What was the issue?
We were recently contacted by an existing client based in Carlisle, who specialises in the production of high-quality ruminant feeds. The client asked us if it was possible to automate the blending process in their animal feed mill, to improve efficiency, accuracy and health and safety.
The existing blending process involved a bucket loader collecting the required product from the material bays in the blend shed and loading the raw materials into an open top mixer. This was a relatively slow process, which was also creating a large amount of airborne dust. This was creating a hazardous working environment as well as being extremely messy – lots of time was being spent cleaning and they were constantly sweeping to maintain a clean working and production area.
What was our solution?
The customer wanted to be able add the raw materials directly to the mixer from their existing external storage silos, using the transfer conveyor which was being used to transfer product into the mill. We visited, assessed and surveyed the process and machinery, and worked closely with the customer to devise a plan to include a holding bin to receive the product from the external weigher, and discharge directly into the mixer.
We designed and manufactured two flush fitting pneumatic slides for the bottom of the existing transfer conveyor, which allowed the product to flow into our new 26m3 holding bin which was also designed and manufactured at our facility. The holding bin included a double hopper, with pneumatic slides to discharge into the mixer when called for. All supporting steel and walkways were manufactured in accordance with the BS EN 1090 standard, for the manufacturing of supporting steel structures.
How we did the installation
Working to ensure that the customers production schedule remained prioritised, we arranged a shutdown of the blending process, which was an agreed period of 7 days, and the installation was then carried out by 5 of our trained and highly skilled site installation engineers.
To further help control the dust, we also manufactured and fitted a bespoke canopy to cover the entire top area of the open top mixer, allowing enough room for the bucket loader to continue to operate. This project demonstrated the skills of our installation team, who were able to manoeuvre the canopy into place using a telehandler and manual chain blocks. This has already meant a 50% improvement in the control of the airborne dust. The second part of this project will see the installation of a separate dust unit, which will further aide improvement. Due to the long lead time on the unit from the supplier, the installation of this will be completed at a later date, meaning we can revisit the project then for the final results.
What was the outcome?
In the meantime, we have been successful in automating a significant part of the process, improving production time, accuracy of the finished product formulation, and reducing health and safety risks. The customer is extremely happy with the work that has been carried out, even stating that the mill looks fantastic! Of course, we would have to agree!
Check out images from the project below.
