Implementación de sistema dosificador gravimétrico para la disminución de costos por mermas en envasado de azúcar Empresas Iansa.
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Date
2024
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Publisher
Universidad de Concepción
Abstract
Empresas Iansa S.A. es una empresa agroindustrial líder en la producción y distribución de azúcar y otros alimentos naturales en Chile. Fundada en 1953, ha expandido sus operaciones a lo largo de los años, con presencia en el 98% de los hogares chilenos y siete plantas productivas. La dosificación es un proceso fundamental en la fabricación, y los dosificadores volumétricos y gravimétricos juegan un papel crucial en la precisión y eficiencia del proceso de envasado.
Actualmente, el proceso de envasado en Corte Menor utiliza dosificadores volumétricos que, aunque eficientes, presentan una desviación máxima de 10 gramos por unidad envasada, lo que ha generado un sobreconsumo de azúcar promedio de 0,86% entre octubre de 2023 y abril de 2024, equivalente a 301 toneladas de azúcar y un costo asociado de 223.171 USD. La meta de la empresa es reducir el sobreconsumo a un 0,6% o menos.
Para abordar este desafío, se propone la implementación de un dosificador gravimétrico de la marca Perfor, conocido por su alta precisión con una desviación máxima de solo 2 gramos. La metodología empleada en este estudio incluyó un análisis comparativo entre los sistemas volumétricos y gravimétricos, así como pruebas de campo para evaluar la efectividad del nuevo dosificador en términos de reducción de mermas y mejora de la eficiencia operativa.
En el año azucarero 2022-2023 el costo por merma de sobreconsumo fue de un total de $297.602 dólares en el área de corte menor, mientras que el año 2021-2022 el costo alcanzó los $459.230 dólares Los resultados obtenidos muestran que el dosificador gravimétrico permite una reducción significativa en el sobreconsumo de azúcar, logrando un ahorro de 4.527 USD mensuales en un solo cabezal (54.324 USD al año). Con respecto al sistema de dosificación volumétrico.
Finalmente, las conclusiones de este estudio destacan la viabilidad técnica y económica de implementar dosificadores gravimétricos en líneas de producción similares. Se recomienda extender esta tecnología a otras áreas de la planta para maximizar los beneficios y continuar con un monitoreo constante para optimizar los procesos de envasado.
Empresas Iansa S.A. is a leading agro-industrial company in the production and distribution of sugar and other natural foods in Chile. Founded in 1953, it has expanded its operations over the years, with a presence in 98% of Chilean households and seven production plants. Dosing is a fundamental process in manufacturing, and both volumetric and gravimetric dosers play a crucial role in ensuring precision and efficiency in the packaging process. Currently, the packaging process in Corte Menor uses volumetric dosers, which, although efficient, have a maximum deviation of 10 grams per packaged unit. This has resulted in an average overconsumption of 0.86% between October 2023 and April 2024, equivalent to 301 tons of sugar, with an associated cost of 223,171 USD. The company's goal is to reduce overconsumption to 0.6% or less. To address this challenge, the implementation of a Perfor brand gravimetric doser, known for its high precision with a maximum deviation of only 2 grams, is proposed. The methodology used in this study included a comparative analysis between volumetric and gravimetric systems, as well as field tests to evaluate the effectiveness of the new doser in reducing wastage and improving operational efficiency. In the 2022-2023 sugar production year, the cost of overconsumption wastage in the Corte Menor area was a total of 297,602 USD, while in the 2021-2022 year, the cost reached 459,230 USD. The results show that the gravimetric doser allows for a significant reduction in sugar overconsumption, achieving savings of 4,527 USD per month on a single head (54,324 USD per year) compared to the volumetric dosing system. Finally, the conclusions of this study highlight the technical and economic feasibility of implementing gravimetric dosers in similar production lines. It is recommended to extend this technology to other areas of the plant to maximize benefits and continue constant monitoring to optimize packaging processes.
Empresas Iansa S.A. is a leading agro-industrial company in the production and distribution of sugar and other natural foods in Chile. Founded in 1953, it has expanded its operations over the years, with a presence in 98% of Chilean households and seven production plants. Dosing is a fundamental process in manufacturing, and both volumetric and gravimetric dosers play a crucial role in ensuring precision and efficiency in the packaging process. Currently, the packaging process in Corte Menor uses volumetric dosers, which, although efficient, have a maximum deviation of 10 grams per packaged unit. This has resulted in an average overconsumption of 0.86% between October 2023 and April 2024, equivalent to 301 tons of sugar, with an associated cost of 223,171 USD. The company's goal is to reduce overconsumption to 0.6% or less. To address this challenge, the implementation of a Perfor brand gravimetric doser, known for its high precision with a maximum deviation of only 2 grams, is proposed. The methodology used in this study included a comparative analysis between volumetric and gravimetric systems, as well as field tests to evaluate the effectiveness of the new doser in reducing wastage and improving operational efficiency. In the 2022-2023 sugar production year, the cost of overconsumption wastage in the Corte Menor area was a total of 297,602 USD, while in the 2021-2022 year, the cost reached 459,230 USD. The results show that the gravimetric doser allows for a significant reduction in sugar overconsumption, achieving savings of 4,527 USD per month on a single head (54,324 USD per year) compared to the volumetric dosing system. Finally, the conclusions of this study highlight the technical and economic feasibility of implementing gravimetric dosers in similar production lines. It is recommended to extend this technology to other areas of the plant to maximize benefits and continue constant monitoring to optimize packaging processes.
Description
Tesis presentada para optar al título de Ingeniera Civil Industrial
Keywords
Agroindustrias, Azúcar, Administración de la producción