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Dosing systems are a line of hoppers, feeders, filling machines, and checkweighers that operate in sync to dispense materials accurately. Dosing is an essential feature of the packaging process, whether you’re filling shampoo bottles or tea bags. But dosing equipment is critical for formulations, too, particularly in the pharmaceutical and chemical industries. Imprecise dosing may cause quality degradation in the best-case scenario. In the worst scenario, it creates serious health risks.

Dosing

Industrial feeders and hoppers are used to provide a consistent, regulated flow of material to the production line for further processing. Feeders and hoppers are generally used in the industry in conjunction with other processing machines like crushers, dryers, conveyors, and mixers. Considerations for choosing a suitable feeding system include the physical state and particle size of the infeed, the output volumetric flow rate required and the type of connection to be made with the processing machinery.

Batch

Industrial

Manual

Manufacturing hydroalcoholic gels, which contain a significant amount of alcohol, requires efficient dispersion of hydrocolloid products. Traditional agitators can fail to provide a homogeneous mix, leading to issues with product consistency.
<h2>Efficiently mix hydrocolloid products</h2>
The CMC-ATEX mixing unit by INOXPA is designed for the fast dispersion of hydrocolloid products like carboxymethylcellulose (CMC), flours, carbopol, pectin, and guar or xanthan gum, crucial in the production of hydroalcoholic gels. The system includes a rotor-stator mixer at the bottom of the tank, enhancing the water-additive contact area to prevent lump formation. An agitator with a cowles-type propeller ensures efficient powder circulation, reducing dispersion time. The system can also handle highly viscous products, adapting to viscosities up to 5000 cP. For safety, the ATEX version is designed for use with potentially explosive products, ensuring compliance with strict standards. Key features include a vertical agitator, high-shear mixer, CIP spray balls, manual butterfly valves for discharge, and a control panel for non-classified zones. The unit is constructed from AISI 316L stainless steel with polished welds for durability and hygiene.

Hydroalcoholic gel mixing system

Blending

Dispersion

Handling

Industrial mixing equipment is used to combine two or more solid, liquid or gaseous segregated ingredients into a homogenous single product. The choice of mixing technology depends largely on the physical state of the ingredients and the desired final product. But the sensitivity of the ingredients, the process temperature, and pressure requirements are also critical factors. All these parameters result in a wide range of industrial mixers.

Mixing

liquid

Handling ground coffee to preserve its aroma and prevent demixing requires specialized technology. This is particularly critical when transporting coffee from silos to packaging machines to ensure quality and consistency.
<h2>Preserving aroma during coffee transfer</h2>
The ExtraMAX by IMA is a mechanical extraction system designed to maintain the homogeneity and prevent the agglomeration of ground coffee during extraction from silos. This system employs a flat extraction mechanism which is effective for various coffee types, including filter, Espresso, and Moka coffee. Unlike traditional vibrating systems, ExtraMAX ensures more consistent homogenization and precise control of dosing, significantly reducing issues related to demixing. Furthermore, IMA's Petroncini handling solutions provide advanced transport mechanisms to avoid oxidation and contamination, essential for maintaining the coffee’s aroma and quality. The system includes tangential air flows and vacuum-based methods to handle long-distance transfers and high production rates efficiently.

Ground coffee handling and conveying system

Conveyor systems are used for moving materials from one location to another. Considerations for choosing a suitable industrial conveying system include the nature of the product, its physical state, the desired conveying rate, and sensitivity of the product to heat and mechanical shock. Conveying equipment is used in the food, pharmaceutical, chemical, biomass, and mineral industries to move materials around a warehouse as well as to transport bulk powders, granules, and grains for processing and filling. These types of systems are usually automated and there is a wide variety of solutions to choose when it comes to the type of conveyor. Types include screw, gravity, chain, roller and belt conveyors.

Conveying

Industrial extraction equipment unlocks the valuable compounds hidden away in natural materials. Automated extraction equipment is applied in the pharmaceutical and cosmetic industries to extract active compounds from medicinal plants or herbs. For example, extracting cannabinoids from cannabis plants. But the process is also fundamental to the food industry, recovering various components like aromas, oleoresins, and proteins.  Considerations for selecting suitable extraction technology include the type of plant material to be processed, the extract's heat sensitivity, and the production volume.

Extraction

solid

Continuous

In industries dealing with powders and bulk solids, uniform mixing is critical to maintaining product consistency and quality. Traditional manual mixing methods are often labor-intensive and can lead to variability in the final product, necessitating more precise and automated solutions.
<h2>Ensure uniform mixing of powders and bulk solids</h2>
The powder mixing systems from Hosokawa Micron are designed to deliver optimal performance and precision. These systems integrate various components like conveying, handling, dosing, and weighing to create a complete and tailored solution. Offering a wide range of mixer types, including low, medium, and high-shear mixers, they cater to both batch and continuous operation needs. Key elements include accurate dosing systems, efficient weight control, and custom-built designs focusing on safety, reliability, efficiency, and hygiene. These systems are suitable for numerous industries such as food and beverage, pharmaceuticals, and chemicals, ensuring consistent product quality. With modern control systems including HMI-PLC panels for operator identification and lot traceability, seamless automation is achieved. Hosokawa Micron leverages its century-long expertise to provide bespoke mixing solutions tailored to specific application requirements.

Powder mixing systems

Weighing

Powder

In the sugar industry, achieving finely milled, storage-stable icing sugar without additives is a challenge. Conventional sugar milling systems often require extensive additional equipment that increases the investment and operational costs.
<h2>Achieve shelf-stable icing sugar in one compact system.</h2>
The Sugarplex SX Flow by Hosokawa Alpine is an advanced fine impact mill specifically tailored for the sugar industry. Designed as an all-in-one solution, it integrates grinding and recrystallization processes inside a pressure-shock resistant stainless steel vessel. What sets the Sugarplex SX Flow apart is its ability to recrystallize amorphous icing sugar within the mill, ensuring shelf-stability without the need for additives. The compact design eliminates the need for additional filters, fans, or cooling equipment, reducing space requirements and maintenance costs. The system can achieve throughputs of up to 3 t/h at a fineness of 99% < 450 µm or 1.5 t/h at a fineness of 99% < 150 µm. Powered by an 18.5 kW three-phase motor and regulated by a frequency converter, the mill allows for precise control of fineness. The grinding chamber includes two integrated pin discs, easily accessible for cleaning through the wide mill door. This system's design ensures lower energy consumption, making it a cost-effective solution for producing high-quality icing sugar.

Sugar grinding and recrystallization system

Crystallization

Grinders use a spinning blade or rotating abrasive elements to reduce the size of various materials. The specifications, RPM and grit of the engineered grinder, will result in various particle sizes. As a result, what you want to make will determine the type of grinder you need. Grinding is used for improving the texture and flow properties of various products and to enhance the flavor of food products such as coffee, spices, sugar, nuts, sesame, poppy seeds, lentils, wheat, and rice. Choosing the right rotational speed, grinding elements, and processing power allow the grinding and shredding of a wide range of materials into coarse or fine powders. Popular types of heavy duty grinders in food processing include angle grinders, bench grinders and meat grinders.

Grinding

Industries dealing with materials that do not flow freely from silos and containers face challenges in ensuring smooth discharge. These bulk materials often require additional mechanisms to facilitate flow, preventing blockages and ensuring consistent output.
<h2>Ensure smooth discharge from silos</h2>
The range of discharging systems by Hosokawa Alpine addresses the issues of handling difficult bulk materials. These solutions include vibration, aeration, and mechanical agitation designed to suit specific product characteristics and operating conditions. The systems are categorized into four types: Solids Basic, Solids Clean, Solids Hygienic, and Solids Heavy, each designed to meet varying operational needs and standards. For example, the ‘ExtraVib’ vibration bin dischargers ensure mass flow discharge, reducing clearance volumes and segregation, thus supporting high load capacities and consistent flow. Additionally, aeration systems like the FLC type provide gentle discharge and homogenization of fluidizable powders. These systems are essential in industries such as chemicals, food processing, and pharmaceuticals, where material consistency and hygiene are critical.

Discharge systems for difficult bulk materials

Aerators are devices used for mixing air (oxygen transfer) with a liquid such as water or oil to form a homogeneous product. Selecting an industrial aeration system involves choosing a suitable mixing head and considering the desired input and output flows, temperature, level of aeration, properties of the liquid phase, and the degree of automation and pressure control. Aerators are used in the food industry for the production of fat-based center masses and crèmes and in the chemical industry for wastewater treatment. When it comes to water treatment, surface aerators are most commonly used.

Aeration

In the agricultural industry, the efficient storage and transfer of seeds are paramount. Seeds getting stuck in storage containers can result in incomplete emptying and potential product loss, posing significant operational challenges.
<h2>Securely store and efficiently empty seeds</h2>
The specially designed seed containers by Hoopman Equipment are engineered to prevent seeds from getting stuck. Featuring a unique design with no sharp corners, these containers ensure complete emptying. A highly functional slide valve, positioned at the bottom, is easy to operate, even during the emptying process. These containers are available in several standard dimensions, with custom sizes available upon request to suit specific needs. The flexible seed outlet facilitates seamless dosing into standard hoppers, eliminating risks during transfer. Easy stackability further enhances their utility in storage operations.

Seed containers with easy operable slide valve

A loading system feeds your continuous or batch processing machine with the specified material or item in line with the flow of production. Loaders transfer the articles from one stage of preparation to the next with uniformity and accuracy.

Loading

Almost all manufacturers will require industrial storage systems and solutions at some point during their production process. The raw materials that go into your products need dedicated storage solutions to protect them from spoilage and contamination before they enter the manufacturing cycle. Storage usually refers to particular storage space. For example, having enough warehouse storage. Or clearing out a production facility for more floor space.  However, in this case, we are referring to the equipment and solutions that make storage manageable and easier. Such equipment includes solutions such as storage racks, pallet racks and shelving systems. These are just some of many storage options available to manufacturers. Advanced technology facilitates the management of heavy duty and high density tank and silo systems by automating the delivery system and linking it with the rest of the production line.

Storage

In many industrial processes, handling bulk materials involves the challenge of efficiently emptying material containers. Manual unloading can be labor-intensive and time-consuming, resulting in productivity loss. The solution often requires a streamlined and adaptable system to facilitate this task effectively.
<h2>Facilitates easy container unloading</h2>
The MCED Material Container Emptying Device by Hoopman Equipment is designed to simplify the unloading of material containers used in conjunction with various fluid bed dryers and related systems. This device comes with standard mounting options, including units that can be easily attached to walls or building ribs. The system includes an electrical lifting mechanism to lift and tilt the containers, allowing for smooth and efficient emptying of contents. It is compatible with different seed bins through available adapters. This adaptable solution ensures that material handling is streamlined and ergonomic, reducing the need for manual labor and associated risks. Suitable for various industries, this device offers a practical approach to improving efficiency in material management.

Material container emptying device

In high-volume tortilla and corn chip production, traditional masa preparation methods often lead to extended processing times and excessive water usage. These inefficiencies can increase costs and impact production schedules, making it critical to find a more streamlined approach to masa production.
<h2>Produce fresh masa in minutes</h2>
The Masa Maker from Heat and Control is a recipe-driven, continuous system designed for rapid corn masa preparation. Instead of relying on traditional simmering and soaking techniques, this system converts dry, clean corn into fresh masa in just minutes. This eliminates the need for masa flour and allows on-demand production, ensuring consistent quality and flavor profile as per your brand requirements. By substantially reducing water usage to just what is required for the recipe and sanitation, the Masa Maker contributes to significant water savings. Additionally, it eliminates the necessity for steam generators, simmer kettles, and soak tanks, saving on energy and freeing up floor space for other operations. The Masa Maker is ideal for producing tortilla chips, taco shells, and other corn-based products.

Corn masa preparation system

Whether it is marmalade or pizza, sauce or hummus, chocolate or fruit puree, most food products undergo a cooking step during their production process. Cooking is nothing more than applying heat to food, but there are different methods to do it. For instance, baking, frying, and roasting involve cooking food without using water, unlike boiling or steaming. Industrial cookers such as vacuum and pressure cookers, industrial fryers, industrial ovens, and industrial roasters focus on specialized applications that meet the different needs of the food industry by helping producers achieve a homogeneous cooking process.

Cooking

Handling large volumes of potatoes, onions, and other fresh produce efficiently can be challenging, especially when ensuring a consistent flow to processing lines. Safely and quickly tilting crates to empty their contents can optimize material handling and reduce downtime.
<h2>Tilt and empty crates with hydraulic control</h2>
The Crate Dumper from Heat and Control is designed to safely tilt crates weighing up to 3,300 pounds using a machine-mounted hydraulic tilt system. Its heavy-duty construction and adjustable dump speed control make it suitable for various produce such as potatoes, onions, and fresh vegetables. It helps maintain a consistent flow to the metering hopper and downstream processing equipment. The unit includes a pre-piped and wired hydraulic power pack, adding to its reliability and ease of installation. Ideal for applications in the production of potato chips, onion rings, fresh produce packs, and French fries, this crate dumper improves operational efficiency.

Crate dumper for potatoes and fresh produce

Handling and transporting tablets in the pharmaceutical industry requires precise methods to avoid breakage and contamination. Ensuring the tablets remain intact and uncontaminated during storage and transport is crucial for maintaining product efficacy and meeting regulatory standards.
<h2>Store and transport tablets safely</h2>
The Tablet IBC by Hanningfield Process Systems is a specialized container designed for the gentle handling of tablets. Featuring a shallow body angle and a flexible-vane outlet valve, it minimizes the risk of tablet breakage and damage. Constructed from 316L stainless steel for all contact parts and equipped with FDA-compliant seals, it ensures safe and sanitary conditions. Non-contact parts are manufactured from 304 stainless steel, and the design can be customized with features such as castors for mobility, corner stacking profiles, and lifting loops for handling via forklift or post hoist. The tablets can also be transferred into a coater using an outlet chute. These containers are suitable for validatable cleaning processes using a wash booth or wash station. Hanningfield's Tablet IBCs are ideal for the pharmaceutical, food, and allied industries.

Tablet storage and transport containers

The essential objectives of containment systems are personnel protection and preventing the release of toxic or infectious material into the environment. Containment is also used to prevent a product or sample from contamination by the external environment. In the chemical and pharmaceutical industries, containment solutions are used to protect the personnel from the leaking of airborne particles of hazardous substances, as powders or liquids are handled or transferred during processing.

Containment

transportation

Entry level

In pharmaceutical and food processing, efficient particle sizing is essential for product quality and consistency. Combining milling and sifting into a single process can save both time and equipment costs, ensuring uniform particle sizes for a variety of applications.
<h2>Achieve precise particle sizing with flexible operation</h2>
The Hanningfield Particle Sizing Solution is a versatile and cost-effective system that combines milling and sifting operations in a single unit. This dual-function setup allows you to easily switch between a conical mill and a centrifugal sifter, making it ideal for a range of powder processing needs. The machine features stainless steel construction with 316L contact parts and FDA-compliant seals, ensuring it meets stringent industry standards. The system is designed for high throughput with inline feed and discharge for ease of integration. It operates with low heat, dust, and noise generation, creating a safer and more comfortable working environment. The Particle Sizing Solution is scalable from lab to production levels, making it suitable for small-scale studies as well as full-scale manufacturing.

Particle sizing solution for milling and sifting

Milling machines are used to reduce the size of material by cutting, crushing, or grinding it. The choice of industrial milling equipment depends on the industry and the materials to work with. Besides, there is a significant difference between those aimed to remove layers from metal or other materials workpieces and those designed to reduce particle size for materials that come in bulk.

Milling

Sieving machines are available in various designs such as linear sieves, tumbler sieves, and vibrating sieves each employing a different sieving action. The choice of a suitable sieving machine depends on the desired particle size distribution, required amplitude and frequency of vibrations, and the physical state of the mixture. Sieving machines are used for removing dust from granular products and for grading grains. They are also used for the classification of granular material and the separation of solids from a slurry mix in the food processing industries.

Sieving

In industries where precise particle size reduction is critical, traditional grinding methods often fail to deliver uniform results. Achieving consistent particle sizes while maintaining product integrity can be challenging, especially for heat-sensitive materials or rugged applications.
<h2>Reduce particle size with adjustable settings</h2>
The Hanningfield Uni-Mill B-Series is a conical mill suitable for achieving high-efficiency size reduction with minimal heat generation. Utilizing the industry-standard over-driven design, the mill features a belt-driven impeller rotating inside a screen. This setup allows for the compression and shearing of particles to reach sizes as low as 150 microns (80 mesh). Constructed from 316L stainless steel for all contact parts and 304 stainless steel for non-contact parts, the unit complies with FDA regulations. The Uni-Mill B-Series includes models M10-B, M20-B, M30-B, and M60-B, each designed to provide varying throughput capacities from 360 kg/hr to 7200 kg/hr. Optional features like temperature monitoring, nitrogen purging, and ATEX compliance offer flexible customization. This makes the Uni-Mill suitable for pharmaceutical, food and beverage, chemical, cannabis, and nutraceutical industries.

Conical mill for particle size reduction

Size reduction

In pharmaceutical and food industries, secure and efficient storage and transportation of powders is critical. Meeting safety and contamination prevention standards is challenging without the right containment solutions.
<h2>Store and transport powders safely and efficiently</h2>
The stainless steel Intermediate Bulk Containers (IBCs) from Hanningfield Process Systems are designed to safely and securely transport, store, and handle powders and bulk materials. Featuring 316L stainless steel contact parts and FDA-compliant seals, these containers ensure high standards of hygiene and safety. With capacities ranging from 150 to 2000 litres, they offer flexibility for various process requirements. Custom design options are available to suit specific needs, including dust-tight charging and discharging methods, mobility with castors, and handling via forklift or post hoist. The robust construction with 304 stainless steel non-contact parts further enhances the durability and longevity of the containers.

Stainless steel intermediate bulk containers for pharmaceutical use

Discharging

In industries like pharmaceuticals and food processing, unloading sacks and bags often leads to dust emissions. Controlling this dust is crucial to maintain a safe and clean working environment, especially when handling fine and reactive powders.
<h2>Controls dust emissions during sack unloading</h2>
The Hanningfield sack tip station is a solution designed to empty sacks and bags efficiently while minimizing dust emissions. Operators lift the bag onto the station's shelf, pierce it, and allow the contents to flow into the downstream conveyor system. The unit features a dust extraction hood that protects the operator and the environment during this process. Constructed from 316L stainless steel for contact parts and 304 stainless steel for non-contact parts, this station meets FDA compliance. As an added benefit, the station can be customized with integrated dust extraction systems, like filters and fans. This is ideal for small-scale to large-scale applications in various industries including pharmaceuticals and food processing.

Dust-control sack tip station for industrial loading

Industrial cleaning equipment is used to wash or disinfect machinery and the production/warehouse area. It may also be used to sterilize the product, equipment, tools, floor or work surfaces and to purify or clean the product by removing impurities. Choosing a suitable cleaning system depends on the type of product or equipment to be cleaned, the sensitivity of the product to heat, pressure, and chemicals, and the level of sterility desired.

Cleaning

In pharmaceutical manufacturing, the delicate transfer of filled capsules from filling machines to bulk containers is crucial to avoid damaging the products. Handling filled capsules manually can lead to inconsistencies, contamination, and additional labor costs.
<h2>Gentle transport of filled capsules</h2>
The Hanningfield CapsuJet FCC is a filled capsule transfer system designed specifically for pharmaceuticals. It uses a patented venturi to create a cushioning airstream that gently transports filled capsules to a bulk container, minimizing damage. The compact design allows the system to be positioned directly beneath the outlet of capsule filling machines. Key features include a large diameter, 200-liter storage hopper for easy loading, and an easy-clean design that uses Tri-Clover clamps for quick dismantling without special tooling. The system is mounted to a mobile trolley, making it easy to move and position as needed. With a capacity to transfer up to 200,000 capsules per hour, and vertical and horizontal convey distances of 5m and 2.5m respectively, the CapsuJet FCC ensures efficient and gentle handling of pharmaceutical capsules. Constructed of 316L and 304 stainless steel, it promises durability and compliance with industry standards.

Filled capsule conveyor system for pharmaceutical production

In pharmaceutical manufacturing, maintaining a continuous supply of empty capsules to the filling machine is crucial. Challenges such as manual handling, capsule damage, and keeping the machine from running empty often arise, disrupting production and reducing efficiency.
<h2>Ensures continuous capsule supply without manual handling</h2>
The CapsuJet C20 by Hanningfield Process Systems is an empty capsule transfer system designed to tackle capsule handling challenges. This system enables the gentle and repeatable transfer of empty capsules into the capsule filling machine. Capsules are loaded into a 200-liter storage hopper, accommodating a full, standard-sized box. A tangentially discharged airflow from a multistage fan, combined with a patented venturi, creates suction that gently conveys the capsules. The system also includes a fully adjustable optical sensor that controls the capsule level in the receiving hopper, automatically starting and stopping the convey cycle. The CapsuJet C20 is mounted on a mobile trolley, weighing approximately 150 kgs, with dimensions of H1180mm x W760mm x L1215mm. It is capable of transferring up to 300,000 capsules per hour, with a maximum vertical convey distance of 10m and a horizontal distance of 5m.

Empty capsule transfer system

Handling bulk materials in industries like food, pharmaceuticals, and chemicals requires an effective system to unload big bags safely and efficiently. Challenges include dust containment, ensuring flowability of various powder types, and maintaining hygiene standards.
<h2>Safe and dust-tight unloading of big bags</h2>
The Gericke Big Bag Unloader BBU is designed to tackle these issues with its modular, flexible design. It allows for customization to meet specific needs and future adjustments. With options like vibrating tables for medium flowing powders and under massagers for poor flowing powders, it ensures efficient material handling. Safety features such as stretch units for outlet spout stretching and hoisting from different angles enhance operator safety. It also offers solutions for dust containment and hygienic execution, meeting high safety and hygiene standards. The system can integrate into various process lines, either discharging directly into hoppers or conveying systems.

Big bag unloader for industrial bulk materials

Unloading

Pharmaceutical production requires efficient handling and storage solutions to maintain product integrity and streamline processes. Ensuring proper storage and transport of pharmaceutical tablets involves addressing challenges such as ease of movement, secure containment, and compatibility with existing process equipment.
<h2>Facilitates safe storage and easy transport</h2>
The IBC Tablet Bins from Freund offer practical solutions for handling and storing pharmaceutical tablets. Designed with versatility in mind, the bins come in two main types: wheeled and palletized. The wheeled bins include a removable trolley for easy transport and alignment with process equipment. Palletized bins are optimized for movement via forklifts or pallet jacks. Both types boast sloped upper heads for superior drainage, rounded edges to prevent product retention, and smooth surfaces suitable for high hygiene standards. Additionally, the 110° discharge cone and manual butterfly discharge valve make unloading straightforward. Constructed from AISI 316L stainless steel with FDA-approved silicone gaskets, the bins are robust and meet stringent pharmaceutical regulations. Available in various capacities from 150 to 350 liters, these bins offer flexible storage options.

Ibc tablet bins for pharmaceutical storage and handling

In bakery and food production facilities, managing heavy mixing bowls and transferring their contents efficiently is a common challenge. Manual handling can lead to inconsistent results and pose safety risks, especially when dealing with large-scale operations.
<h2>Lift and tip bowls with ease and precision</h2>
The ESBL Sollevatori, from Escher Mixers (Middleby), is a sophisticated solution designed to transfer the contents of mixing bowls with precision and minimal effort. It boasts two primary lines: the ESBL Line, suitable for artisan needs with table and standard divider outputs, and the ESBL Industry Line, tailored for industrial operations with variable heights up to 3.5 meters. One standout feature is the option for bowl rotation via a friction wheel or the patented Escher system, ensuring smooth and consistent content transfer. Additionally, the models can be equipped with a bowl scraper and safety grid to enhance safety and cleanliness. The lifting mechanism can be semi or fully automatic, offering flexibility based on your operational needs. Interface systems are available for seamless integration with feeding hoppers and subsequent processes.

Industrial bowl lifter-tipper

Industrial feeding systems allows you to control the flow of solid bulk materials throughout the manufacturing line. After loading your material onto the vibrating hopper, a screw at the base drives it out in uniform doses to the next stage of processing. New feeding technologies are designed to deal with challenges of powders clumping together in the hopper (bridging and ratholing) that interrupt the outflow. Common feeder systems include centrifugal feeders, vibratory feeders as well as elevator, linear and pneumatic feeders.

Feeding

In large-scale bakery or food production environments, the efficient transfer of heavy loads of dough is crucial. Traditional manual methods are prone to inconsistency and labor-intense, impacting productivity and safety.
<h2>Automate dough feeding with precision</h2>
The HK 300-600 is an advanced elevator tipper designed by Diosna for top performance in industrial applications. Built for robustness, it can handle continuous 3-shift operations, ensuring reliable and consistent dough feeding. Available in mobile or stationary models, the tippers come in two variants: the HK 300 and HK 600, accommodating maximum loads of 600 kg and 1,000 kg respectively. The inclined design optimizes dough feeding, and the device can be paired with Diosna hoppers for a versatile and comprehensive system. An integrated frequency converter ensures optimized lifting speed, and the tong lock provides a secure hold. Ideal for large-scale operations, the elevator tippers also serve as efficient cleaning tools, making them versatile additions to your production line.

Industrial dough feeding elevator tipper

When handling large volumes of powdered or granular materials, it's crucial to ensure a safe and dust-free environment. The risk includes potential dust exposure, which can be hazardous, and handling awkward and heavy Big Bags that might lead to safety concerns for operators.
<h2>Safely unload materials with minimal dust</h2>
The Modular Big Bag Unloading Station by Dinnissen ensures a safe and ergonomic product intake process. It allows the dust-free unloading of Big Bags, making it ideal for environments where both safety and efficiency are critical. Suitable for various materials including poorly flowing products, its modular design can accommodate numerous customizations. Options like an integrated hoisting system, negative pressure chamber for toxic products, and automatic weighing and dosing system can be added based on specific needs. This versatility allows the unloading station to fit seamlessly into different production lines, addressing stringent safety requirements and ensuring minimal residue in the bags. Dinnissen offers versions adhering to ATEX standards, making them suitable even for hazardous environments. The system’s efficient design allows it to be adapted both before and after the unloading process.

Modular big bag unloading station for various materials

Handling large quantities of bulk materials can be challenging, requiring efficient solutions that ensure safety and minimize product loss. Operations involving hazardous or high-volume substances necessitate specialized systems to handle, empty, and dispose of bags proficiently, while maintaining operator safety and reducing emissions.
<h2>Streamlined bag emptying for safe and efficient operation</h2>
The DIMA® Bag Emptying System by Dinnissen is designed to handle bagged products efficiently, offering solutions that can manage between 1 and over 1,200 bags per hour. The system ranges from manual to fully automatic versions. The DIMA®-MAN allows operators to manually cut and empty the bags, enhancing flexibility for low-capacity operations. For semi-automatic functions, the DIMA®-100 cuts the bags automatically, leaving the operator to empty and discard them. The DIMA®-200X caters to more critical applications, featuring emissions lower than 0.1 mg per m³, ideal for toxic product handling. For high-volume applications, the DIMA®-300, DIMA®-600, and DIMA®-1200 can process up to 40 tons of product per hour. All models can be fitted with ATEX-certified components, integrated extraction systems, and empty bag compactors. The system's durability is ensured with reinforced structural components, minimizing maintenance needs.

Bag emptying system for bulk material handling

Bagging is the process of packaging measured portions of a product into bags that protect it from spoilage, enable easy and safe transportation, and secure the product against tampering and pilferage. The choice of bagging equipment depends on the desired mass or volume per bag, the flow characteristics of the product, and bag construction and design. Bags vary in size from small sachets to bulk flexible containers. Bagging systems are often the last processing step that is generally integrated into a production line.

Bagging

Filling lines are used extensively in all industries, such as food, pharmaceutical, chemical, and cosmetics, to accurately package different products into a container suitable for that product. Although the filling process is at the very end of the production line, it is no less important than the earlier steps. Last but not least, the idiom that dates back to 1382 when John Wyclif wrote the firste the laste, and the laste the firste, indicates just that the last things on a list are just as valuable as the previous ones. In this case, this idiom fits perfectly.

Filling

Handling large chunks, fibrous materials, or sticky substances can pose significant challenges in industrial settings. The task of reducing these materials to smaller, more manageable sizes often requires a robust solution that provides consistent results without excessive energy consumption.
<h2>Reduces large materials with low energy consumption</h2>
The industrial breaker by Dinnissen is a robust equipment designed to reduce large lumps, clods, and agglomerates into smaller pieces. Using the rotor/stator principle, it operates at low rotational speeds, enabling high capacities ranging from 100 kg to 80 tons per hour with minimal energy consumption. The breaker is suitable for a wide variety of materials, including elastic and fibrous structures. Its design includes a sifting section for fine powders, with finenesses ranging from 150 microns to 10 mm. Available as an EHEDG version for hygienic applications, it is made entirely of stainless steel. The breaker is optimized for food, feed, pet food, chemical, and mineral industries. Dinnissen's track record of improving efficiency and product consistency over decades backs the breaker's long service life and low maintenance requirements.

Industrial breaker for reducing large lumps and agglomerates

Crushing is the process of applying an amplified force to a material to break it down into smaller pieces. A crusher is a machine designed to crush large chunks of material into smaller bits or a powder. They are used to reduce mineral rocks to smaller rocks, gravel, or dust. They are also used to reduce the size of waste materials for easier disposal/recycling or to reduce the size of a solid mix of raw materials. Crusher equipment selection depends on the physical properties of the material to be processed, the in-feed size, and the desired output particle size.

Crushing

Sifting

Many manufacturers face challenges when emptying Big Bags filled with highly compacted or clumped materials. These issues can lead to significant production delays and increased labor costs, especially when materials are agglomerated due to factors like dampness or compression during transport.
<h2>Conditions and empties big bags efficiently</h2>
The Big Bag Conditioner by Dinnissen is designed to address these issues by combining the conditioning, emptying, and discharge of Big Bags in one station. The system utilizes a hoist to lift the Big Bag and guides it through a conditioner, which loosens the compacted product using a mangle or massaging mechanism. This allows the product to flow out of the Big Bag easily and quickly, minimizing product loss and speeding up the production process. The system is built and tested in-house, ensuring high quality. It is suitable for various industries like food & pharma, dairy, pet food, feed & aquafeed, and chemicals & minerals. The unit can also handle toxic substances and integrate into existing production lines. Ergonomically designed, it reduces the need for physical effort by operators and is validated for high discharge rates.

Big bag conditioning system for compact materials

Conditioning

Emptying

In industrial settings where precise and consistent particle size reduction is critical, traditional hammermills and other crushing methods may leave much to be desired. These methods can pose challenges such as uneven product size, higher maintenance requirements, and inefficiencies that impede throughput.
<h2>Ensuring uniform particle size with advanced roll technology</h2>
The 1600 Series Roll Crushers by Roskamp, under CPM, are designed for demanding crushing applications, featuring 16-inch roll diameters and horsepower ranging from 50 to 300 HP. These crushers offer unique bearing slides for precise, consistent production and can easily adapt to full automation. With self-aligning, double-row spherical roller bearings and split pillow block bearing housing, the 1600 Series ensures durability and continuous performance. Available in single, double, or triple roll configurations, it suits various uses with roll corrugations and speed differential ratios. It features an axial fan for air circulation, adjustable motor bases, and manual roll adjustments via jack screws to tailor the operation to specific needs.

Heavy-duty roll crushers for crushing applications

In food processing facilities, moving bulk ingredients efficiently from one stage to another is crucial. Traditional methods can lead to delays or material loss, especially when handling heavy or wet products. Achieving precise, hygienic transfer of materials requires specialized equipment.
<h2>Transfer materials with efficiency and precision</h2>
The Inclined Screw Loader from Cozzini (Middleby) is designed to meet the demanding requirements of food processing environments. This loader features quick-release, watertight shaft seals that enable thorough washdown sanitation. Its heavy-duty, stainless feedscrew auger is available in diameters from 9″ (230 mm) to 20″ (500 mm) and can handle capacities ranging from 2000 lbs. to 8000 lbs. (900 kg-3600 kg). Customizable hopper sizes, discharge angles, and heights ensure that the unit can be tailored to specific facility needs. The optional agitator prevents product bridging, ensuring smooth operation. Accepted by the USDA and CE approved, the Inclined Screw Loader conforms to AMI sanitary design principles.

Inclined screw loader for food processing

In large-scale food processing, efficiently storing and transferring materials between different processing stages is critical. Handling issues such as product bridging or maintaining sanitary conditions can be challenging, especially with heavy and continuous loads.
<h2>Transfer and store bulk materials seamlessly</h2>
The Horizontal Screw Loader from Cozzini is designed to store and transfer products efficiently in food processing operations. The loader features a 9-inch diameter heavy-duty stainless steel feedscrew auger, which ensures reliable and consistent transportation of bulk materials. An optional agitator is available to prevent product bridging, enhancing the flow of material. The unit has capacities ranging from 500 lbs. to 10,000 lbs. and is equipped with quick-release, watertight shaft seals for full washdown sanitation. The Horizontal Screw Loader is USDA accepted and CE approved, built in conformity with AMI sanitary equipment design principles, making it a robust solution for maintaining strict hygiene standards.

Horizontal screw loader for food processing

Creating precise and consistent casing and flavoring liquids is vital in the tobacco industry. Manual processes often lead to inconsistencies and inefficiencies, impacting product quality and production timelines. Advanced preparation systems are necessary to maintain high standards and enhance operational efficiency.
<h2>Automate casing and flavoring liquid preparation</h2>
The Casing and Flavor Preparation Kitchens by Comas, part of the Coesia Group, are designed for the tobacco industry to handle various aspects of liquid preparation. These kitchens are customizable, offering solutions such as bulk ingredient transfer, dry powder handling, and homogeneous mixing. The systems utilize steam or electrical heating and include fully automated vessel and pipework cleaning. Highly accurate flow control ensures precise liquid transfer, and integrated recipe and batch traceability help maintain consistency. All systems are pre-assembled in Italy, using AISI 316 grade stainless steel for hygienic transfer pipework. They comply with ATEX or other local explosion-proof regulations, ensuring safe operation.

Casing and flavor preparation kitchens for tobacco industry

<span style="font-weight: 400">The heating process is a step of raising the temperature of food, pharma, cosmetics, and many other types of products. You may employ different heating solutions for this process, depending on the type of product you intend to manufacture. Selecting the appropriate heater machine for your product is quite important since various products require different ranges of temperatures and different ways of heat transfer using exchangers. Industrial heating equipment varies in two ways - the type of material it can process and the reaction you want to achieve.</span>

Heating

In pharmaceutical manufacturing, handling and transporting plastic containers securely and efficiently is crucial to maintain product integrity and prevent contamination. Ensuring that these containers can be managed effortlessly during lifting and docking processes is essential for seamless operations.
<h2>Facilitates secure clamping and effortless handling</h2>
The PuroGrab™ by Chargepoint Technology is a specially designed clamping solution for PuroVaso® pharmaceutical containers. Machined from high-strength PET (polyethylene terephthalate), the PuroGrab™ features precision machined profiles that match the PuroVaso® container. This allows the container to be securely clamped, making it easy to lift and dock. The PuroGrab™ includes a positive spring-loaded clamping system with a locking knob to ensure secure fastening. Additionally, it has profiled side handles with precision machined through-holes for accurate alignment on docking points, post hoists, pharma lifts, and blending forks. This design facilitates integration into various process equipment setups, enhancing operational efficiency.

Pharmaceutical container clamping solution

Lifting

During powder transfer operations in pharmaceutical or chemical processing, maintaining clean and efficient containment is crucial. Minimizing product loss and avoiding exposure to dust are common challenges that need to be addressed.
<h2>Ensures clean and accurate powder dispensing</h2>
The Dispensing Funnel from Chargepoint Technology is a specialized funnel designed for precise and clean powder dispensing through ChargePoint® valves. This funnel enhances containment performance and ensures accurate filling of transfer bags or containers. It directs powder cleanly through the valve, minimizing product loss and reducing dust exposure. Constructed from 316L Stainless Steel, the funnel is compatible with valve sizes ranging from DN50mm (2”) to DN150mm (6”). Typically used within a dispensing isolator, the funnel legs sit to the side of the open valve disc, ensuring that powder does not come into direct contact with the valve during the transfer. This results in a clean transfer process, providing an additional safety factor. By enabling the use of more basic valve designs, the Dispensing Funnel can eliminate the need for more advanced systems.

Powder dispensing funnel

Dispensing

Producing high-quality chocolate or other fat-based compounds requires precise grinding, consistent mixing, and effective conching. Achieving the right end-product fineness within a limited timeframe is crucial for consistency and quality in confectionery production.
<h2>Mix, grind, and conch simultaneously</h2>
The CHOCOCON 150 by Caotech is a specialized unit combining a horizontal 500L mixer/conch and a vertical low-speed ball mill CAO C150. Designed for the mixing, fine grinding, and conching of chocolate, creams, bread spreads, and fat-based compounds using crystal sugar, this equipment can achieve an end fineness of 22-25 microns in around 3 hours. Its high flexibility and attractive price have made it a favored choice for those in the chocolate processing industry. Recent upgrades include a redesigned mixer opening for faster and easier ingredient loading. Specifications include a batch capacity of 500 kg, an installed power of 24.7 kW, and dimensions of 2600 x 1540 x 2100 mm.

Chocolate processing unit for mixing, grinding, and conching

Conching is a critical step in the manufacturing of chocolate. In this phase, your chocolate mix is agitated and superficially scraped by a conch, allowing the cocoa butter to separate amalgamated particles and distribute your cocoa butter more evenly. The heat generated by the process volatilizes acids improving the texture and aroma of the finished product. Early machines used vessels in the shape of a conch shell, giving the equipment its name.

Conching

In the rice processing industry, ensuring high yields of head rice while maintaining a consistent quality remains a critical challenge. Traditional whitening methods often lead to increased breakage and reduced output, necessitating advancements in technology for greater efficiency and product quality.
<h2>Achieve consistent rice quality with reduced energy use</h2>
The SuperWhite DRWB is a rice whitener designed by Bühler to overcome the limitations of conventional whitening processes. Utilizing a grinding rotor and screen arrangement, it ensures consistent high yields of head rice while maintaining a compact design for energy savings. The SuperWhite features a specialized airflow system that minimizes temperature increases during operation, preventing rice kernel damage and thereby enhancing yield. The easy-to-operate hand wheel mechanism allows simultaneous adjustment of frames and brakes, ensuring seamless maintenance and operational efficiency. Additionally, the device's stainless steel construction facilitates even airflow, reducing residues and maintaining product quality.

Rice whitening solution for high yields

Industrial separation equipment encapsulates the separation process which is to separate components of a liquid mixture, for recovering dissolved solids from liquids. The choice of a suitable technology depends on the identification of the key physical or chemical property, such as size, mass, density, or boiling point, which sets the product of interest apart from the rest of the components. Separation technology is widely used in the pharmaceutical and chemical industries for the isolation of active ingredients and high-purity chemicals. As well as in waste management and recycling industries.

Separation

Industries dealing with pulses like beans, lentils, and peas often face challenges in removing seed coats efficiently while maintaining product quality. Conventional methods may result in inconsistent yields and higher amounts of broken pulses, impacting overall productivity and quality.
<h2>Ensure uniform hulling of pulses</h2>
The Pulsroll Huller DRHG by Bühler is designed to effectively remove the seed coats of various pulses while offering improved yields and uniform product quality. The Pulsroll features adjustable grinding gaps, emery stone grits, and sieves, which enable it to handle a wide range of pulse types and shapes. The hulling capacity can reach up to 4 tons per hour, driven by motor sizes between 11 kW and 18 kW. Its robust design ensures maximum uptime and low maintenance costs. The machine has a balanced construction with a large hulling surface, making it ideal for high-throughput applications. Bühler's Pulsroll also complies with global safety standards for electrical and mechanical operation.

Pulse huller for high throughput applications

In brewing and distilling, achieving efficient grain processing is essential for enhanced brewhouse yields and reduced lautering times. Traditional milling methods often struggle with uneven grinding and high energy consumption.
<h2>Optimize grinding and increase yield</h2>
The Maltomat III by Bühler is a versatile grist mill designed for dry or conditioned malt and unmalted grain. It features an automatic roller gap adjuster that optimizes the grinding process for different types of grain. The system ensures lower energy consumption with its efficient direct drive, reducing energy use by up to 10% compared to traditional dry grist milling. The Maltomat III's unique 'grinding-grinding-sifting-grinding' approach provides outstanding husk separation, aiding in shorter lautering times and higher brewhouse yields. Available in various sizes and configurations, it can be tailored to specific brewing and distilling needs. The front flaps allow easy access for maintenance and cleaning, and only one person is needed for sieve changes.

Grist mill for brewing and distilling

In modern milling operations, achieving uniform grinding quality and energy efficiency through traditional systems can be challenging, especially when processing a variety of grains like wheat, corn, and barley. These challenges can impact production capacity and operational costs.
<h2>Enhance grinding efficiency and energy savings</h2>
The Arrius integrated grinding system by Bühler is a fully integrated solution designed to optimize the grinding process for wheat, durum, rye, barley, corn, and spelt. This system features a completely new feed module with an asymmetrical inlet and screw, ensuring homogeneous product mixing and even distribution over the entire roller length. The integration of motor and gearbox in one drive unit reduces energy consumption by up to 10%, and mechanically recovers energy with a specially developed gear. Additionally, the compact design of the Arrius system allows for saving an entire floor in building investments. The system includes a newly developed roller pack that provides unmatched grinding stability due to its pre-stressed and backlash-free design, which enhances energy transfer to the product.

Integrated grinding system for wheat and grain

When producing high-quality beverages like beer or cider, maintaining the sterility and propagation of yeast is essential. Without careful propagation and optimal conditions, yeast performance can suffer, impacting the consistency and flavor of the final product.
<h2>Propagate, store, and pitch yeast under sterile conditions</h2>
The Yeast Plant by Bucher Unipektin is designed for the vital propagation, storage, and pitching of yeast in beverage production. It offers a flexible design that caters to various yeast strains, ensuring the highest hygienic standards. The system includes features such as gentle homogenizing and optimized aeration to maintain yeast vitality. It also encompasses yeast harvest, treatment, and storage, as well as precise pitching, autolysis, and disposal. This comprehensive approach ensures that yeast remains effective and consistent, enhancing the quality of beverages produced. The system’s design focuses on reducing contamination risks while allowing easy adjustments to meet specific production requirements.

Industrial yeast propagation system

Homogenization is the process of reducing particle size in mixtures to improve the consistency, uniformity, and stability of the product. The choice of a homogenizer depends on the nature of the product, desired particle size, the physical state of the ingredients, and pressure requirements during the process. Homogenization is widely used in the biotech industry for cell lysis and in the pharmaceutical industry for the emulsification of creams and ointments; it also finds applications in the cosmetics and food industries for improving the consistency and uniformity of various products.

Homogenization

In industries like plastics and pharmaceuticals, managing the bulk handling of raw materials is critical. Ensuring efficient transfer from reception, storage, and batching to the feeding stage requires precise and reliable systems.
<h2>Comprehensive management of raw material handling</h2>
The raw material handling system from Brambati is designed to manage a variety of raw materials in powder, pellet, or liquid form. This system supports operations from tanker reception to specific process feeds like extruders, including storage, batching, weighing, and conveyance stages. The entire process is controlled via an electric panel with PLC and PC supervision, ensuring accuracy and efficiency. The electrical and supervisory control system can be customized according to specific needs, enhancing operational flexibility for the plastic, pharmaceutical, and similar industries. This integrated approach reduces manual handling, improving safety and reducing the potential for material contamination.

Raw material handling systems for plastic and pharmaceutical industries

Batching

In large-scale waste paper sorting operations, maintaining a consistent flow of material is crucial to optimize sorting efficiency. High variability in input material can lead to downtime and inefficiencies, requiring a robust solution to streamline the feeding process.
<h2>Ensures continuous material flow</h2>
The BRS Drum Feeder from Bollegraaf is designed to enhance waste paper sorting systems by providing a consistent feed of material. This drum feeder includes a drum with Hardox combs, a durable steel deck, and material carriers driven by a chain with two tension bearings. These bearings, equipped with a grease cartridge, ensure a minimum of 10,000 working hours. The Drum Feeder also features ring seals and self-adjusting bearings to minimize pollution between the side walls of the bunker belt and the drum. By offering a buffer for material, it increases the capacity and improves the quality of sorting installations. Additionally, the feeder reduces the operation time for shovel operators as it only needs filling a few times per hour. It can be combined with an HBST steel belt conveyor that has a 2000mm high side wall or placed in a recessed or concrete pit for easier material loading.

Industrial drum feeder for waste paper sorting systems

Sorting is the process of arranging items systematically, using a specified criterion, to categorize and group similar items and identify non-conforming items for removal. The choice of a sorting machine depends on the type of item to sort, the sorting criteria, the number of categories that the items need to be sorted into, sorting speed, and accuracy. Sorting machines can be used in the food processing industry for sorting and categorizing fruits, vegetables, empty bottles, crates, and other items; other examples include sorting of tablets and capsules by weight for quality control in the pharmaceutical industry. As well as sorting waste in the recycling industry. Manual sorting is a laborious task however, with the use of specialized equipment, manufacturers are able to automate their sorting at high speeds.

Sorting

In industries dealing with fine-grained suspensions, achieving an effective filtration, washing, and dewatering process poses significant challenges. High process pressures and temperatures further complicate the situation, necessitating advanced solutions for optimal outcomes and minimized residual moisture.
<h2>Achieve high throughput and low residual moisture</h2>
The BoHiBar Drum Filter from BOKELA specializes in the filtration, washing, and dewatering of fine-grained or difficult-to-filter products. Operating with high filtration pressure differences up to 6 bar(g), it ensures high specific throughput and effective cake washing with low residual moisture. Its closed design provides gas-tight, leakproof operation, suitable for scenarios where contamination needs to be prevented or specific process conditions need to be maintained. The steam pressure filtration option is an innovative hybrid process that combines mechanical and thermal actions, resulting in particularly dry solids. Available in sizes with a filter area of up to 40 m², it supports continuous, fully automatic operation, making it ideal for applications such as plastic intermediates, crystallization and precipitation suspensions, and fine-grained pigments, fillers, and dyes.

Pressure drum filter for fine-grained products

Dewatering

Industrial filtration equipment separates solid matter from liquid by using a filter medium. The filter allows only the fluid to pass through but retains the solid matter. The choice of filtration equipment depends on the particle size, the consistency of the mixture, and the nature of your product.

Filtration

Industrial washing systems are used to clean and disinfect a variety of items in research and manufacturing facilities. Industrial washers use solvents and cleaning agents with mechanical action to remove deposits and residues from stainless steel machinery components, empty containers, and other soiled surfaces. The selection of an industrial or commercial washer depends on the type of items and surfaces to be cleaned, the type of deposits/residue that is typically present, whether drying is required after rinsing and the level of sterilization necessary. Manufacturers will have cleaning specifications and as a result, require washers to be engineered to meet these specs.

Washing

In the food industry, producing high-quality ketchup and vegetable sauces involves handling diverse recipes and strict hygienic standards. Ensuring consistent blending, homogenization, and pasteurization processes are crucial to delivering a final product that meets consumer expectations while maintaining production efficiency.
<h2>Ensures consistent and flexible sauce production</h2>
The Ketchup Production Line from Bertuzzi is designed to meet advanced technological and stringent hygienic requirements. This production line is flexible, allowing the processing of various recipes with or without thickeners, vegetable particles, or preservatives. The system includes several ingredient preparation groups customized to specific needs, such as tomato paste dilution, sugar and salt dosing, and spice blending. The blending section uses special horizontal mixing tanks for homogeneous mixing and high-performance recipe reliability. Additional processes include deaeration, high-pressure homogenization, and pasteurization using a tubular heat exchanger. The line can handle high-capacity plants with automated ingredient dosing systems and integrated cleaning through the Bertuzzi CipMatic system.

Ketchup production line

Deaeration

The Pasteurization process is the method of subjecting liquids to mild heat at a specific temperature and time, and quickly cooling them down again in order to destroy pathogens in your fermented or semi-fermented products. Thus, increasing the shelf life of the manufactured products. Untreated microorganisms may lead to diseases, spoilage, or unwanted fermentation. Most pasteurization equipment operate in a continuous method using plate heat exchangers to keep a uniform level of high efficiency sterilization.

Pasteurizing

In the dairy industry, producing different types of cheese efficiently and hygienically requires versatile and reliable processing equipment. Challenges include maintaining consistency in cheese quality and ensuring high hygiene standards during production.
<h2>Versatile processing for various cheese types</h2>
The Universal Cheese Vat by Bertsch is designed for the production of a wide variety of cheeses, offering optimized process technology and excellent design. Constructed from stainless steel, with hermetically sealed gear chambers and whey suction drives, it ensures high hygiene and product quality. The Double-O shaped vat provides a large surface area for low breakage of cheese kernels, and it can be heated with hot water or steam. Its self-supporting agitators and special cutting knives guarantee uniform cheese curd distribution. Additionally, the vat's control system allows for individual recipe adjustments and remote monitoring via Ethernet.

Cheese vat for varied cheese types

Cutting

Complex processes call for continuous tracking and monitoring systems that help you to keep the manufacturing operation under control. The technology analyzes the components in the production phase for divergence in behavior or changes in conditions. Based on advanced software applications, monitoring platforms make sure that your products satisfy the quality criteria while they are being developed.

Monitoring

Fruit and vegetable puree production often faces challenges in maintaining the natural taste, color, and nutritional value of the produce. These challenges arise due to the need for effective enzyme deactivation and the preservation of raw product qualities through the extraction process.
<h2>Cold extract purees with thermal deactivation</h2>
The EOS LINE from Bertocchi is designed for the production of fruit and vegetable purees utilizing a cold extraction process combined with thermal deactivation. This system includes a closed-circuit enzyme deactivator that heats raw puree quickly through high recirculation at elevated temperatures, eliminating the need for a buffer tank. This rapid heating results in immediate enzyme inactivation while preserving the taste, color, and organoleptic properties of the produce. With a capacity range from 1000 kg/h to 24 t/h, the EOS LINE can process various fruits such as apples, pears, peaches, apricots, grapes, and tropical fruits, as well as low-consistency vegetables. It features components for washing, sorting, cutting, destoning, cold extraction, cold deareation, thermal deactivation, and both hot refining and deareation, making it suitable for producing deactivated purees intended for concentrates, single-strength juices, baby foods, and nectars.

Line for production of fruit and vegetable purees by cold extraction

In pharmaceutical production, ensuring a consistent supply of closures to packaging lines is vital to avoid unnecessary stoppages and inefficiencies. Managing the precise and automated feeding of closures can significantly streamline operations and improve productivity.
<h2>Automate the feeding of closures</h2>
The BZV 8110 bin and feed unit, from Bausch+Stroebel, is designed for the controlled feeding of closures. A supply bin containing the closures is placed on an electrically operated telescopic column at a comfortable working height. The unit then automatically positions itself to load closures into a sorting vibrator. By controlling the quantity of closures fed, the unit helps avoid stoppages that occur due to a lack of closures. It is a versatile solution within the VarioSys modular system, suitable for integration with other Bausch+Stroebel modules and machines, facilitating seamless and efficient pharmaceutical production processes.

Bin and feed unit for closures

Handling heavy packing drums safely across different building levels is common in various industrial settings. Challenges include precise positioning, risk of leaks, and the need for versatile modular systems to adapt to different loads and configurations.
<h2>Lift, lower, rotate, and turn heavy loads</h2>
The AZO Lifting Column is an advanced drum handling solution designed for industrial use. Featuring an electromechanical drive with a drive chain, it eliminates hydraulic unit issues such as leaks. The motor brake ensures accurate positioning both upwards and downwards, as well as during rotation. The standardized design accommodates different extension arms and carrier plates, making it fit for modular configurations. The lifting function is anchored as a free-standing unit and can be mounted to the floor, ceiling, or wall. It includes an overload safety device for load excess prevention and a position controller for programmable movements. This design makes it ideal for safely lifting, lowering, rotating, turning, and docking heavy loads within buildings across different levels.

Lifting column for industrial packing drum handling

Rinsing

In industries handling bulk solids, maintaining high hygiene standards is critical, especially in food and pharmaceutical processing. Typical challenges include contamination risks, difficult cleaning processes, and compliance with stringent safety regulations.
<h2>Ensures safe and clean material feeding</h2>
The Hygienic Feeding Hopper Type ET-H from AZO is designed for the safe and efficient feeding of powdered and granular products into closed material handling systems. It's constructed from high-quality stainless steel with an interior surface roughness of less than 0.6 µm or 0.8 µm, making it easy to clean and residue-free. The integrated jet cleaner enables thorough wet cleaning. Its silicone gasket is metal detectable and simple to replace, reducing downtime. The cover opens with gas springs, and a safety-compliant cover switch controls the system functions. Suitable for ATEX zones 22 and 2, the hopper is ideal for applications where explosion risks exist. Additionally, an aspiration process can be connected to prevent dust escape during sack discharge, ensuring a cleaner working environment.

Hygienic feeding hopper for bulk solids

In industries handling bulk solids, managing dust during big bag connections poses significant operational challenges. Ensuring a clean and efficient discharge process is crucial for maintaining safety and minimizing environmental impact, especially with big bags lacking discharge spouts.
<h2>Ensures dust-free connection and efficient discharge</h2>
The Vac Docking system by AZO offers a reliable solution for the dust-free docking and discharge of big bags, ideal for those with no or short discharge spouts. This system consists of a cylindrical housing featuring a circumferential vacuum channel, creating a dust-tight seal upon contact. An underpressure generator forms a vacuum that prevents dust emission during discharge. This patented technology, registered under the number DE 20 2012 003 109.0 by the German Patent Office, facilitates quick and complete emptying of big bags. The construction from high-grade chromium-nickel steel ensures durability and ease of cleaning. Preferred for industries handling free-flowing bulk solids, the system streamlines operations by saving height and space.

Dust-free big bag connection system for bulk solids

In the food, pharmaceutical, and chemical industries, ensuring the contamination-free transfer of bulk materials during production is crucial. Contamination can lead to significant quality control issues, safety hazards, and potential downtime, requiring a reliable solution for clean docking and undocking processes.
<h2>Ensures clean and accurate material transfer</h2>
The AZO CleanDock® is a sophisticated solution designed for automatic contamination-free docking and undocking of mobile containers like hoppers, drums, and big bags. This system establishes a dust-tight connection between the container and the dosing device, ensuring that bulk material does not escape into the atmosphere. Equipped with integrated scale decoupling, the system provides exact dosing and weighing results. It protects both the operator and the product by maintaining a sealed system throughout the transfer process. The AZO CleanDock® features a user-friendly design that is easy to clean and avoids the need for ATEX zone designation due to its low dust emissions. The solution is especially beneficial for processes in the food, pharmaceutical, and chemical industries where maintaining high levels of hygiene and safety standards is essential. By offering automatic and reliable contamination prevention, the CleanDock® enhances productivity and ensures compliance with strict regulatory requirements.

Contamination-free docking system for bulk solids

In automated production processes, handling bulk materials efficiently and accurately can be challenging. Proper tracking of batches and dust-free feeding systems are crucial for maintaining quality and reducing downtime.
<h2>Automates bulk material handling with precision</h2>
The AZO BATCHTAINER® from AZO is designed for the automated handling of bulk materials, especially for those with poor flow properties. This system allows for precise batch tracking and efficient material handling in automated production processes. The BATCHTAINER® can be easily mounted on a docking station and locked pneumatically. An electronic ID system eliminates identification errors, while its patented docking sleeve ensures dust-free product feeding. The container remains on the docking station as long as needed, and changing containers is straightforward, requiring only the closing of a gate and release of the pneumatic restraint. This system is particularly useful as a transport and storage container for medium throughputs and in systems where bulk materials are received in bags.

Automated bulk material handling system

When processing industrial broths, vegetable creams, or convenience foods, maintaining high-quality product integrity and hygiene standards is essential. You need reliable technology for efficient and safe thermal processing without risking contamination.
<h2>Enhance processing efficiency and product quality</h2>
The Single Cooking Line with Two T-Sensation units from Aurum Process Technology is a high-efficiency aseptic cooking system designed for diverse industrial applications. The T-Sensation reactor is horizontal and crafted from stainless steel, capable of processing between 50 to over 1000 liters of product volume. With an optimized scraping system, the reactor maximizes heat transfer efficiency, significantly reducing processing time. It also supports both pressurized and vacuum conditions, making it versatile for various products such as broths, sauces, and infant food. The unit's capability for low fouling and minimal product loss during cleaning cycles ensures a high level of operational efficiency. Ideal for maintaining the quality and nutritional properties of processed foods, the T-Sensation guarantees a high-quality end product with low levels of crushing and shearing.

Aseptic cooking and filling line with two reactors

In food production, creating uniform and well-textured meatballs or fish balls can be labor-intensive and inconsistent when done manually. Challenges include ensuring uniform size, preventing sticking, and maintaining efficiency during high-volume production.
<h2>Form meatballs and fish balls efficiently</h2>
The FMB-60 by ANKO is a versatile solution for automatic production of meat balls and fish balls. By placing meat or fish paste into its hopper, the FMB-60 forms ball-shaped foods without manual intervention. It features a rotary round platform designed to hold a bowl of water that collects the produced balls and prevents them from sticking. With dimensions of 500 (L) x 800 (W) x 1,400 (H) mm and a power requirement of 0.75 kW, this machine can produce up to 300 pieces per minute for 20 mm balls, 200 pieces per minute for 25 mm balls, and 100 pieces per minute for 35 mm balls. The FMB-60 includes three extruding nozzles of standard sizes, ensuring versatility in ball dimensions (18–35 mm unadjustable). Weighing 150 kg (net) and 250 kg (gross), it is suitable for producing a variety of ball-shaped foods from fish, pork, beef, and other paste materials. ANKO’s design ensures efficient operation and minimal downtime, catering to industries dealing with high-volume food production.

Automatic meat ball and fish ball forming solution

The extruder was first developed to make lead pipes in the late 18th century. But the extrusion process technique quickly spread to other manufacturing sectors, including food, feed, and biomass products. An extruder machine presses a fluid or solid material through a die. Depending on your use case, extruders adopt single- or twin-screw systems to push the premixed feed material through a barrel. Thermal pressure applied in this step can chemically modify the mixture, so the screw system must be precisely calibrated to achieve the desired result. Finally, a knife head cuts the extruded material into your designed dimensions. Extrusion machinery produces items of a uniform size, shape, and consistency.

Extrusion

The process of forming allows you to shape your products homogeneously. Forming machines are fed the manufactured material in bulk and cut it down to specification, so the process takes place between formulation of the mass and the packaging of the final item.

A special class of this equipment – Form, Fill, and Seal Machines (FFS) – creates bags and pouches from flat material such as plastic sheets, fills them with your designated product, and seals them.

Forming

In chemical, pharmaceutical, and food industries, handling and transporting powders efficiently while avoiding cross-contamination is a common challenge. Optimizing these processes is crucial to ensure smooth production flow and maintain high quality standards.
<h2>Lift and rotate drums and bins automatically</h2>
The Colonna Girafusti e Giracesta by Agierre is designed for the handling, lifting, and rotating of both drums and bins. The lifting column supports systems for powder transport (Vacuum Conveyor), Fusti, and Pharma BIN. It features an internal galvanized iron structure and an external AISI304 stainless steel casing. A self-braking gear motor drives the lifting mechanism, which includes a leadscrew and a 'nutshell' fixed on a mobile slide with four wheels, providing stable support. The system is managed through an automatic control panel, offering customizable horizontal and vertical movements, as well as rotation, which can be either manual or motorized. Safety is enhanced with a second 'nutshell' that activates in case of wear on the primary 'nutshell', indicated by a warning light on the control panel. This column is adaptable for various powder processing tasks, such as transport, dosing, mixing, and moving within the production line.

Lifting column for drums and bins

Effective drying of plastic resins is crucial for producing high-quality molded parts. Insufficient drying can lead to issues such as surface defects, internal stresses, and poor mechanical properties, compromising the final product.
<h2>Stainless steel construction with mass flow design</h2>
The WH Series Drying Hoppers by AEC (ACS Group) are tailored for small to medium size operations. They feature stainless steel interiors, ensuring durability and easy cleaning, even in the toughest environments. The unique mass-flow design optimizes material throughput, while the dual-wall insulation minimizes heat loss, making the system energy efficient. These hoppers come with practical features such as a slide gate material shut-off valve, large access doors, and quick release clamps for easier maintenance. Mounting options include stand or machine mount configurations, adding versatility to the equipment.

Stainless steel drying hoppers for plastic processing

Industrial drying machines are designed to remove moisture from your product. But the drying process must cater to variations in the state of matter and molecular structure of the input material. Industrial dryer technology exploits the modes of heat transfer (convection, conduction, radiation, evaporative cooling) to control the moisture content.

Drying

In the production of confectionery items like meringue masses, sponge dough, and chocolates, achieving precise and uniform shapes can be challenging. These challenges often stem from inconsistent deposit patterns and the need for quick changeovers during production processes.
<h2>Ensures reliable and precise depositing</h2>
The Bertha™ rotating stencil depositor from Aasted is designed to handle a variety of masses, including meringue, sponge dough, and chocolate. Mounted on a height-adjustable, stainless steel C-frame with wheels, it ensures easy servicing and cleaning. The precision of the stencil drum results in reliable and uniform product formation. An internal scraper provides a clear-cut deposit onto the conveyor belt, maintaining product consistency. Control is facilitated by an integrated PLC and HMI system, which also offers remote access. The Bertha™'s automation raises the scraper upon machine stoppage, enabling an efficient changeover of the stencil drum.

Rotating stencil depositor for confectionery products

Depositing equipment is a very common production line process in the food industry. Whether you want to make muffins or jellies or garnish and decorate cakes, all of this is impossible without the depositing step. Depositing is a form of extrusion used primarily to produce pieces of dough that will be further processed to create several food products. The dough is passed through a depositing machine and poured in equal parts from holes in a die plate with nozzles or a conveyor belt. But that’s not all. Depositors are also used to fill, layer, or cover your food items with other ingredients before proceeding to the next step of the production process which is usually packaging.

Depositing

Pharmaceutical powders in metered doses demand maximum filling precision. This is particularly challenging with materials in the micro-gram range. Fine powders may exhibit complex behaviors that develop into a bottleneck in the production line.
<h2>High precision multiple powder dosing in the mg range</h2>
µPTS from Dec Group is a patented technology offering precision dosing of minimal powder weights at a fast turnover. The PTS technology performs powder dosing from a &lt;1 mg in less than a second and with an accuracy rate reaching 2% RSD. The hopper is designed for powders with challenging flow properties to facilitate the powder transfer process. The system does not have an integrated filter, and it can dose ultra-fine and sticky materials.

The solution employs vacuum technology to transfer the powder to the calibrated chamber. Before dosing, the µPTS automates vial charging, positioning, and taring. The measured dose is then ejected using a piston and weighed ahead of filling. A linear motor may be regulated in a closed loop with a weighing device to change the volume automatically.

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Powder micro-dosing system

Micro-dosing powders of high-value food or chemical products can be challenging when high precision and zero error is required. You need a highly accurate and efficient dosing solution of relatively large quantities of micro-ingredients which can meet the the relevant ISO standards.


<h2>Save time with optimal dosing accuracy</h2>
Alba’s Dosing system DUPLEX is a gravimetric microdosing system which enables the fast dosing of small amounts of powders. It has unparalleled precision with 99.8% accuracy making it ideal to for implementing a good quality system. Its modular design also allows for a great amount of flexibility when it comes to specific process requirements.

Fast gravimetric powder microdosing 50 - 200 g is configured with a duplex or two-tier dosing technology. It requires a dosing time only between 8-12 seconds which is dependent on the characteristics of the material. This allows fast and accurate dosing of relatively large quantities from 50 - 200g of material. It is also equipped with a check-weighing function for the ejection of overweight dosages. This makes it particularly suitable for filling applications with zero tolerance to non-conforming end products.

Industrial hoppers

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