Case Study: Enhancing Efficiency in Mineral Grading for a Leading Manufacturer

Overview

Precision and efficiency in the mineral industry are of critical importance in satisfying the varied demands of customers. One of our esteemed clients, a renowned manufacturer of various calcined minerals and industrial absorbents in South Africa, faced significant challenges in grading their products. Available from a vast number of customers with varied size requirements in granules, they looked for a robust solution for the optimization of their production chain. This case study examines how Galaxy Sivtek delivered an innovative solution to address their requirements.

Requirements & Challenges

The client reached out to Galaxy Sivtek with needs and challenges:

Client’s Requirements:

1. Efficient Grading: The client’s need was the grading of their calcined minerals as well as industrial absorbents under 5 different sizes that could be done by one machine with “highest efficiency” and “maximum capacity.
2. Reduced Human Dependency: 4-5 manpower are needed at one time; therefore, there is a huge human dependency.
3. Minimized Product Loss: Handling and spilling the products manually was the reason for significant product loss, reducing overall productivity.

Client’s Goals:

1. Minimize Manpower Usage: Reduce the reliance on manual labour to streamline operations.
2. Achieve Zero Spillage: Eliminate product loss due to handling and spillage.
3. High Accuracy in Gradation: Ensure precise grading to meet diverse customer requirements.

Challenges Faced:

The initial objective was to accomplish the correct five-size separation in one go. Earlier, the client was using a single deck vibro screen, resulting in multiple screenings to get grades. Thus, increased manual handling and time made production efficiency worse.

Galaxy Sivtek Solution

Galaxy Sivtek performed a valuable process analysis on the client’s process and recommended the 60” Four Deck Sifter. As this is an advanced sifting solution, it was developed to meet the client’s particular problems and needs.

Key Features of the Solution:

1. Five Separations in One Unit: The 60” four-deck sifter allowed the client to sort materials into five different sizes in a single operation, greatly reducing the necessity for multiple screening processes.
2. Time and Labor Efficiency: By streamlining the grading process into one machine, the solution decreased manual handling and lowered the reliance on labour.
3. Enhanced Accuracy and Zero Spillage: The latest design of the sifter will hold better on gradation, and there will not be a case of loss due to spillage.

Results

The introduction of the 60″ four-deck sifter improved the performance of the client’s operations:

1. Increased Production Efficiency: The client saw a notable decrease in manufacturing time, resulting in increased production volumes.
2. Reduced Labor Costs: The dependence on manual labour decreased, resulting in cost savings and a more efficient use of resources.
3. Improved Product Quality: Precise grading enabled the client to meet diverse customer demands with top-quality products.

Client Feedback and Testimonial

The customer has expressed utter satisfaction with the Galaxy Sivtek solution. They have noted a much greater increase in efficiency, accuracy, and productivity. Within three months of the first installation, the client placed orders for two more machines, underscoring their confidence in Galaxy Sivtek’s solutions.

Conclusion

This case study highlights how Galaxy Sivtek’s innovative sifting solutions can address complex challenges in the mineral industry. Through a custom solution that optimizes efficiency, lowers dependence on labour, and guarantees a high degree of accuracy, Galaxy Sivtek can help clients reach their operational objectives.