A medium-to-large industrial raw material processor in Turkey required a fully automated solution to upgrade its existing semi-automatic workflow. The customer produces various functional powders and customized additive formulas for downstream factories, so batching accuracy, batch-to-batch consistency, and packaging flexibility were essential.
Customer Background
The factory processes multiple powder materials used in chemical raw materials, construction additives, and functional powder applications. Their products are formulated according to fixed recipes and supplied to different end users. As production capacity increased, the customer sought to improve automation levels, reduce manual errors, and streamline the entire batching-to-packaging process.
Customer’s Key Requirements
The customer outlined several core requirements for the upgraded production line:
- Ability to automatically batch six different powder materials
- Each raw material has a fixed ratio but must remain adjustable within the recipe
- Higher batching accuracy and improved batch stability
- A large buffer silo to balance batching and packaging speeds
- Gentle and uniform mixing without damaging particle structure
- Continuous connection to downstream conveying and packaging equipment
- Dual packaging capability: Big bag (ton bag) and 50 kg bag packaging
- Unified PLC control for the entire line with minimal manual intervention
Our Customized Solution
Based on the customer’s process flow, material characteristics, and available factory space, HONGDI designed a fully integrated line combining automatic batching, centralized buffering, bottom-drum mixing, conveying, and dual packaging modes.
1. Automatic Batching System with Six Material Silos
Six independent storage silos correspond to six different powders.
Each silo is equipped with an individual weighing system and control module.
Raw materials are automatically dosed according to the recipe and discharged together after batching is completed.
This ensures high consistency and eliminates manual weighing errors.
2. Central Buffer Silo
A large-capacity buffer silo is installed beneath the batching system.
It stores pre-batched materials and ensures continuous feeding to the mixing and packaging sections.
The buffer design stabilizes the overall production rhythm and improves line efficiency.
3. Drum Mixer for Batch Mixing
Located directly under the buffer silo, the drum mixer performs gentle and uniform roller-type mixing.
This structure is ideal for powder formulations where particle integrity must be preserved.
The design is simple, efficient, and easy to maintain for long-term industrial use.
4. Belt Conveyor System
After mixing, the powder is transported through a belt conveyor to the packaging station.
The conveyor ensures smooth, continuous feeding while preventing material surges, blockages, or inconsistent flow.
5. Dual-Mode Packaging System
The packaging silo simultaneously connects to:
- A big bag (ton bag) packing machine
- A 50 kg sack packing machine
The customer can switch between the two packaging modes depending on order requirements.
This greatly improves flexibility and reduces redundant investment in separate lines.
6. PLC Centralized Control System
A single PLC cabinet manages the entire production line, including:
- Automatic batching
- Mixer operation
- Conveyor feeding
- Packaging line coordination
The system provides a clear operating interface, simplifies worker training, and minimizes human error.
Project Highlights
- Automatic batching for six raw materials with high accuracy and stable control
- Smooth workflow from batching to mixing to packaging, reducing manual handling
- Dual packaging modes integrated into one line for maximum flexibility
- Centralized PLC control significantly lowers labor requirements
- Clear system structure with future scalability for adding more silos or packaging modules
This integrated solution helped the customer achieve a fully automated, flexible, and efficient production line capable of handling both large-volume and small-volume packaging needs. The upgraded workflow improved stability, reduced operational risks, and positioned the factory for long-term growth.