CPI mortars Ltd implemented a project to improve its recycling hopper at its Carlton Manufacturing site. The hopper was used to split bulk bags and transfer the contents into a powder tanker. The existing system had poor access for maintenance and cleaning, unsafe access to the top of the powder tanker and no protection from the weather.
The poor design resulted allowed material to harden on the inside of the hopper and transfer screw. In addition lumps formed in the bulk storage bags caused blockages in the hopper. Access to clear the blockage was via a raised platform with a door about shoulder height. Operators were exposed to manual handling risks, fall from height hazards and exposure to dust. The bag splitter was positioned on top of the inlet of the hopper and was poor at containing dust emission. Sometimes, the dust spilled onto the forklift. The only access to the top of the powder tanker being loaded was the tankers built in ladder, handrail and walkway.
Please view the video to see how CPI addressed these issues.