Optimizing Process and System

of Auxiliary Machine to Zero Defect Effect

Optimizing Process and System

of Auxiliary Machine to Zero Defect Effect
ZERO DEFECT
LOST TIME
DOWN TIME
COST EFFICIENCY

Optimizing Process and System

of Auxiliary Machine to Zero Defect Effect
MECHANICAL
ELECTRICAL
HUMAN
MATERIAL
ENVIRONMENT

Material and Process Identification

1. Properties of Plastic Material
a. Hygroscopic or Non
b. Bulk Density
c. Moisture Content
d. Drying Time
e. Drying Temperature
2. Output/Production Capacity
Total production capacity to calculate of drying and system design.
3. Production Process
Kind of production process working;
a. Injection / Extrusion
b. Blow/Stretch Process
c. Coating Treatment
4. Close Loop Design System
d. Material Handling
e. Close Loop Design
5. System Design
f. Injection / Extrusion
g. Blow / Coating Process

Root Cause Analysis

Problem Found

Cause

Cause Analyzing

Fish Eye

Material Identification

Porosity
Lenses in Films

Problem Solving

High Moisture Content

of plastic material

Gassing
Silver Streaks
Black Dot

Dust Contamination

Metal Spot

Metal Contamination

a. Incorrectly of drying calculation

capacity.
b. Drying not working properly
c. Incorrectly of system design

1.
2.
3.
4.
5.

a. Virgin raw material supplied

b. Granulating/recycle process
produce of high dust contain.
c. contains of dust

Recycling Handling
1. Adding for dust cyclone features
2. Dust separating system
3. Regular maintenance for
granulator

Some of metal substance

contamination

Properties of Plastic Material

Output/Production Capacity
Production Process
Close Loop Design System
System Design

Material Handling
1. Adding for electromagnetic metal
detector/separator
2. Controlling of material handling

Sampling
Porosity

Fish Eye (Bubble/Blank Spot) or Black/Dust Spot

Sampling
Gassing/Fogging

Metal Spot

Sampling
No

Result

Moisture Content

Remark

Moisture :
1

1.A : 0,040%
1.B : 0,012%

Unqualified

Moisture :
2

2.A : 0,052%
2.B : 0,024%

Unqualified

Sampling

Moisture :
3

3.A : 0,130%
3.B : 0,136%

Unqualified

Moisture :

4.A : 0,186%
4.B : 0,243%
4.C : 0,199%

Unqualified

Material and Process Identification Flow

Material Identification

Hygroscopic

Properties of Plastic Material

Bulk Density

Output/Production Capacity

Drying Time

Drying model

Drying/Hopper Capacity

Recycle
Ratio of Mixing
Moisture Content

System Design

Production Process

Moisture content
allowed

Dehumidifying Model

Close Loop Design System

Material Handling
Close Loop Process
Additive Melting Point

System Design

Blow Stretch

Coloring Process / Additive

Coating Treatment

Coating Treatment

Accuracy of Ratio

Lead Time

Material Processing Flow

Process
Output Quality
(Quality Control)

Coating Treatment

Raw Material
Virgin/Recycle

De dusting /
Mixing

Granulating /
Recycling

Drying &
Dehumidifying

Injection
Extrusion
Blow Molding

Not Good NG
Reject

Output Quality
(Quality Control)

Not Good NG
Reject

OK

Waste

OK

Factors That Affect to Zero Defect Target

1.

Environments
Temperature
Relative Humidity (RH)

2.

Kind of Material
Hydroscopic Material
Hydroscopic materials have an affinity for water and are sensitive to high relative humidity

Hygroscopic Material
Plastic materials that absorb moisture from the air

3.

Material Properties
Moisture Content;
Before Drying
After Drying
Target Moisture
Drying Time, Drying Temperature, Bulk Density

4.

Ratio
Recycle / Virgin / Master batch / Additive

Factors That Affect to Zero Defect Target

5.

Hopper Capacity
The related of material properties with hopper capacity
Output Capacity (Kg/hr)
Formula:
Bulk Density (Kg/L)
Drying Time (hr)
HC = ((C x DT)/BD)/ES
Empty Space (15 ~ 20%)

6.

Flow

When used for Per form or injection molding, the unit drying air reference value needed for
PET is 1.7~2.5Nm/hr-kg; when used for extrusion molding, the corresponding value is 1.2Nm/hrkg. In fact, since values from the raw material suppliers are often various, the specific values is
necessary for reference.
The related parameter for air flow calculation;
Bulk Density
Distance
System Design (piping, conveying, etc)
Hopper Capacity

Factors That Affect to Zero Defect Target

7.

Kind of Dehumidifier Type

Molecular Sieve
Silica Gel
Honeycomb
UV

8.

System Handling and Maintenance

Close Loop System Design
Standard Operational Procedure
Standby Procedure
Maintenance

Potential Lost Efficiency Calculation

Calculation for Potential Lost Efficiency:
Study Case:
-Material
-Capacity
-Bulk Density
-Drying Time

:
:
:
:

PET
1000 Kg/day
0.85 Kg/L
6 Hours

Comparable product:
a. SHINI Econo Hopper Dryer, type SHD-25T and SHD-50T
b. SHINI Euro Hopper Dryer, type SHD-40U and SHD-80U
c. SHINI All In One Compact Dryer, type SCD-40U/30H and SCD-80U/50H
d. SHINI Separate Vacuum Loader, type SAL-800G
Target of calculation:
a. Electricity Efficiency
b. Waste of Product
c. Potential of Lost Cost Efficiency

Potential Lost Efficiency Calculation

Specification of Comparable Product:
Hopper Dryer

Auto Loader

Loading Capacity
(kg/hour)

Heater Power
(kW)

Blower Power
(kW)

Conveying
Capacity
(kg/hour)

Motor Power (kW)

SHD-25T

0,12

300

0,75

SHD-50T

3,9

0,12

300

0,75

SHD-40U

0,12

300

0,75

SHD-80U

3,9

0,12

300

0,75

Conveying
System

Drying system

Dehumidifying System

Loading Capacity
(kg/hour)

Process Heater
Power (kw)

Process Blower
Power (kw)

Conveying
Blower Power
(kw)

Regenerating
Heater Power
(kw)

Regenerating
Blower Power
(kw)

SCD-40U/30H

0,18

0,75

0,18

SCD-80U/30H

3,9

0,4

0,75

0,18

Potential Lost Efficiency Calculation

NG = 20%

NG = 10%

Econo Hopper Dryer

NG = 0%

Euro Hopper Dryer

All In One Compact Dryer

Product

Pre-Heating
SHD-25T

SHD-50T

SHD-40U
(Pre-Heating)

SHD-80U

SCD-40U/30H
(Pre-Heating)

SCD-80U/50H

Electricity
Cost (Yearly)

IDR
300.931.200

IDR
185.457.600

IDR
210.651.840

IDR
129.820.320

IDR
660.527.784

IDR
381.466.260

Electricity
Lost If Use
Pre-Heating
Reject/ NG

Total Lost

IDR

IDR
115.473.600

IDR

IDR
80.831.520

IDR
540.000.000

IDR

IDR
270.000.000

IDR
655.473.600

279.061.524

IDR

350.831.520

279.061.524

Note:
Waste material will be produce when using of Econo Hopper Dryer and Euro Hopper Dryer, we must add for additional
process for recycling, mixing, etc. So we need to spare of cost for recycling process.
For dehumidifying using, will be produce non-waste material, so will be optimized the production and reduce the
Electrical power.

Potential Lost Efficiency Calculation

Potential Lost (Material Waste Only)
Production Material 1Ton/day
Reject / NG

Potential Lost/ day

Potential Lost/ month

Potential Lost/ year

10%

IDR

750.000

IDR

22.500.000

IDR

270.000.000

15%

IDR

1.125.000

IDR

33.750.000

IDR

405.000.000

20%

IDR

1.500.000

IDR

45.000.000

IDR

540.000.000

25%

IDR

1.875.000

IDR

56.250.000

IDR

675.000.000

30%

IDR

2.250.000

IDR

67.500.000

IDR

810.000.000

35%

IDR

2.625.000

IDR

78.750.000

IDR

945.000.000

40%

IDR

3.000.000

IDR

90.000.000

IDR

1.080.000.000

45%

IDR

3.375.000

IDR

101.250.000

IDR

1.215.000.000

50%

IDR

3.750.000

IDR

112.500.000

IDR

1.350.000.000