Introduction
Syngenta, world’s leading agribusiness and seed multinational, has establishments in more than 90 countries with a singular mission: to bring plant potential to life. They are constantly developing new seed varieties to maximize crop yields for farmers worldwide, now and in the future. However, the challenge lies in accurately counting seeds, especially hybrid ones. This article delves into Syngenta’s quest for a solution and their transformative partnership with Cremer.
Business challenge
Syngenta was looking for a machine that would allow them to count all product shapes, even the smallest vegetable seeds, coated and static seed, with 100% accuracy and with unrivaled speed. The seeds were already being counted with counting machines, but these were technically outdated. The controls and design of the safety circuit was also not user friendly. When an operational mistake was made, the whole machine stopped completely and a technical engineers was needed to read out the fault.
Dennis Wong Swie San, expert packaging at Syngenta explains: “Together with our engineers, we investigated how to realize our needs, what was desirable and whether they were already familiar with possible solutions. They proposed a concept and suggested Cremer as a supplier because of their prior experience with machinery for living products like flower bulbs, ensuring minimal damage during handling.
After a visit from Cremer at Syngenta they teamed up to conceive and develop a pilot project for a 100% accurate seed counting solution. It started with a counting machine but ended with a fully integrated seed counting and packaging line. Walter Hermans, Business manager agricultural at Cremer states: “We are proud to have gained the trust and recognition of such a highly reputable company.”
CSC seed counting machine
For more than a year and a half Syngenta and Cremer worked together to develop a counting and packaging solution meeting today’s business and technical requirements. The collaboration resulted in the next generation of seed counting technology, combining many decades of experience in the agricultural industry with the most advanced and reliable counting technology on the market. Dennis says, “The goal of the machine was to streamline the counting process and eliminate the need for manual adjustments. Users should be able to select the desired seed program (recipe) and press start upon which the machine autonomously completes the program.” The CSC seed counting machine is specially developed for high-speed metering of seed counts in conjunction with any third-party bag filling or packaging machine.
Line integration and management
The seed counters with 2 x 20-channels of 17 mm were placed on a platform and at the same spot as the original counting machine, directly above the bag filling machine and over the existing conveyor belt. Walter: “We developed the seed counter and installed it at Syngenta where they tested the machine functions. Then they asked us to also handle the infeed and transition of product to the counting and packaging machine, as well as integrating the end of line packaging robots in the scope of the project.”
Counting 25.000 seeds per minute requires a seamless integration between the counting system and the packaging machine to ensure there is no possibility for product spillage. Walter continued: “As Syngenta was the first company to use this machine, we had to learn and adapt together. In consultation, we carefully selected the machines that best suited our system, making adjustments where necessary to align with the production line or specific requirements.”
Advantages of the seed counter
Utilizing the seed counter offered Syngenta a number of advantages.
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- Autonomous management of large orders: The CSC seed counting machine excels in managing large orders autonomously. Up to 12,500 seeds per minute per counting module.
- Guaranteed accuracy and reliability: With a guaranteed counting accuracy of 100% and unwavering reliability, users can trust that once a task is initiated, the machine will see it through to completion; interruptions overnight are rare.
- Quality control with sensor technology: Equipped with sensors throughout, the machine ensures quality control at every stage, meticulously checking for proper bag opening for filling and ensuring bags are correctly aligned for sealing.
- Efficient handling of sachets: Moreover, it efficiently handles sachets, sourced either from a warehouse where pre-prepared bags are stocked or from rolls, with minimal downtime during transitions.
- Easy maintenance: The seed counter is easy to disassemble and generally does not require any change parts for different seeds. Because of its GMP-compliant and modular design, removal of the product contact parts requires no tools.
- Convenient positioning: The counting system can be conveniently positioned above most industrial bagging and pouching machines.
- Adaptability: Remarkably, the machine is adaptable to transport all seeds without necessitating any change parts for different varieties. However, it’s crucial to note that while the system excels in counting, it’s not designed for sorting purposes; seeds must be thoroughly cleaned beforehand.
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Modular design and scalable performance
The CSC is a modular system based on the concept of Cremer’s pharmaceutical tablet and capsule counters with a GMP-compliant design. Its modular configuration allows for scalable performance and output. One module can count 12,500 seeds per minute or will discharge 50 discharges per minute. When more output as 12,500 seeds per minute is desired, more modules can be added to a maximum of three. There is no difference in speed and accuracy to count tomato seeds or for example pumpkin seeds. The scalable output and amazing precision makes the CSC the most reliable, efficient and versatile seed counter on the market.
System configuration
The seeds start in a bunker and are transported upwards through a pneumatic vacuum conveyor for dust-free seed transport. They are metered in volume, so there is always an equal amount of seed deposition on the first vibratory plates.
By means of vibration the seeds are transported forward and separated on the vibratory plates. To count with 100% accuracy, good separation is very important. At the end of the vibratory plates, the seeds falls through the seed counting module by means of gravity and are counted by LED light beams.
After counting, the seeds fall through a rotating filling nozzle into a sachet on the cartoner and the sachets are filled with an exact count. The filled sachets are closed and further handled in the bag filling machine and transported via a conveyor belt to the end-of line robots which pack the sachets in bulk packaging (boxes).
Revolutionizing efficiency and quality
Dennis highlighted the impact of the CSC counting machine at Syngenta: “With the addition of the CSC counting machine, we have significantly enhanced efficiency, resulting in higher production output and 100% accurate counts, thus ensuring top-notch quality for our customers.” Eliminating incorrect packaging marks a significant step forward, setting a precedent even among competitors. “By pooling our knowledge, we are strong together. Walter added: “The CSC counting machine has been received with great interest and expectations because of its high speed / capacity and 100% counting accuracy. Meanwhile we already received new requests for quotation for this solution.”
Challenges
‘’During commissioning and start-up of the total solution there were some challenges remembers Ahmet Bilgen, operator 1 at Syngenta as he reflects on the initial challenges and lesson learned.’’ However they were quickly resolved in a timely and satisfactory manner. Dennis further elaborates on the specific challenges with small size seeds in the beginning. Cremer took action and initiated a design change to further improve the performance.
A collaborative journey
Our collaboration was a journey of learning and growth,” reflects Ahmet. “But we also had many ambitions”. Confidentiality as well as detailed and intensive technical discussions marked the early stages, as Walter recalls: “We signed confidentiality agreements and thereafter deeply immersed into the technical possibilities and alternatives together. It took us 1,5 year to develop the concept.”
Working together brought challenges in meeting the high demands for Syngenta’s customers. However solutions were always found together, as Dennis asserts: “If we were told it couldn’t be done, we didn’t resign ourselves to it.” Walter acknowledges that there were challenges, as usual in product/solution development, yet emphasizes, “We kept communication open, which resulted in making this a successful project.” Dennis nods in agreement and adds, “This keeps us sharp, pushing boundaries and finding solutions together.”
Conclusions
The collaborative effort between Syngenta and Cremer exemplifies the power of partnership in innovation within the agricultural industry. Through conscious and thorough development and integration, the CSC seed counting machine has revolutionized efficiency and quality, enabling higher production output and ensuring 100% accurate counts. This advancement not only meets the demands of Syngenta’s demanding customers and markets but also sets a new standard in seed counting technology.