Ice Cream Case Study

How one ice cream manufacturer doubled capacity using the latest mixing technology.

Opportunity

This privately held ice cream manufacturer needed to double their capacity to keep up with their dramatic growth.

Industry: Dairy

Our Approach

Semi-Bulk Systems designed a Process XStreamlining Solution that:

  • Utilized our fully automated dry handling system consisting of bulk bag unloaders, small bag dumps stations, and our newly designed cocoa hopper.
  • Leveraged our patented Vacucam® In-line Mixing Process to create large-scale batches
  • System developed to handle various types of milk powders, sugar, cocoa, as well as various powder and liquid minor ingredients.

The Results

We delivered Our Performance Guarantee that:

  • Delivered significant scalability for dry handling and mixing automation.
  • Achieved higher capacity with higher batch-to-batch consistency
  • Significantly reduced labor requirements for batching process.
  • Doubled capacity that allowed consolidation to one manufacturing operation with no loss of capacity.

To see if Semi-Bulk’s state-of-the-art VACUCAM mixing technology can improve your production efficiency, capacity and consistency, contact us.

Semi-Bulk has been installed around the world.

Industries Served

Multi-Product Capabilities Case Study

Incorporated 50+ powders producing dozens of different products.

Our Benefits

We’ve worked with major food & dairy processors that have…

  • Incorporated 50+ powders producing dozens of different products
  • Reduction of Batch times by 75%
  • Reduced energy cost by 50%
  • Achieved Batch-to-Batch consistency allowing quality product
  • Achieved rapid batch time enabling CIP between product runs without process delays
  • Eliminated problems related to operator safety and dust

Back to back consistent savings!

Final Results

Incorporated 50+ powders producing dozens of different products.

Location: Illinois
Industry: Dairy, Food

Semi-Bulk has been installed around the world.

Industries Served

Sugar Liquefication Case Study

Realized a Capital ROI in Less Than One Year!

Our Benefits

From sugar in bulk to Sugar Liquefication.

That’s not all. Our ice cream manufacturing customers have…

  • Reduced inbound syrup transportation costs by more than 32%
  • Significantly reduced raw material cost by buying granular sugar
    on the open market.
  • Eliminated quality issues related to carmelization by lowering the
    process temperature.
  • Eliminated supplier and storage problems by moving syrup production in-house.

It all adds up to some Cool Savings.

Final Results

Realized a Capital ROI in Less Than One Year!

Location: Georgia
Industry: Dairy

Semi-Bulk has been installed around the world.

Industries Served

Thickeners Case Study

Reduced Batch Times by 80%, Increased Capacity by 400%.

Our Benefits

That’s not all. Our whipped topping manufacturers have…

  • Improved downstream efficiencies by increasing batch-to-batch consistency.
  • Reduced ingredient requirements by 10%.
  • Reduced equipment cleaning time by 75%.
  • Reduced energy costs by 50%.
  • Eliminated ALL problems related to incorporating guar and xanthan gums.

Savings like these really top it all.

Final Results

Reduced Batch Times by 80%, Increased Capacity by 400%.

Location: Wisconsin
Industry: Dairy

Semi-Bulk has been installed around the world.

Industries Served

Milk Reconstitution Case Study

Reduced Batch Processing Times by 65%.

Our Benefits

That’s not all. Many of our cheese processing customers have…

  • Eliminated fallout/dropout of material in silo.
  • Increased quality by eliminating batch-to-batch consistency issues.
  • Eliminated problems related to dust.
  • Eliminated problems related to handling bulk bags including safety and injury concerns.

It all results in a huge chunk of… CHANGE.

Final Results

Reduced Batch Processing Times by 65%.

Location: New Jersey
Industry: Dairy

Semi-Bulk has been installed around the world.

Industries Served

Non-Fat Dry Milk Reconstitution (NFDM) Case Study

Batch times reduced by 80%

Our Benefits

That’s not all. We’ve worked with pudding companies that have…

  • Reduced batch times by 80%
  • NFDM reconstitution to 46% solids
  • Eliminated material fallout and dropout in silos
  • Eliminated foaming
  • Improved batch-to-Batch consistency to eliminate quality issues

Savings until the cows come home!

Final Results

Batch times reduced by 80%

Location: Wisconsin
Industry: Dairy

Semi-Bulk has been installed around the world.

Industries Served

Milk Rehydration Case Study

Reduce process time by 90%, 38 minutes vs. 6.5 hours!

Our Benefits

That’s not all. Our major dairy processors have also…

  • Achieved product consistency
  • Eliminated fallout/dropout of material in silo
  • Eliminated quality issues
  • Reduced cure time in silo by 80%
  • Reduced energy by 80%

Don’t cut corners, cut time!

Final Results

Reduce process time by 90%, 38 minutes vs. 6.5 hours!

Location: California
Industry: Dairy

Semi-Bulk has been installed around the world.

Industries Served

Bulk Ice Cream Mix Case Study

Processes a capacity of 25 million gallons per year with excess processing time available for additional process opportunities.

Our Benefits

Our ice cream producer customers have…

  • Produced standard, no sugar added and low carb mixes all at full capacity
  • Achieved complete batch-to-batch consistency
  • Achieved ergonomic, dust-free environment
  • Reduced labor and process time.

Three Scoops of Savings please!

Final Results

Processes a capacity of 25 million gallons per year with excess processing time available for additional process opportunities.

Location: Iowa
Industry: Dairy

Semi-Bulk has been installed around the world.

Industries Served