In the production and feeding stages of rubber additives, issues such as dust emissions, low labor efficiency, and high material loss have long troubled many enterprises. A rubber manufacturer in Anshun, Guizhou, implemented a sealed feeding and conveying system to achieve fully automated and dust-free flow of additives from storage to production lines. The system was designed and integrated with the overall solution by Head Powder, and its operational performance received high recognition from the client.

Case Summary

This project serves a large rubber products enterprise in Anshun, Guizhou, mainly focusing on upgrading and renovating the feeding and transportation processes of rubber additives. The original process used manual weighing and open-end feeding, resulting in high dust concentration on site, harsh working conditions, and a material loss rate close to 5%. After system upgrades, feeding operations achieve a fully enclosed environment, dust emission concentrations below national environmental protection standards, labor costs reduced by 60%, and material loss controlled within 0.3%.

Customer pain points

The main issues faced by the customer during production were threefold: First, severe dust pollution, which not only endangered employee health but also led to workshops failing to meet environmental standards, putting pressure on rectification; Second, manual feeding efficiency is low, requiring 3 workers to spend 40 minutes per batch, and weighing errors are difficult to control within 1%, affecting the stability of final product quality; Third, during feeding and transportation, exposure of exposed surfaces leads to frequent dampness and caking phenomena, causing considerable direct economic losses.

Solutions and product advantages

To address these pain points, Head Powder customized a sealed feeding and conveying system for the customer. This system uses pneumatic conveying principles, delivering additives directly from the ton bag unpacking station through sealed pipelines into the silos of each production line, with no material spillage throughout the process. Core equipment includes automatic unpackers, screw conveyors, pulse dust collectors, and PLC control systems. The advantages of the solution are reflected in:

• Sealing: All joints use sealed flanges and flexible connections, combined with negative pressure dust removal design, ensuring dust-free operation throughout feeding, conveying, and metering;
• Automation: Through PLC and host computer linkage, only one person can operate the touchscreen to complete multiple batch settings and execution, achieving a weighing accuracy of 0.2%;
• Energy saving and consumption reduction: The total installed power of the system is reduced by 30% compared to traditional solutions, and the material recovery rate is increased to over 99.5%;
• Easy maintenance: The equipment adopts a modular design with quick-release key components, reducing daily maintenance time to under 30 minutes.

Currently, this system has been operating normally for over 12 consecutive months. Customers have reported improvements in workshop cleanliness, a product pass rate of 99.8%, and reduced overall operating costs, effectively solving the long-standing issues of dust and efficiency.