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Examples

Typical opportunities with value addition

1. Excess spillage & dust generation:
  • Premature equipment damages, production losses, working environment, environmental compliance, cleaning and repairing downtime and costs.
Excess spillage & dust generation:
Spillage
Dust affected plants:
Dust emissions
2. Inefficient metal separation:
  • Reduced mill capacity, excess roller wear and damages, vibrations and possible gear-box failures, logistics for contaminated reject material (involving heavy vehicles, manpower and products)
Metal separation in auxiliary transport equipment
3. High inbound and outbound handling cost with low automation:
  • Manual port unloading/loading and transport involving manpower and heavy equipment with re-handling at different storage locations without automation.
Inbound and outbound logistics
4. Reduced production capacity due to auxiliary equipment limitations:
  • Reduced grinding capacity due to conveyors, chute blockages, unexpected break down, high bucket elevator Amp’s or air-slides restrictions.
Downtime of main equipment due to auxiliary transport and dedusting equipment
5. Downtime of main production equipment due to auxiliary equipment.
  • Frequent raw mill stoppages due to unexpected belt conveyor break-down’s.
Weak link in manufacturing
6. Targeted raw material quality not achieved.
  • High lime-saturation/fluctuations due to insufficient blending/mixing in the process chain.
ty variations due to mateial handling equipment
7. Excess wear on equipment:
  • Frequent patch work on conveyor chutes and duct works (causing also wear on surrounding equipment as well as high cleaning costs) with limited manpower requirement.
Frequent wear on equipment
8. Operational and organizational efficiency:
  • Permanent manpower requirement to keep production alive at bin/hopper extraction and conveyor chutes blockages as well as extra maintenance and cleaning jobs.
Permanent Manpower and chute blockages
9. Material dispatch (bulk/bags) limitations or demurrage charges:
  • Waiting times for (customer’s) truck’s to receive purchased products or waiting time to unload raw materials causing very costly demurrage charges.
10. Extreme Seasonal Conditions:
  • Conveyor chute blockages during cold winter or rainy monsoon season hampering production and requiring extra manpower and efforts.
Extreme weather conditions in auxiliary transport systems