A specialist nutritional products manufacturer and supplier to the agricultural market contacted ISF about their need for a replacement mixing conveyor at their blending plant in northwest Wales.
With a network of feed mills and blending plants across the UK, this plant is key in the manufacture of nutritional animal feed formulations for all types of livestock.
The mixing conveyor is critical to the process as the bespoke flight ensures an accurately homogenised product. The process works by individual ingredients being loaded into the facilities mixer for blending together. The blended product is then discharged through a conveyor and elevated up to the mixing conveyor. This included a spray chamber and mixing paddles to add molasses to the blended ingredients. The completed blend is then conveyed to the finished product bins in preparation to be distributed to the end user.
What was the issue?
We visited the customer on site to discuss the project in full, and complete surveys to gain a full understanding of how we could help. The existing mixer conveyor was aged, had worn flights due to wear and tear, and the existing spray system was insufficient due to the throughput of molasses struggling to get through to the blend.
What was our solution?
Our in-house designers created the designs for the replacement mixer conveyor, including newly added mixing paddles to upgrade the machine. These mixing paddles improve the homogenisation process and retention time for a better consistency of the finished product.
Our engineers then manufactured the machine at our facility before delivering to site ready for installation.
How we carried out the installation
We worked around our customer’s production schedule and organised a shutdown period for the installation of the conveyor.
Our qualified appointed person for crane operations completed a lift plan and organised the crane hire. Following this, our skilled installation engineers completed the removal of the existing mixer conveyor, and the installation of the replacement 440mm diameter 9m long machine. Our experienced team were able to complete the installation within the agreed one-day shutdown time, remaining on site for commissioning to ensure the new machine was performing efficiently.
What was the outcome?
Replacing the mixer conveyor has improved the quality, consistency and nutritional content of our customer’s finished product. The customer is extremely happy with the result, and we are pleased to be already working on another project with them – what could be better feedback!
