Modernisation and improved operational efficiency

The client, a leading brand and a major producer of food products in India, was using extensive manpower for day-to-day activities. Blending of different grades of grains and packaging them for sale was time-consuming. It was labour-intensive and productivity was low.

Project Scope

At the outset, the processing of grains required more labour, and the client was despatching their finished product in higher number of trucks per day. Modern Sheller Industries came up with the process automation based on their requirement to improve the operational efficiency of the business. We offered a comprehensive turnkey solution to implement the required upgrade without any impact on the client’s day-to-day operations. The proposed modernisation project involved automation across multiple aspects to improve efficiency. The scope of Modern Sheller Industries included developing a custom 3D solution design based on the client’s inputs.

Solution

The proposed solution involved rectangular silos, trough-belt conveyors, Z-type pendulum bucket elevators, working platforms, ladders, and three input hoppers handling the three different grades of the product, which were earlier stored in individual silos, each of which involved space.

Our engineers created an efficient storage design using hoppers to store each grade of grain onto a feeder conveyor at controlled intervals based on the required blend. Z-type conveyors move the grains to a cleaning vibrator for blending.

The Z-type pendulum bucket elevator avoids breakage in the product, and the feeding & discharge system prevents any wastage or spillage. The drawers under the lower horizontal section of Z-type bucket elevator can be pulled out to enable easy cleaning. The different grades of grain are blended into homogenous pellets which are then fed into a hopper with a higher holding capacity. The final material is packaged in bags using an automatic bagging system and is moved onto a double side truck loader for final despatch to trucks.

Benefits

The ROI and long term benefits would justify the investment required. As a direct result of the solution implemented by Modern Sheller, the client was able to reduce the manpower involved in moving heavy loads. Additionally, the mechanised handling with automation led to reduced handling costs. This also resulted in increased efficiency and thereby increased production for better sales volume. The saved space could be used for further expansion in the future.

In this project, Modern Sheller Industries provided single-window, end-to-end project management solutions from concept to commissioning, including design, engineering, manufacturing, erection and commissioning, followed by lifecycle support for sustained high performance.