When materials determine processes

In metal processing, efficiency and safety are of paramount importance when handling fine or free-flowing metal powders, especially if they are prone to clumping or dust formation. Minebea Intec has implemented an automated weighing system for Egyptian Ferro Alloys that enables the precise filling of metal powders from silos reliably and efficiently.

As one of the leading producers of ferrosilicon and other metallurgical additives, Egyptian Ferro Alloys Company supplies international customers in the steel and foundry industries. The powdered products are used in the desulfurization, deoxidation, and alloying of steel, among other things – key process steps for the quality and durability of metallic materials. In order for these additives to be fully effective, they must be batching precisely and processed reliably. This is precisely where the challenges lie: The materials are heavy, sometimes highly adhesive, and place high demands on silo weighing. Precise measurements and maximum process reliability are essential, as even the smallest deviations can have a significant impact on production quality. For these reasons, Egyptian Ferro Alloys Company has switched from manual to fully automatic dosing processes.

Root cause analysis and system adaptation for a more stable
filling process

The aim of the project was to replace the error-prone manual filling process with a fully automated system that offers both maximum accuracy and ease of use. The analysis phase began by identifying the causes of the inefficiencies, which included fluctuations in powder dosing and problems with handling sticky materials.Minebea Intec then worked with its partner company EAST to develop a specially customized silo system with automated material feed for the customer.

Components, process validation and system start-up

The robust PR 77/100 kg C3MR bending tube load cell impresses with its C3 accuracy class in accordance with OIML R60. Even under difficult conditions, such as those commonly found in the metal industry – including strong vibrations from machine operation, high temperatures, abrasive or sticky materials, dust exposure, and harsh high-pressure cleaning processes – it delivers reliable and accurate measurements. Based on these measurements, the Maxxis 4 weight controller takes over the central control of the filling process. It features modern communication interfaces and is equipped with the IBC filling license – a software function that enables automated, standard-compliant control and monitoring of filling processes in intermediate bulk containers (IBCs), including tolerance checking, logging, and traceability. After extensive process reliability testing, the system was successfully commissioned. Training for the operating personnel rounded off the project.

The result: A stable, efficient, and safe filling process that meets
the requirements of industrial powder processing in every respect.

„By automating the filling process, our customer gains measurable advantages: precise dosing, reduced material losses and greater safety in daily operations.”
Beshoy Kamel, Project Manager, EAST

INFOBOX

Key facts
Manual powder filling caused measurement errors, material losses and endangered occupational safety. An automated filling system with the PR 77/100 kg C3MR load cell, the Maxxis 4 weight controller and IBC filling license significantly improved accuracy, efficiency and safety while reducing costs.

Application & products
The system is used for automated weighing and filling of sticky silicon oxide powder in metal processing. The robust PR 77/100 kg C3MR load cell, a 30 m PR 6135/31 connection cable and the Maxxis 4 weight controller with IBC filling license and flexible interfaces for seamless integration are used.

• Load cell PR 77/100 kg C3MR (bending beam load cell according to OIML R60, accuracy class C3 = 0.02%)
• PR 6135/31 connection cable
• Maxxis 4 weighing controller
• IBC license for single-component filling

Customer benefits

• Operational efficiency – automated processes enable faster and errorfree filling
• Cost savings – Less material loss and reduced labour costs through precise filling quantity control and automated processes that replace manual tasks
• Workplace safety – No manual handling, minimised risks
• Scalability – Solution can be easily adapted for similar powder materials

The customer
Founded in 1972, Egyptian Ferro Alloys Company is a leading manufacturer of silicon-based products for the metal industry. The company supplies international markets and relies on modern, efficient, and safe processes for its production. With the new weighing system, the company is consistently pursuing its goal of further optimising quality, occupational safety, and automation.