Lean Manufacturing

Eliminate waste and improve efficiencies with flexible & agile Powder Handling Systems using Intermediate Bulk Containers (IBCs).

An Introduction to

Lean Manufacturing

With a Powder Handling System that enables Lean Manufacturing, you can improve efficiencies, and reduce your overall manufacturing costs. Applying the correct production methods and equipment in your factory will ensure that you get it right the first time and every time to increase your return on investment.

Using the Matcon IBC method of manufacturing, shorter production runs can be implemented as recipe batch changeovers are quicker and simpler. This means you can ‘make-to-order’ with small inventory levels and minimal work in progress (WIP). You can also cut waste, delivery times and better manage costs, leading to a higher return on the materials you purchase.

Break The Chain

The decoupled nature of our materials handling system gives total flexibility and the agility to respond rapidly to changing customer and market needs.


Related pages

Save Time At Blending

What is Lean Manufacturing?

Lean Manufacturing for Powder Handling and Processing means eliminating anything that does not create value for the end product. Traditional methods of manufacturing often contain hidden wastes (The Deadly Sins of Waste) these are:
  • Overproduction – no need for WIP to maintain flow with an IBC system.
  • Waiting – loading and emptying coupled fixed mixer systems means the whole system has to wait. IBCs enable all process steps to operate in parallel, achieving high OEE rates.
  • Transporting – ergonomic systems are easier to create which reduce material movements.
  • Unnecessary Inventory – ‘make-to-order’ and not campaign runs which risk stock spoilage.
  • Unnecessary motion – with the correct design, the IBC System can achieve good process flows.
  • Defects - quality issues mean whole campaigns are scrapped. With the Matcon Cone Valve, blend segregation is avoided for a quality product every time.
The Challenges

Overcome the Common Industry Challenges

Over the years we have been able to help our customers adapt and grow with the ever changing needs of their markets.

The unique Matcon Cone Valve means that no matter what recipe or ingredient challenge is presented, you can be assured it will handle your powders successfully.

  • Efficiently handle product portfolio variety
  • Improve quality of finished product
  • Shorter lead times
  • Reduced material and labour costs
  • Meet strict regulatory standards
  • Reduce the cost of finished goods

Lean Manufacturing System Example

Discover how IBC Blending enables fast, effective powder handling by removing the ineffective cleaning processes associated with fixed-line blenders (paddle blenders and ribbon blenders).

HubSpot Video

Lean Manufacturing Resources

Learn more about Matcon's lean manufacturing equipment and get best practice insights with these useful resources.

Better Industrial Mixer Utilisation

Learn how changes to your mixing process ensure that you realise savings and efficiencies across production.

HubSpot Video

You CAN have Flexibility AND Increase Production

If short lead times and varied order sizes are a daily challenge for your operators, then this webinar session is for you

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Increase Lean Production Flexibility in your Food & Dairy Application

29 July 2020

Since our foundation in 1980, Matcon has built a world-renowned reputation as..

Companies we work with

Learn about the companies currently using Matcon Systems to optimise their production efficiency and profitability.