Background:

Our client Innovia Films required a high-accuracy weighing solution to improve the precision and traceability of their filling processes. Their existing tank setup needed an upgrade to improve operational effectiveness without requiring extensive modifications.

Challenge:

The primary challenge was integrating a weighing system into Innovia Films’ existing tank infrastructure without significant alterations. The solution needed to be precise, easy to install, and capable of integrating with their production and quality assurance (QA) systems.

Solution Provided by NWI Group:  To meet Innovia Films’ requirements, NWI Group supplied and installed a high-accuracy weighing system comprising the following components:

• PR6212 Low Profile Compact Load Cells with 6042 Series Mounting Kits: These load cells provided a low-profile, high-accuracy solution that seamlessly fit into the existing tank setup. Their compact design ensured easy installation without affecting the tank’s structure.
  
  
• Custom Adaptor Plates: NWI’s fabrication team designed and manufactured custom adaptor plates to eliminate the need for modifications to the existing tank. This allowed for a smooth and efficient retrofit installation.
  
  
• Maxxis 5 Process Indicator with Batching Software: The Maxxis 5 process indicator, equipped with batching software, was integrated into the system to enhance filling accuracy and improve traceability. The software facilitated precise control over the filling process, ensuring consistent and accurate measurements.
  
  
• Two Remote Weight Displays: To improve operational visibility, NWI Group installed two remote weight displays. These provided real-time weight information, enabling operators to monitor the filling process with greater clarity and accuracy.
  
  
• Data Integration with Customer’s System: The entire system was designed to transfer data seamlessly to Innovia Films’ production and QA systems. This integration provided enhanced visibility into site operations, allowing for improved quality control and efficiency.

Results & Benefits:

• Enhanced Accuracy:The PR6212 load cells and Maxxis 5 indicator warranted precise filling measurements, reducing errors and material wastage.
  
  
• Seamless Installation:The custom adaptor plates allowed for an easy retrofit without modifying the existing tank, minimising downtime and disruption.
  
  
• Improved Traceability & Visibility:The integrated software and remote displays provided operators and QA teams with real-time data, improving production monitoring and quality control.
  
  
• Operational Efficiency:With automated data transfer to the customer’s system, production insights became more accessible, facilitating better decision-making and operational improvements.

Conclusion:

NWI Group successfully delivered a tailored weighing solution that met Innovia Films’ requirements with minimal disruption to their existing infrastructure.

The integration of high-accuracy load cells, a robust process indicator, and remote displays improved filling precision, traceability, and operational visibility. This project exemplifies NWI Group’s commitment to providing innovative and efficient weighing solutions to industry leaders.

For more information about NWI Group’s custom Silo and Tank Weighing Solutions, contact us today.