Packaging manufacturer invests in lean, green, gravimetric dosing machine

Polythene packaging manufacturer, Duo Plastics UK, states it has made a major investment in lean manufacturing by purchasing two Gravimetric dosing systems from supplier, Plast-Control. The machines will reportedly improve the quality and consistency of film produced, as well as minimising waste and energy consumption.

Managing Director of Duo, David Brimelow, commented: “Very few companies in the UK have these machines, which make use of the latest manufacturing technology. They represent a significant investment for us and a major step in our lean manufacturing programme, which we’ve been implementing over the past three years.

“The Plast-Control system will give us a vital competitive advantage by allowing us to improve the quality and consistency of our product even further, whilst reducing manufacturing cost and energy consumption.”

By weighing the raw materials of polythene as they are dosed directly into extruder, gravimetric dosing virtually eliminates the need for ‘pre-mixing’ the process traditionally used in polythene manufacturing, and allows blending to be more accurate. The combination of Gravimetric dosing with Gravimetric nominal thickness control improves both the quality and consistency of the film produced and reduces scrap levels, which in turn cuts both the amount of virgin material needed and the amount of energy used in the manufacturing process.

The technology allows the ability to change raw material specification quickly, something that is essential at Duo, explained Mr Brimelow.

“As a bespoke packaging manufacturer, each order may require different specifications which obviously require different ratios of raw materials, so being able to change the material specification speedily and with a minimum of waste is incredibly useful for us, particularly when we pride ourselves on being able to manufacture products for clients at short notice.” 

Mike Calderbank of Plast-Control commented: “We’ve worked with Duo for a number of years and we are delighted that they have chosen to invest in gravimetric dosing and extruder control. The system is highly modular and easily expandable, so it is a very flexible option if Duo’s operational needs were to change in the future.”

Duo also expects to benefit from lower maintenance and operating costs compared to standard DC motor technology.