EPIC Systems implemented a comprehensive, engineering-driven solution that addressed both the mechanical limitations and process inefficiencies of the existing dosing line. Beginning with a front-end engineering (FEE) phase, EPIC conducted a detailed evaluation of the customer’s current workflow, material handling constraints, and production requirements. This allowed the team to develop a fully optimized system design, reduce risk, and provide an accurate project scope and cost.
At the core of the solution was a portable, skid-mounted dosing system designed for flexibility, repeatability, and ease of changeover. Each skid was engineered with integrated heating and mixing capabilities, allowing solid makeup product to be received, liquefied, and maintained at optimal temperature directly at the packaging line—eliminating delays associated with remote tank preparation.
Key system innovations included:
- A motorized lift mechanism built into the skid, enabling precise vertical positioning to align with the filling point without manual adjustment
- A swing-out agitator motor assembly, allowing operators to access and fill the tank without removing equipment—significantly reducing downtime and simplifying operation
- An integrated heating system to efficiently transition the product from solid to liquid state while maintaining consistent temperature throughout the process
- A custom dosing system utilizing a servo-driven, positive displacement pump to deliver accurate, repeatable volumes regardless of product viscosity
To ensure seamless integration with the packaging line, EPIC incorporated photo-eye triggered filling, synchronizing dosing with container position on the conveyor. This automation improved timing precision, reduced product waste, and supported higher line speeds.
In addition to the mechanical and process improvements, EPIC designed the system with future scalability in mind, recommending the integration of advanced automation controls and machine vision inspection for real-time quality verification and continued performance optimization.
The result was a fully engineered, turnkey solution that not only resolved the customer’s immediate challenges but also positioned their operation for long-term efficiency and growth.
