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    Case Study

    Reliable Conveying & Mixing Solutions for Polymer Compounding

    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
    Key Takeaway

    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

    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.

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