Retrofitting Project for Pre-Mixed Powder Production Plants

In the field of bulk material handling, Wolmec Group stands out for its ability to provide customized solutions to optimize material production and management. Recently, we successfully completed a complex retrofitting project for a pre-mixed powder production plant, aiming to significantly enhance the client’s productivity and energy efficiency.

Needs Analysis and Detailed Planning

The project began with a thorough analysis of the client’s production needs, as they had an outdated facility that needed to be relocated to a new production site. This relocation presented a unique opportunity to completely refurbish the plant, increasing productivity and operational efficiency. Our team of experts conducted a detailed analysis of existing challenges to identify areas for improvement.

We started with a meticulous design phase, which included a complete survey of the existing plant, machine by machine. This process resulted in a comprehensive 3D model of the system, which was used as a foundation for designing the adaptation to the new site, characterized by a two-level structure. This phase allowed us to anticipate all possible issues related to space and layout in the new environment, ensuring a smooth installation process.

Technological Innovations and Solutions Implemented

The retrofitted system included several technological innovations aimed at optimizing production processes. The sand milling section was adapted and optimized to ensure efficient operation with the existing mills. We enhanced the sand transportation system by integrating a series of conveyor belts that ensure a continuous and smooth flow to the nutating screen, designed to select the four different grain sizes required for the client’s recipes.

The plant also includes:

• 16 storage silos with a capacity of 100 m³ each, designed to maximize space and ensure the quality of stored materials.
• 2 big bag unloading stations, integrated with safety systems to minimize human intervention and increase productivity.
• 4 micro-dosing stations with high precision to ensure accurate ingredient measurement, essential for the quality of the final product.
• A manual loading point for handling powders and additives of different types, optimized to ensure safety and ease of use.

Additionally, we installed a horizontal single-shaft mixer with plowshare mixing tools, allowing for homogeneous and rapid batch mixing, improving the overall quality of the finished product.

Intelligent Management System and Advanced User Interface

A key aspect of the project was the development of a fully integrated management system, controlled by an advanced control panel with customized management software. This software was designed in close collaboration with the client to ensure that all specific requirements were met. The operator panel interface, featuring a large touchscreen and a 3D graphical representation of the plant, provides a clear and immediate overview of the production process, facilitating control and management by the operators.

The software is also connected in real-time with the company’s chemical laboratories, allowing the chemical director to modify or update recipes and production schedules according to daily needs. This integration enables flexible and responsive production management, essential for maintaining a high level of competitiveness in the market.

Project Outcomes and Benefits

The new plant significantly improved productivity, with an increased production capacity of approximately 150 tons in 8 hours. This was achieved through the adoption of innovative technologies and the intelligent design of the entire system, aimed at minimizing downtime and maximizing energy efficiency. The use of inverters and high-efficiency motors, managed by advanced software, allowed for optimized energy consumption and reduced operational costs.

Thanks to our turnkey approach, the client was able to seamlessly transfer the old plant and install the new equipment at the new production site. We ensured perfect integration between the new machines and the existing ones, ensuring optimal cooperation between all components of the system.

After the installation, a dry run confirmed the correct installation and functionality of the system, followed by a complete functional test. The final training phase ensured that all personnel were adequately prepared to operate the new equipment and management software.

Conclusion

Wolmec Group is proud to have successfully completed this complex project, enhancing the client’s production system’s productivity and efficiency. We are always open to new challenges and opportunities for collaboration, ready to provide innovative and tailored solutions to meet our clients’ diverse needs in the bulk material handling sector. If you have a project in mind or are looking to optimize your production processes, we are here to listen and develop the best solutions together.