Mooney Thermal Rubber Automates Precision Batching with a Customized 24-Bin System
Company Name:
Mooney Thermal Rubber Pvt. Ltd
Industry:
Rubber Compounding
Product:
Batching Expert
Company Background:
Mooney Thermal Rubber relied entirely on manual batching for more than 150 formulations involving up to 35 ingredients per recipe. With ingredient weights ranging from 1 gram to 20 kg and tight tolerances of ±10 grams, maintaining consistency, speed, and traceability was a major challenge.
Customer Challenge
Mooney Thermal Rubber relied entirely on manual batching for more than 150 formulations involving up to 35 ingredients per recipe. With ingredient weights ranging from 1 gram to 20 kg and tight tolerances of ±10 grams, maintaining consistency, speed, and traceability was a major challenge.
Key Challenges Identified
1. Manual Weighing Errors
Batch quality was vulnerable due to under-weighing and over-weighing.
Small ingredients (1–50 g) were particularly error-prone.
2. High Recipe Complexity
Managing 150+ recipes manually, each with many ingredients, caused delays, operator fatigue, and inconsistent output.
3. No Automated Traceability
There was no automated system to record:
Batch numbers
Ingredient names/codes
Target vs actual weights
Operator identity
Date/time logs
This limited quality assurance and audit readiness.
4. Manual Ingredient Labeling
Ingredient-wise labels needed to be created manually, leading to inconsistent documentation.
5. No Bin Automation or Ingredient Mapping
Operators needed to manually identify and pick the correct bin for each ingredient—a slow and error-prone step.
6. Lack of Scalability
Customer needed the flexibility to:
Add ingredients without bins
Expand from 24 bins up to 28 bins in the future
The Solution
Customized 24-Bin Batching System with Dual-Scale Weighing & PC Reporting
We developed a fully automated batching system integrating bins, weighing, PLC/HMI logic, traceability, and ingredient-wise printing—designed specifically for Mooney Thermal Rubber’s operational requirements.
1. Fully Automated Bin Management
24 motorized bins open automatically for the correct ingredient
Future-ready provision to expand to 28 bins
2. Dual-Platform High-Accuracy Weighing
Two weighing platforms for complete accuracy:
5 kg platform — 0.2 g accuracy
100 kg platform — 10 g accuracy
3. Intelligent Weighing Guidance
Green light + beep when target is reached
Yellow for underweight
Red for overweight
System blocks printing until weight is corrected
4. Ingredient-Wise Automatic Label Printing
For every ingredient, the system prints:
Compound Name
Batch Name
Ingredient Name
Net Weight
Date & Time
Operator Name
(All fields support 25-digit alphanumeric formatting.)
5. Parallel Batching Mode
System supports batching in two modes:
Single Batch Mode
Parallel Mode (e.g., complete Ingredient 1 for all 10 batches before moving to Ingredient 2)
This increases daily throughput significantly.
6. PC Reporting & Data Export
Customer receives full batch reports in Excel format containing:
Date, Time
Recipe Name & Code
Batch Number
Ingredient Name & Code
Target Weight vs Actual Weight
7. Support for Non-Bin Ingredients
Future-proofing: operators can add ingredients not assigned to bins and still include them in weighment and reporting.
Process Flow
Supervisor uploads formulation & ingredient master into the PLC via PC software.
Operator logs in with username & password.
Operator selects the recipe serial number from HMI.
System displays ingredient name, code, target weight, batch number, operator name, etc.
Relevant bin opens automatically for that ingredient.
Operator places an empty bag on scale and tares manually.
Material is dispensed and weighed.
On correct weight → green light, beep sound, auto recording, and ingredient-wise label print.
If underweight/overweight → yellow/red indication and correction required.
Steps repeat for each ingredient until the batch is complete.
Customer exports batch data to Excel via PC/pen drive.
Measurable Impact
1. >90% Improvement in Weighing Accuracy
Automated dosing eliminates manual errors across all ingredients (1 g to 20 kg).
2. 50–60% Reduction in Operator Workload
Automation reduces manual weighing, bin selection, labeling, and data entry.
3. Significant Throughput Increase
Parallel batching supports up to 10 batches at a time and allows 40 batches per shift efficiently.
4. 100% Traceability
Complete ingredient-wise and batch-wise audit trail (Excel export).
5. Zero Labeling Inconsistencies
Standardized automatic ingredient-wise labels printed after each step.
6. Fully Scalable System
Design supports adding new ingredients and expanding from 24 to 28 bins.
Customer Testimonial
“The customized 24-bin batching system has transformed our production process entirely. Earlier, manual weighing for 30+ ingredients was slow and error-prone, but the new system gives us complete control, accuracy, and traceability. The ingredient-wise automation, label printing, and parallel batching have significantly improved our output and reduced operator effort. It is a reliable and future-ready solution that perfectly fits our manufacturing needs.”
— Production & R&D Head, Mooney Thermal Rubber Pvt. Ltd.
Conclusion
The customized bin batching system successfully replaced Mooney Thermal Rubber’s manual, error-prone workflow with a high-accuracy automated solution. This implementation improved dosing precision, strengthened traceability, accelerated throughput, and reduced operator workload. The system is also designed with future scalability to ensure long-term operational reliability.
This project demonstrates how customer-specific engineering, backed by process automation and reporting intelligence, can significantly elevate operational consistency in industrial batching environments.