Industry: Soap , FMCG
Material Handled: Forming soap noodles, flakes, soap bars, bundles, packets, cartons
Product Category: Belt Conveyors
Activity to be Mechanized/Automated:
- Efficiently convey soap during the pre-stamping process, from flakers, roll mills, plodders, and recyclers to the stamper via metal detectors and cutters.
- Convey soap from stampers to wrappers with maximum efficiency, safety, and minimal manual intervention.
- Transport soap from wrapping machines to bundling, flow wraps, carbonators, or further packaging systems, ending in palletized storage.
- Collect packed cartons on pallets or as loose cartons for transfer to the warehouse area.
Designed for precision and efficiency, this advanced conveying system streamlines soap production from pre-stamping to end-of-line processes, ensuring seamless distribution, high productivity, and GMP compliance in FMCG manufacturing.
Challenges vs Solutions
| Challenges | Solutions |
|---|---|
|
Improving equipment design to accommodate the behaviour of soap during different processes |
Sealed Inclined Cleated Belt Conveyors, Horse Shoe Inclined Cleated Belt Conveyors, and Slat Conveyors to ensure smooth handling of soap forms. |
|
High reliability and accuracy required in distribution between stampers and wrappers |
Oscillator (Servo-Based) and Divertor (Servo-Based) for equitable distribution and physical diversion of soaps. |
|
Process conveying to adhere to GMP standards while handling flakes, granules, and tablets. |
Polyurethane Material Belt Conveyors with anti-marking properties for GMP compliance. |
|
End-of-line equipment suitable for a wide range of sizes, weights, and SKUs. |
End-of-Line Solutions like metal detectors, checkweighers, print & apply systems, and carton sealing equipment. |
Results / Benefits:
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Cost Effective: Achieves ROI within a minimum of 1 year, ensuring the lowest cost of ownership.
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Increased Efficiency: Seamless distribution achieves 720 soaps/min, approximately 3 tons/hour, across one stamper and four wrapping machines.
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Energy Saving: Incorporates IE 4+ and servo motors with energy-efficient, torque-optimized transmission systems.
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Low Capital Investment: Proven technologies and components minimize upfront costs.
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24x7x365 Running Capacity: Maintenance-friendly systems ensure minimal downtime and uninterrupted operation.
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High Productivity: Robust, reliable technology supports enhanced operational reliability and capacity utilization.