We have successfully completed a large-scale automation project that modernised the raw-material storage and central feeding processes of a leading high-capacity production facility from end to end. With a system consisting of 11+4 aluminium silos, more than 120 loaders and central distribution tables, we eliminated the plant's manual processes and carried the facility into the era of full automation.
By bringing 30 years of industry experience, a strong R&D infrastructure and our engineering capability to the field, we built the smart factory of the future today.
Needs Analysis: The Necessity of Uninterrupted Feeding
At the starting point of the project, the uninterrupted feeding of the customer's very large, high-capacity machine park stood as a critical problem. Our core objective was to transfer the different raw materials stored in the silos from a single automatic centre to all lines simultaneously, without interruption and without error.
For an operation of this scale — impossible to manage with manual methods — we adopted a facility-specific, high-engineering approach instead of standard solutions.
A Facility-Specific Engineering Solution
Taking the enormous size of the need into account, we designed and successfully installed a system architecture that delivers maximum efficiency. The solution comprises these powerful components:
- 11 + 4 aluminium silos: Safe, contamination-free, high-volume storage of different raw materials.
- More than 120 loaders: A guaranteed, uninterrupted flow of material to every point of the machine park.
- Central distribution tables and silo filling systems: Flexible, safe routing of material traffic from a single centre.
The dried raw material stored in the silos is transferred automatically and synchronously to all production lines through the central distribution tables, so every line is fed continuously with the correct recipe. The central distribution tables manage which material goes to which line from a single point without error, while the precise dosing units automatically adjust the main material and additive ratios according to the recipe.
The stainless transport lines running from the silos to the machine park convey the material in a clean, closed circuit, eliminating dust and raw-material loss.
Challenges Overcome with 30 Years of Experience and R&D
Commissioning a central automation system of this scale with zero errors and running all lines in synchronisation requires a strong R&D infrastructure. We overcame the biggest technical challenge of the project thanks to 30 years of accumulated industry know-how. Throughout the process we worked in full synergy with our customer; with regular coordination meetings that clarified tasks and responsibilities, we delivered the project on the planned schedule and with flawless quality.
Concrete Gains After Commissioning
Following completion of the project, clear and measurable gains were achieved on the customer's production lines and operational costs:
- Fully automatic loading: A human-independent infrastructure was established that requires no manual raw-material handling inside the plant.
- Logistics and space optimisation: Forklift and pallet-truck use in the production area ended; internal traffic and accident risk decreased.
- Maximum quality, near-zero scrap: Uncontrolled raw-material losses and area contamination were prevented, and additional cleaning-related costs were removed.
- Workforce and OHS assurance: Costs tied to the need for multiple operators ended, while the risk of work accidents from manual handling fell to a minimum.
- Data security: The previous problem of insecure recipe data was completely eliminated through central automation integration.
A Signature for the Future
Our customer openly expressed satisfaction with the quality of our engineering, installation, delivery and especially after-sales services. With our balance of quality, speed, reliability and price-performance, we continue to write new success stories in industrial automation. For a similar central raw-material and silo automation project, you can contact our engineering team.
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