Stores

The materials received at the stores are barcoded (if the last option H is selected) and stored in the respective places in the stores. Based on the scheduler and the material availability at the production floor, the system prompts the operator to select the first come material into the stores. The operator ensures manually by reading the labels for the FIRST IN Material to be taken FIRST OUT.

Through the bar code option system this becomes more easy to the operator using a bar code scanner and ensures no manual error

Chemical Batching

Stationary Silos

Specially designed storage bins are placed in two rows (of 13 Nos in each row total 26 Bins) to enable storing and retrieving of the chemicals at the Production floor. Each bin is fitted with doors at the drawing and filling end. The opening and closing of the bins are automatic through piston arrangement and the same is triggered through the recipe.

A Mobile loading station is provided to enable the operator feed the material to the bin without affecting the production.

Bar code option here reconfirms that the correct material is loaded into the correct bin without manual error

Mobile Weigh Car for chemical batching:

The mobile car which moves from one bin to the other automatically achieves the drawing of materials from each silo as per the recipe. The mobile car is a mobile trolley fitted with 2 weigh scales, weighed material holding bins and a Touch screen display for guiding the operator on the destination of storage bin, indicating the weigh scale to be selected for weighing, and the set weight and actual weights. The operator also travels along with the car. The whole mechanism travels on the rail in between the two rows of storage bins. The mobile weigh car is fitted with an AC Motor and AC Drive to enable a smooth stop and start as an option. Else the operator can push the same manually on rails.

Any error in the process or sequence of operation of the batching system is intimated & registered instantaneously to achieve a highly consistent performance and higher productivity.

The over weight or underweight of material drawn is also indicated by the system along with a voice information to enable the operator to perform the correction.

With the Bar code option the batched materials are given a new batch number using the barcode printer which shall be unique and applicable for the other ingredients such as rubber (wax), Liquid (oil), and Carbon pertaining to that batch and recipe.

The batched chemicals are stored in a bin placed on a trolley which carries this along with other materials to the Kneader.

Carbon Storing and Batching

Different grades of Carbon are Stored in Silos which are provided with Air filter mechanism to avoid Fly off. Each grade is loaded manually using skip hoist. The Silos are provided with slide gates and screw conveyors with coarse and fine feed. Below the screw conveyors the carbon is dispensed to a weigh hopper. This system is connected to the PLC and provides the batching of the carbon as per the recipe. The batched Carbon is collected in a Jumbo bag.

From the Jumbo bag the carbon is retrieved manually at the ground floor by the operator as per the recipe using a weigh scale with respect to each batch.

Barcode option here enables the marking of the batched and weighed carbon contents with respect to the batch and recipe. This becomes handy and useful while feeding to the kneader

Rubber/Wax Storing and Batching

The rubber and wax as per the recipe is cut and weighed manually on a weigh scale. The recipe is prompted trough the LCD touch screen display placed near the operator. The weigh scale is linked to the Central PLC to ensure the correct weight. Optionally the rubber and wax can be placed in bins as for the chemical system to ensure that to pick up the correct material for each recipe.

Actually the Bar code option here shall ensure that the operator takes the first in Rubber and Wax as well as the correct grade is selected during weighing as the scanner reads the material before it is being weighed.

OIL Storing and Batching

The Oil Barrels are placed in the Oil Batching area, which are fitted with steam jacketed pipe lines to enable smooth flow of the oil. The oil is batched by switching On/Off of the control valves. The oil falls into a weigh hopper and the weigh hopper dispenses to the collection bin when desired by the operator.

With Barcode option the Oil Barrels are Traced from the Stores for FIFO as well as the batched oil container is fixed with a new Barcode unique to that particular Batch.

Batched Material Handling

All the batched materials such as Chemical, Carbon, Rubber and Oil are placed in a Container pertaining to that Batch. This is moved to the kneader area through a conveyor.

With the barcode option. The authenticity of the ingredients pertaining to each batch can be ascertained as well as the timing of the feed of each item into the kneader monitored and logged in using a bar code scanner.

Else the same have to be acknowledged by the operator on an interface panel provided with suitable marked switches.

Kneader Loading and Power Integrator

At the kneader loading area the operator receives batches of material which are prebatched and placed in separate containers for chemical, oil, carbon and rubber. As per the time settings given to him which will be prompted on a display near to him he feeds one ingredient after another into the kneader.

The Power integrator the ideal situation for the mix which is taught to the system for that particular recipe will prompt the operator for the timekeeping in feed as well as monitor and control the other factors of temperature and energy.

Optional Bar Code System

This option will eliminate any operator error and ensures FIFO. As this is being used from the very first entry of the material to the stores, tracking material movement such as loading into production bins, and then to each batched items individually for each section.

The same correlated Bar Code is monitored and checked at the point of feeding into the kneader ensuring the various prebatched items are going into the same batch with monitoring on the feed time.

Centralised PLC and Distributed Control Panels

All the above sub systems will be controlled through a Centralised PLC which monitors and controls all the parameters individually and collectively. The optional Bar Code system will also have a centralized monitoring system linked to the PLC

A PC is used for uploading the recipe and recording the parameters for all process which ensures the report generation.

The PC system accumulates the batch data and produces the following reports for individual sections as well as overall for the batch: