And our mission is simple: to revolutionize the global flood mitigation industry virtually overnight by saving countless lives and preventing billions of dollars in property damage, in what must be the most catastrophic conditions known to man - tsunamis, hurricanes, floods, mudslides, and even armed conflict itself - using our unique, fully-automated sandbagging technology.
The worse, the better. And, yes, as a matter of fact, fiasco really is our middle name.
And then hanging out with the wrong people, of course. Seriously, we have always believed that there is a certain poetry in imagining elegant, effective and simple solutions to the everyday problems that plague us (no matter how crazy or mundane), and then trying to turn those solutions into reality. A thing of beauty is a joy forever, as the saying goes, especially if it works.
Back in 1995 we became involved with a visionary group of industrial designers and world-class engineers and, after 5 years of hard work and sweat, we built a prototype that was impressive enough to get us in the door at Vermeer Manufacturing in Pella, Iowa.
A big part of our inspiration for "Sandhog" was born of a shared frustration: we really disliked the mediocrity and waste we saw all around us, especially when it was due to a failure of imagination, or intellectual dishonesty, or sloth, (shoddy workmanship also galled us all) that then became accepted as inevitable and somehow "good". So we gave ourselves a real challenge - could we advance our civilization 1200 times/hour simply by filling sandbags faster and with more finesse than they've ever been filled before?
"SandDog" is the 2.0 version of this revolutionary machine. We went back to basics by simplifying things, making it easier to operate and service, cheaper, and more reliable too. Long may it rain.
Magically delicious. Just kidding. Let's be clear about one thing, the SandDog is not a reinvention of the wheel. It's not even a particularly clever use of a technology that's already used extensively in the packaging industry - the vertical form fill sealer (VFFS) - whenever bulk granular material of any description needs to be bagged. If you want to see what we're talking about, just go to your pantry and take out a box of Lucky Charms, or any cereal you have on hand for that matter - they're a perfect example of this ubiquitous method.
Open the box and pull out the cereal bag. You'll see that the bag is made up of one piece of plastic sheeting that's been formed into a tube, filled with the cereal, and then sealed and cut on both ends.
The brilliance of the SandDog is not the machine at all but the sandbags it produces. All we're going to do is remake (and resize) the sandbag itself in terms of VFFS production, just like the Lucky Charms, but this time taking it out of the factory and into the field. We'll start with a roll of polypropylene and make the sandbag out of it while filling it with sand at the same time. We're going to repeat that last sentence because it is the key to this ground- breaking idea: we are going to make the sandbag itself using well-proven VFFS techniques while filling it at the same time.
The SandDog then just becomes the manufacturing vehicle while the sandbag, the "Dogbag" if you will, is the real revelation/souce of revenue. We can all but give away the SandDog, because, much like the razor/ razor blade concept, our money will be made on the bagrolls. We estimate that each SandDog, over the life of the machine, will use an order of magnitude above the retail price of the machine itself in bagrolls. And our bagrolls must be used or the warranty is voided. The math's easy for once, at least for us, and the numbers add up.
The way we think about sandbags has been unchanged for 4,000 years, and all our current methods of production and use have been based on this ancient (and outdated) technology if you will. Which isn't wrong, or bad, but could and will be exponentially better, as these following paragraphs will show. It's very rare for a product to be a paradigm-shift in a certain system or industry, but we feel the SandDog will be because it will not only revolutionize the sandbagging industry overnight by fully- automating the entire process, but it will do so by reinventing the sandbag itself.
Sandbag size is a function of its weight, and this is determined by what the average construction worker of past centuries could carry for an extended period of time. Going back to the Egyptians, this weight is about 40 pounds, varying from 30 pounds if the sand is dry and the sandbag half-full, to a little over 50 pounds if the sandbag is 2/3 full and the sand is saturated. Historical builders of sandbag structures gleaned from the agricultural industry that bags of seed are more easily carried if they are rectangular in shape and are held with the long direction vertically. In time, the standard sandbag dimensions came to be 4 inches x 10 inches x 17 inches.
The size and shape of the individual sandbag is the one and only basis for the design of sandbag structures. For flood control sandbags are stacked into walls. A flat 14" x 26" sandbag filled 2/3 full results in a sandbag approximately 4" x 10" x 17". If these are stacked in the standard brick-like fashion with each new layer offset 1/2 sandbag in the vertical direction, the result is a sandbag wall with a pyramidal cross section. Since sandbags are stacked with their long dimension parallel to the wall, the 4 inch and 10 inch dimensions determine a proportion of a height 2.5 times the width.
It has been shown however, that a retaining wall with a base to height ratio of 2.5:1 is not necessarily ideally suited to its purpose, and that a nine inch sandbag is just as effective but much cheaper than a ten inch. Additionally, if a slightly different stacking method is employed, a stable wall with a base to height ratio of 1.5:1 can also be built. A 4" x 9" x 17" sandbag is also sufficiently similar to existing sandbags to be used in conjunction with them. Though the size difference may seem small, if it is multiplied by the 125 million sandbags used in 1993 Mid-Continental Flood for example (at .41 cubic feet of fill per sandbag), it equals 6 million cubic feet of fill which did not have to be moved. We can see the time/labor savings are of an order of magnitude.
Think about it: flooding, hurricanes, tsunamis, and war have plagued man since the beginning of recorded time, and will continue, unabated, recession-proof, immune to borders or ideology, across the globe, forever. The good news is that we will be able to greatly reduce the material and human costs of these disasters.
We'll stick with U.S. to do our figures since we have the most information and experience close to home. Let's just say that a pretty fair round number for sandbags produced in this country per year is 60 million, give or take a few million. Our guess is that each SandDog will make, on average, 500,000 sandbags per year. which means there is a market potential of at least 120 machines, per year.
Our sandbagging material will cost out to an average of 20 cents per bag, depending on the material and use. For comparison, the typical 3-side, drawstring polypropylene sandbags sold today retail for about 30 cents/bag depending on the quantity ordered. So, 60 million sandbags at 20 cents each equals $12,000,000 and change per year, guaranteed, since the bagging material has to be purchased from us or the warranty on the SandDog is voided. So we're looking at up to $6,000,000 in savings on sandbags alone, not counting labor.
Extrapolating, we think the worldwide market for sandbags is at least 2 or 3 times the U.S. market, for a global total of around 120 - 240 million sandbags, with an even greater potential flood damage reduction percentage.
A secondary source of revenue for the SandDog is in the pay-for-service market. We believe it will be lucrative to start-up a flood mitigation division of SandDog with several machines on call in a central location in the continental U.S. Many municipalities and communities with a history of regular or occasional flooding may not have the budget or the foresight to purchase the SandDog right away.
There are many other uses for SandDog, if you think outside the bag: construction and landscaping industry; fire containment; avalanche mitigation; temporary housing for post-disaster relief, i.e. timber frame housing with sandbag walls. We're committed to doing well by doing good.
Incredible. Over the years the U.S. Army has done remarkably little research and prototyping on "field expedient sandbagging aides", considering it is the largest producer of sandbags in the world. And for the fact that sandbags have been proven to be one of the most effective means of saving lives in times of conflict, broadly speaking. This is worth repeating: the U.S. Army is the largest producer of sandbags in the world. Sandbags have been proven to be one of the most effective means of saving lives in the annals of warfare.
Throughout history, most notably during the 1st and 2nd World Wars, various bag holders and sand scoops made from entrenching tools, scrap plywood and lumber were tested in the trenches so-to-speak by individual soldiers or units, with limited success. The first real attempt at an automated sandbagging machine, however, didn't occur until much later.
The U.S. Army Engineer Research and Development Laboratory in Fort Belvoir, Virginia designed and tested a full-scale prototype of an automated sandbag filing machine in 1959. It was designed to have a capacity of 1000 bags per hour, but in reality produced less than half that number. Essentially, the machine consists of a bucket elevator mounted on a trailer, and powered by what looks to be a small gasoline engine. The upper end of the elevator is equipped with a funnel to direct the fill into a bag held below it, but apparently without a valve to control the actual amount of sand flowing into the bag. Conventional sandbags with hand tying methods were used in this machine, and it's speculated that the primary reason for failing to meet the specified goal of 1000 sandbags per hour is a lack of automated methods of bag closure. Its large size, and the fact that it produced only half of the expected goal, led to its early demise.
Other attempts followed: the U.S. Army Medium Weight Sandbagger was the first attempt at a machine capable of procuring its own fill but still relied on hand-tying the bags; the Lightweight Sandbagger Nos. 1 and 2 produced during the Vietnam Era met with more success but still relied on a skilled human operator and were thus not fully automated, managing at best 250 bags per hour.
These machines, in the final analysis must also be seen as failures, or at best, only partial successes. With an output of 150 - 250 bags per hour, they meet less than half the production rate outlined in the original briefs. Due to problems of high maintenance and low bag production, it was recommended in 1971 that that no more research be done in this area.
Incredible. Over the years several machines have been designed which attempted to automate the sandbag production process, but these have been only marginal successes at best. However, even from failure lessons can be learned. On careful analysis, all the machines share a common fault: they rely on the conventional sandbag – an object originally designed to shore up the banks of the Nile. It is the sandbag itself which is wholly unsuited to automation, which we've already discussed in more detail. A lot of well-meaning people still don't understand this simple fact.
An Illinois firm produces a sandbag filler called the Kanzler which consists of a 2 cubic yard bin with four foot-operated chutes underneath. A worker places an empty bag under the chute, opens the valve, and lets sand flow into the bag. This system, though much better than mere shoveling, has two major drawbacks. First, the fill material must be completely dry, or it will bridge in the chutes, severely hampering the productivity of the machine. For this reason, its use is limited to only dry fill. Secondly, it relies in other equipment and labor to source fill. The only step it removes from the conventional sandbag filling process is the shoveling of the fill into the bags. The bags must still be tied, stacked for transport, and the fill somehow acquired. The success of this system relies on brute manpower.
The Quicksander, like the Kanzler Sandbagger consists mainly of a hopper, but in this case it is attached to a dump truck, which conveys sand into bags held at either end by two operators. Sandbagging Systems boasts 3000 filled bags per hour. This should be taken with a grain of salt. To maintain such a rate would require 1 filled bag every 1.3 seconds. No way, Jose.
Like its two counterparts, the Speed Bagger is a hopper with valves for the releasing of sand under which bags are manually held to be filled. In this instance, the operators are allowed the comfort of a standing posture, but capacity is limited to the small size of the hopper and the necessity for all bagging operations to stop when the hopper needs to be refilled. And, a Bobcat or similar machine is needed for operation.
The HESCO Bastion is a collapsible wire mesh container with a heavy-duty plastic liner, filled with sand using a loader or excavator, is essentially a super-sizing of the sandbag for the 21st century, and will prove to be our biggest competitor. After the first Gulf War, HESCO Bastions became a popular flood mitigation (and security) staple because they are easy to set up, and they work. HESCO has been very aggresive in expanding their market share since. However, there are several drawbacks to them: they are very expensive, and must be deployed on site. And the site must be fairly level and allow access to a front-end loader.
Give us a ring anytime on 203.451.5127, or shoot us an email at: firstname.lastname@example.org If you'd like to stop by to see the actual global operation, we're at 13 Wilson Road, Weston, CT 06883. Door's always open.