BASF is a world-leading manufacturer of concrete admixtures and concrete repair products for the civil engineering and concrete manufacturing industries. BASF products have been, and continue to be, used in some of the world’s most progressive construction projects, including the Channel Tunnel.
At its modern, purpose-built manufacturing facility - complete with an on-site development laboratory - BASF operates a meticulously managed production schedule, now supported by two Adelphi Masterfil Boom Arm filling machines.
The Challenge
Disheartened with an existing filling machine that was frequently breaking down and had no spare parts available, BASF needed a more robust and reliable solution. The company required filling equipment capable of handling both foaming and non-foaming chemical products.
At the time, much of BASF’s filling process was manual. To improve time efficiency, reduce costs, and modernise operations, BASF needed to upgrade its filling technology.
The Solution
BASF installed two Adelphi Masterfil Boom Arm filling machines, each designed to improve productivity and operational flexibility:
One machine incorporates an integrated roller conveyor system that uses gravity to move filled IBCs, reducing energy consumption
The second machine features a 120-degree swinging boom arm, allowing IBCs to be filled side by side without repositioning
Both machines include intelligent in-flight adjustment of fill volume, automatically compensating for variations in product specific gravity. This saves time and prevents costly product overfill and waste.
Improved Time and Cost Efficiency
“The previous machine kept breaking down and had no spare parts availability,” recalls Paul Higson, Quality & Environmental Manager at BASF Swinton. He explains that the reliability of the new Boom Arm fillers now allows the Filling Supervisor to confidently leave the machine running while completing other production tasks.
A centrifugal pump constantly feeds the Boom Filler, enabling rapid filling performance. “We can fill an IBC in two minutes, depending on the product,” Paul reports.
The gravity-fed roller conveyor system saves energy by allowing full IBCs to move down the conveyor without powered assistance. The new filling machines also achieve vastly improved accuracy of ±0.2%, significantly reducing product waste and saving costs.
Increased Job Satisfaction and Safety for Operators
The proven reliability of the Boom Arm filling machines has allowed BASF’s operators to focus on higher-skill production tasks while the filler runs automatically. “It works really well!” says Paul.
He also highlights improved operator safety as a key benefit, noting that the machines reduce the likelihood of operators coming into contact with chemical products — an important consideration in chemical manufacturing environments.
Production Versatility for Multiple Products
The second Boom Arm filler’s 120-degree swing facility allows IBCs to be filled side by side simply by rotating the arm. This flexibility supports a wide range of BASF products with varying viscosities.
Some products are particularly prone to foaming; however, the Boom Arm filler includes the ability to adjust the fill style to minimise foam generation.
“We’re reliant on them,” says Paul. “They’re working 8–10 hours per day, five or six days per week, and we fill around 9,000 IBCs per year.”
A Trusted Filling Solution
“We’ve had them quite a while now, and I would definitely recommend Adelphi Masterfil’s machines,” Paul concludes.
