Accuracy Test Results

Objective: To set aside verbal or published accuracy claims in blender technologies and
provide measured “Real World” results. The units tested were in production making film. Two
tests were performed in different facilities and supervised by the customer.

Additive ingredients are the highest of your raw material costs and for that reason these tests
were concerned mainly with the additive ingredient accuracies.

TEST #1 – BATCH BLENDING TECHNOLOGY

Background: A large producer of film located in the Midwest asked CRG Logics to perform
testing on a number of batch blending systems they were considering retrofitting with our PLC
Based Control Systems. We had done a number of other systems in this facility whose controls
had become obsolete. Samples were taken from a number of slide gate style batch blenders.

Methodology: The blenders had been running and feeding a process for 8 hours. Approximately
1 pound samples were drained out of the extruder adapter while the machine was still running.
This prevented any upset to the blender or the extrusion process. The samples were then taken to
an independent lab for separation and weighing.

Batch Blender Test Results: Following is a summary of the results of the batch blender test:

Test 1 Normalized Data

2
1.8
1.6
Weight Percent

1.4
1.2 Target
1 Red
0.8 Green
0.6
0.4
0.2
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

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 Test One Data Analyzed (Target = 1)
High Variation = (Red) 1.8 (Green) 1.5
Low Variation = (Red) = 0.85 (Green) 0.75
High Error = (Red, 0.8/1) = 80% (Green, 0.5/1) = 50%
Low Error = (Red, 0.15/1) = 15% (Green, 0.25/1) = 25%
Average Error = Red = 6% Green = 31%

Test 2 Normalized Data

2
1.8
1.6
Weight Percent

1.4
1.2 Target
1 White
0.8 Yellow
0.6
0.4
0.2
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Test Two Data Analyzed (Target = 1)

High Variation = (White) 1.6 (Yellow) 1.85
Low Variation = (White) = 1 (Yellow) 0.8
High Error = (White, 0.6/1) = 60% (Yellow, 0.85/1) = 85%
Low Error = (White, 0.0/1) = 0% (Yellow, 0.2/1) = 20%
Average Error = White 26% Yellow = 28%

TEST CONCLUSION

This real world test shows an average error of 6% - 31% over several batches for a 1% additive
(Approximately 20 lbs of material). Using the accuracy statement supplied by the vendor the
error should be 5% (variation/Target = 0.05 of batch size/1 = 5%). The individual samples
varied as much as 80%. The sample size was about
of the batch size and this variation
indicates a poorly distributed blend. (Apart from blend accuracy this is the main weakness of
batch blending.)

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TEST #2 – CONTINUOUS BLENDING TECHNOLOGY

Background: Test 2a. A large producer of film located in the Southeast had purchased a CRG
SIMPLICITY Continuous Blending System on trial pending accuracy testing. Test 2b. A large
producer of film in the Midwest purchased 7 simplicity blenders and verified the accuracy of the
blend at their facility

Methodology Test 2a: The feeders on the blender were reversed to keep the material separated.
This prevented the need for manually separating the pellets. The blender was run for 5 minutes
and then stopped. Empty buckets were then placed under each feeder. The blender was then
restarted for 5 minutes and then stopped. The material was taken offline and weighed by the
customer.

Methodology Test 2b: Same as test 2a except the blenders were run to a set weight of 50 lbs
and then shut off automatically.

Continuous (SIMPLICITY) Blender Test Results:

Test 2a:
Hopper
1 Hopper 2 Hopper 3 Hopper 4
act weight 17.36 4.075 0.82 18
desired weight 17.7122 4.0255 0.8051 17.7122
pct error absolute 1.99% -1.23% -1.85% -1.62%
Act pct of total 43.13% 10.12% 2.04% 44.71%
Set pct of total 44.00% 10.00% 2.00% 44.00%
act pct error 0.87% -0.12% -0.04% -0.71%
feeder rate pph 211.20 48.00 9.60 211.20

Test 2b:
Hopper 1 Hopper 2 Hopper 3 Hopper 4
act weight 34.01 9.99 5.01 1.07
desired weight 34.0544 10.016 5.008 1.0016
pct error absolute 0.13% 0.26% -0.04% -6.83%
Act pct of total 67.91% 19.95% 10.00% 2.14%
Set pct of total 68.00% 20.00% 10.00% 2.00%
act pct error 0.09% 0.05% 0.00% -0.14%
feeder rate pph 136.00 40.00 20.00 4.00

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TEST 2 CONCLUSION

The average blend accuracy for the additive components was 4.37% absolute. The sample size
was small. The dispersion of the blend in a continuous blender is absolute due to the fact that
materials are dosed simultaneously. There will be near zero sample to sample variation.

OVERALL RESULTS AND CONCLUSION

Actual results showed the average additive ingredient accuracies to be 4.3 times greater
with the CRG Logics SIMPLICITY blending system than various Batch Style Slide Gate
Blending Systems.

The customer in Test #1 has switched to Continuous Technology on all future blending system
purchases. The Customer in Test #2a accepted the equipment and is in the process of purchasing
additional systems. The customer in Test #2b has gone on to purchase 23 Simplicity blenders
and has standardized on CRG Logics, Inc Simplicity blenders.

IMPACT TO THE BOTTOM LINE

Based on the results of these tests it can be shown that our customers are realizing the following
savings by switching to the CRG Logics, Inc Simplicity blender:

Additive cost/lb $4 Additive cost/lb $4

Average error (batch) 18.50% Average error (batch) 31.00%
Average error (continuous) 4.37% Average error (continuous) 1.00%
System rate in lbs/hr 1500 System rate in lbs/hr 1500
% machine downtime 7% % machine downtime 7%
Additive % 2% Additive % 2%
Additive rate in lbs/hr 30 Additive rate in lbs/hr 30
Hours in a year 8760 Hours in a year 8760
Hours in production 8146.8 Hours in production 8146.8
Savings per hour $16.96 Savings per hour $36.00
Yearly savings $138,137.14 Yearly savings $293,284.80

The first chart above assumes worst case scenario for the additive error in a continuous blender
(4 PPH federate). If you look at the test results it is very clear that accuracy improves at higher
rates. This is the opposite for batch blending. As rates increase accuracy is sacrificed. Most
companies that manufacturer batch blenders state this. This is due to the fact that each ingredient
is dosed and weighed separately. As you speed this process up you lose the ability to tightly
control the feed device and accurately weigh the disbursed material. The second chart above is a
much more realistic chart for comparing batch and continuous at a system rate of 1500 PPH.
These are real dollars that impact your company’s bottom line. CRG customers are realizing
these savings.

610 BAETEM ROAD, GREEN BAY, WI 54304 • PH: 920 • 884 • 7400 • WWW.CRGLOGICS.COM • FX: 920 • 884 • 7404