Optimization of ESD plastic production
In a context where efficiency and sustainability have become priorities for the electronics industry, a major player in eastern France is innovating by transforming its ESD plastics handling processes. Thanks to the installation of an industrial marquee and automated silos, the company is reducing material losses and improving resource management, while minimising its environmental impact. Discover how this pioneering solution reinforces the company’s ecological and operational commitment, while optimising employee comfort and safety.
Project background
Our client, based in eastern France, is a recognised leader in the production of ESD plastics (Electrostatic Discharge) and flexible and rigid anti-static packaging. These innovative solutions are specially designed to prevent electrostatic discharge, thus offering optimal protection for sensitive electronic components.
With its expertise in anti-static materials, its commitment to certified quality and its technological innovation, our client meets the specific needs of the electronics and technology industries. As a key player in national and international markets, it stands out for its tailor-made solutions, perfectly adapted to the unique requirements of each customer.
The customer’s problem
Our customer receives their raw material in rolls. These strips are cut to size and then thermoformed on specific moulds. During the thermoforming process, excess plastic and parts that are poorly formed or rejected during quality control are systematically collected for recycling. This waste is crushed and transformed into a new raw material in the form of sheets, ready to be reused.
During the recovery stage for the crushed plastic, the big bags are handled using forklift trucks. However, due to the high production rates, it is not uncommon for crushed plastic to scatter on the floor, particularly outdoors. This loss of material is not only wasteful, but can also cause significant environmental and logistical constraints.
The handling solution provided by Syvrac
Our client chose to expand its infrastructure by adding an industrial marquee to house all of the storage silos. Among these installations, a 61 m³ flexible silo was specially designed to perfectly match the factory’s production capacity.
The ground product is transported directly by blower to the main silo, ensuring fast and safe transfer of materials. An automatic switching system has been integrated to prevent potential PVC contamination. In the event of contamination, the materials can be diverted and drained into a big bag positioned on an existing structure, thus limiting the impact on production. Although contamination is rare, it can occur if unwanted objects (such as a broom, notepad or pencil) accidentally fall onto the conveyor belt. This solution ensures the safety of materials and maintains a reliable, high-quality production process.
The main silo, measuring 4000 x 4000 x 7000 mm, consists of a 120 x 120 mm tubular welded structure on 3 levels. The canvas, equipped with the patented EasyVrac® system, allows for quick assembly and disassembly if necessary. From the storage silo, a vibrating bottom ensures a smooth and regular flow of crushed plastics to the two transfer screws. This system guarantees efficient material transport while preventing blockages in the silo.
Details of the proposed solution
To facilitate screw maintenance, a guillotine valve, positioned on the vibrating bottom and controlled by a 0.37 kW electromechanical actuator, isolates the storage silo without requiring complete emptying of the materials stored in it.
The independent gantry
- To avoid disrupting weighing due to the weight of the transfer screw motor resting on the weighing silos, an independent structure has been installed. This solution allows the weighing silos to be covered without exerting physical stress on them, thus preserving their accuracy.
- The structure is equipped with a standardised ladder and a secure platform, providing operators with easy and safe access to the screw motor for any maintenance work.
The weighing silos
- These silos are simple to operate. Each silo is equipped with a 5-tonne load cell under each foot, with an anti-lift device.
- With a capacity of 24 m³, they receive the product alternately via the main screw of the 61 m³ storage silo. A flap valve allows this orientation from weighing silo 1 to weighing silo 2.
How weighing silos work
- While one silo is dedicated to conveying the product to the injection presses, the other silo can simply be filled. A maximum weight safety feature, managed by load cells, prevents the silos from being overfilled, thus ensuring optimal stock management and continuity of production.
- Underneath the silos, a vibrating suction bottom allows production to call up the product on demand. This system guarantees a smooth and regular supply of materials to the injection moulding machines, thus avoiding production interruptions.
- A switch allows the operator to vacuum the silo that is not being filled with product. This operational flexibility ensures efficient use of resources and increased responsiveness to production needs.
The advantages of the Syvrac solution
Full automation eliminates the need for manual handling of big bags, which reduces noise pollution due to the absence of forklift trucks. This solution ensures optimised and secure storage of materials, minimises the risk of contamination and dispersion of plastic granules, and guarantees continuity of production thanks to weighing silos. This solution also improves comfort for employees and local residents, while having a positive environmental impact that limits waste and optimises production processes.
A positive environmental impact should also be highlighted: plastic granules are no longer scattered on the ground, reducing the risk of them being carried by rainwater into ditches and natural environments.
Thanks to the installation of a 61 m³ storage silo under an industrial marquee, the company has significantly reduced the handling of big bags, thereby reducing nuisance and optimising its processes. Our client now has access to precise quantities of shredded plastic weights, enabling more efficient and sustainable resource management.
This project, scheduled for installation in March-April 2025, promises to enhance the company’s operational efficiency and environmental commitment.