Manufacturer – 3Sigma
Product – Corn Starch
Case History # 114

Replacing a Troublesome Screw Feeder with
A GeoMate™ Loss-in-Weight Feeder
Extremely Low Feed Rates

3Sigma Replace Screw Feeder
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Background
A Southeastern Fortune 100 firm contacted us to replace an existing loss-in-weight feeding system featuring a screw feeder, due to yearly mechanical issues and expensive repairs. 

Existing Problem
-The customer had been using a Brabender Loss-in-Weight Screw feeder for a number of years.  Each year maintenance costs for the screw feeder would be in the thousands of dollars plus the extreme cost of downtime for a facility that is completely “sold out.”  Any downtime translates into huge profit losses.
-This screw feeder is the final pH adjustment before product goes to the client’s load out silos.  Any error in the screw feeders feed rate accuracy can be devastating.

The Solution
Based upon previous work with 3Sigma’s parent firm, Carolina Material Technologies, the customer asked us to review the Brabender Screw Feeder installation and offer a solution.  Their requirements were straight forward:
-Provide an accurate and reliable continuous loss-in-weight feeder system.
-The loss-in-weight feeder system must follow an input signal from downstream equipment to properly adjust the feed rate, hence the pH level, based upon the amount of product in process.
-Feed rate range of feeder 0.05 to 0.07 PPM.

To meet these requirements 3Sigma provided:
-A GeoMate™ loss-in-weight vibratory feeder system which consisted of a 4” GeoTray™, a platform scale and a LIW control system, in order to replace the troublesome screw feeder
-The GeoMate™ vibratory feeder is a mass flow system that operates with no moving parts.

Geomate Vibratory Feeder
Vibratory Feeder Batching Controller

Flexible Sleeve & Dust Sock




MassMate™ Mass Flow Hopper





GeoTray™ Feed Tray




Platform Scale

Loss-in-Weight Control with Manual Control

GeoMate™ Loss-in-Weight Vibratory Feeder 

Results
-The Loss-in-Weight Vibratory Feeder System was designed, built and delivered in 4 weeks to meet customer’s year end fiscal requirements.
-The Loss-in-Weight Vibratory Feeder System was installed in 2012. 
-To date the Loss-in-Weight Vibratory Feeder System has met all requirements without any downtime.

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