Material Bulk Processing Case Studies
Bear Metallurgical
“It is literally everything we expected, and accomplishes all we wanted it to.
In addition to eliminating handling steps that added no value, we were also
able to eliminate three high-maintenance scales that required quarterly
calibration. Plus, the system is robust and ‘worker-proof,’ with zero
unscheduled downtime.” pdf file
Dave Carey, Plant Manager, Bear Metallurgical
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JTM Food Group
"Everything is done automatically now. The system records each spice batch
by lot number, detailing such information as recipe ID, ingredient quantity
dispensed, and batch start and stop times, so we know exactly what goes
into every batch. The system also improved the accuracy of the ingredient
amounts in each batch, which minimized product loss and reduced operating
costs. Additionally, the system reduced housekeeping costs because the
ingredients room is much cleaner." pdf file
Joe Maas, Vice President of Operations, JTM Food Group
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Dinovite
"With sales of Dinovite dog (food) supplement on a tear, we purchased a
52,000 sq. ft. manufacturing plant and decided to see what Ingredient Masters
could do for us in the very competitive, and highly regulated, field of canine
nutrition." pdf file
Ed Lukacevic, Dinovite
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Oceanside Glasstile
"We are now able to feed 4,200 pounds of material into a furnace in
two minutes instead of several hours, using three hoppers instead of
14 drums." pdf file
Mike Taylor, Purchasing Manager, Oceanside Glasstile
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Integrated Bakery Resources
"The savings in time between manually breaking the bags, measuring the
material and verifying its weight – as opposed to simply suspending the
bulk bags in the frame – has been significant. There's also a great ergonomic
benefit since we've eliminated manual handling. Sales are increasing,
helped in part by our ability to go from product concept to market in
30 days, if the customer circumstances are right." pdf file
Mike Lengacher, Director of Operations
Integrated Bakery Resources
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S.E. Rykoff & Co. (Now US Foodservice)
Dispensing bins transfer weighed quantities of ingredients into bulk
batching bags for faster handling, increased production.
pdf file – English | pdf file – Chinese
James Peterson, Operations Manager
Victor Holman, Assistant Operations Manager
S.E. Rykoff & Co.
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Cincinnati Tyrolit
"More material is being processed, product waste has been reduced and
quality has been enhanced. In addition, delays from change-outs have been
eliminated, and the maintenance needed to keep the area clean has been
reduced. The system is also well accepted by workers. We estimate that
improvements in all of these areas is at least 10%-and greater in
some areas." pdf file
Bob Hegener,
Process Engineering Manager
Cincinnati Tyrolit
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Calhoun Bend Mill
"We have a more consistent product, a lower ingredient cost, and reduced
risk of injuries. I would say it's a safer setup. Trash dumpsters are only
picked up once a week, and cleanup time has been reduced. We have a
simple fail-safe system. You almost have to be brainless to not be able
to operate this." pdf file
Jesse Calhoun, co-owner,
Vice President and Plant Manager
Calhoun Bend Mill
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Uni-Ref
"Production throughput has increased 15 percent, and the plant
now operates at near 90 percent capacity. Aside from the cost savings
and production gains, the greatest benefit has been achieved in
quality control." pdf file
Fred Daniels, Production Manager
Uni-Ref
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Eli Lilly
"The new material handling system converted a labor-intense manual process
into a simple automated process. The new system drastically reduced the
need for the operators to manually handle materials." pdf file
Mike Svenstrup
Eli Lilly
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Morganite Crucible
"In addition to increasing the plant's batching accuracy and reducing dust
emission, the automated batching system has also increased production
flexibility, reduced manual handling of the raw materials, and reduced
labor requirements." pdf file
Dave Okamoto, Operations Manager
Morganite Crucible
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Redland Brick
"The system is completely automated, so it's much more accurate and
efficient than the manual batching system we used in our old plant.
We can easily do the same operations in half the time with the
automated system." pdf file
John Vrobel, Plant Manager
Redland Brick
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Pigment Producer Cleans Up Minor Ingredient Batching
"I was totally satisfied with the service received from Ingredient Masters
from the initial contact to installation of our system. Ingredient Masters'
engineering crew supplied excellent drawings that allowed us to change
the system from the initial design to a system custom fitted to our exact
requirements. We have been happy ever since."
Bill Floor, Process Engineer
Stimsonite Corporation
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Automated Mineral Batching System Increases
Productivity and Improves Worker Safety
"We were looking for viable options to increase production while also
improving our quality. Ingredient Masters' solution, an automated system,
provides a more consistent product while generating more controlled data.
Other advantages of our system include reduced risk of back injuries and
lower raw material costs due to the bulk packaging. Our production has
increased 70%, while our labor costs have decreased about 30%."
Shawn R. Elliot, Director of Research
Quality Manager Universal Specialties
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Labor Costs and Trash Reduced for
Food Products Manufacturer
"From the first day we put our bulk containers into service, my labor cost
reduced by almost 25 percent in production as well as cleanup. In the first
month of operation, using these bulk containers, my company surpassed
the garbage reduction requirements imposed by the city of Hayward, CA.
Ingredient Masters has gone beyond my expectations of quality and workability."
Ronald C. Yates, President
Old California Sour Dough Pizza Crust & Mining Company
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Bulk Bag System Increases Refractory
Manufacturer's Batching Accuracy
"We were looking for a flexible system that would rapidly switch between
formulas. Now the computer can tell which material is in which discharge
station and weigh out the required amount of material. That's one of the
features everyone likes. It reduces the potential for making a mistake."
Bob McCutcheon, Engineer
Zedmark Refractories
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Health and Beauty Aid Manufacturer Greatly Increases
Production With Company's Bulk Bag Lifting Frames
A Binghamton, New York manufacturer of hair and skin care products
can now receive truckloads of bulk bags, rather than paper bags,
and substantially reduce solid waste disposal costs.
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Automated Batching System for Pottery Manufacturer
Improves Accuracy and Lowers Costs
A midwest pottery manufacturer building a new processing plant in the
south sought more efficient ways to handle the mixing of raw materials.
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Integrated Bakery Resources
"We achieved a 250% production increase, and reduced our reliance on
outsourcing following installation of a 16-stage, PC/PLC-driven Ingredient
Masters system. The savings in time is also significant – as is the ergonomic
benefit realized by eliminating manual handling and potential injuries." pdf file
Mike Lengacher, Director of Operations
Integrated Bakery Resources
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Morganite AM&T
"The system produced significant benefits in improved batch accuracy,
shorter batching times (the average cycle is just five minutes – 1/3 of what
was required by the previous manual system) reduction of manual labor, and
better housekeeping due to more effective control of fugitive dusts." pdf file
David Brown, Development Engineer
Morganite AM&T
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Ingredient Masters Case Studies that appeared
in Powder Bulk & Engineering magazine:
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Ingredient Masters offers a comprehensive Powder Process Analysis
package that encompasses all facets of a powder handling operation.
Our analysis details workable alternatives for expanding production
capacity (without adding floorspace), reducing labor costs, shortening
cycle times - or achieving other objectives. Notably, implementation
can be completed in stages, or all at-once, at your option.
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Ingredient Masters is represented by leading
experts in the powder handling industry: http://www.ingredientmasters.com/partner_profile.htm.
There are currently opportunities for qualified sales
representatives in five regions: Chicago, Atlanta, southern
California, Dallas and Denver. Email for more information.
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