Magnum Systems, an esteemed designer and manufacturer of material handling and packaging systems for dry bulk materials since 1960, has recently launched a pioneering product in its portfolio - an all-stainless-steel integrated system. This innovative offering is the first of its kind and was dispatched to a customer from the food industry, marking a significant milestone for the company.
Magnum’s Automated Open Mouth Packaging System is an all-stainless steel integrated system that exhibits many benefits, especially for customers in the food industry. The primary advantage is that it is a washdown unit, bringing ease of cleaning and hygiene maintenance, which is a paramount factor in food handling and processing. Magnum Systems foresees a market for many manufacturing industries and plans to manufacture more of these integrated systems.
This groundbreaking system results from Magnum's commitment to delivering quality equipment and components. It includes features like stainless steel augers and agitators, which are integral to this integrated packaging system.
Given Magnum’s expertise in engineering and designing quality packaging solutions catering to diverse industries, the company is well-equipped to innovate and adapt to industry needs. Magnum’s key players for this project shared insights about how this revolutionary system was conceptualized and brought to life. The journey involved meticulous planning, design considerations and answering critical questions, such as the choice of construction material, which significantly influences the system pricing.
The all-stainless steel integrated system signifies a new era of efficiency, safety and quality in the material-handling sphere. This state-of-the-art washdown system, engineered with the highest regard for hygiene and easy maintenance, is a game-changer for customers in the food industry and other industries that require a high level of system hygiene. Its introduction underlines Magnum Systems' commitment to continual innovation, as evidenced by their growing portfolio of tailored solutions for diverse industries. From start to finish, the execution of this groundbreaking system is a testament to meticulous planning and a deep understanding of industry needs. With this latest offering, Magnum Systems fortifies its position as a trusted provider of pioneering solutions in material handling and packaging for the ever-evolving demands of the food, chemical and plastics industries, among others.
A Unique Product That Came With Some Unique Challenges
This system's FAT (Factory Acceptance Testing) process was unique, with its own challenges and wins. The absence of the product and the room to set up the entire system in the shop necessitated a Level 2 dry run FAT. While this allowed for a functionality test, it also meant that adjustments would need to be made in the field due to product behavior differences.
A significant challenge was the new washdown specification from the customer, which required a great deal of work to meet. This included passivating tubular structures, which added weeks to the project timeline and demanded top-notch fabrication work and design. Vendor delays also played a part in extending the timeline, adding roughly three months to the project.
Despite these setbacks, the team overcame them through a lot of coordination, collaborative discussions and custom solutions. These early lessons from this experience will undoubtedly be valuable for future projects, especially those that require meeting new specifications and dealing with unpredictable vendor situations.
This project was a first for the team on many levels. Constructing an all-stainless-steel TOMP that is also wipe-down friendly and easy to clean posed unique challenges, mainly because it required a different approach and components than the team was accustomed to. The team had to find alternative components that would suit a stainless-steel unit rather than the carbon steel parts they typically use. This search for suitable sprockets, bearings and other parts added another layer of complexity to the project.
Magnum’s determination and problem-solving skills are commendable, as is their commitment to delivering quality work despite obstacles. It's a testament to the resilience and adaptability often needed in such projects. The electro-polishing process was one of the significant tasks that needed attention, ensuring that the overall layout was correct. Despite a few hiccups and changes in the assembly that required some rework, the team was dedicated to staying on top of things and ahead of things where possible.
This hard work and dedication created a fully automated end product. The customer has to load bags into the machine, and the system takes care of the rest – from loading to sealing, checking weights and even rejecting any that aren't up to standard. This automation significantly reduces workforce and inefficiencies and only requires one or two people to monitor the machine and make minor adjustments as necessary. The result is a machine that will save the customer time and resources, which is a significant achievement.
Overall, the project was challenging, but the team rose to the occasion and delivered a product they are proud of. It's a reminder that persistence and creativity can lead to successful results even when things don't go as planned.
Product Ships Upon a Successful FAT
The FAT went very well after addressing the abovementioned challenges, as the team knew it would. Magnum then shipped the parts, and the customer began assembling them. The next steps will involve a service trip to their facility to ensure everything is set up correctly and then training the customer on operating the equipment.
The next step is training the customer on operating the system's TOMP. Given that the customer already has experience with the APOD part of the system, the training is expected to take around three days. The team should start hearing about when to begin this process in the coming weeks.
Magnum is excited about the potential for expanding the usage of stainless-steel units beyond the food industry. This new system could be utilized in various chemical, pharmaceutical and agriculture sectors. The system could also benefit industries with unsuitable carbon steel, such as fertilizer production.
The all-stainless steel design is highlighted as a significant selling point, particularly for industries concerned with cleanliness and hygiene. Perfect for those customers who like its washdown properties or prefer dry cleaning methods, which involve blowing off debris and wiping down surfaces with dry rags.
Customer Collaboration Is the Key to Success
The customer's feedback played a crucial role in the development process. Regular contact allowed for updates on progress and adjustments as needed, and the customer was overall pleased with the result. They even commented that it’s the only system of its kind that they have ever seen, which is high praise coming from such a significant player in the food industry.
In the future, the team expects that the client's standards will drive further improvements in future designs, and these ongoing improvements will have other customers requesting similar systems. Magnum sees this as a significant milestone and expects it will pave the way for future improvements. The experience will make subsequent projects less daunting and allow for more washdown-friendly designs.
The customer's enthusiasm for the Automated Open Mouth Packaging System has also sparked optimism about its potential market appeal. They believe that other companies will be equally excited about the product, especially those not yet ready to take on such a project from start to finish. This positive reception from the customer has boosted the team's confidence and affirmed their willingness to tackle more challenging projects.
This hard work and diligent focus resulted in a unique product that will be a standout in the market. The team's perseverance and adaptability, coupled with the customer's positive feedback, have made this project a rewarding experience for both teams.
Magnum Systems podcast series, AIM!
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