Overview
A specialty manufacturing company producing high-performance flooring and coating systems experienced sustained growth driven by a strong commitment to quality, testing, and customer support. As demand increased, the company sought to modernize its raw material receiving process to improve safety, efficiency, and cost control.
The existing approach relied heavily on manual handling of bagged materials, which created operational inefficiencies and safety concerns. Cyclonaire was engaged to design and implement a bulk material handling solution tailored to the facility’s operational constraints.
Challenges
The manufacturing facility faced several key challenges:
- Limited available space in the receiving area
- Labor-intensive manual handling of bagged raw materials
- Increased safety and ergonomic risks for operators
- Inefficient material flow impacting productivity
- The need to receive bulk materials from delivery trucks and route them to storage and packaging operations
- Requirements for robust dust control and system safeguards
Any solution needed to fit within tight spatial constraints while improving safety, cleanliness, and overall efficiency.
Solutions
Cyclonaire engineered a custom bulk material receiving and conveying system designed specifically for confined spaces and specialty materials.
Key elements of the solution included:
- Bulk truck unloading into compact intermediate storage bins
- Pneumatic conveying from bins to bulk packaging stations
- Integrated dust collection to maintain a clean operating environment
- Intuitive, touch-screen control interface for simplified operation
- Safety-focused system design allowing controlled unloading while monitoring material levels
- A layout optimized to minimize footprint while maintaining reliable material flow
The system was developed using proven test data and application experience to ensure dependable performance and ease of operation.
Results
The Cyclonaire solution delivered meaningful improvements across the operation:
- Significantly improved workplace safety by eliminating manual bag handling
- Cleaner material receiving and transfer operations
- Streamlined raw material flow from delivery through packaging
- Reduced labor demands through automation
- Improved operational efficiency and lower handling costs
- A scalable foundation to support future expansion
The success of the project positioned the manufacturer to continue growing while maintaining a safe, efficient, and well-controlled production environment.
To view the full case study, please fill out the form below.