Addressing the challenge of inventory waste through equipment rental
Inventory waste remains a pressing concern in the manufacturing industry, particularly within pharmaceutical production, where precision and efficiency are paramount. Here, Stephen Harding, Managing Director of Gough Engineering, specialists in sieving and screening, explores the advantages of opting for rental solutions for sieving equipment instead of immediate purchases. He provides insights into how this approach can assist manufacturers in developing more sustainable production lines while reducing waste.
Waste poses a considerable challenge in the pharmaceutical industry. Overproduction is one issue, according to research by nVentic: “Many manufacturers make [according] to forecast and in large batches, with long lead times and little spare capacity reserved. This makes it extremely difficult to respond quickly to sudden changes in demand.”
nVentic’s survey of 28 companies found that manufacturers “systematically overproduce” with around four per cent of inventory being written off each year. Some companies did not provide any disclosure, while others reached as high as 15 percent.
On the other hand, the same report found that manufacturers still run short of specific medicines from time to time. The estimated cost of medicines written off at cost across the 28 benchmarked companies amounted to approximately $12.5 billion, a significant waste of capacity and resources.
Elsewhere, the University of Bath estimates that, for every kilogram of drug manufactured in the pharmaceutical industry, a staggering 100 kilograms (kg) of waste is produced. This presents a pressing challenge for pharmaceutical manufacturers who must seek innovative ways to minimise this significant waste output.
Minimising waste
The sieving process holds critical importance in the production of pharmaceutical powders. Consistency in particle size is paramount for quality control, directly impacting drug potency and patient safety by preventing incorrect dosing amounts.
Sieves with specified apertures play a vital role in minimising waste, alongside features such as high-quality stainless steel construction, precise welding and polished surfaces. United States Food and Drug Administration (FDA) compliance and meticulous machine design are other important factors, all contributing to easy cleaning and reliable sieving or separation capabilities.
In the ongoing quest to reduce pharmaceutical waste, manufacturers are exploring various strategies. One approach gaining traction is the rental of material handling equipment, instead of outright purchase.
Long-term returns
Investing in new machinery presents numerous challenges. There may be a significant financial burden associated with upfront costs. Additionally, predicting the long-term returns of machinery can be challenging, considering factors such as integration into the production line, reliability, and performance against key performance indicators (KPIs).
Quality and flexibility are also crucial considerations, particularly in terms of how well the equipment can adapt to industry changes. Selecting the appropriate machinery requires extensive market research, technical evaluations, and consideration of potential disruptions and training costs for staff upskilling.
Rather than purchasing the equipment outright, opting to hire equipment serves as a crucial confidence-building phase for manufacturers. This allows them to directly experience how the equipment integrates into their operations and performs. Let’s explore how renting equipment empowers manufacturers to test, adapt, and refine their operations while also alleviating the initial investment burden.
Sifting and separating
Various industries, spanning from food processing to chemical production, find value in equipment rental services. Renting equipment provides a flexible and cost-effective solution that caters to operational needs, whether it’s for proof-of-concept trials or routine quality checks. However, equipment rental entails more than just providing a machine; it’s about ensuring optimal performance tailored to specific applications.
Consider industrial sieves and separators as an example. These tools are essential for sifting and separating particles of different sizes, contributing significantly to material processing and manufacturing. They ensure product quality, consistency, and compliance with material resale or production requirements.
However, there’s no one-size-fits-all approach, and the equipment must be meticulously specified to meet the unique demands of each production line. Optimising the performance of industrial sieves and separators involves various design engineering considerations, including size of machine and screen areas, aperture sizes, mesh types (such as wire mesh or perforated plates), and machine vibration weight settings.
Avoiding risks
The approach of hiring equipment has been successfully adopted in various industries. For instance, Gough Engineering was approached by a manufacturer specialising in recycling small round plastic pellets.
Manufacturers in the plastic industry rely on plastic and masterbatch pellets for various production processes like extrusion and moulding. Despite their importance, these pellets often come with imperfections such as conglomerates (sticking together) or forming long strands and fine particles. These defects can lead to major product defects in the next forming processes, necessitating thorough screening to remove unwanted materials.
To address this need, Gough Engineering developed the Vibrecon Pellet Screen, offering an efficient solution for sieving plastic and masterbatch pellets. This innovative equipment employs a gyratory vibrating action across two screening decks to separate the mixed pellets into three fractions: longs, fines, and good pellets. Different aperture screening plates and sieving meshes can be fitted based on pellet size requirements, making the Pellet Screen versatile for various applications.
The manufacturer required equipment to separate oversized and fine particles consistently to ensure the quality of each pellet and maintain uninterrupted production. By providing vibratory screening equipment and conducting thorough testing, Gough Engineering demonstrated the efficacy of the rental solution, avoiding potential financial risks associated with purchasing unsuitable equipment and minimising product waste and rejection. The effectiveness of the Pellet Screen has led to its widespread adoption, with many pellet manufacturers utilising multiple units across their production lines to maintain quality and efficiency as a Masterbatch end-of-line final quality checking process.
The result is a consistent and accurate separation process that ensures high-quality pellets, minimising the risk of damage to production equipment and reducing material wastage.
Cost-effective operations
Pharmaceutical production shares similarities with other industries in the need for precise sieving and separation processes to maintain quality standards. However, due to the significantly smaller particle sizes involved, especially in pharmaceutical powders, additional techniques such as ultrasonics may be necessary for micron-level separation.
The rental model for manufacturing equipment offers several advantages, particularly for businesses contemplating long-term investments. By integrating rented machinery into their production lines, companies can thoroughly evaluate its performance before committing to a purchase. Furthermore, renting equipment can alleviate the financial burden associated with upfront purchasing costs, particularly for small or medium-sized enterprises, thus enabling cost-effective operations.
In summary, opting for rental solutions for material handling equipment not only aids in waste reduction but also enhances operational efficiency and mitigates risks. Gough Engineering further extends its support by providing specialised engineering assistance for testing ultrasonics equipment, catering to the very fine powder and particle sizes with specific requirements in sieving or separating at client sites.
In an era of increasing focus on sustainability and efficiency, the adoption of rental solutions for material handling equipment emerges as a strategic choice for pharmaceutical manufacturers. By partnering with experienced providers like Gough Engineering, companies can access cutting-edge technology, mitigate risk, and reduce waste throughout the production process. By renting, rather than buying, pharmaceutical manufacturers can pave the way for a more efficient, sustainable future.
For more information on Gough Engineering’s range of material handling equipment that’s available for hire, visit its website.
