To reduce supply chain costs, a multi-site consumer packaging manufacturer transitioned from trailer-based polyethylene terephthalate (PET) resin deliveries to a flexible, cost-effective bulk bag handling system. Partnering with Gerhart, we implemented an integrated conveying solution across five facilities—enhancing flexibility while maintaining production continuity.
Introduction
Identifying the Opportunity
The customer recognized a cost-saving opportunity by diversifying their PET resin supply chain. Instead of relying solely on pneumatic trailer deliveries, they identified an alternate supply stream utilizing super sacks (bulk bags). This shift required a new material handling solution to seamlessly integrate bulk bag unloading into their existing silo-based storage and pneumatic conveying systems.
Conceptualizing the Solution
Gerhart collaborated with the customer to develop a turn-key solution. After in-depth analysis of throughput needs, site conditions, and production requirements, our team designed an integrated system featuring a bulk bag unloading and a pneumatic conveying line to support both existing trailer-based and new bulk bag-based material streams.
Problem Description
Supply Chain Challenge
The customer’s supply chain analysis revealed the potential for multi-million dollar annual savings by introducing an alternative PET resin source in bulk bags. However, to capitalize on this opportunity, several challenges needed to be addressed:
- Current State: PET was delivered from port terminals via pneumatic bulk trailers and conveyed into on-site storage silos.
- Target State: PET delivered in super sacks would require a new material handling system to transfer resin into the existing silos at a controlled rate, maintaining production continuity.
- System Complexity: Five production facilities with unique layouts and silo configurations required customized solutions.
- Dual-Source Flexibility: The new system needed to support parallel operation of trailer-based and bulk bag-based material deliveries.
Project Implementation Challenges
Developing the solution required attention to several critical factors:
- Defining throughput and operational requirements (targeting 7-minute cycle per bulk bag).
- Sizing equipment for reliability and throughput while meeting budget and timeline constraints.
- Designing an efficient pneumatic conveying system.
- Managing complex field installations across varied facility layouts in multiple locations.
Solution
Laying the Groundwork
A structured project approach ensured alignment across stakeholders:
- Collaborative project planning between customer Project Management teams and Gerhart.
- Site-specific planning for the phased rollout—beginning with a pilot installation, followed by implementation across the remaining four sites.
System Design and Engineering
A dedicated Gerhart team engineered and manufactured a complete solution:
- Pneumatic Conveying System:
- Optimized pipe routing and elbow radii to maintain flow efficiency and material integrity.
- Strategic placement of diverter valves for operational flexibility.
- Properly sized blower systems with integrated heat exchangers for consistent conveying performance.
- Modular Equipment Package:
- Bulk Bag Unloader with operator access platform designed for ergonomic and safe operation.
- Integrated Control Panels with PLC/HMI and motor controls to enable seamless system management as well as integration to existing control systems..
- Detailed design review and approval process with customer engineering teams.
- Site-Specific Adaptations:
- Custom piping layouts developed for each facility based on on-site evaluations.
- Real-time adjustments made during field installation to accommodate as-built conditions.
Safety, Reliability, and Monitoring
The system was engineered for robust, reliable operation with advanced safety features:
- Equipment interlocks and instrumentation for system health monitoring.
- Physical barriers such as fencing and bollards installed per site-specific requirements.
- Operator-friendly controls and fail-safes to minimize risk and ensure consistent performance.
Installation and Commissioning
Gerhart provided full-service execution from design through commissioning:
- Mobilized skilled installation teams and provided on-site supervision.
- Maintained transparent project documentation and progress reporting.
- Collaborated with site facility management teams to ensure smooth integration with existing operations.
Continuous Improvement and Adaptability
As the system evolved, Gerhart was flexibile to meet emerging needs:
- Integrated custom safety gates with interlocks after initial installations, addressing feedback from facility Health, Safety & Environmental (HSE) reviews.
- Incorporated iterative improvements based on operational insights from each site.
Conclusion
Choosing the right partner is key to successfully transforming material handling processes. Gerhart combines deep industry knowledge with a hands-on approach—delivering solutions that are efficient, scalable, and built to last.
From initial concept through design, manufacturing, installation, and ongoing support, we collaborate closely with our customers to ensure every system meets operational goals and safety standards. In this project, our ability to manage complex, multi-site rollouts while adapting to evolving needs helped the customer achieve significant cost savings and long-term flexibility.
Whether you’re building a new facility or upgrading existing equipment, Gerhart works with you from concept to completion — and beyond.