chemicalmachinery

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What is the future of industrial machinery?

The industrial machinery and components sector is often on par with, or ahead of, other sectors when it comes to using advanced technologies.

For example, this industry embraced the Internet of Things (IoT) long before many others had heard of it. At present, industrial machinery is adopting cloud solutions (Cloud Computing), as-a-service business models (as a service) and other advanced technologies such as Blockchain and Machine Learning.

In short, the future of industrial machinery and Industry 4.0 will be characterized by the following:

·        A perfect network and a perfect organization in which all elements of the production process are connected.

·        New communications in which all aspects of a production process are monitored, data is generated and information is collected.

·        All remote actors in the production process will be remotely managed and supervised so that product orders are designed, manufactured and delivered in the most optimal and efficient way.

·        Products will be programmed to "know" the next step in a manufacturing process and communicate with the machinery that will carry it out.

·        The IoT will be leveraged to make manufacturing more efficient and faster.

Companies tend to use advanced technologies to keep improving their businesses and meeting customer demands.

Blockchain is expected to be the next technology to transform the sector. However, companies will have to continue to use new technologies to remain competitive.

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Advantages of the application of automation and robotics in industrial processes

The application of robotics and automation in industrial processes, in addition to improving productivity, enables greater precision and - something very important - provides greater security in the execution of productive tasks. What other benefits does the application of automation and robotics bring to industrial production chains?

When we talk about industrial robotics, we refer to all those robots that are used in manufacturing processes and industrial automation, such as assembly lines or automobile manufacturing cells. The application of these technologies supports production processes and allows tasks to be carried out more precisely and faster.

What is an Industrial Robot?

An industrial robot is "a reprogrammable multifunctional manipulator, capable of moving materials, parts, tools, or special devices, according to variable trajectories, programmed to perform various tasks"

The application of automation and robotics to industrial processes implies enormous advantages, which is why industries from various sectors have incorporated these technologies into their production processes. Industrial automation is present in the textile, food, renewable energy, automotive, metal or furniture industries, among others.

The application of automation and robotics to industrial processes offers numerous advantages:

Reduction of production times.

Greater process control (in real time)

Detection of errors during production.

Better results tracking.

Improve product quality.

Maintenance cost reduction.

Improved worker safety.

Market expansion (improved productivity allows the industry to access new markets)

At our industry we offer process automation solutions, based on the application of different technologies: robotics, artificial vision and PLCs. From our technical advice we study the best solution for your industrial processes.

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Industry: ideas to improve safety at work

Any professional activity involves an element of risk. The world of industry is no exception; operators operate in the midst of equipment that is sometimes heavy, bulky, powerful, and sometimes in the presence of potentially dangerous substances. Manufacturers must therefore provide their teams with optimal safety conditions, because the health of workers is as much a factor as it is for the performance of the company, as well as its image.

To ensure safety at work, it is essential to work on three aspects:  the identification and analysis of risks, the implementation of good practices and the awareness of personnel of said risks.

Assess and analyze risks

According to statistics from the International Labor Organization, 2.3 million people lose their lives as a result of occupational accidents or illnesses each year worldwide. Worker safety is one of the major issues facing the industry and for which it is vital to provide effective and sustainable solutions and ensure well-being at work.

Before setting up an action plan for industrial company safety, it is necessary to carry out an assessment and management of occupational risks so that the measures developed subsequently truly respond to the various alert situations likely to occur. to arise.

The identification of risks is a long-term and multidisciplinary task, involving a variety of protagonists, between occupational safety specialists and managers of the services and departments concerned by these measures. It implies a perfect knowledge of the processes, the specificities of the positions and their requirements.

Prevention of occupational risks

Once the identification and assessment of risks is carried out with precision, managers can move on to the implementation of preventive measures and good security practices.

This involves defining the actions to be taken, distributing roles and responsibilities and deploying all the technical and material resources necessary for the safety of operators.

This includes the installation of signs, pictograms and other safety signs compliant with standards (See Visual Management), the behavior to be adopted in the event of an accident, the coordination between the various services and the safety equipment. PPE (personal protective equipment: helmets, earplugs, high visibility vests, gloves, masks, protective glasses, etc.) are the subject of particular attention and benefit from technological progress, in particular those of digital and connected. We can cite the “Connected operator” project, jointly carried out by Bouygues Construction, Suez, Air Liquide and the CEA technical research department. It includes, among other things, the development of a connected sleeve guiding and informing the worker in real time, an intelligent vest capable of analyzing the quality of the air breathed by the employee,

Raise awareness and involve staff

Wearing PPE and new connected tools developed in this area promise to improve operator safety. However, all these technologies are not worth much if they are not accompanied by adequate training to ensure their proper use, as well as the involvement of staff.

It is crucial to make the operator responsible for the risks associated with their workplaces, as well as the means to prevent and react to them. Communicating compliance with work and safety instructions among staff is an obligation for any company, which thus avoids the negative repercussions that incidents can have on its performance, on the morale of its employees and on its image. Also check out our article on: Establish Security Procedures.

In any case, the requirements related to personnel protection are constantly revised upwards to allow a continuous reduction of the risks related to the work. ISO is currently developing a new standard, called ISO 45001, aimed at improving occupational health and safety management systems. Its publication is scheduled for February 2018.

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Advantages of industrial automation in companies

The advantages that a company would have thanks to industrial automation are numerous. Know which are the most important.

The use of computerized and electromechanical systems that control machines and processes is also known as industrial automation. Today companies grow and have new needs, they require new tools for their operations and many of them are oriented towards automation.

Thanks to it, organizations reduce labor and simplify work, making processes more effective and faster. To know if industrial automation is viable, it is necessary to know if the economic and social benefits that they will obtain will be greater than the costs of operation and maintenance of the systems.

What are the advantages of industrial automation?

Implementing industrial automation is related to the type of company that wants to do it. For example, among the most benefited would-be textile, fishing or mining companies, which would obtain great advantages:

Improve the quality of the work of the operator of the machinery or system that has been installed to develop a process.

Reduce costs, reduce heavy work, time and, consequently, reduce the money invested in company processes.

Reduce pollution and the company's environmental impact.

Monitor production processes with more accurate data, less work, and greater opportunities.

Automation provides managers with reliable information about factory operations, which is useful for finding problems and solutions quickly.

Reduce dangerous jobs such as lifting heavy loads or operating in high-risk environments. Increasing at the same time jobs as system or machinery operators or as creators and managers of the same.

30% reduction in errors in repetitive processes (a production factory) and up to 30% reduction in total human resources costs through self-services.

To implement an industrial automation system, different professionals are needed, but above all an industrial engineer capable of managing production systems and innovating in terms of products and processes. This professional has the ability to perform an optimal management of integrated systems and thus contribute to the development of a company.

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ISO 9001: quality management in the industrial sector

In many sectors and for informed customers, ISO 9001 certification is a guarantee of quality and therefore of satisfaction. In other words, it is a criterion on which they can base themselves to sort out the companies. This management standard is therefore an undeniable asset for any organization seeking to develop and gain market share in an increasingly competitive environment. Integrated into the strategy of industries, its vocation is to help them become more efficient and better able to meet or exceed customer expectations. It is undoubtedly one of the centerpieces of Industry 4.0.

Stick to the requirements related to the QMS

When we think of quality, QMS (quality management system) and continuous improvement, we inevitably have to evoke the ISO 9001 standard. This is, in fact, the fundamental support for companies aiming to strengthen their presence on markets by focusing on a process of efficiency and optimization.

The establishment of this standard aims mainly to support companies towards a long-term logic by following the principle of continuous improvement. It defines the requirements related to the QMS and emphasizes customer satisfaction.

In its 2015 version, it is marked by significant changes, encouraging in particular to re-study the quality approach to make it better suited to industry strategy, but also to better integrate risks and opportunities.

While the ISO 9001 quality standard encourages customer needs and expectations to be taken into account, it also promotes the integration of the needs of employees and partners (suppliers) into company policy.

The principles of the ISO 9001 standard

The application of the ISO 9001 standard for industries requires compliance with 7 fundamental principles, which facilitate the implementation of the quality management system:

Customer orientation: for organizations, this involves ensuring that the present and future needs of customers are met, by deploying the tools and techniques in this direction.

Leadership: the ability to lead and ensure that everyone in the organization knows their role and the objectives to be achieved.

Staff involvement: it is not enough to have competent staff. They must also feel involved in order to create value.

Process approach: this recognized standard considers that only an organization in which the activities are considered as interdependent processes can aspire to a gain in efficiency.

Improvement: It is assumed here that every aspect of the activity of the industry can be improved in one way or another. Hence the need to carry out audits and constantly search for the points to be optimized and the tools to do so.

Evidence- Based Decision Making: Evaluating and analyzing information helps you maximize your chances of achieving your goals.

Management of relations with interested parties: the quality of relations with suppliers and partners in general makes it possible to support sustainable performance.

ISO 9001: what are the benefits for the company?

By integrating the new ISO 9001 standard into their strategy, industries are ensuring better control of their internal operations at the same time as building confidence on the part of their customers and suppliers. This standard also makes it possible to guarantee the quality of services ensuring customer satisfaction.

Also see our article on: Updating quality documents

This approach allows us to define our objectives with greater precision and to aspire to new business opportunities through a realistic assessment of the environment and the context in which we operate. At the same time, it promotes efficiency and productivity thanks to the process approach and its understanding by all staff.

It constitutes a lever for the loyalty and attraction of customers by satisfying their needs, through a quality system.

Finally, the ISO 9001 standard leads the company to identify and manage the risks associated with its activity.

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The 5 mistakes not to make to succeed in your Industry 4.0 project

Talking about industry 4.0 refers to a new generation of factories that are both connected, robotized and intelligent. The number 4 is to mark and celebrate the 4 th industrial generation. We can even say that with the digital revolution the boundaries between the physical and digital world are narrowing to give life to a 4.0 factory.

The notion of “Industry 4.0” first appeared in 2011 at the World Industry Forum in Hanover. This “industry of the future” project refers to a new way of imagining the means of production. It is based on technologies such as the Internet of Things, augmented reality and virtual reality. This new innovative approach makes it possible to move forward towards better management of industrial resources. It also makes it possible to achieve a real qualitative leap in terms of services.

To ensure the success of the transition to Industry 4.0, we offer you a list of errors to avoid.

Do not put the operator in discussions

One of the main developments in Industry 4.0 is the digitization of information. However, do not think that these new modern technologies will make the tasks performed by humans disappear. Indeed, it is important to always place the operator at the center of any automation and computerization procedure.

Since he is very often the end user of a software or solution, it is important to bring him into the discussion. Human intelligence is essential to operate and monitor new production tools, however sophisticated they may be. As a result, by taking into account the specificities and requirements of the operators, this allows them to be upgraded, and this, by placing them among the fundamental elements of the business strategy.

Thus, Industry 4.0 is synonymous with valuing employees by evolving their tasks and roles towards missions with high added value.

Do not allow software, machines and robots to communicate with each other

We notice in the field of industry, the interaction of connected equipment without human intervention is developing at high speed.

In a smart factory, all devices and software must cooperate. Indeed, it is important that all systems are connected to each other. The inability to communicate can interfere with the production process. Indeed, one of the crucial challenges of Industry 4.0 is to provide reliability and productivity as well as time savings.

As a result, this “factory of the future” must ensure that its production site communicates machines with software and robots. The idea is to make the working process faster and more flexible.

Note that the advent of what is called the Internet of Objects gave birth to a set of disciplines such as Machine to Machine, better known under the name M2M. The latter is presented as a subset of the Iot. It brings together different information exchange technologies allowing machines to communicate with each other without human intervention.

In other words, we can say that M2M refers to everything that allows software, machines and robots to communicate with each other automatically.

Not having specific goals or problems to solve

Introducing the new technologies of Industry 4.0 must first of all be carried out with great clarity. We should not opt ​​for this concept of “industry of the future” without a specific goal or objective. Indeed, before investing large sums in digitization, the factory must properly diagnose the return on investment in order to measure the real needs of a company. As a result, each industry must ensure that moving to digitalization will bring it real business benefits. The primary goal of these new technological developments is to optimize the productivity and turnover of any industry.

To know if a company should opt for Industry 4.0, the first step to perform is to carry out an assessment. The adoption of this concept should absolutely not be rushed. It is essential to analyze all aspects before embarking on such an approach without predicting its profitability.

Note that the success of any conversion to Industry 4.0 is essentially based on this step, failing which, it could quickly become a real waste of time.

Do not mobilize teams internally

This new generation plant is also based on the mobilization of internal teams. Indeed, this allows the transition to industry 4.0 to begin.

Therefore, it is important to train employees to increase their skills. One person is unable to put everything in place. Indeed, it affects all services and departments and everyone must be involved in the management of the project to be successful. The teams must therefore learn to use the new tools, follow continuous training in terms of quality and maintenance.

Do not accompany the change

Switching to Industry 4.0 also means initiating the digital transformation of your industry, but in subtlety. You're not going to start over or just wipe out everything you've put in place with the back of your hand. Indeed, you will simply optimize what already exists.

This transformation is able to affect all aspects of the industrial enterprise. Therefore, any industry must adopt tailor-made change measures and, of course, step by step. Indeed, it is not easy to make a radical and abrupt change in your working method. We must therefore undertake a process of transforming the habits of employees over the long term.

Thus, we can say that the implementation of change management is able to ensure the proper evolution towards Industry 4.0.

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Industry and technology: towards improving productivity

New technologies, especially those brought by the digital boom, benefit all company departments. So much so that, for industries, making the switch to digital has become as much a driver of performance as a necessary process. And if there is one area in which the digital factory of today and tomorrow is likely to make great strides thanks to advanced technologies, it is productivity. In the industrial sector (automotive industry, aeronautics, agri-food, pharmaceutical, etc.), technical and technological innovations constitute, in fact, real boosters for production capacities, both in terms of quantity and quality.

Digital transformation: a necessity for industrial companies

In the field of industry, the transition of almost all of the company's services and activities to the era of ICT (Information and Communication Technologies), these famous information technologies, is therefore both an imperative and an opportunity for her. the industrial innovation is supposed to ensure him significant gains in efficiency and performance. It is designed to optimize productive capacities, exchanges, communication between all information systems and mobility. To be overtaken by this trend is to compromise its competitiveness, perhaps even its survival, because the business environment is increasingly competitive. Adapting to change is a vital issue.

The industrial company therefore complies and, in doing so, offers itself opportunities for improvement thanks to innovative and efficient tools, such as Cloud computing, for example. The latter corresponds to an outsourced solution allowing, among other things, to enjoy colossal data storage and management capacities. Technological advances also make it possible to better identify customer needs, and therefore improve their satisfaction. Being able to offer them an adapted and personalized offer is undoubtedly a major advantage.

The factory of the future must be able to produce more and better by using advanced technology industrial systems and equipment. The goal is to be both productive and efficient.

Productivity boosted by industrial technological innovations

Pillars of Industry 4.0

Cyber-physical systems (CPS) are a great example of what technology can do for productivity. In this type of device, advanced computer elements and working in a collaborative manner are in control of sophisticated physical equipment (machines), which increases its reliability, efficiency, industrial performance and safety. These CPS make it possible to process large quantities of data and to pilot complex industrial production management resources, where the best of robotics and sensor networks are brought to bear, thus helping to raise the productivity of the new plant and respond the expectations of manufacturers.

At the same time, new technologies are undoubtedly leading to profound changes concerning the place of employees in the industry of tomorrow, which retains a stranglehold on productivity and whose role is far from being devalued. Computerized and automated systems take on an ever-wider range of repetitive and complex tasks that fell to the employee (maintenance technician, technician, project manager, team leader, engineers, etc.). The latter can thus concentrate more on the management, monitoring and industrial maintenance of this equipment, leaving the machines to do what they know best: to produce in ever greater quantities and in constantly improved quality.

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Industrial safety: prevention and industrial risks

Safety in industrial companies and performance go hand in hand. This has always been the case in the world of industry and even more so in the emerging one, Industry 4.0, where the working environment is constantly evolving and the demands are constantly increasing. The continuous improvement therefore also involves the analysis, processing, and implementation risk prevention plan of various kinds that threaten organizations and especially workstations.

Safety instructions: ensuring employee safety at work

In industry, whatever the continuous improvement strategy implemented and applied, the latter includes an essential component, which is that of employee safety (industrial risk management and accident prevention).

It is, in fact, inconceivable for a company to operate normally and, a fortiori, to want to be efficient, without taking into account industrial risk and preventing occupational risks in the various workplaces.

We can define industrial risk as an accidental event occurring on an industrial site causing immediate serious consequences for personnel, residents, property and the environment.

This concerns first of all the safety of operators and personnel in general. It is undeniable that by ensuring that the work environment is safe from dangers (falling object, fall of the operator himself in his workstation, exposure to chemicals, dangerous, or toxic fumes, major risks of electrocution, etc.), work incidents and therefore absenteeism can be reduced. However, we know that this absenteeism is one of the worst enemies of performance and a powerful obstacle to continuous improvement. Therefore, it is important to put in place an approach to prevent occupational risks.

On the other hand, we cannot ask the operator to be productive and to feel totally involved in his mission if he does not feel safe.

Also discover our article:  3 things to do to improve operator safety

Actions to prevent occupational risks: dematerialize procedures

Specified in writing and integrated into the company's industrial documentation, the procedures are now dematerialized in a logic, again, of continuous improvement.

The digitization of procedures, which describe in particular the organizations, working methods, operators and services concerned and the tools to be deployed, makes them more efficient at the same time as it contributes to the protection of employees, information and resources. of production.

The procedures contain the security measures to be applied on a daily basis and in the event of an incident. Digitized, they are easier to transmit, update and protect against destruction or loss, whether caused by accident or by malicious action.

Adapt communication tools and media

While written instructions are important and even essential, visuals have an even greater impact because they promote understanding at the same time as they arouse interest.

Centered on visual perception, the tools relating to visual management are precisely intended to improve communication with the various actors of the company. We can take the simple example of a panel used to facilitate periodic meetings within the workshop and dealing with essential topics, including personal safety and performance. Short, but regular sessions, where relevant indicators are analyzed and instructions recalled to allow teams to stay on course for the objectives set.

Visual management emphasizes the simplification of information, its readability and availability, putting it at the service of safety in particular and continuous improvement in a more global way.

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The transmission of knowledge in the company, in industry

Any company is subject to cyclical movements within its human resources (human capital). As employees prepare to retire, newcomers are expected to take over. This poses the problem of the transmission of knowledge and know-how. This transfer of skills between retirees and the new generations can only be ensured effectively if it is the subject of a carefully designed policy and action plan.

Skills transfer: the challenges

In modern industry, investing in advanced equipment and processes is not enough to stay efficient. When we face the departure of experienced employees - retirement requires - and when we work to integrate new employees, the risk of running a deficit in terms of skills development and know-how is very real.

The company cannot therefore be satisfied with simple handovers between the seniors and the new ones. A whole organization has to be put in place so that the precious skills do not evaporate with the renewal of teams.

It is only on this condition that the level of performance and competitiveness of the company can be maintained and improved. As such, the knowledge transfer policy is a key part of the company's quality system. The ability to achieve quality goals depends to a great extent on it.

You can also read our article on:  Taking charge of new business recruits, an opportunity for continuous improvement.

At the same time, it makes it possible to avoid the transfer of undesirable behavior. In other words, it is as much about establishing the elements of productive know-how to communicate to new entrants as it is about eliminating behaviors that are detrimental to the smooth running of the company. This prevents the latest arrivals from “inheriting” it.

Passing on your knowledge: what benefits can we expect?

For newly recruited young employees or interns, it is obvious that being accompanied by former (tutors) greatly facilitates their learning. They benefit from better and faster integration, finding it easier to acquire the knowledge necessary for the trade. More than the initial professional training plan, it is the proximity with experienced employees that allows you to understand the operating methods of each position (progress and sequence of operations). In addition to the management of technical skills, new entrants are also introduced to informal operating rules within the company: social and relational codes, tips, exchange and communication networks, etc.

For their part, their elders also benefit from this knowledge transfer process insofar as it enhances their role and their professional experience. In the end, this pushes them to continue to invest fully in the life of the company during what remains of their career.

How to ensure the transmission of knowledge?

For the transmission of knowledge to be effective, the company must ensure that it identifies, classifies, modelizers and transfers the important elements of expertise, those that it would really benefit from passing on to new generations of employees. But this should not be done to the detriment of their capacity for autonomy and initiative.

It must also stay abreast of the latest process developments, both those directly relating to production and those relating, among other things, to internal communication. This is one of the main characteristics of Industry 4.0, all aspects of which are affected by digitization.

Passing on knowledge also makes it necessary to implement a business capitalization plan (skills), which involves identifying the knowledge specific to each position and evaluating its criticality.

This policy is not based only on traditional methods such as in-house training sessions and tutoring. It also relies on additional devices such as mentoring, discussion forums or new software solutions.

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What Is The Best Option For The Storage Of Water, Chemicals And Fertilizers In Agribusiness?

The storage of water, chemicals and fertilizers in agribusiness is a very important issue since it must be ensured that the good quality of the products is maintained.

That is why in Rotoplas different options have been developed that adapt to the needs of each project and industry:

Tanks for the storage of water, chemicals and fertilizers

These tanks can be vertical or horizontal and are ideal for storing water during times of drought. Furthermore, they can also be used to store other products such as molasses, food and more than 300 chemicals.

They are manufactured in one piece with 100% virgin HDPR, which prevents the development of leaks and maintains the highest quality. It can also come with a 20% and 40% reinforcement, allowing dense and corrosive substances to be stored.

Its capacity is between 250 and 25,000 liters, thus adapting to a wide range of needs. The design allows no color, odor, or flavor to be added to the stored product and will not rust or corrode.

Horizontal Tanks

Nurses, in addition to storing water and food, can store fertilizers, fuels, gasoline, and more than 300 chemicals.

They are light and easy to transport thanks to their breakwater system that helps provide stability when they are being moved. They adapt quickly to any trailer and have great resistance to highly corrosive compounds.

Their capacities vary from 500 to 5,000 liters, which makes them very practical also to supply drinkers for agro-industrial livestock.

Hoppers

Like the previous tanks, Rotoplas Hoppers are used to store water, food and more than 300 chemicals. However, these have the characteristic that they are ideal for wastewater treatment.

They are made of 100% virgin HDPE, in one piece, and with storage capacities from 600 to 14,000 liters. It has a hermetic closure that is intended to preserve the temperature and avoid humidity.

Its graduated and translucent material keeps its content free of colors, flavors and odors. In addition, its conical shape allows a total emptying to be carried out and a suitable dosage of the stored product.

Feeders and Drinkers

Specially designed for field and corral livestock. They are ideal for the different needs of the agribusiness since they offer different capacities and lengths that adapt to any measure.

They are easy to transport and are manufactured without internal right angles to prevent bacteria from growing.

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Characteristics of Tanks to store chemicals

The different industrial branches, transformation, agriculture, food and marketers that handle chemicals in their processes or that is the resulting product need safe and high-volume repositories for their handling.

A tank for storing chemicals must meet several characteristics:

- Anticorrosive properties, both to protect from external elements and to resist and preserve the properties of the chemical it contains.

a) The tank must be made of a material with these properties or have a special coating. b) Some substances can even corrode paints and internal coatings; consider polyethylene tanks for acidic / caustic substances and others of a corrosive type.

c) According to OSHA regulations (Occupational Safety and Health Administration), they make recommendations for use:  

·         Galvanized steel or lead tin alloy, when chemical purity is not critical.

·         Polyethylene for strong acids and other corrosive chemicals.  

·         Stainless steel when chemical purity is critical.

- Design and resistant walls, capable of resisting mechanical damage, giving greater protection against the risk of leaks.

- Hermetic. They offer few or no weak points, which over time develop into cracks and cause spillage. Regarding content management, the tank seal should prevent leakage, evaporation or loss of properties due to extended exposure to the environment.

- UV protection.

- Durable material. The tank walls should be made of a material that can contain chemical material for extended periods of time without risk of degradation, preferably one that does not require much maintenance to achieve this.

- Depending on the industry, there are some trends towards the manufacture of custom tanks that meet these characteristics, although the price, durability and convenience of installation have led to the choice of polyethylene tanks: ready to use, comply with the standards required and are capable of handling hundreds of substances without risk of corrosion. Quote the best tanks for water and chemicals.

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Journey To The Future Of Chemical Manufacturing

Countries in the developed world with strong industrial reputations are bolstered by the manufacture of chemicals, which generates essential materials for the rest of the secondary sector. From medicines to textiles, paper, paints, perfumes or components for the aerospace and electronics industries, the chemical industry represents one of the key sectors for the Spanish economy.

It currently houses more than 3,000 companies that generate 660,000 direct, indirect and induced jobs. With a turnover that exceeds 63,000 million euros, this sector accounts for 13.4% of the country's gross industrial product, according to data from the "Radiography of the Spanish Chemical Sector" prepared by the Business Federation of the Spanish Chemical Industry. In addition, it ranks second in exports.

The chemical industry has an important presence in the Spanish economy. In the future, the strength of the sector will depend on its ability to respond to market challenges and its ability to differentiate itself. Both factors must be strengthened to maintain the current pace of development and innovation.

Manufacturing operations developed

One of the essential elements for the future of the chemical industry is the adoption of intelligent manufacturing processes. These are characterized by being scalable and agile, as well as by promoting the optimization of resources. Three elements that offer important benefits in the chemical industry.

Today's technology already enables ingenious recipe management to be combined with efficient demand planning. This helps manufacturers streamline their processes and improve resource efficiency.

Highly qualified workforce

The chemical and pharmaceutical industry is a powerful force not only because of its turnover, but also because of the amount of employment it generates. Highly skilled technical workers play a vital role in the success of the chemical industry. Needed expertise in the production of chemicals that are slow to develop and are not easy to acquire or transfer to new markets.

To promote innovation from the workforce, existing processes must be as efficient as possible. Unifying the sales, marketing, and service functions to get a complete view of both the inside and the outside of your business ultimately improves your customer service and product offering.

Promotion of industrial innovation

Driving innovation and streamlining manufacturing processes in chemical companies requires a strong ability to restructure formula management, gain easy access to inventory reports, automate quality control and production planning, and gain valuable information. and big data analysis.

Reducing development cycles, responding quickly to customer trends and complying with changing regulations helps manufacturers improve the quality of research and optimizes resources to increase investments in R&D centers, as well as develop dynamic and innovative work groups in a wide range of technologies.

High value products

The result of this combination of factors will be high-value products that, in turn, will provide greater value to the rest of the industries in which they collaborate. With the right technology, innovative product design is a reality by optimizing operational processes, providing supply chain visibility to expand production and traceability, and increasing your competitiveness around the world.

Every supply chain improvement in the chemical sector represents a new growth opportunity for the future. This future looks bright, but achieving it requires continued investment in research and the development of increasingly efficient and sustainable processes.

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Digitization of the chemical industry: optimization, savings and competitiveness

In an environment marked by constant regulatory and technological evolution, the future of chemical manufacturing involves the automation of processes, complete traceability of materials and products, and real-time knowledge management. This will help reduce risks in the supply chain and react appropriately to any unforeseen events.

Replenishment, production, traceability, cost control and quality controls are some of the critical processes in the chemical industry. Simplifying and integrating these key functions will help you make a quantum leap and embrace new industry trends. This helps you focus on delivering the response your customers expect. Is your company ready to face these challenges?

We give you the keys to take advantage of the digital transformation when managing business critics:

Quality

If in any business it is essential to guarantee the quality of all the products that leave the production center, in the chemical industry it is even more so. Therefore, it is essential to carry out a global quality control of the entire process, from the purchase of raw materials to the shipment to the customer through the entire manufacturing process.

Thanks to technology, quality controls have been perfected. Now it is possible to design them based on product specifications, such as sampling or test preparation, certificate of analysis, etc. It is also possible to directly manage complaints and non-conformities through a specific workflow. Ultimately, technology allows for an integrated quality management system.

Traceability

Thanks to the latest technological innovations, it is possible to carry out a continuous and complete monitoring of the state of materials, products and processes. It allows access to multiple data of interest, such as the lot number, the expiration date or the article number. The ultimate goal is to carry out full multilevel traceability by lot number.

Formulation

Researching new formulas and recipes, as well as managing their production is the heart of the chemical industry. For this reason, innovations around the formulation play a leading role in the sector. The composition of semi-finished products and finished products is defined in a formula. Among the fundamental characteristics of these processes is the relationship between the quantity and components of the formula, the multi-level analysis of the formula in relation to the components, version management or work instructions by formula.

Planning

Planning of supply and production is an essential factor for cost savings. The more precise the planning, the more processes are optimized and the use of resources (from energy to water, personnel or materials) is rationalized. In addition, it provides greater reliability in customer delivery times.

Among the main features of the most innovative planning systems is the planning and scheduling functionality integrated within the system, the finite scheduling capacity based on constraints, the optimization of the preparation times or the detailed calendar analysis: load to limited capacity and unlimited to detect manufacturing bottlenecks.

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Tips For Choosing The Best Industrial Machinery

Choosing a good industrial machinery will help you to offer quality products and will also improve productivity in your company. Here are some tips for choosing the best industrial machines for your company.

Choose the best industrial machinery

The heart of any industrial plant is undoubtedly good machinery, as this will guarantee quality in the production line, which will bring benefits in the income of your company.

The purchase of a machine should always be the result of a plan that includes productivity, savings and energy efficiency. All this is with the aim that the industrial machinery responds to the production requirements of each of the players in the sector.

For example, there is the case of a manufacturer of plastic toys that uses injection processes and let's say that one day the company gets a large order but does not have enough capacity to serve it, so it decides to buy new industrial machinery.

Companies buy equipment based on price, but what costs very cheap at the beginning, eventually turns out very expensive and industrial machinery that initially had a lot of productivity can see it reduced by more than half in a short time.

This can be mainly due to the poor quality of the elements with which this type of machines are made and for which they are 40 to 60% less expensive than the industrial machinery of the best brands and of excellent quality.

Create a project with production requirements

The first thing is that you make a plan that includes the production needs such as times, the quality that is needed and the quantity of manufacture of certain products. Consider that it is not the same to make spoons than automotive components.

Look for different alternatives

It is also important that you look for different alternatives for industrial machinery, since not all industrial machines focused on a certain niche offer the same quality in production.

Scalable machines

Make sure that the industrial machinery you choose is scalable or the technology they use must be current, otherwise you will have serious problems when they need repairs. The technology must be valid for at least the next three years, which is the calculated time to recover the investment.

RELEVANT FACTORS FOR THE PURCHASE OF INDUSTRIAL MACHINERY

the following points should be analyzed:

1. Specialized personnel: The assistance of specialized personnel, with technical skills and knowledge of the machinery, is very relevant when choosing a supplier. The support begins from the first approach that one has with the distributor, the person who advises must know every detail of what he is offering and if necessary, go to perform an inspection of the machine to ensure that it is what the client needs.

2. Multiple sales channels: When purchasing a product, it is essential that they provide effective and transparent support. Therefore, the fact that the provider offers different platforms and purchasing methods is an aspect that provides support and support.

3. Logistics service: Once the equipment has been purchased, it should be expected that it arrives without any complications. Choosing a provider that creates security and trust is key.

On the other hand, regarding the equipment that is acquired, the following parameters must be remembered:

1. Requirements for use: Be clear about the specifications of its use.

2. The specialization of the machine: Place and working conditions to which the equipment will be exposed.

3. Price: That fits the budget without having to put aside the quality of the machine.

4. Forecasting the future: The team must solve the current situation, but must also adapt to future situations.

5. Maintenance cost: Ensuring that repairs or parts are easily accessible.

6. References:  Seek opinions, criticisms and recommendations from companies that are already using this equipment on its operation.7. Local attention: The local specialized service in the equipment, it is necessary that the attention be simple and fast.

8. The strength of the distributor: Check the solvency, the experience in the market, its specialization, the post-sale service and the response time.

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Heat exchanger: what is it and what is it for?

The heat exchanger is a device designed to transfer heat between two fluids, these being in contact or separated by a solid barrier. These are essential components in air conditioning or refrigeration systems, air conditioning, energy production and chemical processing.

To easily understand the operation of the heat exchanger, we can take the radiator of any vehicle as a reference. The engine heats the coolant fluid. The latter is cooled by contact with air currents, thus reducing the temperature of the former after circulating inside.

Heat exchanger uses

Heat exchangers are used for the following uses:

·        Raise the temperature of a fluid thanks to a hotter one.

·        Refresh one fluid using another with a lower temperature.

·        Bring a fluid to the boiling point by the action of a second with a higher temperature.

·        Condense gases using cold fluids.

·        Bring a certain fluid to a boil while another hotter gaseous condenses.

Types of heat exchanger

When classifying the different types of heat exchangers, different criteria can be taken into account. If we analyze the degree of contact between the fluids involved, they can be grouped into two large blocks:

Direct contact heat exchanger

In direct contact exchangers, heat transfer is carried out by means of a physical mixture of the fluids involved in the process. The two currents are easily separable after the energy exchange.

The cooling towers are direct contact exchangers, which are responsible for removing heat from a hot water stream, by means of dry and cold air circulating in the system.

Indirect contact heat exchanger

In the indirect action mechanisms, on the contrary, there is no direct contact between the fluids; they do not get to mix. They are separated by solid elements, by a space and even by a lapse of time. Heat is transferred by convection or conduction through the partition wall.

The heat exchangers indirect contact can be concentric double tube or tubes, shell and tube, plate, compact, regenerators etc.

The double tube kits are the simplest that exist. They are made up of two concentric pieces of different diameter. One of the fluids circulates inside the smallest and the other does it through the annular space between both tubes.

Shell and tube exchangers are widely used in industry. As the name indicates, its basic components are a shell and a multitude of tubes.

For their part, the plate systems are assembled based on a succession of metal sheets, all assembled in a frame and separated by joints fixed to a steel shell. The connection between the sheets allows a certain fluid to flow between the first and the second, between the second and the third another and so on.

Heat exchanger manufacturer in Vadodara

[chemicalmachinery]

What is the most suitable mixer model for my need?

Mixing ingredients is a very important process in food manufacturing, since it is useless to use high-quality ingredients and state-of-the-art equipment if a uniform mixture is not achieved that provides all animals with the nutrients for a good performance in accordance as provided in the formula.

Feed uniformity is very important, particularly when we refer to micro-nutrients such as vitamins, minerals, amino acids, and medications that, when not mixed properly, can impair the performance of animals.

To determine the ideal mixing process for each need, we need to take into account the main factors that affect the final product, which are: the characteristics of the mixed raw material, the construction of the mixer, the process parameters and the uniformity coefficient of mixture measured by the coefficient of variation CV%.

Regarding the mixer, the aspects to consider when choosing the ideal model are the mixing time, the degree of filling, the distance between the helicopter (or the blades) and the type of discharge.

Regarding the total mixing time, we must consider: the dry mixing time, the liquid addition time and the additional time after the addition of liquids (when available). The normally recommended additional time is 1 minute. It is important to respect the dry mixing time, since it is at this time that the uniformity of the micro-ingredients in the total mix will occur, and if the liquids are added before this time, the flow characteristics decrease with the liquids and there is risk of forming lumps in the micro-ingredients and they do not adequately standardize in the mixture.

Degree of filling: the mixer mixes the volume and not the weight. Weight capacity is defined by the volume and power (kW) of the mixer. The higher the RPM and the greater the% of liquids, the greater the power required.

Vertical mixer:

Capacity: 500, 1,000, 2,000 and 3,000 Kg per batch.

Vertical mixers are the cheapest and most common on the market. They are fed at the bottom and the raw material is played to the top through an endless thread. The finished product can be removed from the sides of the equipment, through gates. Due to its low homogenization efficiency, it takes 8 to 12 minutes to complete a batch.

Its main disadvantages are the longer cycle time of the mixture, which decreases its production capacity per hour, and also the lower homogeneity ratio of the final product, since, being vertical, the heaviest product tends to concentrate in the bottom of the computer.

Horizontal twin screw mixer:

Considered a more robust model than the vertical one, its mixing time is 4 to 5 minutes. It only has one axis, but this axis has two metallic tapes that cross inside the mixer, causing the large raw material inside it to move back and forth, that is, in addition to turning, the product goes to the center and turn the walls to make the homogenization. The twin screw mixer allows a degree of filling from 50% to 100%. In the twin screw mixer, a 15 cm portion of the screw must pass the surface of the ration. The distance between the screw and the body of the mixer is 3 to 5 cm. When this distance is approximately 12mm, uniformity may be affected.

Paddle mixer (Fast mix):

Its main advantages are the cycle time of approximately 3 minutes, and it can also work with only 30% of the capacity of the mixer volume (degree of filling 30-100%). It allows, considering the adequate mixing time, a maximum variation coefficient of 5%. The maximum product residue between Bateladas is 0.5% of the total useful volume of the Mixer. Its dilution capacity is 1: 100,000.

An additional advantage of this model is that its paddles are replaceable and adjustable. Another important advantage of this model of mixer is its unloading, because instead of small pneumatic gates that block the production process, all bottom of that mixer is part of the damper, making it fully open, releasing the product more quickly and with this You can increase the number of battings per hour relative to the other mixers.

Ribbon blender

Ribbon blenders mainly need a huge amount of power to function properly. It operates at a relatively slow pace and it mixes the ingredients thoroughly. The agitators are shaped in a unique manner which allows the mixtures to move in two directions simultaneously.

Stalwart International

Ribbon blender mixer manufacturer in Vadodara. We are the prominent organization to offer a qualitative assortment of Ribbon Blender. The offered ribbon blender is designed and manufactured by our professionals as per the set market norms by utilizing best quality raw material and latest technology.