Upstream Auxiliaries & Small-Ingredients Weighing Retrofit at an Auto Rubber Parts Plant
Client Challenge
The customer’s mixing workshop relied on manual charging and manual small-ingredient weighing, leading to high batch variation and occasional whole-batch scrap from omissions or mis-additions. At the same time, dust levels in the workshop created significant environmental and occupational-health pressure.
Solution
We implemented an upstream auxiliaries retrofit while keeping the customer’s existing banbury mixers: new carbon black pneumatic conveying with auto weighing, automated rubber charging conveyors, and small-ingredients auto weighing & bag-sealing machines, plus a control-system upgrade interfacing with the legacy mixers to deliver auto-executed charging and per-ingredient error proofing. The retrofit was executed across two weekend windows without disrupting normal production scheduling.
Results
Charging operations now run with zero errors. Small-ingredients weighing accuracy and traceability records pass the customer’s IATF audits. Workshop dust concentration has dropped visibly; single-shift charging headcount has been cut by half. The customer has since ordered the same retrofit for a second line.
Project Overview
Upstream auxiliaries and small-ingredients weighing retrofit at an auto rubber parts plant, existing banbury mixers retained, zero charging errors, cleaner workshop, and a clean IATF system audit pass.
Project Overview
The customer had heavy manual-charging errors and dust issues in the mixing workshop, and needed the automation upgrade completed without a production shutdown.
Customer Challenge
High batch scatter, omissions and mis-additions causing scrap; significant environmental and occupational-health pressure.
Solution
Existing banbury mixers retained. New carbon black pneumatic conveying + auto weighing, automated rubber charging, small-ingredients auto weighing & sealing, upgraded control system integrated.
Results
Zero charging errors, dust levels dramatically down, IATF audit passed. The customer ordered the same retrofit for a second line.