Engineering Services

AUTOMATIC POWDER TRANSFER SYSTEM

15 Januari 2016
DATA PRODUKSI

LINE
MC.1 MC.2 MC.3 MC.4 MC.5 MC.6 MC.7 MC.8 MC.9 MC.10 MC 11
PRODUK MC 10 A MC 10 A MC 10 A MC 10 A MC 10 A MC 10 A MC 10 A MC 50 A MC 50 B MC 50 C MC 50 E
BOBOT 4.6 gr/sct 4.6 gr/sct 4.6 gr/sct 4.6 gr/sct 4.6 gr/sct 4.6 gr/sct 4.6 gr/sct 20 gr/sct 47 47 47
1
KAP/JAM
(kg/jam) 11,04 11,04 11,04 11,04 11,04 11,04 11,04 360 112,8 112,8 112,8

A B C D
CC 25/ES CC 25/ES
PRODUK CC 50 CC 50 CC 50 CC 50 25 25 TOTAL
BOBOT
2
(gr/sct) 40 40 40 40 20 20

KAP/JAM
(kg/jam) 96 96 96 96 48 48 480

KAPASITAS PER JAM 1255,68 KG

KAPASITAS PER SHIFT 10.045,44 KG
KAPASITAS PER BULAN 251.136,00 KG
SAAT INI

Total 17 operator / manning

Sacharin
(Powder)
5%
V Mixer
Manual T8ipping
Na-Cyclamat
(Powder)
95% Zak to machine
Filling Sachet
hopper chute

Fill to ZAK-Packing

Lift Manually
Put Zak on the
With overhead
Pallet
crane

MIXER 2
USULAN SYSTEM

Total 3 operator / manning

Sacharin
(Powder)
5%
Storage RM , Auto
V Mixer
dosingT8ipping
Manual ke Mixer
Na-Cyclamat
(Powder)
95% Zak to machine
Filling Sachet
hopper FG
Transfer chute
dari
storage FG Tank
Fill to ZAK-Packing
ke Filling Hopper
Storage MIXED
Finished Good
(FG)
Put Zak on the
Lift Manually
With overhead
Pallet
crane
LAYOUT SYSTEM
LAYOUT SYSTEM
 TIPPING TIPPING
Capacity 1 TON Capacity 1 TON
Volume 1,5 TON Volume 1,5 TON

90% 10%
WEIGHER RM 1 12-30bpm 15 L x 2 WEIGHER RM 2 12-30bpm 15 L x 2
Capacity min 180 kg/min Capacity min 180 kg/min
Capacity max 450 kg/min Capacity max 450 kg/min
clean process for 1 ton 900 kg/batch clean process for 1 ton 100 kg/batch
5,0 min/batch 0,56 min/batch
2,0 min/batch 0,22 min/batch

MAIN MIXER
Capacity 1 ton/batch
clean process 1 min - fitting pos
5,0 min - weighing RM
10 min - mixing
1 min - fitting pos
2 min - discharge
19 min - total / 1ton batch

FG HOPPER - 1 FG HOPPER - 2
775,68 kg/hr 480 kg/hr
6,21 ton/shift 3,84 ton/shift

133 min / 7 ton 133 min / 7 ton

2,22 hr / 7 ton 2,22 hr / 7 ton

CLEAN VOL 8 ton CLEAN VOL 8 ton

CAP FOR 1 SHIFT CAP FOR 2 SHIFT VACUUM HOPPER - 1 VACUUM HOPPER - 2
775,68 kg/hr 480 kg/hr
12,93 kg/min 8,00 kg/min
hopper 1 ton hopper 1 ton
vol 1,5 ton vol 1,5 ton

low level 0,5 ton low level 0,5 ton

vacum 100 kg/min vacum 100 kg/min
compare VFFS 7,7 x req compare VFFS 12,5 x req

Total 11 VFFS machine Total 6 VFFS machine

BENEFIT TANGIBLE

Optimalisasi jumlah manning operator

• Total 17 orang  3 orang optimalisasi 14 orang
• 14 x 2j/bln x 1 shift x 12 bln  336 jt / tahun

Mengurangi proses dan waktu handling secara signifikan

1 batch 110kg menjadi 1 ton / batch
• Total 1 shift capacity yang dibutuhkan : 10 ton / shift
• Waktu mixing total 1 shift :
• Current : 110 kg  10 menit 55 detik  11 menit
10 ton  1000 menit  16,7 jam

• System Auto : 1 ton  19 menit untuk perhitungan menjadi 20 menit maximal

10 ton  200 menit  3,3 jam

• Saving time : 800 menit  13,3 jam

• Potential production loss 13,3 jam :

• Kapasitas 1 jam : 1255,68 kg/jam
• Hilang kapasitas 13,3 jam : 16,7 ton product
• Estimasi, harga product per ton : Rp 100jt / ton
• Estimasi profit margin sales per ton : 30%
• Potensial profit loss : Rp 100jt x 30% x 16,7 ton = 501 jt/ tahun
BENEFIT INTANGIBLE

Simplifikasi flow RM FGM PM

• Semua proses flow powder dari RM sd FGM di dalam system, tidak ada yang di luar system

Stock control RM dan FGM lebih baik / lebih mudah

• Storage di tanki yang terpantau volume isi nya dengan mudah

Meningkatkan hygiene product handling

• Product handling menggunakan SUS 304 food grade

Mengurangi jumlah product waste dengan system penimbangan yang akurat

• System batching dilakukan dengan penimbangan secara akurat untuk mendapatkan hasil
masksimal sesuai recipe
PERHITUNGAN ROI

Total Tangible Saving

• Manning saving 336 jt / tahun
• Potential sales margin loss 501 jt / tahun
• TOTAL 837 jt / tahun

ROI
• Investasi total 3,356 M
• ROI : 3,356 / 0,837 = 4 tahun
 PROJECT EXPERIENCES

• PT. NESTLE INDONESIA CIKUPA ( Relay out & installation new

machine, retrofit, conveyor system , electrical & control system
support, application new machine can & filling , making new can
machine.

• PT. INDOLAKTO JAKARTA PLANT (Vacuum transportation system,

retrofit filling, plumbing  process , relay out & civil
contractor)

• PT. INDOLAKTO PANDAAN PLANT ( Application new machine trident

pack cartoner, Application & supply leak detector Taptone )

• PT. INDOLAKTO PURWOSARI PLANT ( Application & supply leak

detector Tap tone, Making Crusher waste machine, conveyor
curving & tipping )

• PT. KRAFT FOODS INDONESIA CIKARANG PLANT ( Wide hygiene

conveyor, carton sealer new application )

• PT. MONDELES INT. KARAWANG PLANT ( Wide hygiene conveyor, carton

sealer new application, pilot plant miniature making)
• PT. INDOFOOD SUKSES MANDIRI ( Retorfit Sachet Filling Machine )
• PT. SARIHUSADA ( Erection & Installation New Machine Filling
Packing, Retrofit / refurbishment, mechanical, electrical &
control system support, spare part supply  for filling & packing
machine, customize spare part order or making order
• PT. NUTRICIA INDONESIA SEJAHTERA ( conveying system, Retrofit
Filling machine )
• PT. ICI PAINT INDONESIA AKZO NOBEL ( Consultant  Project for
Packaging )
• PT. DANONE DAIRY INDONESIA ( Consultant Project )
• PT. JOHNSON&JOHNSON INDONESIA ( Consultant Project )
• PT. DAIRY GOLD INDONESIA ( Conslutant Project )
• PT. ULTRA JAYA ( Hygienic Conveying System Project)
• PT. SCIENTIFIC DRILLING INTERNATIONAL  ( Consultant Project )
• PT. PRIMA MAKMUR ROTOKEMINDO  ( Partition Project )
• PT. UNILEVER Food ( Walls ) Cikarang ( Conveying System Project) 
• PT. UNILEVER SARIWANGI Cicadas ( Retrofit machine, supply new
shrink tunnel  )
• PT. PZ CUSSON TANGERANG ( Supply inline machine linear filling
machine, conveying system machine )
• PT. ARNOTTS INDONESIA ( Conveying system, new machine
installation, plumbing process project,  vacuum leak tester )
• PT.  ASW Food ( Asia Sakti Wahid ) hand wash machine, supply
Terima kasih