Automated Mineral Batching System Increases
Productivity and Improves Worker Safety

Universal Specialties (Corapolis, PA) a division of Universal Refractories,
develops and manufactures specialty refractories for the steel and other industries. 
The company originally used a manual batching process, with the raw materials in
paper bags.  Problems occurred with inconsistent bag weights, bag disposal and
high labor costs due to work-related injuries.  Universal Specialties wanted to
solve these problems, and increase production to meet customer demand.

WANTED: Quality Control

The original batching process required workers to empty hundred-pound bags
onto a conveyor that delivered various powder raw materials to a mixer.  Workers
charged a belt conveyor with the required raw materials by means of paper bags. 
This conveyor then loaded a mixer, which mixed the raw materials.  After the
mixing cycle concluded, the mixer gradually discharged the powder batch contents
into a paper sack bagger.  Finally, the bagger operator filled paper sacks with
product until the mixer was empty.  This procedure usually lasted more than
30 minutes, and operators had to wait until the process was complete before
starting a new batch.

This process posed several problems.  In addition to the length of production
time required, there was a high potential for worker injury.  Additionally, an
experienced worker was needed to make daily changes to the charging bin. 
This added time and labor costs to the production process.

Another problem was that the quantities of powder raw materials going into
a mix varied with each batch due to inconsistent bag weights and laborers
not ensuring that each bag was completely empty.

"Since the superior product demanded by our Quality Control Department
was difficult to achieve, a change to the production process was needed,"
says Shawn Elliott, Director of Research and Quality Manager.

An Automated Solution

Universal Specialties began looking for other viable options that would improve
quality and consistency and decrease manual labor.  After reviewing numerous
options, Universal Specialties contacted Ingredient Masters, which specializes
in powder batching systems.

"Ingredient Masters visited our facility, listened to our needs and exceptions,
and offered a readily available, cost-effective alternative to our powder batching
process.  Their plan included integrating our existing equipment with new equipment. 
This plan did not require extensive modifications to our system or work environment,
explains Elliott.

Ingredient upgraded the way primary powder raw materials were received,
replacing hundred-pound paper sacks with bulk bags of 2,000 to 3,000 pound
capacities.  After a mixer completes a cycle, it discharges its entire contents into
the bulk bag - an operation that requires two minutes, compared to the previous
30 minutes.  The bulk bags of powder material are stored in 70 cu. ft. dispensers
that produce many batches before refill is required.  This reduces the labor
needed for each batch.

Each dispenser is scaled with the aid of load cells and a pneumatic valve linked
to a PLC/computer interface.  This interface stores formulations, records batching
and mixing times, and handles raw materials additions.  It can also generate a
spreadsheet detailing individual amounts of raw materials used in a particular mix,
and total usage for a given production run.  This data helps ensure that powder
raw materials are consistent between batches.

Other raw materials that are a small portion of the batch size are staged at a
bag break station.  This station, also equipped with load cells and pneumatic valve,
allows the operator to load the material into a storage hopper.  The computer
helps ensure accuracy for this manual operation.  When all powder materials are
in place, the computer verifies the weight and the operator can start the batch.

This automated system provides Universal Specialties with reduced manual labor
and injuries, consistent product, and extensive control data.  Additionally, using
bulk bags instead of paper bags provides Universal Specialties a more cost-effective
way to supply product to customers.  "We consider this solution vital to the growth
of our company," concludes Elliott.  "The advantages of such an automated system
begin at a much more basic level than computer control."

"The savings start by lowering the risk of injuries on the job (particularly back
injuries).  There is much less waste generated from spent paper bags, and raw
material costs are reduced by bulk bag packaging.  Production has increased 70%
to 80%, while labor costs have decreased approximately 30%.  The cost of
one back injury easily pays for this system, and the additional benefits will
only accumulate."

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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.