A NEW ERA FOR SPC FLOORING: HOW OUR BELGIUM CLIENT STREAMLINED PRODUCTION WITH ADVANCED AUTOMATION
 

Background:
In the fiercely competitive SPC flooring industry, our client, a leading manufacturer, was facing bottlenecks in their production line. Their existing setup was bogged down by inefficient material handling, inconsistent batching, and outdated equipment. To stay ahead of competitors and meet growing demand, they sought to revolutionize their production process with cutting-edge technology.

Challenges:
The client faced multiple operational challenges:

• Inconsistent Material Storage: Their material storage equipment was outdated, leading to inconsistent SPC compound quality.
• Old Mixing Systems: The existing PVC mixers and high-speed mixers were no longer capable of maintaining high-quality SPC formulations.
• High Labor Costs: Manual ingredient batching systems and old pneumatic conveying systems were driving up labor costs and reducing overall efficiency

Our Approach:
To address these issues, we delivered a comprehensive overhaul of the entire production line, incorporating advanced automation and high-tech equipment:

• Automated Bulk Bag Unloaders: We upgraded their manual bulk bag unloading process with fully automated bulk bag unloaders. These unloaders allowed the client to efficiently handle large FIBC and Jumbo Bags of raw materials, significantly reducing labor costs and improving material handling accuracy.
• High-Speed PVC Mixer: To modernize their mixing process, we installed high-speed PVC mixers. These systems greatly enhanced the speed and consistency of SPC compound blending, resulting in a higher-quality finished product.
• Automated Minor Ingredients Batching Systems: We implemented automated minor ingredients batching systems to precisely manage small material inputs. This automation reduced the chance of human error and improved formulation accuracy.
• Pneumatic Conveyors and Screw Conveyors: We replaced outdated conveyor systems with advanced pneumatic conveyors and screw conveyors. These systems enabled seamless and automated material transport, streamlining operations and improving material flow between production stages.
• Advanced Weighing & Feeding Systems: Precise measurement and material distribution were essential for maintaining consistent SPC product quality. We introduced advanced weighing and feeding systems to optimize material input and ensure each batch met exacting specifications.

Results:

• Efficiency Boost: The introduction of automated bulk bag unloaders, pneumatic conveyors, and batching systems improved overall production efficiency by over 70%.
• Cost Reduction: Labor costs were significantly reduced due to the automation of manual processes, while material waste was minimized through the precise control of raw material input.
• Quality Improvement: The consistency and quality of the SPC flooring were enhanced, thanks to the high-speed mixers and automated ingredient batching, leading to fewer defective batches and better customer satisfaction.

Conclusion:
Our client’s SPC flooring production line underwent a complete transformation. By integrating bulk bag unloaders, advanced mixers, pneumatic conveyors, automated batching systems, and a comprehensive automatic PVC weighing, mixing, conveying, and feeding system, we streamlined operations, increased production, and improved product quality. This successful upgrade positioned the client to not only meet current market demands but also excel in future growth.