Let’s look at the ramifications of not having a central system – and think about the associated costs – can you estimate your yearly losses from these problems?

It is not unusual to discover tens of thousands – even hundreds of thousands of wasted dollars in a plant without a good centralized resin handling system.

PROBLEMS = LOST PRODUCTION TIME, LOST PROFITS AND LOST CUSTOMERS!

Problems Experienced Without a Central System:

• Space needed for plant consolidation
  – If you can’t handle more process machines some other plant will 
• Congestion on the floor around machines
  – Slows workers – increases spillage and chance of injury 
• Lack of material validation/verification
  – Can’t bid on contracts where validation required 
• Wrong material going to wrong machine
  – Lost production time, rejects and lost material 
• High material spillage
  – Loss of material and labor + safety hazard 
• Material related part defects
  – Producing scrap instead of saleable parts 
• High maintenance/labor costs
  – Increased payroll and parts cost 
• Frequent material changes
  – Lost production time 
• Inefficient work flow
  – Wastes space and labor 
• Lack of Automation
  – Adds labor costs and extends lead times 
• Constrained production capacity
  – Can’t increase revenue 
• Lengthy hopper cleanout times
  – Increased labor – lost production 
• Poor drying of material
  – Rejected parts – lost customers

Usually, the cost to install or upgrade an efficient resin handling system is recovered in a matter of months – not years – See examples of central system paybacks. Investment payback in Months – Not Years but a review of conditions in your plant is required to identify areas of loss and possible remedies.