The Problem
One of FES’s customers called to discuss and develop economical solutions to increase their filling and production efficiency for a major Multinational customer. The product is a well-known brand of sports drink powder sold in 51 and 76 oz. composite containers. The problem centered on uptime, labor, poor filling accuracy and speed. Average dual line fill rates were at 22 cpm (51 oz.) with an expected target rate of 75 cpm and weight accuracy outside the acceptable standard deviation specification (51oz. Low: 1435g, Target: 1465g, High: 1495g).
The Solution
FES developed a solution using (2) AS&E’s Portable Servo Auger Fillers with Upstream and Downstream Controls Integration as the current fillers and controls were outdated. The customized controls included a simple, intuitive operator HMI master control section and (2) portable AS&E Servo Auger Fillers which are designed to collect and seamlessly capture a wealth of production performance data in real time. This also allows for QA, Production Teams to see instantly where other issues are occurring in their line and get maintenance to resolve.
The Outcome
The AS&E System (fillers, controls) were able to run at 76 cpm, with precise accuracy and ease. However current nominal rates are at 50 cpm as the customer needs to increase product delivery and containers more efficiently to realize this potential. In addition, fillers potential is at 100 cpm. Nonetheless, the outcome exceeded their expectations: Reduced line labor from 6-8 to 2-4 people, uptime efficiency increased from 45 to 90+%, accuracy at +/- 4-5g from target weight, and profitability significantly increased.
FES is an authorized and leading representative for AS&E. Discover how now. For more details contact FES at 630-864-7892 or gary@frangersales.com to learn more.
