Replacement Polymer Weigh Conveyor for Cooper Tire’s

 

 

 

 

 

 

 

 

C J Waterhouse Company have supplied Cooper Tire’s with a replacement polymer weigh conveyor.  The conveyor is specifically designed for the weighing of block polymer and sheet fed rubbers .  The weigh frame is mounted on 4 load cells which reside upon independent anti-vibration mountings.

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Semi-Automatic Bagging System for UK Rubber Compounder – October 2017

 

 

 

 

 

 

 

 

 

 

 

 

Semi-automatic bagging system supplied to UK Rubber Compounder.  The system is designed to accept bulk FIBC bags of Carbon Black material and automatically dispense it into low melt (EVA) bags to the required weight.  Bags are manually positioned within the bag clamp, the required weight is set using the door mounted HMI before being  commencement of the automated weighing sequence.  The bagging head is fitted with a pneumatic shut off valve for added accuracy and reduction of feeder over-run .

Once the weighment is completed the bag is removed and positioned upon the manual seal station.

For higher throughputs an automated bag placing and removal system can be incorporated or for fully automatic operation using multiple source materials our Smart Cart system can be utilised.

 

 

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Household waste handling conveyor – October 2017

C J Waterhouse Company were initially contacted back in 2014 by Loesche UK, a specialist engineering company working within the power generation industries.  Their initial contact was made with respect to C J Waterhouse Co.  supplying a quotation for an automated handling system for recycleble polymer & fibre household waste materials.  The system initially comprised of multiple bulk storage vessels supplying a number of milling machines via a network of conveying and elevation systems.

 

 

 

 

 

Due to the project complexity and size C J Waterhouse have provided periodic engineering support and materials handling consultancy to Loesche to aid in their tender process.

As part of the system design the raw material must be conveyed from a single source to multiple milling lines using simple mechanical conveying systems.  C J Waterhouse were asked to design and build a prototype conveying system to perform this operation.

Following a number of preliminary design concepts a plough conveyor system developed where by material could be collected from the feed conveyor at multiple opposing locations via pneumatically operated swinging ploughs.

 

 

 

 

 

 

 

Using this system material can be fed out to a single destination (line 4 in above diagram) or to multiple destinations at a reduced rate (lines 1 and 4 in diagram below).  Each of the plough gates comprise of the main plough which incorporates a vertically mounted belt conveyor to actively move material off the feed conveyor and a pre plough system swinging in opposition to the main plough.  This pre-plough allows the discharge opening to be increased for material flow purposes (as shown above) but can also move into the product stream to reduce the potential of material trapping when the main plough conveyor is closing.

 

 

 

 

 

 

 

Following the concept design CJ Waterhouse Co. have been asked to manufacture a prototype machine to prove the theory before incorporating it into the overall system design.  So as to fully evaluate the conveyor system C J Waterhouse built a test rig which included two automated opposing gates (one with belt conveyor and one without) and a secondary manual gate further down the conveyor.  One pre-plough was automated and the second was manually operated.  Incorporating different types of ploughs and operation methods allowed each system to be fully evaluated prior to deciding upon the final design.

The trials of the system we conducted earlier this month and proved to be extreamly successful with the powered belt plough with automated pre-plough being the preferred solution.

 

 

 

 

 

 

 

 

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Batch-off Unit Control Upgrade for UK Rubber Compounder – May 2017

C J Waterhouse have been awarded the contract to upgrade the sequence control and data presentation systems for a UK Rubber Compounders batch off unit .  The VMI batch-off machine has been in operation at the site for many years and still functions well, however the  automation system controlling it and associated data presentation was dated and in need of replacement.

C J Waterhouse company were approached to develop a new control system for the machine based on their specific knowledge of the rubber compounding industry and specifically the machine in question.

The replacement control system comprised of a new panel incorporation Mitsubishi PLC and HMI hardware running bespoke in-house designed software not only to provide the machine sequence control but also to give  graphical representation and data presentation to the operator.

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Bespoke Machine Solution for UK refractory – August 2016

Bespoke FIBC discharge

C J Waterhouse Company was initially approached by a large UK refractory component manufacturer to solve a specific materials handling problem that they have experienced for many years.   The problem was related to the handling and dispersion of a specific  blended material.  This material has a very high bulk density of over 2500Kg/m3 and readily compacts under its own weight due to the blend consisting of a variety of particle sizes.  The downstream process requires that this material be delivered to the mould station in small batches of approximately 2Kg as a fine, well blended material.

Previous methods for completing this process involved; FIBC discharging, sieving, re-blending and dosing. This process was carried out by a series of individual standard machines which is time consuming, costly and ineffective.

With their experience in bespoke machine design, C J Waterhouse co was commissioned to produce a machine to overcome and simplify the existing process.

The product design phase studied all the individual processes and sought to combine them into a single integrated machine.

 

 

The resultant machine comprises of four elements and is designed to accept a bulk bag of material and dispense a sieved, blended product to the operator.

SECTION A – BULK BAG DISCHARGING

This section is generally the same as our standard powder bulk bag discharge station with the addition of a number of internal deflector plates to provide a specific material flow pattern and reduce pressure loading on the machine section below.

A central inverted ‘V’ and two angled diverter plates on each side channel material towards the centre of the chamber and create two voids towards the outer edge.

This material flow pattern is created to deliver material to the required point of the downstream machine component whilst alleviating pressure and therefore reducing potential material compaction.

 

SECTION B – MATERIAL SIEVING

As vibratory sieving can separate particle sizes and cause blockages, especially with compacted materials, C J Waterhouse company looked to design an integrated solution incorporating a mechanical sieving operation.

The process is performed using two counter rotating drums with scraper paddles and a pair or removable curved sieve plates.  These drums occupy the majority of the chamber and therefore only allow a small amount of material to the screen plates.  As the drums rotate the scrappers collect material from the centre of the chamber and sweep it over the face of the screen plate

 

 

SECTION C – RE-BLENDING

This section resides beneath the sieve plates and acts to re-homogenise the material to eliminate any potential particle separation that may occur during the sieving process.

Two counter rotating shafts with blending fingers gently mix the material continuously.  In addition to this blending action the fingers also promote the flow of material to the downstream feeder and eliminate bridging within the compartment cavity.

 

 

SECTION D – MATERIAL DOSING

The final section of the machine is a ‘U’ trough screw feeder which delivers the sieved and blended material to the downstream process at a continuous rate via push button operation.

 

 

 

 

 

Trials of the machine at the clients  manufacturing site have proved extremely successful with the resultant material falling well within the required tolerance for particle size distribution.


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Small But Perfect Packs for S&B Herba Foods – September 2014

UP Mini-001The Spanish owned rice milling company S&B Herba Foods have two UK processing sites both capable of milling, processing and packing a variety of rice types for the UK and overseas markets.

Their central site located in Fulbourne, Cambridgeshire processes up to 300 tonnes per day, the majority of which is packed into 10+Kg bags.  Packing of rice into 10-20Kg bags is currently done using an Umbra Packaging UP1000 automated packing and palletisation line.

Recent trends have seen an increase in demand for smaller pack sizes, S&B Herba Foods therefore made the decision in 2014 to look into adding a second packing line to operate alongside their existing UP1000 to produce pack sizes from 1Kg to 10Kg..

Over the past year S&B Herba Foods have investigated currently available machines capable of handling a wide variety of pre-made small size bags including; gusseted, zip lock and doypack.

CJ Waterhouse Company, acting as the UK agent for Umbra Packaging since January 2014 have been closely involved with the project since its onset.  During the tender process CJ Waterhouse have provided local engineering and commercial support to S&B Herba and have helped with the demonstration of Umbra’s capabilities including overseas visits to their manufacture facility in Perugia, Italy.

S&B Herba Foods have now made the decision to purchase an Umbra packaging UP Mini packing line and UPR palletisation line.  The machine will provide automated packing of rice into a variety of bag types from 1-10Kg with both heat sealing and stitching closure systems at speeds of up to 2000 bags per hour.

The decision to purchase the Umbra machine over its competitors was made not only due to the performance of the UP Mini and the customers knowledge of the UP1000 model but also because of the local engineering support offered by CJ Waterhouse Company both during the purchase procedure and for ongoing service and maintenance works.

In addition to their assistance in the supply of the Umbra packaging line CJ Waterhouse have also been awarded the contract to design, supply and install the material feed system required for the new packing line.

The existing system feeds rice to the downstream equipment from 8 internal and 3 external silos via a series of conveyors, elevators and routing valves.  The new feed system will permit the simultaneous routing of rice to both packing lines using a combination of new and existing conveying equipment.

Both the Feed system and packing lines are currently at design phase with scheduled delivery to S&B Herba Foods at the end of 2015 and start up in January 2016.

For information on materials handling, weighing and process control systems offered by CJ Waterhouse  or Umbra Packaging’s range of equipment please do not hesitate to contact us.

Tel: 01636 610792   –   Email: sales@cjwaterhouse.co.uk   –   Web: www.cjwaterhouse.co.uk

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CJ Waterhouse Complete Mixer Feed System Installation at TARRC – July 2015

C J Waterhouse company have just completed the installation of a new automated mixer feed system for TARRC’s rubber compound research facility in Hertfordshire.  The system is designed to permit the offline weighing of compound batches and automated introduction into the mixer.

The batch ingredients are loaded into a transfer container which is then electronically tagged and transferred to the mixer.  When the transfer container arrives at the mixer the electronic (RF) tag is read and the operator is prompted to place the ingredients in the respective feed stations prior to commencing the mix sequence.  From this point the mixer can be operated manually using the SCADA or panel controls or put into automatic mode which will inject the ingredients and run through the mix sequence in accordance with the pre-specified recipe.

The weighing sequence, recipe handling and production scheduling is provided by our KS-Series production control software operating upon a Windows 8 platform and physical plant control is via a Mitsubishi Q-Series PLC

TARRC panels TARRC feed system

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3rd Generation Smart Cart Minor Ingredients System – October 2014

 

CJ waterhouse company have recently completed the installation of their third generation of Smart Cart systems at a UK custom compounders.

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Introduction
The semi-automatic and subsequent fully automatic minor ingredient systems were first developed over 10 years ago to overcome the negative constraints associated with more traditional systems where feeders are positioned around a static central weigh vessel. Such systems can suffer from lower accuracy, contamination, slow throughput and limited or no expansion possibilities.

Smart Cart Philosophy
The Smart Cart overcomes these issues by moving individual weigh carriages with pre-loaded receptacles (bag, bucket etc.) to the feeder stations around a monorail track. In this way the raw ingredients are weighed directly into the container on the carriage from the feed station therefore eliminating cross contamination.

Each carriage incorporated a high accuracy force motion platform scale to give typical weighing accuracies on minor ingredients of +/- 3g or better. As the smart cart carriages run upon a continuous monorail track numerous carriages can be added to increase overall throughput.  This system can also reduce / eliminate costly downtime due to weigher malfunctions as each weigh carriage can be simply removed from the track for maintenance or repairs.  The remaining carriages will then continue the weighing operations or an additional spare carriage can be added to maintain the same throughput.

It is also possible due to the unique philosophy of the Smart cart to incorporate additional feed stations and track extensions at a later date if expansion should be required.

The fully automatic version of the Smart Cart manufactures bags on-line before loading them onto the carriage clamp system. The weigh carriage then proceeds around the track system collecting the required ingredients in accordance with the pre-specified recipe.  On completion of the batch the bag is printed with a barcode or batch information before being sealed and ejected onto the downstream accumulation system.  Semi & fully automatic systems for bucket, container and bulk IBC can also be supplied although the latter would normally be located upon a linear track.

System Developments
The Smart Cart is now into its 3rd generation (G3), previous developments from G1 to G2 have included; increased speed / throughput, packet separation and dosing systems, variable bag length and control / automation improvements.

CJ waterhouse Co Ltd have now completed the installation of the G3 version of the Smart Cart for supply to the UK custom compounding company Berwin Polymer processing Group in Lydney. Berwin’s Manchester plant first introduced the prototype semi-automatic system in 2002 and upgraded to the fully automatic system in 2004.  The automatic system has now been in operation for over 10 years.  Following Berwin’s recent expansion to the additional site in Lydney they are now looking to increase their minor ingredients output at the new site by the acquisition of a second Smart cart System.

The Smart cart G3 has two main technological advancements over the previous version. The first being the use of wireless communications between the carriages and the main PLC control panel.  A Mitsubishi Bluetooth system will be utilised to send / receive recipe and data information to and from the carriages.  Previous versions used a fixed copper conductor running around the track perimeter and pickup points on the carriages.  The bus conductor system is still utilised for carriage power distribution.

The second improvement is the addition of a radio frequency tag (RFT) positioning system. The G2 Smart Cart utilised a specific pattern of proximity sensors to identify each individual feeder station.  The carriage would stop at the required feeder station and look for a specific layout of sensor activation to check its position before commencing material dosing.  The G3 version weigh carriages now have RFT readers on-board and each feeder station has a programmable RFT fitted.  When the carriage stops at the feeder station it reads the identification tag to confirm the correct location.  This system is less susceptible to positional errors and reduces complexity and installation costs.

In summary the Smart cart provides a fully automated minor ingredients weighing system with the following features:

High Accuracy
High Throughput
Contamination Free
Expandable & Configurable
Full data logging & batch report
Automatic scheduling

 

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CJW takes on UK agency for Comav Italy – Industrial valves & automated sack – October 2014 emptying

C J Waterhouse have been appointed as the UK agent / partner company for Comav Srl.  Comav manufacture a range of industrial valves including, slide, rotary and divertor.  In addition to their valves Comav also manufacture a range of materials handling equipment including automated sack emptying and de-palletisation systems together with bailing presses and other bespoke solutions.

For more information on Comav’s product range please visit www.comav-srl.co or contact CJ Waterhouse on +44(0) 1636 610792.

comav-general-01

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CJW contracted to supply Control System for TARRC – October 2014

CJ Waterhouse company limited, in conjunction with Carters of Rochdale are contracted to supply a new control system and semi automatic batch weighing system for TARRC’s rubber research production facility in Hertfordshire.

The system will comprise of a new 50L internal mixer with semi automatic feed of powders and liquids.  The control and recipe handling system will utilise CJ Waterhouse’s Ks series production control software and Mitsubishi PLC and SCADA system.

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