatic conveying systems provided better control over material flow, minimising material loss and ensuring consistent production input.
2. SCADA integration
A Supervisory Control and Data Acquisition (SCADA) system was integrated to enable real-time monitoring of the material handling process. SCADA’s data-driven tools provided insights into system performance, allowing for quick adjustments and optimisation of industrial processes.
This automation reduced human intervention, which in turn minimised errors and improved the overall consistency of production.
3. Bulk bag unloading system design
MACTEX incorporated a custom-designed bulk bag unloading system, enabling the company to handle large quantities of raw materials with minimal manual involvement. This negated the need for manual forklifts, which in turn, streamlined unloading processes, increased safety, and enhanced operational efficiency in their powder handling systems.
4. Centralised dust control system:
To improve air quality and maintain a cleaner production environment, a centralised dust control system was integrated. This system effectively collected and filtered dust generated during the bulk material handling process, ensuring compliance with safety and environmental regulations.
The Results: Increased production, lower costs, and optimised operations
Following MACTEX’s industrial engineering services and automated pneumatic system, the plastic pallet manufacturing company recorded several notable improvements:
“25% increase in overall production throughput.”
One of the most tangible results was a stark increase in production throughput. The automation of material handling processes reduced human error and improved consistency, leading to a 25% increase, a major win for the company.
This improvement also came as a result of optimised space utilisation. The automated pneumatic conveying systems reduced the need for large storage areas, allowing for better space management and freeing up valuable production floor space. The existing warehouse used for material storage was converted into an additional production line, fully utilising available space and increasing production output.
“A reduction in diesel consumption for forklift transports”
As a result of the newly implemented energy-efficient material handling system, the company was also able to enjoy operational cost savings. The introduction of automated pneumatic systems meant a lesser need for forklift transports in their powder handling systems, directly lowering the company’s operational energy costs.
Besides that, the company improved its labour efficiency. By reducing the need for manual labour in material handling, the company’s industrial automation systems significantly cut labour costs while simultaneously improving safety and reducing the risk of workplace accidents.
“Real-time data, accurate tracking, easy-to-use system”
Another outcome of MACTEX’s advanced material handling system was improved inventory management. The SCADA system provided real-time data on raw material consumption, allowing for more accurate inventory tracking and better planning of material orders.
On the ground, the user-friendly system also made it easier for engineers and ground staff to operate. Now, workers can initiate the conveying system by simply pressing the start button on the control panel.
For an overall verdict, the costs and effort to automate this client’s material handling processes were definitely worth it, especially for the long-run.
Through the implementation of MACTEX’s advanced material handling solution, the plastic pallet manufacturing company dramatically improved its production efficiency, reduced costs, and enhanced overall operational quality.
Beyond experiencing tangible operational efficiency improvements and up-to-date technologies right now, the company placed itself in a position to scale for the future as well.
In a rapidly evolving industry, manufacturers that invest in automation not only reduce operational expenses, but also gain a competitive edge in terms of production consistency, quality, and scalability.
Find out how MACTEX’s industrial engineering services and customised solutions can cater to a variety of material handling needs.
