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If you had posted this a month ago - I'd think you'd be on to something.
I had the exact same problem - and all I ended up doing is losing 4-5 hours of my life and ended up belting all the "Waste" silica into the sink and making fresh silica.
For some reason the waste silica is just a hair too slow - and by the time it gets to the foundries - they would stutter.
The reason I lost all that time was me blaming my pipes - when in fact it was the silica - it was a cascade problem that would bury the issue.
Honestly I can't tell you why it does that - I figured it was something I overlooked or maybe the belts.
Unless someone else can tell me otherwise - generally I'd suggest switching to the sloppy recipe to get rid of the Silica waste all together and/or sinking it and just make it fresh off a Quartz node - odds are you have one already as its not enough to make aluminium. Which is what I did ultimately.
Would love to see your setup and compare notes - the math says it SHOULD work.
Frankly I can see why the popularity favors the recipes that completely remove silica from the equation.
Usually is a no brainer to feed foundries with a mix of produced sica and the silica that you get as byproduct.
But.... If you do exact math you can end up in a bad position (bad planning). Because you use now silica at time zero. But byproduct arrive later as you need to produce aluminium to get a need for more scraps and silica is outputted only after a cycle of scraps production.
My setup (that has tens of hours of continuous go, with start and stops as demand of aluminium is needed)
Considering simple setup of a single belt feeding foundries....
That line has to be coming from your silica production.
A parallel line of byproduct silica merge with main silica just before foundries factory area.
Obviously byproduct silica line need to have (for safety) a smart splitter set with overload to send silica in excess to a sink.
All good and fine - but I preloaded mine as a stop gap - and it took very little time for the silica product to stack up - not to mention I had excess product coming in on the fresh side.
You do raise a good point tho - but you'd think preloading would stop that issue.
Def food for thought.
Isn't that you problem is that refinery is stuck as it can't output silica that is full?
considering the factory as tiers....
tier 1: water and raw resources....
tier 2: refineries to produce solution (with silica by product) (sent to tier 4 if you want)
tier 3: refineries to produce scraps, with by products water (sent back to tier 2)
tier 4: fundries (getting scraps and silica)
if belt with silica in output from 2, it will stop producing solution.
anyway in my case (i can go in further details if you need or want)....
I never primed the factory, it just prime by itself.... depending on situation some silica could be sent to a sink from time to time during first minutes while it get stable (first run).
After that sink is never activated but I keep it just in case something happen.
No - my problem is the silica isn't reaching the foundry in a timely fashion.
But like a second or two - its the damnedest thing.
Everything was perfect in terms of math - just enough units /min to meet demand.
But as you pointed out - the first initial cycle won't deliver that silica so maybe its that - but as I pointed out - preloading SHOULD mitigate that.
It's almost like belt lag - but half a second too slow - not sure how to define it - but it's just about the same issue the OP is pointing out.
And before you ask - belts where same speed - Mk4 at the time. So it wasn't that (I don't mix belts :P)
I'm willing to bet good money this isn't a "max capacity" problem - its stuttering - pure and simple.
I saw it happen ever so slightly as I was troubleshooting why my aluminium factory would "hang"
With my setup I'm pumping out 120/min Ingots a min (I think?) - so that's 2 Refineries spitting out scrap (pretty sure - not there atm) - and when the foundries stopped working - scrap would back up - when scrap backs up - refineries go yellow - keep in mind they make a ton of scrap VERY Fast - and then suddenly empty out - and at some point eventually - it would empty at some point in the production line and stall out all together.
If your math is good - your foundries should all be running at 100% Efficiency.
Assuming your waste water is dealt with and everything else - refineries will fall into line.
In my case I fed the waste Silica to the first 4 foundries (2 split) then merged the "Fresh" Silica in for the rest - the stuttering would start at - you guessed it - the first 4 foundries on that 2 split line.
Which makes you ask - what - the - hell. Even if they had a slight delay - it should start at full speed at pre-fill max load - but it eventually just flat runs out in about 1-2 hours.
That only happens if there's a very very slight latency on the feed of that Silica.
Which is why I flipped my table and just flat removed it all together - sloppy Alumina for the win - and eventually ill do away with Silica all together with the Pure Aluminium Recipe - at some point.
But for the time I didn't use "Sloppy" - I sinked the Waste Silica and just provided more Silica off my quartz node - problem solved and its running smooth as silk.
that way you only need Bauxite, Coal and Water for Scrap to Ingots, and Copper Ingots for The Alclad Sheets.
Valid - and the solution is great - but I want to know.... WHY!?!?!
XD It's maddening....like a crooked picture in my mind.
Id like to see your setup - see if you did anything different or obvious - feel free to hit me up on Steam and we can discord or something.
Maybe what Jack said has an valid point - storage buffer idea could work - but I have my doubts.
The way I fixed it was messing with the scrap producing refineries. Basically they were churning out scrap all at the same time, which would clog my mk4, even though the total production didn't exceed an mk4 capacity overall. So I desynchronized them and it eventually worked, maybe try that
Didn't have this issue - at 120/min (unless I'm misremembering) - I had an even split - so it was two lines of scrap.
Worked out nicely for me.
And again - the OP is having trouble with supply being fast enough - not being overwhelmed.