VACUCAM® Dynamic Beverage Batching Station (DBBS)

This system provides ability to vacuum convey conditioned powder from various powder sources, mix powder with the
liquid media on a single pass, batch recycle, batch and pump or continuous steady-state basis via
Vacucam® Ejector Mixer (EJM) and discharge the mixture forward into an existing tank.

Dynamic Beverage Batching Station

DBBS

One beverage process system can be configured for up to four options.

One Beverage Process System – many process applications for all powder handling and mixing.  System can be configured for one, two, three, or four process options to handle basic Beverage production from small to large volume dry ingredient additions.  Mix tanks range from 250-500+ gallon capacity, depending upon best suited process option.

This system provides ability to vacuum convey conditioned powder from various powder sources, mix powder with the liquid media on a single pass, batch recycle, batch and pump or continuous steady-state basis via Vacucam® Ejector Mixer (EJM) and discharge the mixture forward into an existing tank.  Liquid media is metered into the supply line to the EJM supply pump.  This mixer supply pump provides liquid flow and pressure to EJM to generate a powerful vacuum used to inhale dry ingredients and rapidly mix and dissolve / disperse them into liquid(s).  Mixture is continuously batched in a slurry / mix tank and transfers forward to a blend tank.  Vacucam® DBBS Dynamic Beverage Batching System includes both bulk bag unloading capability as well as dry minor’s funnels and small tank for floor level addition of minor liquid ingredients from totes, barrels, or bins.

Batch accuracy is maintained / confirmed thru use of loss in weight on dry hoppers, liquid flow meters on incoming / recycled liquid and density meter on outbound flow where density and concertation can be gleaned and uses in totalization scheme in batch recipes when using full bulk dry side (silos).

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Higher Quality

  • Optimal accuracy and product consistency — Powders and liquids are combined continuously and uniformly producing higher slurry quality.
  • High product integrity — Dry handling and wet processing are totally separated.
  • Industry standard hydraulic pumping — Centrifugal or positive displacement pumps featuring Fristam quality.

Lower Cost

  • Power consumption reduced by 50% to 75% compared to alternative processes.
  • Minimal downtime and maintenance costs
  • The VACUCAM® has no moving parts. High quality, low maintenance Fristam pumps supply the hydraulic energy,
  • Greater speed and efficiency — The EJM 2000 process can be automated and operated from a centre: control. Process time is greatly reduced with increased capacity. The process offers faster hydration and faster functioning of thickeners or reactive products.
  • Reduced housekeeping effort — Dry handling and mixing are totally enclosed and vacuum conveyed, providing a dust-free environment:
  • For hygienic processes, powder is kept out of wet process area, minimizing potential for bacteria growth.
  • For industrial processes, powder is kept out of process areas, eliminating dust.

Flexibility and Convenience

  • Available with optional centrifugal or positive displacement pumps to meet process requirements.
  • Configured for either single pass or batch recycle processing

Safety and Health

  • Less slipping and fewer accidents — Dust does not accumulate on wet walking surfaces.
  • Fewer respiratory Issues — No more dust-filled air contaminating the work environment.

Single Pass Process w/ Transfer to Blend Tanks:

Process allows for high usage dry ingredients being conveyed and mixed with process water as it is pumped directly to selected blend tank(s).  Dry ingredients can be fed from bulk bags or paper bags.  Used for optimum dissolution of thickeners, gums, dairy protein powders, and sensitive ingredients, typically lower solids (<20-30%).

Batch Recycle Process – Batch & Pump-away of Dry Ingredients

Batch Recycle addresses requirements of typical beverage processes to efficiently convey, mix and dissolve / disperse dry ingredients before transfer to blend tank(s).  Used for handling most medium volume ingredients, including those with higher solids.  Can be configured as batch recycle to/from existing large blend tanks or as batch recycle from SBS skid mounted blend tank then entire concentrate pumped forward (MOT (mixer on a tank, batch and pump))

Dynamic Continuous Steady State Process (DCSS)

DCSS process allows for high usage dry ingredients being conveyed and mixed to a “set-point” solids level while continuously being delivered to blend tank(s).  High usage dry ingredients, such as sucrose can be continuously conveyed, totally mixed and delivered to blend tank(s) without multiple batch transfers.  Density meter measures and totalizes dry product mass for each batch providing weighment accuracy to +/- 1% when coming from total bulk (silos, bulk trucks, railcars).

Liquid Concentrate Transfer

Integral liquid funnel allows liquid concentrates to be dumped at floor level and transferred to blend tank(s) via DBBS transfer pump

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Industrial Applications

  • Chemical Processing — Automated reaction a catalyst addition, waste stream pH adjustment. filter aid incorporation.
  • Paint & Coatings Processing — Silica incorporation. thickener additions. pigment slurries {e.g. TiO2, calcium carbonate, talc, oxides)
  • Aluminum Heat Exchanger Manufacturing — Brazing flux slurry preparation and distribution
  • Power Generation — Limestone/fly ash slurries, waste stream pH adjustment
  • Paper Manufacturing — Starch slurry. waste water pH treatment. specialized coating slurry preparation and distribution (e.g. calcium carbonate. clay. Ti02)

Sanitary Applications

  • Pharmaceutical — Sodium bicarbonate slurries, salts dissolution
  • Dairy — NFDM reconstitution, sugar liquefication, (Batch Processes or Single Pass), ice cream mixes
  • Brewing — Filter aids. silica and activated carbon slurries
  • Processed Cheese — Wet mix (high protein) slurries
  • Margarine — Whey slurries
  • Dressings — Spiced ingredients, starch slurries, egg mixes
  • Confectionary — Dry ingredient recovery/reintroduction
  • Health/Personal Care Products — Carbopol slurries (thickeners), compound dispersions

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VACUCAM® Ejector Mixer

Semi-Bulk Systems VACUCAM® Ejector Mixer Dynamic Batching Station provides the most efficient dispersion, mixing and hydration of ALL dry ingredients used in today’s broad range of product types and ALL Beverage Processes.

The Vacucam® Ejector Mixer is the most effective system available for conveying, wetting, and dispersing powders into liquids.

Here is how it works.

Conditioned powder is conveyed into the mixer by a near-perfect vacuum, which is created when pressurized fluid is discharged as a high-velocity, hollow jet into which the powder is drawn.

The high speed dispersion mixer.

The Vacucam® system achieves high-speed, instantaneous and complete wetting by bringing together conditioned powder and highly atomized liquid from two separate streams, incorporating particles of liquid with particles of powder. The reactive surface areas of both the powder and the liquid are maximized before intimate contact is actually made. The result is consistently uniform, superior wetting without the agglomeration or “clumping” usually associated with conventional mixing methods.

Semi-Bulk Systems can design and integrate the Vacucam® in-line system to feed finished slurry into multiple locations of your preference, such as storage or mix tanks. Your entire process can be physically separated and centrally controlled. Semi-Bulk Systems provides options such as mounting the Ejector-Mixer on your tanks or integrating our system with your existing process.

The best fluid ejector upgrade with improved efficiency over the traditional fluid mixer.

Since the Vacucam® system achieves high-speed, instantaneous and complete mixing, it makes it perfect for fluid mixing too. You can bring together highly atomized liquids from two separate streams for batch to batch consistency and uniform mixing.

Unsure if the Semi-Bulk Systems can improve your efficiency?

Contact us for a free review of your project.

Industries Served