Frymakoruma Continuous Manufacturing Plant
Innovative Solution for Continuous Manufacture of Semi-Solids
Competition and cost pressure are important factors in semi solids manufacturing. However, the potential for raise of productivity in batch processing is nearly exhausted and only marginal improvements may be possible.
The continuous manufacturing is the alternative to the common batch process. Due to fact that the required dosing accuracy and the composition of the final product could not be guaranteed, this goal could not be achieved. The continuous manufacturing could not meet the requested quality standards.
The Plant
At semi-solids manufacturing, liquid and solid ingredients must create an homogenous mass. Liquids like water or oil must be emulsified, and dry ingredients must be dispersed in the liquid phase.
The plant is directly connected to your powder and liquids storage system. The powders and liquids are dosed in the new, revolutionary FrymaKoruma powder wetting system where powders and liquids are mixed. Depending on your process, you can either use one or two powder wetting steps.
Depending on processes, we can integrate heating or cooling of the product. Then, the product is de-aerated. This eliminates included air in the product.
After that, the product is pumped to an inline-homogeniser for final homogenisation. Then, the product is fed into the finisher-skid, where flavours or colours can be added.
Finally, the product is fed into a buffer tank or directly to the filling line. The finished product offers perfect features regarding durability, stability and filling. In addition, this plant offers highest possible flexibility regarding the feeding of active agents and additives. Depending on the recipes, these ingredients can be fed into every phase of the process.
Dosing of Liquids
It is important to achieve a very high dosing accuracy in liquids dosing. This requires the use of magnetic inductive res and coriolis flow meters. In the basic version a dosing accuracy less than 0.5% can be achieved. Due to safety reasons the dosing devices are executed with double seat valves. That guarantees that there is no mixture of CIP medium with the liquids coming from the storage systems.
Dosing of Powders
The dosed powders are fed pneumatically to the plant, where they are stored. This guarantees a continuous feeding of the powder dosing units. The dosing units work with dosing screws and highly precise load cells. The dosing accuracy of the basic version of these units is less than 1%. Each of these units are adjusted to the characteristics of the powders. This means that even in case of extremely low throughout the requirements of dosing accuracy can be met.
The Quality Control
During the whole process, all important process parameters are under online control. The dosing of powders is realized with a gravimetric dosing system. All the liquids are constantly dosed via dosing pumps. Flow meters control the quantity and the temperature of the liquids.
This fully automated dosing guarantees the exact production according to the recipes and the safety of the process. After each single step of the process, there is the possibility to check all important parameters. We suggest the control of the following parameters: temperature, viscosity, flow rate, pressure, density and pH-value. Other combinations and additional parameters are also possible.
All surveyed parameters are continuously available on the operator panel. As soon as one parameter does not meet the pre-set value, the system can be stopped for re-adjustment. The data during the whole process are filed for analysis and documentation.
This fully automated manufacturing process offers a very high reproducibility and a constant product quality. The possibility of errors caused by the operator is nearly eliminated.