Background

A leading US manufacturer specializing in insect control solutions required a more efficient way to manage raw material handling at its Dallas, Texas production facility. The site supports the manufacture of insect growth regulators (IGRs) and other insecticides, alongside the development of proprietary pest control technologies for agricultural, professional and public health markets. It also supports livestock and agricultural environments through targeted insect control solutions.

With production demand increasing, the business identified the need to modernize part of its ingredient handling process to improve throughput, reduce reliance on manual labor and create a safer, more streamlined production environment.

Akona Process Solutions was selected to design and deliver a fully integrated bulk handling solution that would work seamlessly with the customer’s existing Marion by Akona mixer and support future growth.

The Challenge

The existing process relied on manual loading of ingredients into the mixer, resulting in long batch times and limiting overall plant capacity. In addition to being labor-intensive, the process created inefficiencies that restricted throughput and consistency.

The manufacturer required a more advanced solution
that would:

• Increase production capacity
• Reduce manual handling and operator involvement
• Improve batch consistency and process control
• Minimize dust during material transfer
• Introduce surge capacity between material intake and mixing

Ultimately, the goal was to transition from a manual process to a fully integrated bulk-handling system capable of higher output while improving operational efficiency.

The Solution

Akona Process Solutions designed and delivered a bespoke system that combines multipletechnologies into a cohesive process.

The solutions included:

• Bulk bag unloader
• Bag dump station
• Cablevey tubular drag conveyor
• Custom-designed surge hopper
• Integration with the existing Marion mixer

Engineered to convey material at 3,000 lbs per hour, the system provides precise dosing, enclosed dusttight conveying and controlled surge capacity to optimize mixer feeding.

A key feature of the system is the custom surge hopper, designed with an access door to improve maintenance and usability. The overall system layout was carefully engineered to fit within the existing plant footprint while maximizing performance.

During installation and commissioning, Akona implemented additional enhancements—including an air knife assembly—to ensure optimal system performance and alignment with site requirements.

The Result

The completed system successfully transformed the customer’s material handling process, delivering increased throughput and improved operational efficiency.

Key benefits include:

• Increased production capacity
• Reduced manual labor requirements
• Faster and more efficient batch cycles
• Improved cleanliness through enclosed, dust-tight conveying
• Greater consistency and dosing accuracy
• Enhanced process reliability and scalability

By automating material intake, transfer and controlled discharge to the mixer, the manufacturer now benefits from a more efficient, safer and future-ready production operation.

“Akona worked closely with us to understand our process and delivered a solution that aligned with our production goals. By automating key stages of material handling, we’ve been able to improve throughput, reduce manual intervention and create a more consistent and efficient operation.”

Want to learn more?

If you’re interested in our bespoke systems and want to learn more, speak with our team. We’ll work closely with you to find the best solution for your material processing and operational goals.