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Return on Investment – The proof is in the pilot

Investment in new equipment brings an opportunity to rethink established ways of working. Involving Greaves consultants can bring tangible benefits. With our external perspective, we will often ask unexpected questions.  These help us to understand your wider business objectives. This approach can also pinpoint new opportunities for efficiency gains and savings all contributing to enhanced ROI.

People working together

Our customers invariably know their products, processes and markets better than anyone. They have often set out their goals and objectives at the outset of a project. However, different individuals may not be fully aware of the potential opportunities from the latest mixing technologies.

This is where Greaves engineers can contribute with their up-to-the-minute knowledge and application insight. Consequently, we know what works elsewhere and what doesn’t. By getting this teamwork right we aim to identify additional opportunities for even greater gains – resulting in increased ROI on our customers’ investment

“Having worked in the industry for many years, I still find every customer project brings fresh challenges and opportunities to come up with creative engineering solutions. The most satisfying aspect of my work is helping a customer find an effective way to run their production more efficiently – and prove it through a trial.”  Tim Neville, Technical Sales Manager

Once we have worked with a customer to specify a new project, the next step is to test. By trialling the proposed specification we can demonstrate the real-world performance that our customer can achieve from their new mixer.

Phase 1 Trials: Laboratory & Pilot Batch

Small-scale Laboratory Trials

Once the project team has agreed on the preferred solutions based on the customers’ objectives and the Greaves expertise, the next step is to bring together the products for mixing with the proposed mixing technology. As a first step, we can test the recommended solution in the Greaves MixLab. Customers are welcome to attend these tests if they wish. Once the processes are proven in principle, we can then scale up to pilot batch volumes. In most cases, these tests are ample to satisfy our client that our proposed solution will deliver the results they need.

Phase 2 Trials: Large batch/ Full-scale trials

Full-scale batch trials

In some cases, particularly where a major investment is involved, and even where the solution has been proved at pilot scale customers may need further validation in an extended trial on their own site.

To facilitate these situations, Greaves can offer high volume trial mixing systems.

Our aim is to deliver real-world effective mixing solutions that deliver significant and sustained benefit and value to our customers.

 

 

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Greaves Solution: Capacity Up 660%

Borregaard are an innovative additive producer servicing a wide range manufacturing industries including Construction, Agriculture, Animal Feed, Oil & Gas, Food and Pharmaceutical.

The single largest use for lignosulfonates is as plasticisers in making
concrete, blocks and bricks

Borregaard is the leading UK manufacturer and distributor of Lignosulphanates.

Lignosulphanates are widely used in construction products to increase manufacturing efficiency, reduce energy usage and improve product performance.

Project Brief:

Borregaard UK Production Manager, Chris Barrick takes up the story…

“To meet increased demand and to improve efficiencies, we needed to rapidly increase our production capacity and turned to Greaves for help. Our manufacturing process is very challenging as it includes the dispersion of a fine, hygroscopic powder in liquid.  Process time for large batches was often upwards of two days from start to finish and required a significant amount of operator input.”

Chris invited Greaves to study the companies existing production set-up and offer alternative solutions.

The Greaves Proposition...
Greaves technicians conducted a thorough process review and proposed a change in mixing technology using Borregaard’s existing process vessels. The next step was to perform small-scale trials in Greaves MixLab R&D centre. The trials confirmed the suitability of the new technology which gave Borregaard confidence to invest in Greaves full-scale solution.
The Results...

The first two Greaves mixers were installed in Borregaards existing 5000L & 24000L vessels and had an immediate impact on operations.

Chris Barrick continues: ” This has resulted in improved efficiencies for operators and production output.  We are now able to produce 5 times more product in our larger process and 10 times more product in our smaller process over the same period of time as previous methods of mixing technology had produced.

We are extremely pleased with the outcome and would like to thank the team at Greaves Mixers for helping us to achieve this significant step forward in our production efficiencies and capacity.”

Project Update...

The Borregaard parent company has been so pleased with the commercial success of this new technology that they have now made funds available for investment in 3 new vessels and mixers.

Greaves is delighted to work with Borregaard and its team and we look forward to assisting their future growth.

If you have an issue with mixing capacity and would like to talk to Greaves, please get in touch.