Industry: Textile
Material Handled: Viscose, Cotton, Polyester Fibre Bales
Product Category: Chain Conveyors, Roller Conveyors
Activity to be Mechanized/Automated:
- Conveying fibre bales continuously from baler press at a rate of 1 bale per minute to two warehouse locations:
- One warehouse 200 meters away across an access road in a separate building.
- Another warehouse in an adjoining building.
- Capturing bale characteristics such as moisture content, weight, and labeling through integrated sensors and instrumentation.
- Ensuring redundancy to mitigate failures in equipment or controls.
This project highlights the successful integration of chain and roller conveyors to facilitate efficient fibre bale handling in a sulfuric environment, ensuring reliability, safety, and enhanced operational performance.
Challenges vs Solutions
| Challenges | Solutions |
|---|---|
|
Corrosive sulphur environment requiring robust material and design. |
Heavy Duty Metal Slat Chain Conveyors designed with corrosion-resistant materials. |
|
Non-stop baler operations demanding highly reliable equipment. |
Powered Roller Conveyors and Idler Bridge Roller Conveyors ensuring continuous operations with mechanical redundancy |
|
Complexity in lifting/lowering systems and high dependency on instrumentation. |
Simplistic layout using Inclined and Declined Slat Conveyors to minimize instrumentation and automation complexity. |
Results / Benefits:
-
Cost Effective: Achieves ROI within 2 years, ensuring minimal ownership costs.
-
Increased Efficiency: Simplified layout reduces dependency on complex instrumentation, enhancing operational reliability.
-
Energy Saving: IE 2+ motors with torque-efficient transmission systems for optimized energy usage.
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Low Capital Investment: Proven technology and components minimize upfront costs.
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Uninterrupted Operations: Maintenance-friendly design ensures 24x7x365 reliability.
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High Productivity: Robust systems maximize capacity utilization for greater productivity.