In the previous articles, we examined the challenges faced during powder filling and the types of powders. In this article we will focus on selecting the right equipment that suits your requirements and your powder.

Key Objectives to Define First

• Volume in tons per shift per SKU
• Fill accuracy desired
• Powder characteristics — especially bulk density and expected changes
• Dust, moisture content, product breakage concerns
• Packaging material and pack style
• Feeding system and feed rate integration
• Secondary packaging and its integration
• Data acquisition and integration with your systems

Developing a Comprehensive RFQ

1. Clarifying Equipment Requirements

Articulate specific powder filling needs, considering the type of powder, its properties, and unique characteristics impacting equipment selection. Clearly define desired production volume, speed, and accuracy requirements.

2. Establishing Technical Specifications

Provide detailed technical specifications including size ranges, dosing mechanisms, and specific features required. Specify industry or regulatory standards (e.g., GMP) the equipment must adhere to.

3. Ensuring Compatibility

Emphasise compatibility with the existing production line. Address integration requirements and potential challenges for seamless alignment within the manufacturing environment.

4. Quality and Compliance

Clearly outline quality standards expected, including materials of construction and finish. Highlight regulatory compliance requirements.

5. Budgetary Constraints

Provide a realistic budget range, considering initial costs, ongoing maintenance expenses, and potential hidden costs.

6. Delivery and Implementation Timeline

Specify the desired delivery timeline. Include information on installation, training, and other services required for seamless implementation.

7. Product Dust and Breakage Avoidance

Analyse the nature of the powder for dustiness and potential for breakage. Select a filling system with features designed to minimise dust generation and product breakage.

8. Hygiene and Cleanability

Consider ease of cleaning and sanitation, especially for processes with frequent changeovers.

Evaluation and Decision Making

Total Cost of Ownership

• Fill Accuracy — Overfill or give-away is the number one cost of ownership. When we evaluated a leading MNC's packaging line, the cost of overfill was over ₹10 million per annum.
• OEE — Equipment speed is important, but OEE is more important. It captures stoppage time, changeover time, and setup time.
• Wastages — Calculate wastages during setup and due to rejections.
• Power and Space — Ensure your new line is optimised for both.
• Projected Spares Consumption — Agree on cost of spares and consumables for two years. MTBF is a critical metric.

Application Experience and References

This is the most crucial criterion. Your vendor will be your partner in keeping the line running efficiently. Include a vendor visit, conduct trials to verify claimed performance, and visit customer sites for firsthand feedback.

Data Acquisition

Data acquisition is a must going forward. You should be able to capture output, stoppages with time and reason, give-away, cost of give-away, and OEE — all in real time.

Conclusion

Value can be measured on three metrics: Speed, Accuracy, and Price. If your product cost is low, speed and price become more important. If product cost is high, accuracy and cost of ownership become important. Focusing on the right two criteria will give you commercially attractive options.