Efficiency is at the core of any industry. Production that handles powders and fluids faces immense challenges in drum packaging. The transition from traditional empty drum storage to a fully automated filling system is required to enhance the efficiency and productivity of fluids and powder packaging (especially oil and lubricants). However, this transition requires careful planning, the right tech, and an understanding of the best practices of the engineering industry.
In this blog, we will explain a step-by-step guide to seamlessly integrate an automation system for your drums. Whether you’re upgrading your current processes or starting from scratch, this comprehensive approach will set you on the path to efficient and automated operations.
What is a fully automated filling system?
A fully automated filling system is designed to efficiently and accurately:
- Convey empty drums from storage to filling
- Convey drums from filling to palletizing area
- Weigh, orient, fill, cap, seal, and palletize drums on a pallet
- Deliver pallets with minimum downtime
These systems typically include various components such as:
- Modular Conveyor Systems
- Filling Machines
- Automatic pallet dispenser machine
- Control Systems
- Capping and Sealing Machines
- Cleaning Systems
- Powered and Idler Roller Conveyors
- Powered Slat conveyors
- Automation systems
Benefits of a fully automated filling system
- Increase efficiency of operations
- Eliminate the need for manual labor
- Minimize material waste
- This leads to cost savings
- Provide consistency
- 24x7x365 running capacity
- Easily scalable
- Energy saving
- Safer operations
The working principle of this automation solution encompasses multiple steps. At Dhanvanthri Engineers, we have standardized procedures to ensure an accurate and efficient transition to an automated filling system. Below is the overview of the critical steps to follow for accurately transitioning to automated filing operations.
CRITICAL STEPS FOR TRANSITIONING TO AUTOMATION FILLING OPERATIONS
To accurately transition to a fully automated filling system, you must understand its functionality, challenges, and overall design. To begin the transition to automated filling operations, we have outlined specific steps as below:-0
- Assess current operations: The initial step for a successful transition is to thoroughly assess your current operations and turnover rates.
- Identify bottlenecks in the operation: Look for inefficiencies in your current operations—are your drums overflowing? Are there delays in filling drums? While you identify the bottlenecks, also review your safety and compliance standards.
- Defining Goals and Requirements: Once you have a clear picture of your current operations, it’s time to explain your goals. What do you want to achieve with an automation system? We have already defined the typical objectives in the previous sections. However, it is best to identify objectives considering your particular requirements. For example, if you are looking to streamline your product stacking process, you may consider a palletizing system.
- Consider compatibility with the current system: If you already have a system in place, you should always check how the new system will integrate with your existing industrial equipment and workflows.
- Selecting the right technology: In a fully automated filling system, various drum-handling conveyor systems, control panels, and automation integration are available, such as
- Power roller conveyors
- Idler roller conveyors
- Weighing rollers
- Pallet dispenser
- Modular chain conveyors
- Pallet conveyors
- Overhead chain conveyors
- Loop chain conveyors
- Hanger conveyors
- Trolley chain conveyors
- Carousel conveyors
- Cross transfers
- Popup transfers
- Filling machine integration
- Control panels
Each technology offers unique advantages. The selection of the technology depends on the above points.
- Designing the new system layout: A well-thought-out layout can significantly impact the efficiency of your new filling system. Consider space requirements for all industrial equipment, ensuring enough room for operations without crowding. Create a timeline that outlines the phases of your transition.
- Train the staff: Training in the new system is essential. We also recommend a pilot test to troubleshoot issues before the final rollout.
- Monitor and Evaluate: After the final rollout, it is essential to establish and monitor KPIs to measure overall effectiveness. For continuous improvement, have the team operating the automated system regularly review your processes.
Conclusion
Transitioning from empty drum storage to a fully automated filling system is a strategic move that can yield significant benefits. You can achieve a seamless transition by following some simple steps. An experienced conveyor manufacturer like Dhanvanthri Engineers can help you choose what is best for your operation.
GET EXPERT HELP WITH FULLY AUTOMATED FILLING SYSTEM:
While we’ve outlined the essential steps for transitioning to automation, there’s so much more we can offer to ensure your success. As a conveyor systems manufacturer and automation solution provider, we have helped many clients in the oil and chemical industry in India and overseas since the early 1990s.
We can advise on the most appropriate type of automation system for your application after considering your specific requirements, product types, and goals.
Partner with us to automate and revolutionize your operations.