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Parallel processing saves time

IBC blender with integrated intensifier
Parallel processing saves time

Often the most critical aspect of a powder process, mixing is the step where the manufacturer adds the most value. With more stringent regulations, rising labour costs and international pressures, there has never been a greater emphasis on production efficiency. Using an IBC blender with an integrated intensifier allows small batches of diverse products to be mixed at high speed.

The author: Frank Maringer Business Development Manager Matcon

There are many different mixing technologies and methodologies available, e. g. batch or continuous, high, low or no shear, horizontal or vertical, etc. Yet what is the best path for lean powder processing? Conventional wisdom would suggest analysing all the mixing requirements for a process and simply selecting a system that can do everything. This approach is fantastic for successful mixing but may not address process efficiency or flexibility. To maximise efficiency, key items of process equipment such as a mixer need to keep running; this is referred to as overall equipment effectiveness (OEE). Simply put, the more the mixer is actually mixing, the higher its OEE.
Even if the batch mixing time is only a couple of minutes, it cannot be considered efficient if it takes too long to fill or empty the mixer. While measures can be introduced to improve mixer filling and emptying, the effort required to clean the mixer can make product changeovers (a necessity to respond to customer orders) a time consuming endeavour. This not only reduces the mixing system’s OEE but also limits the flexibility that is essential to react to unexpected changes in the production schedule.
Detachable blending vessel
One mixing technology that is capable of achieving a very high OEE is containerised (IBC) blending. With this blending approach, a rigid IBC is used as a detachable blending vessel. What this means is that formulation (filling), emptying and cleaning of the vessel are done separately from the actual blending. This method of working is sometimes referred to as “parallel processing”. After blending one batch, you can simply remove the blended IBC and replace it with another that is filled with an unblended, possibly different, recipe. You can begin to mix this next batch almost immediately.
If we assume that a 1 t batch is produced in both scenarios, a simple cycle time analysis can be carried out: decanting bags (20 min), mixing operation (10 min), packing into 25 kg bags (20 min). The first batch processed will take 50 min in both scenarios; however, with the in-line approach, every batch thereafter will also take 50 min to process, enabling a maximum of 9 to 10 batches to be produced in an 8-hour shift.
If the decoupled (parallel) approach is adopted instead, the batch cycle time will be dictated by the duration of the longest process – in our typical example this equates to 20 min for decanting (or packing). In other words, while the first batch still takes 50 min, all subsequent batches require only 20 min. Suddenly, 21 batches can be produced in the same 8-hour shift.
More than double the throughput is achieved by realising this simple change in philosophy. The difference in efficiency becomes even more apparent when we consider cleaning between rec-ipe changes. In the sequential system, all powder has to be processed before cleaning can begin. With a decoupled system, the operator can start cleaning individual processes as soon as they are complete – without waiting for the subsequent process to finish.
Technology improvements
Although IBC tumble blending offers a high OEE, mixing capability can be a limiting factor. Recent developments in IBC tumble blending are, however, pushing back the boundaries of what can be mixed within one IBC. Matcon has developed an intensifier option, which in itself is quite a complex technical challenge. In order to fully embrace the lean approach, it is imperative that all product-contacting parts are contained within the detachable blending vessel (IBC). This means that an automated and very precise docking sequence is required between the drive unit on the blending cage and the IBC mixing lid. Furthermore, the fast-rotating intensifier includes a sophisticated seal arrangement to avoid ingress of material, ensuring the highest hygiene standards.
Most of the projects realised so far are from within the food industry, where hygienic design is a primary consideration. As part of ongoing improvements, the intensifier is available as a single piece, reducing the strip-down and cleaning times to an absolute minimum. The applications for the intensifier option appear to be endless in the food industry based on testing done to date, with the biggest impact in the flavouring and savoury business. Liquids can now be added if IBC blending technology is chosen and what was historically always done with complex multi-stage mixing can often be achieved today in one step. It is also remarkable to watch blocks of fat being dumped into an IBC and then emerging as a homogeneous mix after being blended for ten minutes. Other areas where significant inroads have been made include speciality drinks, cake mixes, nutritional ingredients, soup powders, bouillons and many more besides.
The Matcon IBC blender is made of stainless steel and is suitable for container sizes ranging from 500 to 3000 l. The IBC fill ratio is 30 to 80 %. A separate mixing tool can be utilised if required, operating at between 500 and 3000 rpm. The IBC clamping and cone valve locking sequences are fully automated. A mix recipe is registered and stored in a local PLC. All data can be easily exchanged with any MES or ERP system for material tracking purposes. The blender is supplied with a safety fence.
80/20 rule is the key to success
So, looking ahead, what is the path? While there is no single answer for all processes, using multiple blending technologies and applying the 80/20 rule can result in increased efficiency and flexibility. This would suggest adopting an IBC blending approach where this is feasible and using an alternative mixing technology (such as a high-shear vertical mixer) whenever IBC blending is likely to be less effective. It is also critical to view the range of stock-keeping units (SKU) from a volume perspective. The “long runners”, where many tons per week are sold, may well be produced on in-line, high-speed mixing lines. However, the key is to remove all extraordinary SKUs from these lines, so that high speed and OEE can be achieved. It is no good running a line at 3 t/h for two hours and then cleaning it for four. Since fewer SKUs are produced with high-speed lines, fewer changeovers (cleaning) are required. This means that both types of mixing systems will have a high OEE, which is critical for lean powder processing. It is this kind of shift in thinking that may be called for to maximise mixer effectiveness in modern powder processing plants.
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