|Our Technical Specifications booklet outlines the possible savings in color costs when using a Weigh Scale Blender.
Here are a few more points:
Of course, the higher the throughput of the process machine, the more savings are possible.
They have injection molding presses that have an average throughput of 50 to 100 pounds per hour. They justified 80 blenders for 2 reasons. Color usage and Scrap rate.
Previously regrind was added back into the process using proportional loaders. Layering in the hopper meant parts were molded with varying degrees of Regrind. Regrind does not process the same as Natural, and consequently, short shots were common.
With Maguire blenders, regrind was now metered into the blend at a uniform controlled rate. The rate of rejected parts dropped from 9 percent to 1 percent. That is the equivalent to expanding the factory by 8 percent or adding 7 additional injection molding presses. Compared to what that would have cost, the capital cost of the blenders was a bargain.
Color usage was also cut by about 20 percent, which, in itself, provided full payback in less then one year.
Here the color savings were more dramatic. The first blender they installed paid for itself in about 6 weeks. Control of color using volumetric feeders was very poor. With volumetric equipment, color was often being added at rates as high as 14 percent, instead of the specified four percent.
The savings enabled them to justify the capital investment of $750,000 in blenders plus an upgrade to their central conveying and drying systems worth 3 million dollars. We estimate that, on average, the blenders returned there cost every 3 to 4 months.
Briefly, the math for color savings at Your Company might look like this:
A machine may process 100 pounds per hour. Color may be added at 4 percent.
Color cost might be 4.00 per pound (3.50 net cost)
At a minimum, usage is probable at least 20 percent too high.
20 hours / day, 250 days / year = 500,000 pounds / year.
That is 20,000 lbs of color, = $70,000 net added cost
20 percent = $14,000 savings.
And that is at 20 percent. 30 to 50 percent is more typical.
Customers can review their color costs for 1 year and compare to what they should spend if percentages are held accurately on color usage. The difference is the savings that these blenders deliver.
The scrap rate is the next factor that can be measured quite accurately. If a plant is near capacity, then reduced scrape rate equates to an inexpensive capital expansion of the facility.
In addition, labor costs drop when scrap rates drop. Less labor producing more goods.
Quality also goes up, making customers happy and adding additional dollars to the bottom line.