Removing Malt Production Bottleneck with Flexible Screw, Bulk Bag Filler, Unloader

Removing Malt Production Bottleneck with Flexible Screw, Bulk Bag Filler, Unloader from Flexicon Corporation (Australia) P/L

By: Flexicon Corporation (Australia) P/L  30-Oct-2013
Keywords: Food, Food Processing, Chemical Processing

HERNE BAY, UK — Muntons Malt, a division of Britain's Muntons plc, began manufacturing malt (fermented cereal grains that contain sugars) and liquid malt extracts in 1921 for brewing, distilling and food industries worldwide. The independently owned company currently sells more than 231,500 tons (210,000 metric tonnes) of malt annually, and is one of the UK's five major malt producers. In producing dried malt, a vacuum band dryer converts liquid malt extracts into a coarse powder, which undergoes final granulation in a cone mill. Originally, the final granulation was fed from the cone mill into 1,764 lb (800 kg) tote bins stored in a 200-bin capacity holding area, before bagging and shipping. A worker filled orders by lifting a tote bin by fork lift to a mezzanine where a second worker transferred the bin about 33 ft (10 m) to the tipping unit, which unloaded the malt into the hopper feeding the bagging machine. Each tote then was cleaned to comply with Muntons' strict hygiene standards. On the bagging line, another operator applied labels to the 55 lb (25 kg) bags and fit each bag to the fill head, after which the bags were sealed, palletized and shipped. Downtime on the manual bagging line led to bottlenecking on the tote fill line, disrupting product shipment to customers, raising operating costs and adversely affecting operating efficiency. The downtime also threatened to interrupt operation of the band dryer, which would necessitate a costly and time consuming washdown that would vastly increase wastewater treatment and water use. Muntons replaced the tote bin handling operation with an in-line conveying system in a new, hygienic packaging room built directly beneath the cone mill. The system would ensure an uninterrupted work flow from band dryer to bagging machine resulting in improved reliability, higher throughput and reduced manpower. The bagging line was also automated. The in-line system was designed and installed by Flexicon (Europe) Ltd.

Keywords: Bag Filler, Bulk Bag Discharger, Bulk Bag Filler, Chemical Processing, Flexible Screw Conveyo, Food, Food Processing, Food Processing and Distribution, Malt,

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