Our work ranges from turnkey, customized, complex solutions for food, beverages, Pharma, chemical, tobacco, and personal care industries, to relocations and upgrades of production facility. Take a look at some of the most successful and rewarding projects we’ve completed:
Category: Gum & Candy
Location: Asia
Year: 2016
Project background: The customer decided to relocate it’s gum production capacity form Ireland to Turkey. Most of the old equipment was relocated to Turkey by the customer, except the ingredient handling for fat. These fat is used in manufacturing of artificial sweetener that goes in the recipe of chewing gum. The used type of fat was behaving more as a high melting point wax, requiring temperatures up to 110 °C for melting. This is unusual for regular food industry solutions. Initially, in Ireland, fat was delivered molten by truck, but in eastern Europe this was not possible. The wax blocks needed to be melted and stored.
Target: (Re)Design, manufacture, test and supply new & innovative fat melting & handling system for fat. The system in the original location was posing a great amount of operating problems, generating frequent production stoppages. This (design) problems needed to be overcome.
The challenges that have been overcome, were:
They have been addressed by developing:
Deliverables:
The greatest outcome of the project is the contribution of improved line General Efficiency factor of the line, much higher than the calculated target, during the first production days. The line was expected to reach 65% efficiency, but achieved 82%.
Category: Chocolate
Location: Eastern Europe
Year: 2012
Project background: Chocolate manufacturing consumes a high amount of sugar, next to other ingredients, that are mixed and ground together into a very fine paste before becoming the soft product we know. Handling sugar is easier if the sugar is 100% small size crystals and now powder. But powder containing crystal sugar is much cheaper and of course harder to handle. Our customer decided to upgrade its existing sugar handling system to be able to handle a greater capacity and also a large percentage of powder sugar.
Target: Redesign and upgrade the existing sugar handling system assuring a higher capacity, powder content capability and high efficiency.
The challenges that have been overcome, were:
They have been addressed by developing:
Deliverables:
Silo discharging by pneumatic transport designed for high capacity. The product was conveyed 3 stories high. Product distribution system realized by innovative vibratory conveyor integration. An almost doubled capacity. The greatest outcome of the project is the contribution tour customer’s cost cutting efforts and by implementing one of the first such mixed product systems.
Category: Chocolate
Location: Eastern Europe
Year: 2012-2016
Project background: Due to continuous rise of the cocoa beans price, chocolate manufacturers are getting more and more involved in developing alternatives to chocolate bars, or hybrid products like chocolate products that include biscuit, creams or any other kind of inclusions. This lead to the launch of a new type of product, consisting of a bar plated with biscuit pieces
Target: Develop a highly flexible outside and inside storage system, capable of handling 2 to 3 different chocolate recipes. The system needed to be able to do line dosing and also assure high efficiency product rework.
The challenges that have been overcome, were:
They have been addressed by developing:
Deliverables:
The greatest outcome of the project is the contribution to realizing a new innovative chocolate product. The second greatest outcome is the high degree of innovation included in the project:
Category: Dough, Filling, ingredient handling & CIP
Location: Mexico
Year: 2016
Project background: Original project was meant to be installed in Russia, but, due to the international restrictions, the customer decided to install the line in Monterrey Mexico. The initial request was for a system capable of transferring the dough from mixers into special designed buffer tanks capable of maintaining the requested temperature (fitted with cooling and heating units), then through a pressurized transfer system to feed the depositors. The buffer tanks, pipping, mixers, depositors were automatically cleaned with a CIP system specially designed to reduce cleaning time, and increase productivity .
Target: Design and built an efficient system capable of:
Challenges & Actions:
As initial system was built for Russia where we have power supply at 50Hz 400 V, The line was reconverted for Mexico electrical standards where the power supply is 60 Hz at 480V, Also UL electrical certification was required.
Deliverables:
