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Mixer refurbishment provides perfect opportunity to make maximum impact

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Sector: Manufacturing

Service: Control & Automation

Bond It’s planned mixer refurbishment provided AES with the opportunity  to revolutionise the production  process through control and automation.   The solution provided multi-faceted benefits including a 33% uplift in product efficiency, product consistency, reduced plant downtime and staff safety.

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Challenges

As an international supplier of silicones and adhesives it is crucial for Bond It to produce a consistent range of quality products, which was the driving aim behind the project. AES were tasked in finding a solution that would ensure product consistency was a given and that the process eliminated any manual input errors. The existing process involved two old control panels, that no-one understood, which also led to unnecessary prolonged period of downtime. Mistakes were occurring due to inaccurate weighing of products due to a lack of visibility of ingredients “in flight”.

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Solution

AES analysed the existing process and designed a system which completely automated the process. AES merged the two existing control panels into one with a colour coded visualisation display. The new mixer integration was included in the project, with a 250KW motor and new power supply which provided a single dosing system and an increased batch size. AES also installed a Siemens VSD safety system to ensure the mixer could not be opened whilst running (for health and safety).

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Solution (continued)

Not only could the new set-up produce an extra tonne of product within the same time, further efficiencies were realised by enabling the hopper to be filled whilst mixing a second batch. A second “mirror” remote terminal was also included for “view only”. Manual intervention has been completely removed from the process and the new set-ups means downtime is a thing of the past.

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About

For almost two decades, Bond It has been a manufacturer of high-performance, high quality building chemicals such as sealants, adhesives, grouts, cleaners, expanding foams, fillers, decorating sundries, landscaping products and other similar products.  Now firmly established as a major player in the market and serving customers across Europe, the Middle East, Africa, Asia and North America.

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Challenges
Solution
Solution (continued)
About

AES were tasked with providing a solution to improve one of our existing production processes. The resulting output has been amazing and I can’t recommend them highly enough!

Bond it
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