Industrial Consulting - Raffia

• The Portfolio of Activities that we will present is a set of several actions that can be developed in modules format, through a technical consulting work with the objective of identification, reduction/disposal of waste, increase quality and increase productivity in manufacturing processes, according to the specific needs of your company and in the best cost-benefit ratio.
• The contracted activities will be developed using the best and most updated Industrial Management Techniques, with qualified team and proven experience in the segment, in the development and improvement of the entire manufacturing chain of heavy fabrics for Big Bags, conventional and laminated lightweight fabrics for sewn or welded suction (feed, sugar, salt, fertilizer and flours, etc.), handles, shoelaces, threads, etc.
• We can act in improvements from the formulation of your extrusion recipes, going through all the processes of fabric manufacturing, lamination, printing, finishes, maintenance, quality, PCP, logistics and operational trainings, according to what you want.

• Revision of the Raw Material Formulations – updating the composition of raw materials and additives used in the production of the raffias, seeking to improve the performance, cost and increase of productivity in the extruders.
• Extrusion Process Parameters – evaluation and adequacy of the extrusion process, seeking improvements in the mechanical properties of current ratios (tensile strength, elongation, toughness, etc.) thus allowing the reduction of breakage and residues in extruders and other following processes.
• Operational Procedures of the Extrusion Sector – evaluation and review of operational procedures, adapting them to the best practices of market operation seeking to ensure the increase of quality and operational efficiency;
• Laboratory Procedures – evaluation and adequacy of the tests in the produced raffias, in order to ensure that they are suitable for use according to the parameters defined in the datasheets.
• Document Control in the Laboratory – analysis and adequacy of the control of documentation issued by the laboratory and technical areas, in order to ensure that the technical sheets and test results used are always up to date.
• Technical Sheets for Extrusion and Recipes – evaluation, review and adequacy of technical sheets in order to ensure the repeatability of the production process in the production of raffias.
• Implementations of the Suggested Changes – follow-up on the “factory floor” of implementations with the technical staff and company leaders, through follow-ups and trainings, in order to consolidate the improvement processes raised by the consultancy.
• Extrusion Sector Maintenance – evaluation, review and adequacy of the methodologies/practices applied to the respective coupled devices/utilities (water cooling system, air compressors, dryers, gravimetric or volumetric dispensers, resistors, fans, etc.) currently being performed in the sector (Corrective, Preventive and Predictive Maintenance), diagnosing opportunities and defining joint action plans to improve equipment performance and increase production and quality of produced raffias.

• Process Parameters of Weaving – evaluation and adequacy of parameters (light and heavy weaving) to obtain and improve the mechanical properties of the current fabrics (tensile strength, width control, weaving, processability, etc.)thus allowing the reduction of breakage and waste generation in weaving processes and other following processes.
• Technical Sheets of Fabrics – evaluation, review and adequacy of the technical sheets of the current fabrics in production, in order to obtain the best relation x benefit x quality ratio, taking into account the mechanical properties, technical and safety requirements of the respective products/markets/customers within the projected cost.
• Weaving Sector Operational Procedures – verification, evaluation and review of operating procedures, adapting them to best market operation practices, with the aim of improving operational efficiency and quality.
• Laboratory Procedures – assessment and adequacy of textile laboratory procedures according to relevant technical standards, in order to ensure that the tested fabrics are suitable for use according to parameters defined in the technical sheets and requests agreed with the Customers.
• Test Frequency – evaluation and adequacy of the amount of tests in the tissues (structure, width variation, tensile strength, elongation, residual shrinkage, etc.)in order to ensure that the defined sampling is relevant to the desired final results.
• UV Aging Control – evaluation and adequacy of the frequency, in accordance with the respective relevant technical standards, of weathering tests (%RT/KLY)in order to ensure that additives practised in extruders are within the specifications and warranties agreed with the customer/market.
• Maintenance of Weave Sectors – evaluation, review and adequacy of applied methodologies/practices regarding MPC (Maintenance Planning and Control) and Maintenance in Weaves currently being performed (Corrective and Preventive Maintenance), diagnosing opportunities and defining action plans to improve equipment performance and increase production and quality of the fabrics produced.

• Revision of the Raw Material Formulations – analysis and updating of the compositions of raw materials and additives used in the lamination of fabrics, improving the quality, performance, cost and increase of productivity in the lamination process.
• Process Parameters of Lamination and Printing – Evaluation and Suitability of Lamination and Printing Process Parameters (control of widths, mixing, temperatures, cannon profiles, blade thickness, clichés, paint, solvent, temperatures of the drying zones , Anylox, etc.), seeking the reduction of waste generation and increase of quality and productivity.
• Operating Procedures Lamination and Printing – verification, evaluation and review of the operating procedures of the lamination and flexographic printing sectors, adapting them to the best practices of market operation, with efficiency gain, quality and waste reduction.
• Laboratory Procedures – evaluation and adequacy of the frequency of laboratory tests for the lamination and printing sectors (film and ink delamination, grammage, tear resistance (Tier Test), color, structure, cut, seams, welds, etc.) in order to ensure that the fabrics produced are within the quality and specifications, defined in the technical sheets and specifications of the customers.
• Maintenance of the Lamination and Printing Sectors – evaluation, review and adequacy of the methodologies and practices applied with regard to MPC, the maintenance of Laminating Mills (Coating Machine) and Flexographic Printers, currently being executed (Corrective and Preventive Maintenance), diagnosing opportunities and defining action plans to improve equipment performance and increase production and quality of laminated and printed fabrics produced.
• Implementations of Suggested Changes – monitoring, evaluation and review, if necessary, of the implementations suggested by the consultancy in the lamination and printing sectors, in order to consolidate their application in the respective finishing processes (Big Bag, Sewn Bag and/or Welded Bag).

• Finishing Process Parameters – evaluation and adequacy of process parameters of Small Bags and Big Bags finishes, through the analysis of:
  • cycle times of the production operations of small bags and big bags – comparative between current x market standards (best practices);
  • provision and allocation of supplies, intermediate and finished products;
  • identification of production/maintenance bottlenecks;
  • installed production capacity x current efficiency;
  • load optimization/installed equipment;
  • productivity (scs – bags/operator) current x Market;
  • current machinery and equipment maintenance processes;

with the objective of decreasing losses and increasing sectoral productivity.

• Analysis of the Factory Layout – analysis and, if relevant, propose updating of specific design for equipment disposal (production cells), to increase productivity and decrease of the process lead time for small bags and big bags.
• Laboratory Procedures – evaluation and/or definition of a implementation plan for drop tests of small bags and and compression and resistance tests of big bags, with respective definition of their frequency, in such a way as to ensure that the packaging produced is of an agreed quality/defined in the customer reference standard or specification.
• Packaging Data Sheets – evaluation and, if necessary, presentation of a plan to adjust/update the respective data sheets of the current types of bags and bags in production, in order to obtain the best cost x benefit x quality, meeting the technical and safety requirements of the respective markets/customers within the projected cost.

The suggested schedule for the chosen project will be adapted to your needs and urgency of expected results, and can be met with one or more consultants, depending on the amount of activities defined in the project to be hired.

The projects/Modules will be suitable to your need and desire!

For the execution of the project, you will be able to define representatives from within your staff, in order to follow the consultancy throughout the execution time, in order to absorb the technical knowledge that will be passed on by the consultants and then multiply it for the other representatives of the company.

The Investment for execution will be defined according to the amount of activities and duration, which will compose the project to be chosen by you.

Any technical information obtained during the performance of the activities involved in the consultancy, operation, organisation or performance of the undertaking shall be considered confidential and confidential when such a condition is requested.