Maximizing Production Efficiency with GEMCO
The choice of equipment can significantly impact both the time and cost associated with blending processes. Traditional ribbon and paddle blenders often fall short, leading to material loss and increased costs due to rework. However, GEMCO’s advanced blending technology offers a solution that maximizes yield and minimizes waste.
Superior Yield
A recent cooperation with a customer highlighted the superior yield achieved with GEMCO blenders. While traditional ribbon blenders often provide yields from 80% to 90%, GEMCO blenders consistently achieve yields up to 99%. This remarkable efficiency is due to the design of GEMCO machines, which prevent material loss and minimize dust. GEMCO equipment not only enhances production efficiency but also ensures safety and reduces the need for extensive engineering controls.
Customer Success Stories
Customers are primarily focused on cost and results. Recently, a client of Advanced Powder Solutions (APS), GEMCO’s affiliate company, successfully produced two batches, achieving higher yields and improved safety compared to their previous methods. APS uses GEMCO machinery for their powder contract manufacturing services. Previously, the customer relied on ribbon and paddle blenders, which led to significant material loss and an inefficient process that failed to deliver the desired final product. This inefficiency resulted in substantial financial losses and dissatisfied customers. The success with GEMCO is due to its precise control over the blending process, which minimizes material loss and enhances safety.
Currently, we are collaborating with this client on a new contract manufacturing project. They are using xanthan gum, a common ingredient in cosmetics used as a thickening and stabilizing agent. Their project involves adding moisture back to the initial starting material in a very controlled process. Too much heat or too much moisture and the product can easily be ruined. This unique process method has proven to be more effective with GEMCO equipment compared to the customers’ previous blenders and dryers. Following testing in a GEMCO, the precise control and efficiency of GEMCO machinery has significantly improved the customers’ production process, reduced material loss and enhanced the quality of their final product.
Recipe Management and Future Enhancements
GEMCO’s machines come equipped with a recipe management system, allowing customers to store and recall various recipes, batch sizes, and raw material specifications. This feature streamlines the production process and ensures consistency. Moisture measurements for vapor are available in a GEMCO, monitoring relative humidity or dewpoint. Most other systems cannot or do not have this ability. Having this built into a GEMCO further improves process control and efficiency.
Significant Cost Savings
GEMCO’s impact on cost savings is highlighted by an example from a cosmetics company in Las Vegas. By making a single adjustment to their blending process, GEMCO enabled the company to save $800,000 each quarter, totaling $3.2 million annually. This significant saving was achieved by streamlining operations, reducing the need for multiple machines, and cutting down on labor and quality control expenses.
Long-Lasting Equipment and Process Improvement
GEMCO’s equipment is built to last, offering long-term cost savings. Unlike competitors, GEMCO provides robust machinery that requires minimal maintenance and refurbishment. This longevity is a significant advantage, as it reduces the need for frequent equipment replacement. Additionally, GEMCO’s expertise in process improvement and refurbishment ensures that even used equipment can be upgraded to meet current standards, further extending its lifespan.
While competitors may offer cheaper equipment, GEMCO’s focus on quality and longevity provides a better return on investment. GEMCO machines, though initially more expensive, offer superior performance and durability. Additionally, GEMCO’s refurbishment services ensure that older machines can be upgraded to meet current standards, providing a cost-effective alternative to purchasing new equipment.
Conclusion
GEMCO’s blending and contract manufacturing solutions offer unparalleled cost efficiency, superior yield, and long-lasting equipment. By choosing GEMCO, customers can achieve significant cost savings, improve safety, and enhance production efficiency. Whether through new equipment or refurbished machines, GEMCO provides the tools and expertise needed to optimize blending processes and achieve outstanding results.
