News & Updates

September 16, 2013

Compound Formulation System

SG Systems ground breaking Compound Formulation System helps eliminate inaccurately weighed batches leading to reduces material giveaway.

Squeezed by rising commodity cost and price conscious consumers, pvc, plastic & rubber compounders and other chemical manufacturers are examining their processes to minimize waste and inefficiency.

Compound Formulation System

Compound Formulation System

By avoiding operator error with advanced batch and lot tracking systems, some of the most proactive producers are eliminating “out of specification” batches to save from 2-6% on raw material cost and are typically achieving a return on investment (ROI) within 3-6 months.

Today’s operators and more prone to making mistakes on the plant floor, especially when temporary labor is used or less well trained operators are employed. When operators over or under scale, improperly set bulk dispensing equipment, forget to hand add an ingredient, or mix the batch for the wrong length of time, the batch can become a total loss. These sorts of problems can result in unnecessary scrap, inventory losses, and inventory shortages that stop production, and can cost significant amounts of money and purchasing problems.

It is particularly difficult for management to troubleshoot problems on the plant floor when operators are asked to create paper records of production operations. These records are usually inaccurate, not just because operators must interrupt their other tasks to create them, but simply because of human nature and a reluctance to create records in real time.

Compound Formulation System – Eliminating operator error

Helping to reduce waste, troubleshoot more effectively, and provide full lot traceability, an advanced batch and lot-tracking system called SG Compound Formulation System is available from SG Systems – a Dallas, TX-based leader in cost effective batch control, lot traceability and production safety solutions.

SG Compound Formulation System is a personal computer-based automation solution that can be interfaced to PLC based compound control systems on the production floor. It is based on the premise that the only way to prevent operators from making mistakes is to confirm and verify everything they pre-scale and add into the mixers, thereby removing their ability to deviate from the set recipe. With the product installed, operators cannot make a batch that does not meet the recipe specification, in terms of required compound proportions, as well as mixing time, speed, and mix temperature.

After a company loads their Compound Formulations into the product’s database, the formulations are sent to control stations on the production floor as needed to meet daily

Ingredient Weighing Scale

Ingredient Weighing Scale

production schedules.  It is now more common for SG Systems to draw data from existing ERP and Cost Accounting Systems to eliminate double handling of data.

The Compound Formulation System software then prompts the operator step by step through the formulation on a display at the control station, which is can be connected to the mixer, necessary scales, temperature probes, and other equipment.

For the minor and micro compounds which are hand weighed or counted (non-weighed), touch screens connect to scales and balances, label printers and scanners to allow the Compound Formulation to be weighed within target zone, enforcing +/- tolerance levels to ensure accuracy.

Compound Formulation System – Lot & Batch Traceability

Lot tracking for raw material traceability is also addressed by the SG Compound Formulation System Software. This is important for production safety in the event of a product recall (often 10-15 years in the plastics industry). The Compound Formulation System gives manufacturers the tools to track raw material lots to specific batches, and to quickly identify other batches made with common lot numbers. Batch numbers created by the mixer can be automatically passed through to the end of line terminal (designed to connect to label printers, inkjet coders and other identification systems) to create a link between the mix and the finished product if required.  This tracking number is then tied to the shipping operation to create complete traceability.

The SG Compound Formulation System is currently used by Compound, Plastics and Chemical companies such as GE Plastics, Cooper Avon Tires, Opticolor, Kamatics, Shell Oil, Esso Lubricants, Advanced Composites.

Over 2000 worldwide locations depend on SG Systems for Compound Formulation control.

If you would like to know more about SG Systems, please feel free to contact our corporate office (214) 819-9570.

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