Case Studies

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Precision Packing
Janitorial Product Formulation & Blending
Developing Biocides
Biocide Granulation & Size Reduction
Oil Well Biocides
Static Sensitive Biocides
Coloured Dishwasher Additive
Detergent Colourant
Medicated Feed Supplement
Veterinary Medicine

Precision Packing

The Challenge
To weigh and pack temperature sensitive hazardous catalyst in 2 and 5 gram quantities plus or minus 10 mg.

Our Approach
We constructed a product specific, dehumidified and temperature controlled clean room where we use precision pharma measuring apparatus to meet the customer’s requirement.

The Result
The customer eliminated a key production constraint by outsourcing the problem. Crack now have preferred supplier status.

Janitorial Product Formulation & Blending

The Challenge
Meeting short term capacity constraints on a range of granular chlorine donor products.

The Task
Formulating, blending and packing 20 and 25 Kg. UN approved pails and sacks.

The Result
We now provide a total supply solution to meet our customer’s seasonal needs.

Developing Biocides

The Challenge
A personal care product customer required minute quantities of a hard clear glass like resin Hygroscopic Biocide in powder form.

Our Approach
Trials on our pilot plant established the product became deliquescent (slush like) with conventional milling. We developed a dry air milling process and in a dehumidified room packed the end product into foil laminate bags with a long shelf life.

The Result
The company was able to provide new P.C.P.’s with a much extended shelf life.

Biocide Granulation & Size Reduction

The Challenge
Conversion of solid cast 100 Kg. drums of a hygroscopic active biocide in sub-micron powder and then pack and distribute.

Our Approach
Trials of various methods resulted in cutting the steel drums to expose the product followed by 3 stage size reduction.

The Result
The customer outsourced a hazardous labour intensive task and has a better product with reduced fines.

Oil Well Biocides

The Challenge
Our client, a multi-national oilfield chemicals supplier wished to develop a safe down-well bactericide based on liquid highly toxic active ingredients and, lacking in-house expertise, approached us to solve the problem.

Our Approach
We developed a slow release granular product on our pilot plant and then went into production packing the finished safe handling product into 5 Kg. UN approved large opening containers for site use.

The Result
Safe global use in the oil industry of a highly effective active ingredient not otherwise useable.

Static Sensitive Biocides

The Challenge
Our customer required regular but periodic packing for a powdered biocide with a high risk of electrostatic explosion.

Our Approach
We developed a stand alone, earthed and explosion resistant packing plant to meet our customer’s exacting requirements.

The Result
Our customer’s safety problems were overcome and small quantity orders met.

Coloured Dishwasher Additive

The Challenge
To produce small volume multi-coloured Sodium Carbonate additive for a detergent manufacturer for internal use.

Our Approach
We contacted the clients’ European plants to establish demand and performance specifications. We developed a customer specific medium sized colour coated granule with minimal dust.

The Result
A satisfied customer. We are producing pilot runs with a view to long term production.

Detergent Colourants

The Challenge
A multi-national customer, due to existing supplier problems, asked us to develop non-staining multi-coloured hand wash additive with less than 4% moisture content.

Our Approach
We contacted customer approved dyestuff suppliers, formulated and colour matched new formulations for pilot trials and field testing.

The Result
An improved product using alternative dyestuffs and mixing technology at reduced cost with better market acceptance.

Medicated Feed Supplement

The Challenge
A U.S. manufacturer shipping antibiotic based medicated feed supplements wished to reduce EEC import dues and improve their margins by selling small packs.

Our Approach
Using our veterinary approved plant, the bulk active ingredients were delivered direct to our plant, blended and formulated to the customer’s specification and the finished product packed in 8 to 3 Kg cartons.

The Result
Our customer substantially improved their products profitability and reduced stockholding and lead times.

Veterinary Medicine

The Challenge
A major veterinary and pharma supplier in the course of restructuring made the decision to move site and outsource the processing, packing and blending of their medicated animal pre-mixes as well as storage and warehousing.

Our Approach
We developed a total supply concept to meet our customers’ needs. We agreed to purchase some of the ingredients and all of the packaging and stock-hold these other than the active anti-biotics and provide regular short run bulk blending, applying the active ingredients to an inert base in both powder and granular forms.

he Result
The customer was able, due to our short lead times and as the result of outsourcing, to substantially reduce their warehousing costs and stock levels.