How Akshar Polymer Increased Packaging Speed by ~70% with SmartFill Altus
Industry
Tile Accessories Manufacturing
Application
Tile Leveling Wedges & Tile Spacers
Product Range
- Tile leveling wedges
- Tile spacers (2mm to 10mm)
Pack Sizes
50g to 200g
About Akshar Polymer
Akshar Polymer is a growing manufacturer from Gujarat of tile leveling wedges and tile spacers used across the construction and tile installation industry.
As production volumes increased, the company needed:
- faster packaging
- better weighing consistency
- improved machine reliability
- reduced operational bottlenecks
The challenge was clear:
their existing packaging setup had started limiting growth.
The Challenge
Akshar Polymer was already using a 10 Head Multihead Weigher.
While the machine performed adequately during the company’s early growth phase, the owner always believed that:
choosing only the “economical option” would eventually limit long-term scalability.
The existing setup delivered:
~40–45 WPM
for 50g–200g packs.
But increasing production demand required:
- higher throughput
- smoother product handling
- more reliable operation
- lower packaging losses
Looking Beyond Conventional Solutions
The Akshar Polymer team visited SmartFill’s manufacturing and R&D facility in Ahmedabad to explore faster and more advanced weighing solutions.
During the visit, the newly developed:
Altus 14 Head Multihead Weigher
immediately drew attention.
What it offers?
- upgraded architecture
- higher-speed combination capability
- advanced product handling
- modular electronics platform
gave confidence that it could solve the company’s production challenges.
Akshar Polymer decided to move forward with Altus.
A Real-World Engineering Challenge
During final inspection before dispatch, the SmartFill team observed an unexpected issue.
The:
90mm long tile wedges
were occasionally getting stuck inside the individual discharge chute after release from the weigh buckets.
This was not a standard food-product flow problem.
The geometry and length of the wedges created:
- product alignment issues
- chute congestion
- inconsistent discharge behavior
Engineering Response
Instead of forcing the product to fit the machine,
the SmartFill team redesigned the machine around the product behavior.
Within:
48 hours
the R&D and mechanical teams:
- redesigned the discharge chute
- developed a new mounting structure
- optimized the product release path
to allow:
- freer product movement
- smoother discharge
- stable high-speed operation
This is where application-focused engineering becomes critical.
The Result
Before
10 Head Multihead Weigher
- ~40–45 WPM
- standard discharge system
After
14 Head Altus Multihead Weigher
- ~70–75 WPM
- optimized chute architecture
- improved product flow
- higher operational efficiency
Result:
~65–70% increase in packaging throughput
without compromising weighing stability.
Smart Rejection Feature
Reducing Unnecessary Packaging Costs
One of the most valuable additions in the Altus system was:
Timing Bucket Rejection Logic
Traditional systems often detect:
- underweight packs
- overweight packs
only after packaging using a checkweigher.
This results in:
- unnecessary pouch usage
- additional packaging material cost
- product wastage
- rework handling
SmartFill Solutions
Altus was configured with:
Pre-Packaging Weighment Rejection
Correct weighments:
→ sent directly to the FFS machine
Underweight / overweight combinations:
→ diverted to rejection chute before packaging
This helped Akshar Polymer:
- reduce packaging wastage
- save film cost
- reduce rejected finished pouches
- improve production efficiency
Why This Project Matters
This project was not simply about installing a faster machine.
It demonstrated how:
- application understanding
- product behavior analysis
- rapid engineering response
- customization capability
can directly improve factory productivity.
At SmartFill Solutions, we believe:
machines should adapt to products — not the other way around.
- +91 9099035243
- [email protected] | [email protected]
- www.smartfill.in
- Ahmedabad – Vatva, Gujarat, India
