In many installations brick plants are struggling with an extremely high amount of sand mix waste at the making line.

At the point of application this final, mixed product has gone through numerous, expensive, material handling processes including:
- Crushing, Screening, Crushing, Screening and Dust Control
- Weighing, Mixing and Dust Control
- Transportation across the plant to the making line
- Capture of product in bins & totes

At this point one of two processes occur:
- Product is reintroduced into the process at the mixer
- Product is disposed

At the end of the day this can be affecting your bottom line in a significant manner. 

Pneumatic Reclaim System

- Dust - Extreme amounts
- Labor Costs associated with manual reclaiming
- Labor and Equipment costs associated with fork trucking the reclaim or waste at the plant
- Equipment costs associated with reprocessing
- Waste - Costing thousands of dollars per month

- Product is captured and returned to the source system dust free
- This is eliminated by an automated system
- Reclaiming the product eliminates this profitability drain

Old System

Automated Reclaim System

Does this look like your reclaim system?

As product was fed product dropped into the waste container, and on the floor.  The operator is “maintaining” the full bin in this photo.  This was a very dusty, time consuming, wasteful and costly process.

3Sigma provides both mechanical and pneumatic reclaim systems based upon your needs.  Moisture content, physical product size, existing equipment, physical constraints and other variables are the main factors in determining the type of system provided.

Mechanical systems are the simplest although they are often difficult to install within the physical constraints of the making line.  Inclined and Vertical Conveyors are used to reclaim the header mix without the need for dust collection or venting.

Pneumatic Conveying systems typically require a dust collector or bin vent filter at the receiving end to remove the product and dust from the air stream while returning clean/filtered air back into the plant.  3Sigma utilizes a very small blower package, about the size of a basketball, a receiving hopper and an eductor to recycle the product.  Special care must be taken in sequencing the system and, at times, wear resistant elbows are required within the conveying line.

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-Minimizing labor costs as your operators no longer need to monitor your waste bin levels, while eliminating product spillage.

-Minimize labor and overhead costs as your operator is no longer spending time on a fork truck moving product from point A to point B.

-Minimize operating costs by not preprocessing final, mixed product.

-Eliminate final, mixed product waste.  This will translate into thousands of dollars of savings per month!

Header Reclaim Systems

In 2006 3Sigma installed a compact pneumatic conveying reclaim system that freed up valuable floor space and…

Reduced raw material mix use from 31,200 lbs. to 9,600 lbs. per 8-hour shift, saving thousands of dollars per week.
 
The customer stated that the automated reclaim system paid for itself in two months while minimizing dust.