Expand Production with the
'Parallel Processing' Method
Guest article by Carl Andrews, General Manager, Matcon USA, Inc.Introduction
 Cross
contamination of allergenic materials in the food industry has
become a major issue and is leading to a strong demand for product
'containment' during the manufacturing cycle. The food industry has
traditionally had to concentrate on avoiding contamination of its
product by employees and operators.
Now, with our increased knowledge of
the effects of allergens, or sensitizing agents the industry needs
to concentrate on avoiding 'contaminating' its employees and
operators with it's product. Add to this the desire to integrate
automation, the increasing costs of employment, the diversification
of product offering and the inevitable squeeze on the bottom line;
there is little wonder that the industry is looking for the 'next
big thing'. The answer lies in automated high-accuracy batch
formulation with in-bin blending and parallel processing technology.
Traditional Batch Methods
In traditional manufacturing
processes, feeding a hand pre-formulated batch of product into the
mixer, and bagging are done in line with the mixing process; i.e.
when the mixer is being fed it is not mixing and there is no bagging
off. When bagging off from the mixer, again, it is not mixing.
Finally, when cleaning the mixer, the mixer is not mixing it is not
being fed and again there is no bagging off.
From the traditional hand-crafted
batch formulations, expensive mixers and inline packaging systems,
grows the need for dust-free, automated, high-speed batch production
where clean down and formulation are taken off-line, having no
effect on production time, quality or process efficiency.
The standard designs which allow the
formulation of an infinite number of recipes on a single unit IBC
System, offering the high levels of flexibility today's ingredient
manufacturers demand. It is not uncommon for a customer to require
small batches of a certain product, perhaps as low as 500 kg within
just a few days. Speed to market is essential, with the producer
whose plant offers the greater flexibility achieving the order.
Product must be formulated, mixed, packed, quality approved and
delivered at no extra cost and with no reduction in product quality.
IBC Systems as part of Parallel
Processing Unit Operations
 IBC
Systems achieve the most dramatic cost savings combining flexibility
with speed to market. Systems eliminate a large part of the manual
lifting of sacks and drums, allowing automated formulation on demand
from the central management control system. Recipes and quantities
are down loaded to local controller, which in turn allow the
ingredients to be dispensed simultaneously. Ingredient weights as
low as 5 kg can be dispensed to accuracies as low as + 10 g with
typical batch formulation times being in the region of 4-6 minutes.
Direct IBC formulation can be
utilized in many applications, all kinds of products and over a
diverse range of industries. However, the regulated conditions that
exist within the food industry make IBC technology and batch
production techniques an attractive option. Accurately dispensing
from day bins into process IBCs can be achieved automatically using
a precision discharge station. The remote controlled pre programmed
discharge station maneuvers accurately below each day bin then
discharges the product at the pre-programmed volume into the process
IBC.
 The
process IBC is then moved to a pre-designated blending area where it
is secured into an IBC tumble blender. Again through pre programming
the blender can secure and rotate the container at any RPM over a
pre-set time. Blenders can include no, low or high shear to ensure
that the product is homogeneously mixed.
On completion of the blending cycle,
the IBC is removed and transported to packaging. Discharging the
product directly onto sieves, through metal detectors or through any
process control equipment is carried out using a secure cone valve
that not only ensure product containment during product transfer,
but it also ensure that the mixed product remains homogenous.
This new batch processing technology
maintains complete batch integrity, instant product change over,
limited need for external dust control and complete protection
against the unwanted migration of allergenic materials. All this can
be achieved using a rigid IBCs direct formulation system, IBC
blending and cone valve technology. Directly formulating and
blending in this process can be done in an enclosed system, dust
free and automatically.
We call this approach to automatic
manufacturing 'Parallel Processing'. This approach can easily be
integrated into any traditional processing method in 3 stages. By
separating the various process steps as described below, customers
begin to see improvement immediately.
'Parallel Processing' Batch Method
Step One - Separate Mixing from
Packaging Operations
In step one, the mixing and packaging
line is separated. The finished blend is discharged into an IBC and
fed into the packaging line without degradation or segregation of
the mixed product. This frees up the mixer to be cleaned, or to mix
another batch while the first batch is being packaged.
Step Two - Separate Filling from
Mixing Operations
In Step Two, the filling and mixing
is separated. Product is added to an IBC via a formulation island or
staging area. These IBCs will hold the entire production volume.
This vastly reduces the down time of the mixer, as it is no longer
has to be manually loaded. As soon as the loading cycle is complete,
the next blend formulation can be filled into IBCs and the previous
batch is still mixing. This allows the mixer to operate while
subsequent batches are formulated. This frees up valuable mixer time
and maintains a clean mixing environment.
Step Three - Incorporate In-Bin
Blending
Step Three incorporates another
advancement in powder handling technology. By replacing the batch
mixer with an IBC Blender, you allow the IBC to become the mixing
vessel. In-Bin Blending is a simple process whereby an IBC is filled
with the products that you wish to blend as in step 2 above, then
sealed with a lid. The container is then loaded onto a Tumble
Blender that lifts and clamps the bin. On a signal from an operator
the entire IBC is then rotated in an asymmetric axis of rotation.
The cone valve geometry and rounded corners within the IBC insure no
dead space or pockets.
After blending the IBC is transported
to the bagging area where it follows the exact procedure as step 1.
In this final step, an IBC is blended, a second IBC is being filled,
a third bin is in packaging, and a fourth bin is being cleaned.
In Conclusion
'Parallel Processing' is where your
production is done in parallel, instead of in series. By separating
your filling from your blending, and your blending from your
bagging, Parallel Processing enables you to increase production
immediately. Your production will increase, enabling you to reach
your production quotas without adding more shifts, or even by
reducing your present shift schedule. Improvements include:
- Expand production capability
200-400%.
- Produce a product that is free of
segregation and degradation.
- Insure batch integrity throughout;
Quality Assurance.
- Create a clean, safe working
environment.
- Reduce allergen risk and prevent
cross contamination.
- Provide a flexible solution for
future expansion.
- Reduce the effect of equipment
down-time.
Contact Our Author
Mr. Carl Andrews
General Manager
Matcon USA, Inc.
233 North Delsea Drive
Sewell, New Jersey 08080
Phone:
856-256-1330
Fax: 856-256-1329
Web site:
http://www.matconibc.com/
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