The Customer
A Yorkshire-based animal feed manufacturer supplying customers worldwide. We have supported operations at this site for around 20 years, working closely with the team to adapt and improve their processes as production demands evolve.
The Challenge
The customer needed greater flexibility in how the finished product left the mill. Their existing storage bins fed product back into the main factory process, but they wanted the ability to divert material to a new transfer route serving a small packing plant.
Demand for smaller 20kg bagged orders was growing alongside bulk supply. While the customer already served both markets, the existing system limited output and constrained packing capacity. To keep pace, they needed to increase throughput and improve efficiency without disrupting day-to-day production.
Our Brief
The brief was to convert the outlets on two existing storage bins to allow product to either:
- Continue into the original factory process, or
- Divert across the mill to the new packing plant
The solution needed to handle multiple product types, support higher production rates, and be installed with minimal downtime.
Our Solution
We began with a detailed site visit to survey the mill and fully understand the customer’s requirements. Our design team then developed a hopper conversion for bins 6 and 7, incorporating divertor valves, slide valves and a new chain conveyor transfer system.
Our manufacturing engineers fabricated all new equipment in-house at our York workshop, ensuring quality control and a precise fit.
Working closely with the customer, we planned a structured four-day shutdown. The customer emptied one bin at a time, allowing production to continue using the remaining bin and keeping disruption to a minimum.
Our installation engineers removed the existing under-hoppers and installed the new hopper arrangements, complete with chute work, back into the original process route. They then installed the newly designed transfer system, carrying 3mm and 6mm pellets and 13mm cobs up to 25 metres across the mill to the new packing plant via twin chain and flight conveyors.
The finished system allows product to discharge either through the slide valve into the original process or divert seamlessly to the packing plant.
The Result
The upgraded system has transformed packing flexibility and efficiency. The customer can now pack multiple product lines simultaneously, eliminating the need to flush the system between different products and removing the risk of cross-contamination.
As a result, the mill has:
- Increased efficiency by removing unnecessary downtime
- Improved packing flexibility for bulk and bagged products
- Increased production by 6–7 tonnes per hour
Another successful project delivered for a long-standing customer, helping future-proof their operation and support continued growth.
To discuss your next mechanical upgrade, get in touch with the ISF Team.
