Case Studies

COMPANY

A world-leading fragrance manufacturer was looking for a filling and batching solution that would increase the efficiency and traceability of their processes and help to save them money.

OVERVIEW

The customer was creating recipes of end product by hand using lab, bench and floor scales with paper instruction sheets. This was a time-consuming process that needed attention to accuracy due to the high costs of the raw materials. What the customer wanted was an automated system that would not only significantly speed up the production process, but also provide consistently high accuracy in dosing bulk and very fine ingredients, providing a potentially huge cost saving. Pre-existing off-the-shelf solutions cost up to 7 figures which was beyond the customer's budget.

APPROACH

We provided a Baykon BX30-Fill automated panel system with 10.1" HMI, PLC control and 80, 2-speed output relays to batch recipe formulas. This was configured to take 80 high accuracy valves with 3 position pneumatic actuators allowing the batching of both kilograms and single digit grams of material. The solution was programmed to not only meet the customer's current requirements, but it is also able to be re-programmed, should the customer's needs change in the future. The operation requested was to select a formula, enter target weigh and press start. The valves will open in sequence and product will be dosed. Once complete, the records are saved for traceability. The system will meet any printing demands and can communicate with the customer's bespoke software.

To ensure the solution met all of the customer's requirements, it was extensively trialled over a 3 month period. The trial was a huge success and the production speeds exceeded the expectations, saving the customer huge ongoing costs. The accuracy again exceeded the expectation and initial quotation. This was the main project target, to increase efficiency, keeping its high accuracy and a huge future cost saving. The customer benefitted from a bespoke solution whilst costing a fraction of one of the few pre-existing solutions on the market. As the company expands, partly in thanks to the new system, repeat orders are planned.

CUSTOMER TESTIMONIAL

"We are delighted with the finished results of this project, the fact the speed and accuracy exceeded our customer's expectation was the icing on the cake.

This will help our customer achieve its growth projections and they will be looking to buy several of these systems to meet future production demands. AWM were also very supportive during the trial to address any adjustments and software modifications. James was fantastic on this project with his support and product knowledge."

Read more of our customer testimonials, here.