SCALING UP EFFICIENCY: HOW A LEADING PVC FLOORING MANUFACTURER BOOSTED PRODUCTION WITH ADVANCED MIXING AND CONVEYING SYSTEM

Overview:
PVC flooring is one of the fastest-growing segments in the global construction materials market, valued for its durability, ease of maintenance, and aesthetic versatility. One of our top clients, a major PVC flooring manufacturer, was struggling to keep up with increasing demand for their products. With outdated equipment and inefficient processes, they needed a solution that would streamline their production and increase their output without sacrificing quality. Enter our **Automated PVC Mixing and Conveying Systems**—a game-changer in the industry.

Challenges:
The client had been relying on older machines and manual labor for critical steps in the PVC flooring manufacturing process. This led to several major issues:

• Inconsistent Quality: Variations in PVC compound mixing resulted in uneven texture and color across different batches of flooring, leading to customer complaints and higher product returns.
• Low Production Speed: Their existing system couldn’t meet growing market demands. Each production cycle was slow, particularly during the manual handling of PVC powder and other additives.
• High Labor Costs: The need for manual oversight at every stage of production, from ingredient weighing to material transport, increased labor costs significantly, while still leaving room for human error.

Our Solution:
To address these challenges, we provided the client with a comprehensive, fully automated **PVC Mixing and Conveying System**, specifically designed to meet the demands of high-volume flooring production.

• High-Speed PVC Mixer: The heating-cooling mixer that could rapidly blend PVC resin, plasticizers, and stabilizers into a perfect compound.
• Automated Material Handling: The introduction of pneumatic conveyors and bulk bag unloaders for handling PVC powder and additives minimized human involvement and sped up material transfer between different stages of production. This cut down on material waste and significantly reduced cycle times.
• Finished Material Storage Silos: We installed multiple finished material storage silos to hold PVC compounds ready for extrusion, allowing the client to streamline production schedules and reduce downtime between batches.

Results:
The results of these upgrades were immediate and transformative:

• Production Output Increased by 30%: The new system allowed the client to more than double their output, meeting the rising demand for high-quality PVC flooring in both domestic and international markets. With faster cycle times and automated handling, they were able to produce 50 tons of PVC flooring per day, far exceeding their previous capacity.
• Improved Product Consistency: With the new high-speed mixer, every batch of PVC compound was perfectly uniform in texture and color.
• Labor Costs Reduced by 27%: Automating the material handling process removed the need for manual oversight during weighing, mixing, and conveying. This allowed the client to cut down on labor costs, while also improving overall operational efficiency.
• Reduced Waste and Material Costs:** With precise weighing and automated dosing of raw materials, the client was able to reduce material waste by 15%,saving money on costly PVC resin and additives.

Conclusion:
For this PVC flooring manufacturer, upgrading to an **Automated PVC Mixing and Conveying System** was a turning point in their business. By automating critical processes like mixing, conveying, and material handling, they were able to increase production capacity, cut costs, and significantly improve product quality. The result? A more efficient operation that could meet growing market demands while offering high-quality, innovative flooring solutions to customers around the world.