Nutritional Beverages Case Study

Co-packer of nutritional beverages increases efficiencies by automating the batching of multiple dry and liquid ingredients.

Opportunity

This Nutritional Beverage co-manufacturer wanted to automate batching of multiple dry & liquid ingredients including milk proteins powders, gums, and sugar, so turned to Semi-Bulk for our Total Solution expertise for dry ingredient handling/dry liquid mixing.

Industry: Beverage

Our Approach

To meet the increased efficiency goals, Semi-Bulk Systems engineered a customized Process XStreamlining Solution including:

  • The Vacucam® In-Line Slurry Process fed from three bulk bag handling systems with loss in weight controls and our unique 2.7 cubic foot hopper design. Also supplied was one bag break hopper for pre-weighed minor powders.
  • A liquid funnel for minor liquid ingredients to accommodate floor-level operation for all powder handling
  • Integrated controls for batch automation

The Results

We delivered Our Performance Guarantee that:

  • Total automation of batching dry and liquid ingredients.
  • Batch to batch consistency.
  • Significant reduction of batch cycle times.

Would you like to know how Semi-Bulk System’s solutions can improve your beverage production profitability? Contact us or call 800-732-8769.

Semi-Bulk has been installed around the world.

Industries Served

Lactose Hydration Case Study

Nutritional beverage company updates their lactose hydration process.

Opportunity

A Nutritional Beverage inherited a lactose hydration process in their production facility and needed to significantly update the process and add new features.

Industry: Beverage

Our Approach

To meet the goals for updating the manufacturer’s process, Semi-Bulk Systems engineered a customized Process XStreamlining Solution including:

  • Our patented Vacucam® Mixer on Tank (MOT) Slurry Skid.
  • A dry handling solution delivering dry sugar from our unique Bulk Bag Unloader with a 2.7 foot cubed dry hopper design.

The Results

We delivered Our Performance Guarantee that:

  • All modular designs for ergonomic installation into confined space.
  • High capacity throughput.
  • Dust control and containment

Would you like to know how Semi-Bulk System’s solutions can improve your beverage production profitability? Contact us or call 800-732-8769.

Semi-Bulk has been installed around the world.

Industries Served

Hard Seltzer Brewing Case Study

One of the country’s largest brewers significantly ramps up production of hard seltzers.

Opportunity

One of the largest ready-to-drink producers of hard seltzer beverages needed to significantly ramp up production of sugar syrups, while also bringing a new manufacturing facility on-line.

Industry: Beverage > Brewing

Our Approach

To meet the increased capacity goals, Semi-Bulk Systems engineered customized Process XStreamlining Solution including:

  • Our patented Vacucam® DBS Sugar Liquefication system that unloads bulk trucks, conveys, and liquefies dry sugar at a rate of 500-800 pounds per minute (30,000- 48,000 pounds per hour).
  • A state-of-the-art explosion detection and protection equipment with features seamlessly integrated into system design and controls.

The Results

We delivered Our Performance Guarantee that:

  • Reduced inbound syrup transportation costs by more than 32%
  • Maximum incorporation rates for high capacity mixing and syrup production.
  • Dry sugar dissolution WITHOUT high shear or heat which saves energy and prevents wear at the mix point, reducing costs of ownership.
  • Improved automation with standard for non-weighed side with unique Semi-Bulk control strategies; control +/- 0.1° Brix

Would you like to see the advantages Semi-Bulk Systems can provide to increase the efficiency of your brewing production? Contact us or call 800-732-8769.

Semi-Bulk has been installed around the world.

Industries Served

RTD Non-GMO Sugar Case Study

Ready-to-drink beverage manufacturer increased profitability and quality by batching their own non-GMO sugar liquefication.

Opportunity

This manufacturer of ready-to-drink beverages wanted to supplement their purchasing of liquid GMO sugar with the ability to batch non-GMO sugar, at 55-58” Brix syrup, from bulk bags.

Industry: Beverage

Our Approach

To meet their sugar liquefication goals, Semi-Bulk Systems engineered a customizedProcess XStreamlining Solution including:

  • Utilized Vacucam® Mixer on Tank (MOT) Batch Sugar Liquefication Process
  • A dry handling solution delivering dry sugar from our unique Bulk Bag Unloader with a 2.7 foot cubed dry hopper design including load cells.
  • A modified liquefication skid design that allowed the manufacture to produce the required non-GMO liquid sugar on a batch basis with a small plant footprint.

The Results

We delivered Our Performance Guarantee that:

  • Self-manufacturing of non-GMO liquid sugar.
  • Limited space usage.
  • Short batch cycle times.
  • Reduced inbound syrup transportation costs.
  • Reduced raw material cost by buying non-GMO sugar on the open market.
  • Managed risk of syrup quality by using own treated water.

Would you like to know how Semi-Bulk System’s solutions can improve your beverage production profitability? Contact us or call 800-732-8769.

Semi-Bulk has been installed around the world.

Industries Served

Ready To Drink Beverage Case Study

How a major beverage manufacturer increased capacity with no loss in quality or consistency.

Opportunity

One of the world’s largest beverage manufacturers needed to increase capacity in their hot-fill bottling lines to meet higher consumer demand.

Industry: Beverage

Our Approach

Semi-Bulk Systems designed a Process XStreamlining Solution that:

  • Utilized our patented Vacucam® Dynamic Beverage Batching Process
  • This state-of-the-art process accommodates total beverage mixing including minor dry ingredients and the unloading and mixing of liquid additives from drums or pails.
  • Incorporated our dry handling expertise to unload beverage mix powders (Sugar, Citric Acid, Erythritol) with an automated feed from multiple the Semi-Bulk Systems bulk bag unloaders
  • Conditioned dry ingredients for mixing using our patented Air Cone® technology.
  • Accommodated single pass, batch recycle and continuous steady-state processes for the Total Solution.
  • Provided flexibility to handle small volume (minor) ingredients within the large capacity mixing operation.

Leveled all operations to floor level – no platforms required.

The Results

We delivered Our Performance Guarantee that:

  • High capacity rates – can feed several bottling lines with minimum batch cycle times
  • Minimum batch times
  • Batch to batch consistency
  • Improved overall beverage mix quality. Maximized efficiency of the UHT process.
  • Low / No maintenance – Pump is only moving part.
  • Low energy consumption
  • Sugar – high capacity, using Semi-Bulk Systems unique powder handling / sugar liquefication processes.
  • Improved ergonomics with all operations at floor level – no platforms required

Pour on the profits by installing a state-of-the-art Semi-Bulk engineered solution, featuring our patented VACUCAM mixing technology. Contact us to determine if we can help improve your production capacity and quality.

Semi-Bulk has been installed around the world.

Industries Served

Cocoa Beverage Case Study

Tripled capacity, reduced dry storage needs and improved mix quality for cocoa beverage.

Opportunity

A major beverage manufacturer needed to increase capacity and
“de-bottleneck” the batching process to meet higher capacity bottling lines and customer demand.

Industry: Food & Beverage

Our Approach

To meet the increased capacity goals, Semi-Bulk Systems engineered customized solutions including:

  • Replaced bulk bag system (400 lbs./min) with high capacity bulk truck unload to silo, conveyance to hi performance EJM skid process (650-750 #/min dry) feeding Vacucam 340 gpm In-line Sugar Slurry Process
  • Flexibility to move from bulk bag handling to bulk truck unload process delivering to bulk silo.
  • Minimized capital expenditure by retrofitting process with existing equipment.
  • Dry sugar dissolution WITHOUT high shear or heat which saves energy and prevents wear at the mix point.
  • Utilized standard for non-weighed dry side (i.e. bulk truck, rail car, etc.) with unique Semi-Bulk control strategies to control +/- 0.1° Brix.

Specifically for their cocoa production, we utilized our Vacucam® In-line Slurry Process with the following approach:

  • Accommodated high fat (10%+) containing cocoas by de-agglomerating the cocoa in dry state with sifter
  • Delivered significant improvement versus traditional / vacuum high shear mixers. Generated no agglomerates or fish-eyes using Vacucam® dynamic dispersion.
  • De-Agglomeration and Dynamic Dispersion of cocoa powders prevents inclusion of dry / un-wetted agglomerates lessening potential encapsulation of spore forming organisms in the slurry which may protect them during UHT treatment.
  • Validated to meet stringent requirements for UHT cocoa processing.

The Results

We deliver Our Performance Guarantee:

  • Tripled capacity by reducing batch cycle time
  • Reduced dry storage and improved work-flow moving from bulk bag sugar to bulk truck.
  • Improved overall beverage mix quality. Maximized efficiency of the UHT process.
  • Reduced labor costs.
  • Allowed for parallel processing – eliminated sequential batching for functional ingredients, sweeteners, cocoa, and sugar.
  • Processing – step change improvement
  • Sugar – high capacity, using SBS unique powder handling / sugar liquefication processes.
  • Cocoa – Integrates into UHT process with complete dispersion and controlled amount of shear on cocoa.

Would you like to see the advantages Semi-Bulk Systems can provide to increase the efficiency of your beverage production? Contact us to evaluate your next project.

Semi-Bulk has been installed around the world.

Industries Served

Alternative Beverage Case Study

Reduced Batch Cycle Time by 300% and Improved Batch to Batch Consistency for Alternative Drinks.

Opportunity

Our beverage manufacturing customers are often seeking ways to reduce their plant processing footprint and significantly reduce manufacturing costs (i.e. energy costs).

Industry: Alternative Beverage

Our Approach

We utilize our Vacucam® MOT Batch Slurry Process to mix both pre-weighed and loss-in-weight powders with ambient water on a batch basis.

The dry side contains multiple bulk bag unloader assemblies & paper bag break hoppers utilizing Semi-Bulk’s unique surge hopper design and incorporating our patented Air-Cone® Pick-Ups for powder conditioning.

The Results

We always deliver Our Performance Guarantee:

  • Reducing batch cycle time by 300%.
  • Significantly improving capacity within a reduced plant footprint.
  • Reducing ingredient handling by moving to bulk bags /super sacks from paper bags
  • Eliminating high frequency injuries with ergonomic process design
  • Easily mixing multiple beverage ingredients (i.e. alternative sweeteners, and thickeners)
  • Improving quality of final product due to process efficiencies and consistencies
  • Reducing energy consumption
  • Reducing mechanical maintenance
  • Completing control of dust in work environment
  • Integrating Batch Menu Controls

Semi-Bulk Systems can deliver solutions for your beverage plant with sweet money saving results. Contact us to evaluate your next project.

 

Semi-Bulk has been installed around the world.

Industries Served

Nutritional Beverages Case Study

Increased Capacity by greater than 120% allowing consolidation of multiple plant operations and significant improvement in manufacturing costs.

Our Benefits

Our nutritional beverage customers have…

  • Reduced Process Time by 54%
  • Increased capacity by greater than 120% allowing consolidation of multiple plant operations and significant improvement in manufacturing costs.
  • Eliminated high frequency injuries with Ergonomic process design
  • Eliminated paper bag handling resulting, in significant cost savings
  • Improved quality of significant final product due to process efficiencies
  • Reduced mechanical maintenance
  • Reduced energy usage
  • Reduced dust in work environment.

So many savings, you’ll need to shake them off!

Final Results

Increased Capacity by greater than 120% allowing consolidation of multiple plant operations and significant improvement in manufacturing costs.

Location: California
Industry: Beverage

Semi-Bulk has been installed around the world.

Industries Served

Powder Liquid Mixing Maltodextrin Case Study

Reduced cycle times by 70%. Increased capacity by 200%.

Our Benefits

Our juice company customers are able to…

  • Convert their process to 100% rapid liquefication
  • Minimize dense airborne dust
  • Eliminate bags and bag waste
  • Eliminate lifting injuries completely

You will be surprised how we can Squeeze Savings out of your processes.

Final Results

Reduced cycle times by 70%. Increased capacity by 200%.

Location: California
Industry: Beverage

Semi-Bulk has been installed around the world.

Industries Served