AUTOMATED DOSING CONVEYING MIXING SYSTEM FOR 80 SPC EXTRUSION LINES: EMPOWERING LARGE-SCALE PRODUCTION FOR OUR CLIENT

Overview:
In a landmark deal valued at $10 million, our client, a global leader in SPC flooring manufacturing, embarked on a transformative journey to expand their production capabilities. Facing increasing demand for their high-quality flooring, they sought to enhance efficiency, streamline operations, and scale up their output. Our solution included the delivery of 60 high-capacity mixers, 20 automated minor ingredients batching machines, and a fully optimized material handling system to support 80 SPC extrusion lines.

Project Scope:
The client’s ambitious goal was to boost their daily SPC flooring production to an astounding 2400 tons per day. To achieve this, they needed a comprehensive solution that would not only enhance mixing precision and ingredient management but also seamlessly integrate with their 80 SPC extrusion lines.

We provided:

• 60 Heating-Cooling Mixers (1500/5000L):These mixers were custom-designed for large-scale SPC flooring production. Capable of mixing massive quantities of SPC compounds at high speed, the mixers ensured consistent and efficient blending, vital for maintaining product quality at such high production volumes.
• 20 Automated Minor Ingredients Batching Machines: Precision is key when it comes to minor ingredient formulation. These automated systems allowed the client to handle small additives with accuracy, reducing human error and ensuring that every batch met exacting standards. This automation not only improved product consistency but also saved valuable labor time.
• 60 Finished Material Storage Silos: As part of the solution, we also provided 60 finished material storage silos. These storage units were essential for managing the increased production output and provided an organized, efficient system for storing the massive quantities of finished raw materials.
• Supporting 80 SPC Extrusion Lines:

To complement the high-speed mixing and batching systems, our equipment was designed to integrate seamlessly with the client’s 80 SPC extrusion lines. The combination of these systems created a fully synchronized production flow, from ingredient mixing to final product extrusion, ensuring that the client could meet their production goals without bottlenecks.

Challenges:
Given the size and complexity of the project, several key challenges needed to be addressed:
1. Maintaining Consistency at Scale: With production ramping up to 2400 tons per day, ensuring the consistent quality of every batch was paramount. The automated batching and high-capacity mixers were critical in maintaining the precise formulation of SPC compounds.
2. Handling Large Volumes of Material: The scale of production required an efficient material storage and handling system. The 60 finished material storage silos provided ample space to manage and store the finished raw materials.
3. Integrating Equipment with Existing Extrusion Lines: The client already operated 80 extrusion lines, so it was essential that the new mixing and batching systems integrated smoothly with these existing lines to avoid any disruptions.

Solution:
Our solution was carefully tailored to meet the client's demands for scale, speed, and precision:

• Efficient Mixing and Batching: The 60 high-capacity mixers, with their 1500/5000L capacity, ensured that SPC compounds were mixed quickly and consistently. These mixers were designed to handle high volumes, significantly reducing downtime and improving output speed. The 20 automated minor ingredients batching machines handled even the smallest additives with precision, ensuring the perfect mix every time.
• Seamless Integration with Extrusion Lines: The new mixing and batching systems were designed to work seamlessly with the 80 existing SPC extrusion lines, ensuring that the production process remained uninterrupted and smooth, from mixing to extrusion.
• Optimized Material Storage: The installation of 60 storage silos enabled the client to efficiently store the finished raw materials. This streamlined their post-production handling and helped to manage the increased daily output without delays.

Results:

• Massive Production Capacity: With our equipment, the client was able to reach their target of 2400 tons of SPC flooring per day.
• Improved Efficiency: The combination of automated minor ingredients batching and high-speed mixers drastically reduced production time, allowing the client to increase throughput while maintaining top-tier product quality.
• Cost Savings: Automation reduced labor costs, while the advanced storage system minimized material handling time, leading to overall operational savings.
• Seamless Integration: The new equipment integrated perfectly with their 80 extrusion lines, creating a harmonious production process with no major disruptions during installation.

Conclusion:
This $10 million investment in state-of-the-art mixing and batching technology revolutionized our client’s SPC flooring production line. By providing 60 high-capacity mixers, 20 automated minor ingredients batching machines, and 60 finished material storage silos, we enabled them to scale their operations to unprecedented levels. The ability to produce 2400 tons of SPC flooring per day positioned them as an industry leader, with the flexibility to meet market demand with ease and efficiency.