At a starch processing company in Weifang, Shandong, the original powder feeding and transportation processes have long relied on manual operations. Workers must frequently carry bagged starch to the feeding port, resulting in high labor intensity and low efficiency, and dust generated during feeding is widespread, significantly affecting the working environment and employee health. At the same time, manual weighing errors fluctuate greatly, making it difficult to meet the stability requirements of subsequent processes.

Customer pain points

The main problems faced by the company include: First, slow manual feeding speed, limited daily processing capacity, restricting capacity improvement; 2. Open feeding causes large amounts of dust to overflow, posing occupational health risks and increasing cleaning costs; 3. Manual weighing accuracy is affected by operator experience, with significant differences between batches and affecting product quality consistency; 4. Lack of systematic planning in material conveying leads to multiple transfers causing raw material loss and efficiency loss.

Solution

To address these pain points, Head Powder designed and deployed a fully automated feeding and conveying system tailored to the characteristics of starch for the company. The system uses a sealed unpacking station combined with negative pressure or pneumatic conveying methods, achieving full automation from bagged raw material dispensing to process equipment. By linking the weighing module with the PLC control system, feeding accuracy can be controlled within a reasonable error range and supports multiple batches of continuous operation. The entire line is equipped with high-efficiency dust removal devices, with sealed treatment at both the feeding port and transfer point to effectively suppress dust dispersion. Additionally, the system adopts a modular structure, allowing flexible layout according to site space and reserving data interfaces for subsequent integration into the factory management system.

Application benefits

After the system was put into operation, manual participation in the feeding process was reduced by about 70%, single-line processing capacity more than doubled, and dust emission concentrations dropped below industry recommended standards. At the same time, the real-time and stable feedback of weighing support uniform proportions, reducing quality fluctuations in the backend process. The equipment operates reliably and is easy to maintain, providing a foundational support for enterprises to achieve refined production management.