How Is Poor Bulk Material Flow Costing You?

The scope of this report is to determine the approximate costs associated with poor bulk material flow and the approximate savings achieved with a TIVAR 88 Lining System. Several intended factors are to be considered and are as follows:

  1. Labour required to keep bulk material moving

  2. Halted/reduced production due to jammed equipment

  3. Degradation and damage to infrastructure and equipment

  4. Contamination issues resulting in rejected product

  5. Housekeeping issues with material spillage

  6. Safety Hazards

Data Collection:

Plastruct has gathered data based on anecdotal reporting from client plant managers and production staff. For the purpose of providing unbiased results, Plastruct has used the most conservative numbers available from the participants. Many facilities have much higher cost prior to installation of a lining system.

It is important to note that in all facilities reviewed for this data, more than 1 of the factors were seen. In many plants all of the above factors were present.


1 - Labour


The chart below illustrates general day to day labour that is required to keep material flowing. All of these examples are from indoor or covered facilities. The labour considered includes: Rodding, Hammering The Bin, Cleaning Out The Hopper, Washouts, Cleaning Spilled Material Due To Blockages.



2 - Lost Production


How is lost production realized?


Lost Production was an elusive beast to collect accurate data on, as there were a large number of factors related to production output and totals of production. It was difficult to ascertain how much could be directly attributed to material flow issues. To obtain data we needed to ask not only about lost production of product, as this can be made up with over-time hours, we also explored time lost due to material flow.


In our analysis we mainly focused on how often a bulk material flow issue occurred to the extent that production had to miss batches. This also included complete stoppages for very-short time frames. The other factor which was easier to collect data on was the shutdown time to unplug a system before restarting production.


3 - Degradation + Damage


Bulk materials are not easy on equipment. Clients themselves know best what raw materials can do to their equipment. Equipment manufacturers know this and either ignore it to keep prices low, or are unaware of the available options. Most of the equipment engineering process is done at a desk where the simulations are done under ideal conditions. Unfortunately, most facilities don't have ideal conditions. Most facilities deal with some of the following issues:

  • Moist or wet bulk material

  • Frozen bulk material

  • Rusted steel

  • Low headroom necessitating need for lower slopes on bins or chutes

  • Budget constraints


How can lining your equipment help?

  • The low co-efficient of friction (COF) of a TIVAR 88 lining system facilitates extreme improvement in flowability. The low COF allows for lower hopper slopes to be utilized effectively.

  • A lining system is the first defense against wear. It takes all the abrasion while at the same time increasing the rate flow. This means steel components do not come into contact with the bulk materi