Case Study: K-Containment® Seal

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Challenge

  • Excessive conveyor spillage
  • Excessive clean-up costs
  • Belt tracking issues

Celebrating 70 successful years in the concrete industry, our customer has developed a stable and reliable source of ready mix concrete, aggregate and other related bulk materials to Auckland’s growing demands, seeing its operations grow to nine branches across New Zealand.

The concrete batching plant utilised standard trough bases and steel rollers.  With no effective skirting & sealing system in place, the site identified two major challenges to overcome.  Excessive material spillage was a primary issue in and around the conveyor as well as the conveyor being fed onto.  This resulted in production slowdowns, with maintenance time, resources and additional costs directed towards cleaning up the excessive material spillage.

Material build up on the conveyor system was also identified, causing inefficient belt tracking, which in turn impacted on the operations continuous productivity aspirations.

Solution

A thorough evaluation of the sites inefficiencies was conducted and assessed.  Due to its unsurpassed resistance to wear qualities Kinder Australia’s K-Containment® Seal skirting solution was recommended and implemented.

Classed as the first line of defence against the sites material spillage challenges, K-Containment® Seal delivered superior quality, performance and low friction engineered polyurethane skirting and sealing system.

The skirting and sealing overhaul also involved new frames to be installed in conjunction with packers to ensure 100% linear loading zone.  Brackets were manufactured and welded to the existing bin structure, ensuring rigidity and superior product performance.  Installation preparation and process was simple and production downtime was minimal to facilitate the changeover, with the whole installation process meeting the client’s satisfaction.

Resolution

  • Elimination of material spillage
  • Elimination of clean-up costs and time
  • Customers product expectations exceeded
  • Improved productivity and profitability

Satisfactory reports from the concrete batching plant highlight K-Containment® Seal’s exceptional product performance and its effectiveness in controlling material spillage, with maintenance crew commenting “virtually no material spillage evident around the skirting area”.  Cleaning up and dumping excessive material spillage costs have now been eliminated and plant production levels have returned to normal.

In addition, potential hazards, production down-time and disruptions due to cleaning up of fugitive dust emissions have also been avoided, paving the way to productivity and profitability improvements.

With plant expansion factored in for later in the year, the outlook is promising for further K-Containment® Seal system to be incorporated at the planning and design phase.