The right solution in the processing, storage and transportation of bulk material solids, powder, granules and tablets.
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To achieve this, a production line must have the capacity and flexibility to meet the demands of today's consumer, whilst incurring minimal overheads associated with downtime and scrapped product. This is where an IBC system comes in.
With the potential to manufacture more than one product at any given time, IBC systems are pivotal in improving the efficiency and profitability of manufacturing companies worldwide.
This is why investing in an IBC system to manage and process your powders is vital to ensuring that you can meet demand and maintain your competitive edge.
Problems often occur due to inadequate or unsuitable equipment and errors because of manual intervention or operations. These can lead to issues in areas such as segregation of blended material, lack of containment or reduced/no flow of powder from a container. In worse case scenarios, this could result in a cease in production while the problem is being fixed.
If you find yourself answering 'yes' to at least one of the questions above, Matcon are here to help.
We have been solving these issues for over 30 years by providing IBC solutions to overcome these issues.
A careful and detailed technical review is required in order to recognise the very significant performance differences that can be expected when comparing one IBC system with another.
Here are a few examples of the weak links that can be caused by inadequate technology, which will negate any Lean benefits of decoupling the system:
Compared to butterfly valve IBCs, the Cone Valve provides superior discharge control, preventing the traditional powder handling issues such as bridging, rat-holing and blend segregation.
What initially looks like a cheaper option is usually cheaper for a reason and may not give you the performance you need. It is worth researching to understand the benefits and limitations of different types of IBC. As well as production quality, the key difference in systems is in the valve outlet itself. Some manufacturers opt for IBCs fitted with a butterfly valve, others supply IBCs with cone valves.
Bridging, rat-holing, and blend segregation. These will be terms that you are all too familiar with, but what steps can you take to mitigate these issues?
Learn more about Matcon Cone Valve technology and how Cone Valves are the optimum solution for manufacturers processing anything from cohesive to free-flowing powders.
Better understand the Matcon range of IBCs:
Explore the highly effective blending of powder with quick cleaning in between batches - achieve high OEE rates with an IBC Industrial Mixer.
The simple design of Matcon's powder packing equipment ensures that manufacturers reduce downtime as change-out parts can be quickly cleaned off-line. Undertake recipe changeovers in minutes not hours.
By decoupling each of the key powder processing stages, these can all take place simultaneously 'in parallel'. This means that your production facility can embrace lean manufacturing and become more efficient.
How can you ensure you ask all the right questions when selecting an IBC supplier?
The Matcon Ideal IBC System checklist will help you ask the correct questions of your IBC supplier.
With the support of the guide, you will solve your powder handling problems and validate your equipment procurement process.
What are the full benefits of a decoupled system?
Efficiency and overheads are two major factors that manufacturers strive to influence on their production lines. The ability to improve these are pivotal to the success of a company, which is why choosing a powder handling system that addresses these areas of concern is so vital.
A manufacturer must be efficient, productive and profitable; and so too should their manufacturing process. This is where a decoupled Intermediate Bulk Container (IBC) system comes in.
Avoid damaging equipment and stock with the correct manufacturing methods.
In addition to 'Bin-rash', we've also seen operators fully clothed in hazard suits rodding the product through the container inlet in an attempt to discharge product.
These issues can be avoided completely when you've got the right powder discharge device.
Read our pharmaceutical blog to learn more about powder and tablet handling best practice.
It is not accurately known what capacity of valuable powder ingredients are lost each year, simply caused by loss of blend uniformity or regular manual intervention during the manufacturing cycle.
These costly issues can be reduced significantly by selecting the appropriate powder handling system. Read this blog to identify the root cause of your problem and discover the solutions available to solve them.