Success Story: MaxZone® System Eliminates Excessive Material Spillage
Problem Summary
A wood chip paper mill in Georgia was experiencing severe issues with material spillage. The mill faced persistent problems of material escaping through the existing skirting, causing not only significant product loss but also requiring frequent clean-up efforts.
Amid falling productivity and rising costs, the mill recognized the need for a comprehensive solution and turned to Benetech for expertise in mitigating material spillage and optimizing conveyor belt performance. The team undertook this project with proven confidence to address the issues relating to material spillage, ultimately resulting in substantial cost savings and improved operational efficiency.
Benetech Solution
Benetech’s solution for mitigating material spillage at the wood chip paper mill encompassed a strategic combination of cutting-edge products and tailored engineering expertise. The solution comprised a MaxZone Load Zone System which included XN Liner Wearliners and a two (2) foot tail box. This provided robust containment for the wood chips while minimizing product loss.
Additionally, Benetech incorporated supplementary belt support measures with Warrior Impact beds to stabilize and support the conveyor belt during loading, thus defending it from damage and reducing spillage.
Benetech products included, but were not limited to:
- MaxZone® Load Zone System — A belt enclosure system with easy-to-access, externally adjusted skirtboards; internal wear liners; dust curtains designed to disrupt air flow streams and prevent dust escaping the enclosure; and rubber skirting to prevent dust leakage along the sides of the conveyor.
- Warrior Impact Beds — Durable steel frames with rubber bars that lie beneath the load zone where abusive impact occurs to cradle the belt and provide stability, and shock absorption to prevent spillage and minimize premature belt wear.
Successful Results
The implementation of Benetech’s solutions yielded remarkable results, significantly exceeding the expectations of the paper mill management. The reduction in material spillage post-implementation was exceptional, with a staggering 99% decrease observed. This drastic reduction not only diminished product loss but also alleviated the need for extensive clean-up efforts, streamlining operational processes and enhancing workplace safety.
Moreover, the financial implications of the project were equally successful. The paper mill estimated annual savings of $25,000, attributed to the reduction in lost material and associated clean-up costs. These significant cost reductions highlight the advantages of investing in innovative solutions for material handling obstacles.
- $25,000 estimated annual savings
- Improved system capacity and reliability
- Reduced material spillage by up to 99%
- Reduced plant risk profile by reducing fire concerns
- Reduced clean-up time
- Minimized plant maintenance expenditures
