Rawlplug’s chemicals. This is how you implement a MASTER PLAN

Stage I: comprehensive machinery replacement

The bottleneck was primarily attributable to the mixing units, which really needed to be replaced with more efficient machines, capable of controlling the mixing process parameters, prepared for integration with further subunits and systems, and efficient enough to meet the rapidly growing market demand. 

This is why the Chemicals Production Department received:

• a new hydraulic press,
• and two identical dissolvers (with a working capacity of 1,000 l) of high shearing force, designed for high-viscosity mixtures, 

only to be followed by:

• the first fully automatic film pack filling machine in the stock, enabling full control of component dosage, pack length and weight (built-in dynamic weighing system), namely the NAP-03 mentioned above. 

• The NAP-01new machine, also designed along with Rawlplug’s partner and operated at the Wrocław HQ since 2019, has substituted for the cartridge filling machines: NAP-01 and NAP-02. What it has contributed to the new equipment stock is fully automatic production: from charging buffer feeders with components (pistons, cartridges) to affixing a label with the pre-printed expiry date and batch number on each individual cartridge. The NAP-01new also features two weighing stations, which makes the machine highly accurate, and which is of paramount importance in terms of compliance with the applicable quality requirements and standards. This state-of-the-art unit is equipped with vision systems (cameras) that verify piston positions and make selections in fractions of seconds. The low waste rates (1–2%) and accurate dosing translate into a lower technical cost of the final product. The fact that the NAP-01new guarantees reduced waste volumes is also extremely important with respect to the company-wide environmental strategy.

Stage II: new production hall

More than a year ago, the Chemicals Production Department was moved to another building, where the other two production departments: Assembly and Plastics, previously reorganised, had already been running their operations. 

Before the reorganisation, the entire hall had been renovated and prepared specifically for that purpose. The work included:

• wall finishing, 
• replacing skylights,
• reinforcing floors,
• embedding the presses into the floor slab (for improved operator ergonomics),
• completely new electrical, lighting, and fire protection systems,
• ventilation suited for chemical production and meeting the ATEX directive requirements.

Stage III: continued automation

Last year, as part of the comprehensive process automation at the Chemicals Production Department, we launched a system for the storage and transport of resin in buffer tanks and sand in a silo. The investment took us three years to complete. The solutions deployed under the project provided the dissolvers with fully automated control of:

• dosing of raw materials from buffer tanks/silo,
• mixing time and speed,
• and vacuum generation process.

A third system, integrated at the same time, extended the capabilities of the mixing units in control of both the resin and sand storage and transport system as well as the mixing process with a capacity to control the operation of the ventilation system’s exhausts at each stage of the mixture production.

Stage IV: partial migration of processes

All the changes taking place at the Chemicals Production Department over the past few years are closely interlinked. The replacement of the machinery stock in Wrocław was combined with the transfer of some processes to Asia.

Thailand performed so well that – despite initial problems – we managed to launch the production of anchors in glass capsules there, and so now they are manufactured by Rawlplug exclusively in Asia (which we wrote about recently). 

Stage V: outcomes and follow-up

Rawlplug’s plans arising from the growing demand for bonded anchors are even more ambitious. In their pursuit, we are supported not only by our qualified personnel and the machinery purchased over the recent years, but also by the consistent automation of the processes implemented at the Wrocław site, providing grounds for the functioning of a truly modern company. 

What’s in store for us? Quite a lot. Only in the nearest future, Rawlplug’s Production Department awaits:

• commissioning of a battery-powered trolley with a drum grab, which will unburden operators and accelerate the processes of component changeover under the presses,
• systematic departure from manual weighing in favour of automated transport and dosing of raw materials,
• continued automation of the previously manual packaging processes for finished products,
• implementation of two new labelling machines, enabling further automation and integration of individual packaging operations