Pneumatic transfer line, mixing and packaging of food ingredients and flavorings at the outlet of the atomization tower

As part of optimizing its production process, a manufacturer of vegetable-based food ingredients wished to modernize and automate the packaging line for its finished products from an atomization tower.

The main objective was to ensure flux continuity between the production of powders (such as mushroom, beetroot, pepper, tomato) and their packaging while adhering to the highest industrial hygiene standards.

The client sought to:

• Directly connect the output of the atomization tower to a conical mixer to homogenize the powders without flux interruption.
• Ensure hygienic and contained handling to prevent any cross-contamination and meet strict food requirements.
• Optimize the ergonomics of the packaging station, particularly by limiting manual handling and reducing the risk of MSDs for operators.
• Ensure controlled deaeration of powdered products during bag filling to improve the compactness and stability of 25 kg bags.
• Integrate a rigorous quality control system with a checkweigher and metal detector to ensure the conformity of packaged products.
• Enable quick and automated cleaning in place (CIP/SESSAD) on all critical equipment to minimize production changeover times while ensuring no contamination.

This project was intended to increase productivity, improve packaging quality, and ensure perfect traceability of operations in a 24/7 production environment.

To meet the client's requirements for continuity, hygiene, and efficiency, Palamatic Process designed a complete solution integrating several specific pieces of equipment:

Vacuum pneumatic transfer: A VFlow® model VF01 system was implemented to ensure the gentle conveying of powders from the atomization tower to the rotary screw conical mixer.

• Nominal flow rate: 150 kg/h for a product density of 0.5.
• Materials: Cyclone body in 304L stainless steel with hygienic finish (argon welding, passivation).
• Total containment: Suction cyclone equipped with a polyester filter with PTFE coating (rejection rate <1% for particles <1 µm).
• Cleaning in place: Integration of a CIP washing system allowing rinsing water suction and line drying with filtered hot air blowing.

Rotary screw conical mixer: The powders are homogenized by a conical mixer ensuring high mixing quality and complete emptying:

• Capacity adapted to continuous production batches.
• Hygienic design: smooth surfaces, no retention zones, integrated washing nozzles for CIP.

Flexible transfer screw: After mixing, a flexible screw conveys the powders to the packaging machine.

• Material: 304L stainless steel, flexible food-grade sleeve, quick disassembly for cleaning.

HALPAQ hygienic packaging station: Packaging is done in 25 kg multilayer paper bags:

• Bottom-up filling with progressive bag lifting, limiting product drop height to reduce dust emission.
• Integrated vibrating table for powder densification.
• Deaeration system by suction lance with vacuum pump, allowing optimal extraction of residual air.

Sealing and cleaning-in-place module: The HALPAQ integrates:

• CIP washing nozzles for automated washing and drying.
• Complete CIP/SESSAD cycle achievable in less than half a day, minimizing production downtime.

Online quality control

• Checkweigher: precise weight control of each bag.
• Gantry metal detector installed on the conveyor to ensure the absence of metallic contaminants.

Automation and control

• Control via PalTouch® touchscreen, automation of all transfer, mixing, packaging, and cleaning phases.
• Ethernet communication for integration with the client's MES/ERP systems.

1. VFlow® VF01 Pneumatic Transfer

Flow rate: 150 kg/h.

Technical characteristics: 304L stainless steel cyclone, 7.5-liter capacity per cycle, high-performance polyester filter with PTFE coating.

Advantages:

• Total product containment during transfer.
• Line purging ensured to prevent batch mixing.
• Integrated cleaning-in-place (CIP) system with quick-drying function via hot air blowing.
• Optimized design to limit wear and ensure no cross-contamination.

2. Rotary Screw Conical Mixer

Hygienic design: polished surfaces, no dead zones.

Equipment: integrated CIP nozzles for automated internal washing.

Advantages:

• Efficient homogenization of food batches.
• Quick and complete cleaning without disassembly.
• Protection against contamination between different products.

3. Flexible Transfer Screw

Materials: Reinforced food-grade flexible tube, stainless steel spiral.

Advantages:

• Continuous and gentle transport of sensitive powders.
• Quick disassembly for external CIP phases.
• Easy maintenance with accessible parts.

4. HALPAQ Packaging Station

Technical characteristics:

• Bottom-up filling via double-jacketed DN250 filling tube.
• Vibrating table for densification.
• Deaeration by suction lance connected to a vacuum pump.
• Simple sealing of multilayer bags to ensure tightness.

Advantages:

• Hygienic filling without dust generation.
• Optimization of filling volume (reduction of logistics costs).
• Integrated CIP system ensuring quick and reliable cleaning, compatible with 24/7 production.

5. Checkweigher and Metal Detector

Technical characteristics:

• High-precision checkweigher for weight compliance control.
• Tunnel metal detector on conveyor.

Advantages:

• Regulatory compliance with international food standards.
• Total product quality assurance.
• Traceability and recording of controls.

6. Automation via PalTouch®

Technical characteristics:

• Magélis IP65 stainless steel touchscreen.
• Schneider M340 PLC with Ethernet communication.

Advantages:

• Centralized control of the entire installation.
• Simplified production changes.
• Archiving and traceability of critical parameters (CIP, weight, production).