A leading polymer compounding manufacturer needed a system to handle polymer pellets and CaCO₃ powder used in filler masterbatch production. Their requirements included:
- Efficient handling of both pellets & fine powders
- Dust-free operations for environmental safety
- Continuous feeding into extrusion lines with high accuracy
The Challenge
- Material Segregation: Different bulk densities of pellets & CaCO₃ created inconsistent dosing
- Dust & Spillage: Manual handling of powders led to contamination & unsafe conditions
- Downtime: Frequent interruptions during feeding & silo changeovers
- Accuracy Issues: Manual dosing impacted product quality & consistency
Orchid’s Solution
- Jumbo Bag Unloading Stations with hoist, massager & dust-tight spout sealing for complete bag discharge
- Positive Pressure Pneumatic Conveying Lines — 2 for pellets & 4 for CaCO₃ powders
- Vertical Ribbon Blender for uniform mixing before extrusion
- Storage Silos with Vent Filters for clean & safe storage
- Gravimetric Loss-in-Weight Feeders for precise, continuous dosing into extruders
Impact Delivered
- Dust-Free Operations: Enclosed systems ensured <1 mg/m³ dust emissions
- High Throughput: Smooth transfer of up to 12 TPH across multiple lines
- Improved Accuracy: ±0.5% dosing accuracy maintained for consistent quality
- Reduced Downtime: Automated systems cut manual intervention by 60%
- Operator Safety: Ergonomic unloading & enclosed conveying ensured safer work conditions
Snapshot at a Glance
| Key Factor | Before Orchid | After Orchid |
|---|---|---|
| Throughput | 6–7 TPH | 12 TPH |
| Dosing Accuracy | ±2% | ±0.5% |
| Dust Emissions | 4–5 mg/m³ | <1 mg/m³ |
| Manual Handling | High | Minimal |
Conclusion
By integrating automated conveying, precise dosing, and efficient mixing, Orchid delivered a turnkey solution for polymer compounding that ensured higher throughput, consistent product quality, and safe operations.
👉 Orchid — powering the future of polymer processing with reliable bulk handling solutions.