BPI industries is the UK's largest plastics films manufacturing group. Manufacturing packaging, protection, and production materials for a wide range of industries. Vega has provided its plics instruments, for level measurement solutions in bulk pellet silos, delivering real improvements in the handling and supply of materials on-site.
An integral part to this business is the BPI Recycled Products Group, largely involved with manufacturing refuse sacks and bags for all industries, such as waste disposal, medical, food processing, janitorial, retail and DIY/garden, etc.
BPI Recycled Products are made almost entirely from recovered materials - a business driven by companies wanting to recycle as well as customers purchasing their products; assisting many businesses with conformance to climate levy changes and packaging waste directives. BPI Recycled Products has six sites which are Environment Agency audited and approved recyclers, at one of the largest sites in the UK, providing millions of bags and sacks every week to business across Europe.
BPI's raw materials are recovered plastics from a wide range of sources, they are graded, shredded, remelted, filtered and shaped/pelletised ready for reuse in their manufacturing process.
Increasing efficiency
The business is highly successful and this is based upon constant striving to improve efficiency and productivity to maintain its position and enhance quality. Old equipment is continually updated along with constant redesign of manufacturing processes and handling of products. For example; a faster more efficient integrated pellet handling system has been introduced across the site, involving pneumatic transportation from silo to silo.
Implementation of this handling system highlighted the need for accurate inventory and stock control for the manufacturing centres to tighten up productivity and enable easier measurement of individual profit centres within the site. The potential benefits were multifaceted, accurate inventory of raw materials ready for recycling, finished blended pellets for manufacture and reliable prediction of usage to meet schedules of production.
The guided microwave (TDR) is one of the most universal measuring principles for continuous level measurement. A microwave impulse is emitted along a rod or cable and reflected back by the product surface.
The level is calculated by means of the pulse running time. Although the sensor is in touch with the product, all Vegaflex series 60 level sensors share the same advantages of non-contact radar technology. In solids applications, dust, noise, moisture fluctuation or material angle do not affect the measurement.
If needed, easy set-up with the plicsCOM indicating and adjustment module can be done as well as via PC using PACTware (DTM/FDT concept) all designed to save time during sensor calibration and maintenance.
Sophisticated but easy
On-site engineers have been assisted throughout, from ordering to installation and commissioning. Vega also provided training to technicians on system set-up for future expansion and installations elsewhere on the facility.
"Vega systems have given us flexibility and confidence in measurements to allow BPI to accurately predict usage and control inventory," said the site director. "The equipment, whilst being sophisticated, was easy to fit, Vega's explanation of the technology helped us to understand its function and operation easily."
The outcome of this project is lower operating costs for materials management on-site, delivered via reliable measurement of stocks, elimination of overfills and product losses as well as assured supplies to process.
Existing materials measurement on-site was carried out with a combination of manual dipping and some unreliable ultrasonic systems caused by dust and material surface profile. Problems had manifested themselves in running out of required materials, overfilling of silos and inaccurate inventory of product values.
Some of the consequential costs incurred by inaccurate measurement of stock in silos were:
* Idle resources/production waiting for product.
* Cleaning up spillages and lost materials.
* Time taken checking and rechecking with manual measurements.
* Safety of personnel climbing silos in all weather and times to make measurements.
First contact
Vega controls were contacted after a mailshot on the site. The outline requirements were discussed along with a site survey of some vessels needing measurements. The sales engineer recommended Vegaflex plics guided microwave TDR sensors, his experience and knowledge meant he was able to describe the measuring principles, advise on installation and options for connectivity to displays and systems already on-site. BPI site director said, "Vega's advice and involvement with this drove BPI to instigate a project for level measurements of critical silos across the site."
Vega specified a system using its latest guided Microwave TDR technology based upon the new plics concept. As a member of the plics series, Vegaflex combines a low cost of ownership with easy selection and installation. Its range of different housings, approvals and modular electronics make it ideal for all applications. The sensors are delivered ready adjusted; the set-up often only requires installation and the electrical connection.
For more information contact Alan Wynn, Vega Insturments, 011 958 1901.
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