By Greg Washburn and Joshua Belisle · Edited by Dana Gardner
Published August 6, 2024 · Reviewed by Greg Washburn · August 20, 2026
Summary
Why should a plastics processor switch to a central conveying system?
A central conveying system automates resin handling, replacing buckets, bags, ladders and manual labor with automatic moving and loading equipment. That reduces waste, manpower and injuries, improves part quality, saves floor space and increases up-time. Self-contained loaders are a step up from the bucket brigade, but they are high energy users, need brush and motor replacements, and leave Gaylords and forklifts on the production floor.
Increasing profits, satisfying customer demands and improved utilization of production floor space are all good reasons to install a new plastics conveying system.
What does that really mean?
What we are talking about is automating the resin handling process – getting the buckets, ladders, pallets, bags, muscle and brooms out of the manufacturing process and replacing those things with efficient, automatic moving and loading devices to reduce waste, manpower and injuries, improve part quality, save space and increase production and response time…in other words… INCREASE YOUR “UP-TIME” AND REDUCE YOUR COSTS TO IMPROVE YOUR PROFITS AND YOUR COMPETITIVE POSITION IN THE MARKETPLACE.
Each time we add a piece of equipment that automatically moves resin from a container to a dryer, blender, process machine or granulator we are taking a step in the direction of automation.
Even the smallest of processors benefit from adding Vacuum Loaders or Air Loaders with self-contained controls to remove resin from a Gaylord. Though these solutions are an improvement over the bucket brigade, they are high energy users and require extra labor to replace brushes and motors. On top of that, the production floor is still clogged with Gaylords and the forklifts to move them on and off the floor. Anyone using vacuum loaders as their primary way of transferring material should consider upgrading to a central conveying system.
Small to medium sized processors can utilize multiple automation methods to develop an integrated system, which gets material containers off the production floor, reduces energy and direct labor costs, virtually eliminates material waste and greatly improves process efficiency.
Large processors have infinitely greater options. Bags, barrels and Gaylords of primary resins can be eliminated in favor of bulk deliveries by truck or railcar. Bulk Unloading Systems can be used to transport resin to outdoor silos or to indoor bulk storage bins away from the production floor. Usually, larger Material Handling Systems include one or more Central Drying Systems, which further reduce overall costs.
Overcoming the Fear Factor
Just the mention of installing an integrated resin handling system can bring fear and uncertainty into the minds of many processors. In truth, there is nothing to fear and the uncertainties about the results are minimized by working with a highly qualified systems group that has decades of experience in designing and installing resin handling systems.
Experience isn’t the only factor to consider. You must also have confidence that the people you choose to work with offer leading edge technology so your system can be expanded as your company grows and the technology will still be relevant in years to come.
The real question is this – Can you justify installing a Central Resin Handling/Drying System? See The Cost of Not Having a Central System and Investment Payback in Months – Not Years.
Frequently Asked Questions
Are vacuum loaders enough for a small plastics processor?
Self-contained vacuum loaders or air loaders on Gaylords are an improvement over moving material by hand, and even the smallest processors benefit from them. They are high energy users and need extra labor to replace brushes and motors. Gaylords and the forklifts that move them still clog the production floor, so plants relying on loaders as their primary transfer method should consider a central conveying system.
What does a central conveying system do for a mid-sized molder?
Small to medium processors can combine several automation methods into an integrated system. That moves material containers off the production floor, reduces energy and direct labor costs, cuts material waste and improves process efficiency. Automation can also be built in steps: each piece of equipment that moves resin automatically from a container to a dryer, blender, process machine or granulator is a step toward a full system.
What does a central resin handling system look like at a large plant?
Large processors can replace bags, barrels and Gaylords of primary resin with bulk deliveries by truck or railcar. Bulk unloading systems then move resin to outdoor silos or indoor bulk storage bins away from the production floor. Larger material handling systems usually include one or more central drying systems, which further reduce overall costs.
About the Authors
Vice President of Operations, Novatec
Greg Washburn is Vice President of Operations at Novatec and has been with the company for more than three decades. He is involved in all phases of engineering design and product manufacturing, giving him a broad perspective on how resin drying and conveying equipment moves from engineering concept through production and into real-world processing environments. Greg holds a B.S. in Mechanical Engineering from the University of Maryland, Baltimore County (UMBC) and an MBA from Loyola University Maryland. His experience spans engineering, manufacturing and operations across Novatec’s material-handling technologies.
Technology Manager, Novatec
Joshua Belisle is Technology Manager at Novatec, where his work focuses on simulation and technology development for resin drying. He earned a B.S. in Mechanical Engineering with a minor in Engineering Business from the University of Virginia in 2023 and joined Novatec that same year. Joshua uses simulation tools to investigate previously difficult-to-measure aspects of the drying process, helping Novatec better understand airflow, heat transfer and other variables that influence resin-drying performance.
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