Kaneka North America of Pasadena, TX, repackages PVC modifiers in 1,000-, 1,700-, and 2,000-lb bulk bags and in 50-lb sacks based on projected customer orders. When the actual orders don’t match the projections, the plant needs to transfer products from one bulk bag size to another.
Recently the company replaced its manual re-bagging methods with automated filling systems. In the new bulk-to-bulk system, the powdered PVC material flows from a Flexicon Bulk-Out® BFF forklift-loading bulk bag discharger through a flexible screw conveyor and into a Flexicon Twin-Centerpost™ bulk bag filler handling different size bags for distribution. In the bulk-to-sack process, material is released from a Flexicon Bulk-Out BFC-C-X electric-hoist and trolley-loading bulk bag discharger through a screw conveyor into a valve-bag filling machine handling 50-lb bags. The flexible screw conveyors and controls are also supplied by Flexicon; the valve-bag filling machine is from a proprietary supplier.
According to Kaneka, the replacement of manual systems with automated ones has reduced safety risks, eliminated dust, and improved productivity. Confirms Brian Wilson, Staff Reliability Engineer at Kaneka North America, “Dust generated from the re-bagging operation has been significantly reduced. The new system improves our productivity by an order of magnitude.”