Processed powder: modified starch, sodium bicarbonate, fat powder, whipping base, gelatin, milled sugar
Company based in Saudi Arabia that manufactures and distributes dry food materials.
The company implemented an automated handling and conveying system in a new extension of the factory specifically designed for preparation, mixing and filling of dry mixes for retail sale.
This was the second phase of the project. Indeed, the customer had already automated the process of the main raw materials such as flour, baking soda, granulated sugar, additives and small ingredients. Previously, they were added manually during the different stages of production.
This step was tedious and dust generator. Also, it needed more handling time that could be a source of error in the process and therefore generate a loss of final product. To avoid this, the customer has decided to invest in the automation of what he calls "small ingredients".
The current factory has three levels. The packaging areas are on the ground floor, the processing and mixing areas are on the first floor, and the preparation areas are on the second floor.
The different materials handled depend on the recipe and vary from one recipe to another. The client has many different recipes and one of the major challenges of this installation was to make it flexible while remaining simple with cleaning in place operation.
Line 1: Intermediate & Small dry ingredients to high speed mixer line:
This extension consists of:
-Tipping stations of small and intermediate ingredients to all mixers (3 manual bag unloading stations, 1 per mixer)
-Intermediate bulk container (IBC) receiving mixed products and conveying to filler hopper
-CIP of all related equipment and conveying system
These 3 bag tipping units respectively feed 3 cyclofilters.
The waste of the empty bag is evacuated through a polyethylene sheath which limits the amount of dust and eliminates the discharge into the workshop of any residual dust in the bags.
Hygienic /safety parts: the manual bag dumping unit is fitted with an integrated sifter: the vibrating screen provides a product free of any foreign object.
Discharging of raw material is carried out at at the same level as the mixer; a pneumatic conveying system feeds the mixer.
Each cyclofilter is equipped with a dedicated vacuum pump which allows simultaneous feeding and operation. Each cyclofilter is connected to one mixer.
A drain line in pneumatic conveying allows a complete emptying of the pipeline after conveying process.
It is particularly used to avoid having product residues in the pipe / process and cross-contamination between the various recipes.
Once the material is mixed, a mobile IBC container with a capacity of 1200L is positioned under the outlet of the mixer to collect the material.
This mobile IBC container is fitted with an anti-bridging system and an easy clean extraction screw that can be dismantled to simplify its cleaning.
The material is then conveyed through a vacuum pneumatic conveying to feed the bag packing machine.
The IBC container works in batch mode but the bag filling operation is performed continuously thanks to the lock. It is no longer necessary to move the container to the bag packing station PalSack®01; this operation is now carried out using the pneumatic conveying line.
The container was specially developed for the application: cleaning ease and flexibility.
Line 2: intermediate & Small ingredients to Kneader
The installation works on the same principle but to feed the mixers in pasty products.
Palamatic Process provided the same design as for the first line to keep a regularity of the production tool (knowledge of the different machines, spare parts ...).
Much has been done in the definition of equipment for sizing the system according to the customer's recipes and according to the desired flexibility. Tests with samples of products have been carried out in our workshops with a conveying screw. We have also carried out pneumatic conveying tests on different products to ensure conservation of the particle size. The whole process is designed and manufactured to have Clean In Place campaigns between each production run.
Both lines are connected to the existing customer dust-collecting network and the full facility complies with Atex standards.
The operating rates are the following: 2t./h. to feed the bag packing station and 1t./h. to feed the mixer.
Examples of factory end products:
- Poultry stock
- Pancake mix
- Vanilla cream
- Cocoa cake mix
- Automaton S7 1200 SIEMENS