How Webster Griffin Helped Reliance Automate Their Throughput & Increase Productivity With Big Bag Filling Lines
Who Is Reliance & What Are They Famous For?
Reliance is an Indian conglomerate with a presence in the petroleum refining industry. They operate the world’s largest petroleum refinery, converting crude oil into fuel and petrochemicals.
They convert these petrochemicals into polymers with different melt flows that are converted into Linear Low-density Polyethylene (LLDPE) and Low Density Polyethylene (LDPE) resins.
These resins are used to make film and packaging products as well as in rotational moulding and injection-moulded and extrusion coating and moulding applications.
What Solution Did Reliance Require At Their Jamnagar Petroleum Refinery?
Reliance approached Webster Griffin for help packing their LDPE and LLDPE resin pellets into Big Bags. Their desired throughput was 45 bags an hour, with each bag weighing up to 1100 kgs. Due to the business’s output, they needed three packing lines integrated into one system.
It needed to be ATEX compliant in line with EU safety directives and able to integrate into the refinery’s control systems. It also had to connect to different product feed points and connect at height to several product distribution silos — without any product cross contamination taking place. The entire system also had to be automated with minimal labour involved.
For quality control purposes, Reliance put in place a rigorous quality assurance system during the machine’s installation. This would involve two third party consultants monitoring the process.
What Solution Did Webster Griffin Suggest & Install?
Webster Griffin customised several IBC-PF4 Big Bag Filling machines to suit Reliance’s requirements. Two storey self-supporting platforms offered access to the system’s dosing valves and feed system and a rail connected it to the silos.
The system allowed the operator to access the buffer hoppers and dosing valves to control the flow of product from the silos. Extraction units prevented dust circulating during filling. Two weighing platforms ensured accurate bag weighing, with a second weighing platform used to fill any underweight bags. A vibrating table would then compact the product in each bag.
The system logged and transmitted all data, presenting bag and weight data to the client for analysis and identification. The system featured a platform, allowing operators to apply bag labels and tie the bags. It also gave them access to an online ticket printing system to apply any tickets. Finally, the system had inline metal detection fitted to the system feeds, again ensuring the resin pellets are safe, uncontaminated and ready for distribution.
Did The Installation Deliver Any Tangible Benefits For Reliance?
After installing the system and training operators at the refinery to operate it, Reliance was able to achieve their desired throughput and throughput speed. Improved weighing accuracy helped prevent product wastage, also preventing accidental underfilling which could displease customers.
As requested the system was highly automated and requiring only the presence of two machine operators and a forklift operator. It was also able to operate 24 hours a day for added productivity.
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