Client – Paper Manufacturer
Location – Kent
Application – Replacement Controller
A Replacement Weigh System and Weigh Controller for Waste Conveyor
Problem: An old Datum DW3032 weigh controller failed at a waste recycling company where it was controlling the 30 tonne conveyor. This created immediate problems for the production process. Owing to space restrictions it was important to house the replacement instrument within the existing enclosure.
Solution: Procon was asked to specify and supply a replacement as a matter of urgency to get the plant running again and chose the EP52 batch controller.
The controller was adapted to fit the enclosure and the software was designed to interface with the PLC system. The plant/terminal points were retained to ensure quick turnaround, with minimum disruption and downtime on installation.
Outcome: The outcome was rapid installation and commissioning of an instrument that enabled production to resume with the minimum of delay.
Client – Food Ingredients Manufacturer
Location – West Yorkshire
Application – Batch Weigh System
Accurate Weigh System to Control Manual Addition of Food Ingredients
Problem: A food manufacturer in the north of England was experiencing inconsistencies in batches which required a large number of ingredients to be added manually.
This system was unreliable as the indicator only showed the cumulative total of ingredients within the vessel and depended on sustained concentration by the operator to add the correct ingredients in the right quantities.
There was no other means of checking, so the process was liable to error and inaccuracy.
Solution: Procon’s solution was to supply a high-resolution pit-mounted platform scale to support the vessel, linked to a recipe batch controller.
The controller now indicates how much of each ingredient by weight is required for any particular batch; the operator is then required to acknowledge each ingredient before the indicator counts down the amount to be added and signals the operator to stop. The process is repeated until the completion of each batch.
The accuracy of the mix is confirmed at the end of each batch with a printout of each ingredient by weight and a label attached to the packaging.
Outcome: The system has improved the quality of the product by minimising the chances of human error and by ensuring each mix is accurate.
Cost efficiencies have been achieved by avoiding wastage of expensive raw materials and the system provides accurate information for stock control which was not available before.
Client – Materials Handling Companies
Location – Worldwide
Application – Loss-in-Weight System
Development of Specialist Loss-in-Weight Controller
Problem: A company in Denmark had eight loss-in-weight feeds dosing materials on to their on-shore beltweigher. The complexity of the weighing process meant it was highly sensitive to noise and interference from local surroundings.
They recognised that with over 15 years’ experience in loss-in-weight systems, Procon had the design capability to develop a new specialist weigh controller to solve their problem.
Solution: A prototype was built which was demonstrated to a leading supplier of bulk materials processing equipment who were impressed enough to agree to work with Procon on development of the software and hardware.
Outcome: The EP50 loss-in-weight controller which constantly reviews the density of material, and applies highly sophisticated knowledge based algorithms to maintain an exact flow rate, even during periods of extreme interference from surroundings.
Procon has supplied the EP50 and its successor the EP52, to materials handling businesses and their clients throughout the world.
Client – Paint Company
Location – Lancashire
Application – Loss-in-Weight System
Design and Installation of Silo Weigh System to Replace Sensors
Problem: A paint company used range sensors to measure the contents of its three large silos. It suspected that these sensors were not giving the level of accuracy needed for accurate stock control and approached Procon for a solution.
Solution: Procon proposed to replace the sensors with a load cell system.
Four 30 tonne load cells were installed for each tank. LP44s were chosen because the mounting kit incorporates automatic lift-off protection and jacking bolts for routine maintenance and calibration. The three weigh controllers were installed within a single control panel.
Outcome: Significantly greater accuracy was achieved and this also enabled tanker deliveries to be verified without the need to use a secondary weighbridge, saving both time and money on all subsequent deliveries.
Client – Pharmaceutical Company
Location – Berkshire
Application – Replacement Load Cells
Replacing Obsolete Load Cell and Mounting Kit
Problem: When the old load cells at a pharmaceutical company failed and the same model was no longer available an alternative solution was required.
The challenge was to find a load cell that would fit the available space and to design a mounting kit to fit the existing vessel feet, ensuring the replacement was fit-for-fit, thus minimising installation downtime and disruption to production.
The client required Procon to use a load cell type that was readily available to future-proof the design for the next 10 years. In addition the vessels had heating jackets as well as an agitator so these needed to be taken into consideration in the final design.
Solution: Procon selected the 7188 shear beam load as the most suitable load cell type, as it has a high accuracy hermetically sealed all stainless construction suitable for the harsh working environment. Two mounting kit designs were adopted, not only to fit the available space but also to take into consideration thermal expansion of the vessel and provide anti lift-off for mechanical security. Procon’s engineering team completed the design and manufactured the parts ready for the installation.
Outcome: As the replacement load cell and mount design were fit-for-fit, the installation process was simplified and downtime was kept to a minimum. Each load cell and mount could be installed one at a time avoiding the need to fully lift the vessel. All vessels were installed and then calibrated by the Procon service team and successfully put back into production use.
Client – Food Manufacturer
Location – Yorkshire
Application – Total Site service contract
Replacing Multiple Suppliers with a Single Procon Total Site Service Contract
Problem: A major food and drinks manufacturer in the north of England had over thirty suppliers visiting its sites each year to carry out calibrations on a range of equipment.
Procon was one of these and was responsible for the maintenance of 500 scales and balances.
Solution: In order to improve efficiencies and because of Procon’s good track record on site, the manufacturer approached Procon to take over all calibrations at the site, including responsibility for all scheduling and record-keeping. A two year transition period was agreed during which time Procon’s engineers were trained to maintain and calibrate a wide range of both weigh and non-weigh equipment.
Outcome: Within two years the supplier base was reduced from thirty companies leaving Procon as the one supplier with responsibility for all weigh scales, checkweighers, metal detectors, temperature probes, pressure gauges, and flow meters under a ‘Total Site’ contract.
The manufacturer reported a cost saving of 50% as well simplified administration and easier access to documentation.
Since then Procon has been able to offer Total Site contracts to all kinds of businesses throughout the UK. Multi-site manufacturers know that the same calibration methods and standard of administration will be applied across their entire operation.
Client – Food Manufacturer
Location – Yorkshire
Application – Breakdown callout
Major Production Breakdown at Christmas Resolved by Procon Engineer
Problem: On a Sunday evening, the last but one day before the Christmas shutdown, with production at full capacity, a Scottish food manufacturer had eleven weigh controllers terminally damaged due to a major water pipe fracture in the roof void. This brought the plant to a standstill.
Solution: While the pipework was being repaired, a Procon engineer collected 15 amplifiers from its northern depot and travelled to the production site where he was met by a team of site engineers.
Outcome: The replacement amplifiers were installed during the night by the Procon Engineer resulting in full production being restored by the time the morning shift arrived.
Client – Major Coal-Fired Power Station
Location – Hong Kong
Application – Replacement Boiler Leak Detection System
Calibration and Commissioning of a Boiler Leak Detection System in Far Eastern Power Station
Problem: One of the largest coal-fired power stations in Hong Kong hasn’t had it’s Leak Detection systems upgraded since they were installed in the 1980s and couldn’t afford to lose the supply of power to Kowloon and the New Territories.
Solution: Procon was appointed to upgrade the existing Leak Detection systems on its six boilers. The work is being phased over several years commencing in 2018 when the original equipment on the first of the six boilers was replaced with the latest Procon T96 system. All the boiler side sensors and head amplifiers were replaced and special interface enclosures were supplied so that the existing cabling could be retained.
Outcome: The start of the calibration/commissioning of the systems is being undertaken during 2019. A Procon Service Engineer is providing support and on-site training during commissioning of the first two boilers. This will enable Castle Peak’s own engineers to carry out the commissioning work on the remaining four boilers themselves.
Procon Engineering provides Boiler Steam Leak Detection Systems for Power Stations all over the world. These systems provide early warning of any potential boiler tube leaks and prevent expensive secondary damage and unscheduled outages.