Case Study: Reducing Scrap Rate by 25% Through Optimization of Granulate Processing

In industrial manufacturing, the quality of the granulate is a crucial factor for the success of the entire production process. In this case study, we explore how a production facility was able to reduce its scrap rate by an impressive 25% through targeted measures in granulate processing. This optimization was made possible by the use of precise measurement technology and regular calibration, based on the solutions provided by ICS Schneider.

The Challenge

The facility faced the problem that significant fluctuations in granulate quality led to an above-average scrap rate. Particularly problematic were inconsistent particle sizes and undesirable moisture fluctuations, which caused processing issues and insufficient product quality.

The Solution

To overcome these challenges, a comprehensive optimization project was initiated, focusing on the following measures:

Inline Particle Size Measurement for Consistent Quality:
- By integrating inline particle size analyzers, the facility was able to monitor and control the particle size distribution of the granulate in real-time. This led to an immediate improvement in consistency and a reduction in processing errors.
Continuous Moisture Control:
- By implementing moisture measurement devices at critical points in production, the moisture content of the granulate could be kept constant. Fluctuations were detected and corrected early, resulting in a significant improvement in quality.
Precise Dosing and Material Mixing:
- The use of high-precision gravimetric dosing devices and industrial scales ensured that raw materials were dosed and mixed in the correct proportions. This resulted in more consistent granulate quality and a significant reduction in scrap rate.
Regular Calibration and Maintenance of Measuring Devices:
- To ensure the reliability and accuracy of the measuring devices, regular calibration and maintenance services were integrated into the facility's operations. This minimized deviations and sustainably increased process stability.

Results

Thanks to the comprehensive optimization, the facility was able to achieve an impressive 25% reduction in the scrap rate. This led to:

Reduced material losses
Cost savings in the production process
Improved product quality and higher customer satisfaction
More efficient production processes

Conclusion

This case study impressively demonstrates how targeted optimization measures in granulate processing, supported by high-quality products and services, can lead to significant improvements in production quality. A 25% reduction in the scrap rate not only means less material waste but also significant cost savings and increased efficiency across the entire production process.

WIKA Models 111.10, 111.12 Bourdon tube pressure gauge, copper alloy Standard version

Reliable and cost-effective
Design per EN 837-1 or ASME B40.100
Nominal size 40 [1 ½"], 50 [2"], 63 [2 ½"], 80 [3"], 100 [4"] and 160 [6"]
Scale ranges to 0 ... 400 bar [0 ... 6,000 psi]

Datasheet

The Challenge

The Solution

Results

Conclusion

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