Jiangsu Kunshan Filler Masterbatch Auto-Conveying System

Case Overview

A manufacturing facility in Kunshan, Jiangsu Province, specializing in filler masterbatch production, faced significant operational challenges due to manual material handling. The plant relied on labor-intensive processes to transport filler masterbatch from storage to production lines, resulting in inconsistent feed rates, dust leakage, and high labor costs. These inefficiencies directly impacted product quality and workplace safety.

Customer Pain Points

The customer identified three critical issues: first, frequent dust emissions during manual conveying caused environmental compliance risks and health hazards for workers. Second, manual weighing and feeding led to batch-to-batch variation, compromising final product consistency. Third, rising labor costs and difficulty in retaining skilled workers made the existing process unsustainable for long-term production scaling.

Product Advantages

To address these challenges, the auto-conveying system from headpowder was implemented. The system utilizes a closed-loop pneumatic conveying design that fully seals the material flow, eliminating dust leakage and ensuring a clean working environment. An integrated loss-in-weight feeder provides real-time, accurate dosing control, reducing batch variation to less than 0.5%. Additionally, the system operates with a centralized PLC control panel, allowing one operator to monitor and adjust multiple conveying lines simultaneously. This solution reduced manual intervention by over 80% and improved overall production efficiency.