Batch to Continuous Processing Brings Reliability & Improvements

Client

Cannot disclose due to confidentiality agreement.

Challenge

A leading adhesives and coating company was having issues with product quality, pressures from customers to reduce cost and increased competition from boutique "shops."

How could the family of products be produced to satisfy the market's needs without a large investment in capital? Was there an opportunity to reduce cost through reduction in waste and better utilization of equipment?

Solution

Leveraging its world-class compounding expertise and integrating techniques from unrelated markets, Aspen developed a system that addressed the client's dilemma. The manufacturing solution employs continuous compounding concepts to process a portfolio of product formulas with minimal transition times, while also bringing an improvement in quality and consistency.

Aspen's know-how helped the client enhance its manufacturing flexibility and market service. The move to continuous compounding technologies has bypassed previous batch processing restrictions. Improved quality, reliability, in addition to faster response times and smaller lot sizes are now feasible at competitive rates. The waste associated with setting up and converting the equipment was reduced to less than 2% by weight, resulting in a dramatic savings in raw material costs and waste disposal costs, while contributing to preserving the environment.

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