Food Starch Manufacturing Case Study

How a top food manufacturer achieved a higher production efficiency for starch slurries.

Opportunity

In order to achieve a higher ROI, a major manufacturer of bulk starch needed to improve efficiency for their food manufacturing customers.

Industry: Food, Starch Slurries

Our Approach

Semi-Bulk Systems designed a Process XStreamlining Solution that utilized the Vacucam® Continuous Steady State technology to improve slurry process efficiency. The system provides the features needed:

  • Incorporates the integration of bulk truck unload process (500 #/min) to Vacucam® Continuous Steady State Slurry Process for Corn and Tapioca starches.
  • Integration of the Vacucam® dynamic dispersion technology to deliver a predetermined solids level (35-40%), fully hydrated and ready to use on a continuous basis.
  • Dry delivery portion designed for effective dust containment.

The Results

We delivered Our Performance Guarantee that:

  • Capacity: significant batch cycle reductions when compared to traditional batching processes.
  • Operating costs: dramatic reductions in both labor and energy costs.
  • Operating costs: lower maintenance, unplanned downtime with no moving parts
  • Quality: batch-to-batch consistency producing no fisheyes or agglomerates

To see if Semi-Bulk’s state-of-the-art VACUCAM mixing technology and pet care production solutions can improve your production efficiency, contact us or call 800-732-8769.

Semi-Bulk has been installed around the world.

Industries Served

Pet Care Manufacturing Case Study

How a top pet food manufacturer achieved a higher capacity for the production of starch slurries.

Opportunity

This pet food manufacturer needed to increase capacity of bulk starch to better control production quality.

Industry: Pet Care, Starch Slurries

Our Approach

Semi-Bulk Systems designed a Process XStreamlining Solution that utilized our Vacucam® Mixer on a Tank (MOT) solution to improve slurry process efficiency. The system provides the features needed:

  • Incorporates the integration of Vacucam® Mixer on a Tank (MOT) Slurry Process for Corn Starch.
  • Integration of the Vacucam® dynamic dispersion technology to deliver a predetermined solids level (9-10%), fully hydrated and ready to use on a continuous basis.
  • Dry delivery portion designed for effective dust containment.

The Results

We delivered Our Performance Guarantee that:

  • Capacity: significant batch cycle reductions when compared to traditional batching processes.
  • Operating costs: dramatic reductions in both labor and energy costs.
  • Operating costs: lower maintenance, unplanned downtime with no moving parts
  • Quality: batch-to-batch consistency producing no fisheyes or agglomerates

To see if Semi-Bulk’s state-of-the-art VACUCAM mixing technology and pet care production solutions can improve your production efficiency, contact us or call 800-732-8769.

Semi-Bulk has been installed around the world.

Industries Served

Bread Case Study

How a major bread manufacturer was able to increase profitability by producing their own syrup.

Opportunity

A major manufacturer of bread and dinner rolls wanted to control quality and improve productivity by buying dry sugar and producing their own 68° Brix syrup, rather than purchasing liquid sugar.

Industry: Food

Our Approach

Semi-Bulk Systems designed a Process XStreamlining Solution that:

  • Utilized our patented Vacucam® MOT Batch Sugar Liquefication Process
  • Leveraged Semi-Bulk’s dry handling expertise with a dry sugar delivery from our state-of-the-art bulk bag unloader.
  • Customized a 35 foot and 3 dry hopper design.

Provided the capability to produce syrup off-line and on off-shift with minimal resource allocation, saving additional labor costs.

The Results

We delivered Our Performance Guarantee that:

  • Reduced manufacturing costs by eliminating the need to purchase liquid sugar.
  • Provided the ability to control liquid sugar quality through in-house production.

To see if you can sweeten your profits, contact us to determine if we can help improve your production capacity and quality using our patented VACUCAM® mixing technology.

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

Dry Food Ingredient Case Study

Added efficiency for soup mixes dry food ingredients handling.

Opportunity

When major food manufacturers relocate production of soup mix lines, they are seeking a more efficient method for the handling of their bulk food ingredients.

Location: New York
Industry: Food

Our Approach

Semi-Bulk Systems provides efficient dry handling systems for a variety of bulk food ingredients. For our customers, we are able to:

  • Design modular-engineered flexible & configurable bulk bag unloading cells arranged in work cells of 4-5 units.
  • Engineer an accommodation for loss-in-weight features.
  • Provide unique designs that allow for inter-changeable mobile hopper & feeder configuration.
  • Utilize standardized SBS vibratory hugger and bag clamp ring designs

.

The Results

We always deliver our Performance Guarantee:

  • Quicker / easier product changeover cycles.
  • Allow for easy product clean-out (C-O-P).
  • Provide a number of Safety Health & Environment (SHE) advantages: Ergonomics and Dust-Free.
  • Eliminate the need to handle small bags.

Would you like to see the advantages of your own “Soup” to Nuts solution for food production? 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