Lean Mixing Process and Lean Six Sigma

Lean Mixing process with innovative transport of powders, granules and granulates.
Developing process technology for Lean Six Sigma companies.

Dinnissen Process Technology specializes in technologies for receiving, transporting, weighing, mixing, grinding, sifting, vacuum coating, and packaging bulk solids for a wide range of markets. The production companies Dinnissen serves are increasingly working in accordance with Lean Six Sigma, a methodology used all over the world that aims to improve efficiency and eliminate waste and activities not valued by the client. Dinnissen is developing process technology, process designs, and intelligent process automation specifically for these clients. Therefore we already built an enviable reputation for delivering sophisticated solutions for mixing powders, granules and granulates.

During the K-Messe in Düsseldorf, Dinnissen is launching its new Lean Mixing concept with a new and integrated transport system that can be more easily integrated and is gentler and less expensive than the pneumatic transport systems now commonly in use.

Specialized process technology for Lean Six Sigma companies
Production companies working in accordance with Lean Six Sigma methodology have six solutions available to ensure that their organization can work more cheaply, more customer-focused, and more efficiently. Technology is one of the most important of these solutions. Dinnissen Process Technology offers Lean Six Sigma companies specialized technology that contributes to these efforts. For example, compact equipment offering high production capacity and ease of access requires a lower initial investment and can also be cleaned more easily and quickly. The Lean Mixing Concept allows companies to realize savings in terms of energy, labour, physical space, and investment costs for transport and storage systems by utilizing innovative and simplified gravity-based transport technology. Multifunctional mixers and vacuum coaters are also cheaper to purchase and operate and require less space and labour. They also offer production companies, now and in future, a great deal of flexibility to make exactly those products that are most highly appreciated by their clients. Other process technologies focus on aspects such as energy savings, minimizing damage to fragile ingredients, product homogeneity, and hygiene.

Process design for Lean Six Sigma companies in four steps
Dinnissen Process offers companies looking to purchase one or more machines a specialized development plan, providing them with certainty upfront and the opportunity to measure the results achieved and fine tune the technology. Many requests for a tailor-made piece of process technology is first subjected by Dinnissen to an applicationstest at its in-house D-Innocenter® and for delivery with a factory acceptance test (FAT). At this testing site, products submitted by clients are tested in combination with Dinnissen's existing process technology. These tests make it clear whether the technology chosen is suitable and how it can best be applied. After the client-specific installation has been produced, mechanical tests are carried out to determine whether the technical installation functions optimally before delivery to the client. After delivery and installation in the overall production line, the site acceptancetest (SAT) is carried out. Extensive test runs are carried out using the process technology delivered under all desired sets of conditions and with all desired raw materials and ingredients. Dinnissen goes through every test run together with its client until the results are approved by the client.

The Lean mixing concept without the disadvantages of pneumatic transport
The Lean Mixing concept offers a total and integrated solution for mixing powders, granules and granulates, including a highly effective and efficient system for transporting the raw ingredients as well as the finished product. This new concept allows for a totally integrated mixing and transport process without having to resort to pneumatic transport with all the related disadvantages such as increased risk of product damage, higher energy costs, higher contamination risks, and extra handling. Lean Mixing utilizes big bags in which the ingredients have to be lifted only once. Once the big bags are hoisted, they are transported via an automatic route guidance system to the proper unloading position on the transfer station and unloaded. The process operator then attaches the big bags to the discharging stations in a dust-free environment, connecting them to Feeder Valves specially developed by Dinnissen. These cost-efficient and fully integrated feeder valves ensure that the feeded ingredients are precisely weighed out when leaving the bag or entering the production process and can handle a wide range of capacities from 6 kg per hour to as much as 50 tons per hour.

Cost-efficient and Easy-to-Clean mixing method
The Lean Mixing Concept also integrates the double-shaft Pegasus® Mixer, which gently suspends powders, granules and granulates in the air while mixing them. The unique fluidized zone that is created in the process makes this multifunctional processing unit the perfect tool for mixing ingredients extremely accurately, gently, quickly, and energy-efficiently. After the mixing process, the finished product goes through an automatic metal check and sieve check, after which it is transported further via an automated big-bag filling system or a filling system optimized for the final packaging step. If desired, this can be carried out in a high-care environment. These processes are also carried out with the help of gravity, thereby saving energy and minimizing the use of moving parts. Last but not least, this Lean Mixing Concept is also designed to be very Easy-to-Clean, which is why the mixer, hopper, sieve, and metal check unit are all fitted with a side guidance system, making it possible to easily and quickly access and clean all interior parts and components.

Higher-quality end product
Dinnissen's Lean Mixing concept is easier to integrate into existing production processes and also requires significantly less space when set up in a new environment. Initial investment costs are therefore much lower. Lean Mixing consumes less energy and is easier to clean than comparable pneumatic transport systems and therefore reduces operating costs. As the transport process is extremely gentle, the materials handled, including powders, granules and granulates, suffer less breakage and damage, resulting in a higher-quality end product.

Data analysis for process automation and intelligent production processes
The ability to analyse data is another important resource for Lean Six Sigma companies. Dinnissen automates the entire production process to provide an optimum, intelligent, and self-regulating production process. It provides PLC controls for machines and transport systems at the field level as well as links to process controllers, variable speed drives, and master control centres in the company network. Dinnissen organizes the collection, forwarding, processing, and visualization of measurement and control signals from production processes via SCADA systems. In doing so, it visualizes measurement data in operator and control rooms and makes it easier for the company to manage its production process more effectively and efficiently. This also simplifies the preparation of reports and the installation and operation of alarm circuits. Dinnissen implements its automation projects using the communication protocols of commonly used ERP systems such as SAP and Oracle, which means that linking and integration should not be a problem. The users of automated systems are also provided with remote control facilities, so that Dinnissen is able to monitor and control the production processes from a distance to reduce downtime and production losses to an absolute minimum.

About Dinnissen

Dinnissen Process Technology offers you a unique mix of expertise plus contracting and manufacturing facilities: from a stand-alone machine to a complete turnkey system, from pre-engineering to project management, and from design to assembly to start-up. Our one-stop shopping concept enables us to operate independently of third-party suppliers. Our extensive international network ensures that we can deliver anywhere in the world.

Wednesday July, 18
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