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Technical Foundation of Waste Prevention
The vacuum conveying system's unique operational model - fully enclosed negative pressure - drives extreme material loss prevention. Where typical mechanical systems have operational poles that result in material loss, airborne dust, and stagnant dust build-up, ZRM systems have a fully sealed, closed-loop system that accurately controls the pressure of the material flow. This control allows for the loss of fewer than 0.5% of even the most precious materials in the system (previously a 5%-8% loss of materials was a standard loss in the industry). This component also prevents the loss of materials and dust environmental pollution by recapturing captured dust.
Working On A Practical Project
Zhongren Machinery has entered into a strategic cooperation with the largest soymilk powder OEM in China. We have implemented our first intelligent integrated vacuum pumping and screening system at their production site. We have demonstrated an application of our system in the reduction of material loss in production. Prior to our system, the OEM lost approximately 3% of their soymilk powder as it was transported via traditional screw conveyor. Loss of material was compounded by product absorbance of moisture and contamination, resulting in noncompliance. After the installation of our vacuum pumping system and with the implementation of closed system transport and automatic recycle material retrieval, the OEM reduced their daily loss to 0.3% and saved approximately 100 tons of raw materials each year. Added to the integrated screening and swinging mechanism was a vacuum pumping system and the operational function enhanced further material loss mitigation by eliminating manual transfer points. The project exemplifies custom engineered and manufactured vacuum pump systems, eliminating material loss in large-scale industrial production.
Zhongren Machinery's Vacuum Conveying System is the first to have international triple certifications on material recovery, and air tightness, and is the first Chinese company to meet the FDA and GMP standards and other international standards. Therefore, it provides the first authoritative international certification on technical standards to Chinese companies for complying with standardized production and reducing material waste.
Subsequent years of the forecast will capture a continuous drop in production waste, less industrial material waste, and increased economic production of a growing target market. Additionally, decreases in industrial material losses will an increased focus in the industry toward resource recycling. Closed conveying technology is a promoted technology listed by the NDRC in the National Encouraged Resource Conservation and Environmental Protection Technologies. Nationally, Closed Converging Systems have a researched validated offering of Environmental Protection and Resource Conservation closure and recycling.
Zhongren's developing a Vacuum Conveying System has established the previous statements to the international level of compliance compared to others in the industry by achieving the first international triple certification to Chinese companies' standards of material recovery, air tightness, and compliance with national industrial standards of GMP and the FDA. Therefore, providing the first international authoritative certification to Chinese industry companies of the compliance of normalized production to minimize industrial material waste.
Vacuum Conveying Systems Comprehensive Cost Optimization Value
Vacuum conveying systems offer multiple benefits to your organization, well beyond the core value of direct material loss minimization. They offer operational cost savings. First, the enclosed mode of operation keeps the materials away from the workers requiring labor-intensive clean up, resulting in about 20% savings of labor costs associated with material handling. Second, less material flying dust means less cost for clean up and no production shutdowns due to contamination. Moreover, Zhongren Machinery incorporates an intelligent PLC control system that allows for volumetric control of material flow. This minimizes underfeeding and overfeeding of materials due to operator error, and, therefore, minimizes the raw materials waste inherent in the production process. For food, pharmaceutical, and chemical companies where raw materials costs are high, the system provides a valuable cost savings in a short period of time, usually from 1 to 2 years.
Zhongren Machinery has been developing intelligent systems for the conveying and screening industries for over 10 years. With the majority of the team being senior engineering and technical specialists, we have the specific capability to develop customized vacuum conveying systems. Certain systems are built to satisfy specific characteristics and requirements for various industries. In the Mill Flour Industry, vacuum systems are fitted with explosion preventive features to provide safe and cost-effective operational systems where the dust explosion risk is high. In the Chemical Industry, vacuum conveyors are specially designed with 316L stainless steel and non-adhesive seal systems to avoid corrosion and material loss due to equipment degradation. In the Pharmaceutical Industry, vacuum conveyors are integrated with CIP/SIP systems to mitigate cross-contamination and material loss associated with cleaning. As an independent global importer and exporter, Zhongren Machinery has the capability to provide systems and after-sales services to businesses in all countries, allowing businesses to manage and reduce material waste in an efficient and effective manner.
Practical Maintenance Tips for Sustained Waste Reduction
To keep the vacuum conveying system effective for the long term in reducing material waste, standardized daily operation and maintenance is essential. Based on maintenance experience from hundreds of projects of Zhongren Machinery, the first important point is the regular inspections of the air tightness of the pipeline and to replace sealing components to prevent air leaks in the pipeline, which causes negative pressure to reduce material loss. The second point is to clean and change the filter element based on the characteristics of the material, which is usually every 500 operational hours, to improve the material recovery effect of the filter component. Because of the inadequate quantitative conductions to the intelligent control system, regular system diagnosis is needed to adjust the parameters to keep the system functioning as accurate as possible. After equipment installation, Zhongren Machinery trains their clients on the operation and maintenance of their equipment for free. They also have a global after-sales maintenance service to keep the system optimized to continuously reduce material waste.