Case Study: Alaron Doubles Productivity with the Russell Compact Sieve®

Background:

Alaron is a leading contract manufacturer based in New Zealand, specialising in health supplements, complementary medicines, therapeutic goods, and skincare products. Known for its commitment to quality, Alaron has been a GMP-certified (Good Manufacturing Practices) company for over 20 years. It has built a strong reputation by delivering market-ready products to customers across the globe, using cutting-edge materials and manufacturing technologies.

The company processes large quantities of powdered raw materials, both locally and internationally sourced, to create various product formulations. However, Alaron faced significant challenges in its initial powder screening process, prompting them to seek a more efficient solution.

The Challenge:

Alaron’s original powder screening method involved manually sieving large batches of raw materials, a process that often led to slow throughput and bottlenecks. The sieving equipment they used also had several limitations:

• Slow throughput: The existing screening methods were inefficient and restricted production capacity.
• Difficult cleaning: The sieves were hard to disassemble and clean, requiring considerable time and effort from operators.
• Design flaws: The equipment design made it challenging to maintain hygiene standards, as certain areas of the sieves allowed product buildup, increasing cleaning time and complexity.

With their production process already operating at full capacity, Alaron needed a solution that would streamline operations, reduce downtime, and improve throughput without compromising the quality of their products.

The Solution:

Alaron was introduced to the Russell Compact Sieve® by Advanced Packaging Systems (APS) during the 2016 Foodtech Packtech trade show in Auckland. The Russell Compact Sieve® demonstrated impressive throughput rates and an innovative design that addressed many of Alaron’s concerns.

After the event, Alaron decided to purchase a Russell Compact Sieve® (UK site) to improve their powder screening process. The sieve’s compact design, higher throughput capacity, and ease of use quickly became evident. Impressed by the results, Alaron invested in more units, eventually acquiring four Russell Compact Sieve® machines, with plans to purchase more. In addition, the company also ordered two Russell Finex Mini Sifters for smaller sieving projects.

Key Benefits:

1. Increased Production Rate: The Russell Compact Sieve® has been a game changer in terms of throughput. By replacing the standard vibrating screens, Alaron was able to double its production capacity. The higher throughput capacity allows them to process more powdered material in less time, directly impacting the company’s ability to meet customer demand without delays.
2. Reduced Cleaning Downtime: One of the standout features of the Russell Compact Sieve® is its ease of cleaning. The machine’s quick-release mechanism allows for easy disassembly, making cleaning faster and more efficient. Unlike the previous sieves, which were labour-intensive to clean, the Russell sieve’s design reduces product buildup, ensuring that operators spend less time maintaining equipment and more time on production.
3. Improved User Experience: The machines are designed to be easy to set up and operate. With minimal training, Alaron’s operators quickly adapted to the new equipment. The units run 24/7, and the simplicity of the sieve’s design has contributed to a smoother workflow and greater employee satisfaction.
4. Noise Reduction: The Russell Compact Sieve® is also equipped with a rubber suspension system, which significantly reduces noise levels during operation. This feature ensures a quieter work environment, which is especially beneficial in a factory setting where prolonged exposure to high noise levels can lead to operator fatigue and safety concerns.
5. Durable Construction: The Russell Compact Sieve® is built to last, with high-quality materials and precise engineering. According to Alaron’s Operations Manager, Nigel Gray, “The units are built by Russell Finex in the UK, and you can see the quality of craftsmanship wherever you look on the unit.” The machines’ durability has contributed to reduced maintenance costs and fewer breakdowns.

Results:

By switching to the Russell Compact Sieve®, Alaron has significantly improved both its efficiency and production capacity. The ability to process powdered materials faster has had a direct positive impact on their overall output. With the ease of cleaning and the robust design, downtime has been minimised, allowing Alaron to focus on scaling its operations rather than dealing with the complexities of machine maintenance.

“Our business has grown rapidly in the last few years and the sieves have played a large part in making that growth efficient and manageable. The Russell Compact Sieve enables us to keep on top of the orders and deliver to our customers in a timely fashion” Nigel Gray, Operations Manager

Any Questions?

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