Matcon IBC supplied an IBC system to Myosyn Industries to help them improve the efficiency of the mixing process.
Myosyn manufactures and supplies cures, seasonings and premixes to the meat and poultry industries in Australia. In recent years it has diversified into manufacture and supply of products to the food service and dairy industries.
The mixer discharge in Myosyn’s existing facility was directly coupled to the bag packing process, which meant that the mixer could not be used until the mixed batch was packed off. The mixer was idle for this period of time resulting in an Overall Equipment Efficiency of <10%.
During discussions with Matcon, Myosyn Industries MD, Mr Ben Rayfield realised that the operation could be a lot more efficient if the mixing and packing processes were separate processes and were de-coupled. The mixed batch would be loaded into a Matcon IBC in a quick process and the IBC taken to the separate packing feed area.
Matcon was awarded a contract in March 2010 for the design, supply and commissioning of a Matcon IBC system for the Myosyn manufacturing facility located in Eagle Farm, Queensland.
The manufacturing process is batch based using Matcon's Intermediate Bulk Containers (IBCs) technology. Raw materials supplied in 25kg bags are manually tipped into the existing ribbon mixer. After mixing, the batch is dispensed into a 1300L IBC, which is then taken and located above the Dendy packing machine and packed into 25kg bags.
The new system consists of a mixer with an IBC filling station directly underneath. The filled IBC is placed onto a Matcon discharge tower, which feeds product into a Dendy packaging machine. The bags are filled and passed through a Q-Stitch in-line sewing machine before they are conveyed through a metal detector.
The Matcon process has enabled Myosyn to save significantly on labour costs, which makes the new project affordable in terms of the rate of return on investment.
According to Mr Ben Rayfield, the system also allows the company to load the IBCs with mixed product on the previous evening to eliminate the early morning downtime of the old system, thereby increasing the daily production capacity through the packing machine.
With reduced spillage, the new IBC system was able to create a dust-free environment and the company could modify their dust extraction system as the dust sources were significantly reduced.
In terms of production flow and efficiency, Myosyn was able to adjust the batching and blending rates to achieve a seamless production flow based on the rate at which the IBCs were emptied.
Key advantages of the de-coupled mixing and packing processes:
- Faster filling, faster emptying and faster mixing improves efficiency
- Close transfer with no cross contamination (GMP)
- Keeps mixing room clean and dust-free with reduced spillage for improved health and safety
- Optimises overall equipment effectiveness (OEE)
- Minimises work-in-process (WIP) and helps eliminate unnecessary inventory
- Improves cash flow and provides a nearly instantaneous ROI