Here are two case studies in which operations needed to expand and manufacturing capabilities needed to be increased along with how the APEC Premix System gave these companies the capability to meet their goals.
Multinational Premix Company
A premix company wanted to expand their operations in North America and needed to greatly increase their manufacturing capabilities at three locations. Management decided that the new system should be fully automated with front-to-back inventory control. Since their product would be distributed to several different feed manufacturers, they needed to track each ingredient that went into their products, as well as each finished good that was produced.
The design-build engineering firm the premix company hired to do their systems approached APEC to see what we could offer them in equipment and controls. They knew our reputation of quality premix systems and were looking for a one source answer for their project.
We worked with both the premix company and the contractor’s engineering staff to develop specifications and an implementation schedule. APEC designed a system that included barcode scanning for ingredients so they could be tracked within the plant, all the way through the process, and to their final finished packaging. The system utilized off-the-shelf components and a software package that can be easily modified as the client’s needs change.
The APEC Premix System gave the customer the capability to automatically produce and track their formulas. The system also keeps track of the quality control functions that are used for both incoming ingredients and finished packages. Since the system is completely automated, the needs for accuracy, record keeping, and ingredient tracking are easily accomplished with reports that are generated by the control system.
A manufacturer of vitamin and mineral premixes formed a partnership with a major pharmaceutical company in Mexico. The success of the joint venture quickly increased the demand for their products along with the number of products offered. The new partnership soon expressed a desire to have improved recording keeping and ingredient tracking. These capabilities were not possible under their current system due to the manual aspect of the machinery.
They also needed the new equipment installed without interrupting production.
The partnership approached APEC with their plan to improve their premix process. APEC’s engineering staff worked with the ownership team to develop a horizontally oriented system composed of a completely automated premix system. This system included 30 ingredient bins, material handling conveyors, three scales, one mixer, and two packaging lines to allow for proper tracking and record keeping.
The major scales, minor scales, micro scales, and support structures were manufactured at APEC with the large carrier bins being manufactured locally (based on APEC’s designs). This was part of a plan to save the partnership’s money on freight and also to assist in facilitating a quick and seamless installation.
To avoid any interruptions in production, the system was installed in a custom-designed warehouse that was being ordered and constructed while APEC designed and assembled the equipment and control systems.
The APEC system gave the client the capability to formulate, mix, package, and track both large and small bags of premix and concentrate. Due to complete automation, the needs for accuracy, record keeping, and ingredient tracking were easily met with the reports generated by the APEC control system.
The capacity of the APEC system easily met the client’s needs on a single shift basis. As the company grows, they are able to easily increase production by adding shifts.
The Advantages of the APEC Horizontal Ribbon Mixer
APEC’s in-house engineers and fabricators have successfully designed an innovative, high-quality horizontal ribbon mixer that can be utilized in the processing of animal feed, pet food, and other products.
Taking great pride in our equipment’s capabilities, we have confidence that our horizontal ribbon mixer will give your processing plant the advantage it needs.
Case Study: From Manual Labor to Automation
From manual to automatic, here is how the needs of a Michigan automotive sealing component and reinforcement company were met when APEC designed and manufactured automation equipment for them.
The client, an eastern Michigan manufacturer of automotive sealing components and reinforcements, had been processing their products completely by hand. Because of this, their batching, weighing, and measuring system was not very accurate or optimal. In addition, this manufacturing process led to excess waste, poor housekeeping, high labor costs, and was prone to human error.
A Pet Food Company Upgrades to APEC's Mistcoater
Here’s why a pet food company decided to upgrade from a tumble drum coater to APEC's Mistcoater Liquid Applicator, and the successful outcome of making the change.
To apply both fat and flavors to their pet food, our pet food client had been using a traditional tumble drum coater for many years. However, this equipment simply wasn’t up for the task and also posed a few safety risks.
Because of the way tumble drum coaters work, suspended solids clogged the spray nozzles. This caused poor uniformity of coatings. Also, due to the excessive backpressure, premature failure of pumps and valves were a common occurrence. To remedy this problem, the nozzles needed to be cleaned and serviced often.
As far as safety went, the open-ended drums created a slipping hazard from the escaped atomized liquid. Constant cleanup of the surrounding area was needed. When it came to cleaning the inside of the drum, its excessive length and lack of easy access meant a person needed to actually go inside the drum to be able to properly clean it. This practice can quickly turn into a dangerous situation.
Dealing with these serious issues resulted in high labor costs, too much down time on the line, and the potential for a work-related accident.
Animal Feed Case Study: Horse, Poultry, and Aqua
When it comes to solving problems for the animal feed industry, APEC has been developing solutions for over 25 years. Our systems deliver constant cost-cutting productivity, intuitive monitoring, reductions in labor and error, and higher overall quality. We are honored that many of our clients come back to us again and again for help with their various processing problems, and that we are able to offer superior solutions.
Here are three cases in point.
A horse feed manufacturer lost a large horse breeding customer due to problems with the manufactured horse feed. The horse feed contained flaked products, grains, and pellets with a molasses coating.
The problem with the horse feed was breakage and uniformity problems. The customer required a uniform texture that had been unachievable due to the turbulent mixing of the manufacturer’s prior equipment.
Major Design/Build Firm Uses APEC's Micro Ingredient System
As a manufacturer of equipment and control systems, APEC offers customizable systems that will meet any processing need. With in-house engineers and a corporate culture that promotes continual innovation, we have been able to build a reputation for problem-solving and exceptional customer satisfaction.
APEC's Liquid Coating System Saves the Day
As one of the world’s largest lawn and garden companies, selling over 20 brands in 18 countries, this lawn care company knew they had a problem that needed to be handled by a company with a similar reputation.