Production of food supplements

The product is supplied in big bags and sacks and contains up to 15 different raw materials, depending on the recipe. Despite this complexity, only two operators work on the installation, responsible for replenishing raw materials and changing packaging material.
All other process steps, including the functions of the HECHT systems and the mixer, run fully automatically. A dedicated recipe management system is linked directly to the existing inventory system. Total throughput is up to 2.25 tonnes per hour.

After goods receipt, the big bags with the various raw materials are taken to two production rooms, where they are fed in via HECHT big bag emptying stations. These consist essentially of four main components:

1. Connection system: for low-dust or dust-free emptying of the big bag.

2. Support table: carries the weight of the big bags and secures the load.

3. Walking paddle: uses a massaging action to help discharge poorly flowing products.

4. Frame with tensioning device: holds the big bag spout securely and pulls it taut.

Depending on the installation situation and requirements, additional options can be added. A chain hoist runway and lifting gear are used to lift and position the big bags safely. Because of the high raw material volume, this project required emptying stations with an outlet connection system, massage paddle and the HECHT suction shoe with lump breaker function.

Minor components and flavourings are added via two semi-open, combined sack/drum tipping stations. One station sieves crystalline products, the second breaks up lumps. The raw materials are conveyed by vacuum conveying through two HECHT ProClean Conveyors PCC700 to a 6,000-litre mixer from Gebrüder Lödige for the next process step.

The conveying technology with the HECHT PCC700 is designed specifically for use between value-adding machines such as mixers and filling systems at high production volumes. The PCC700 meets all GMP and FDA requirements, ensures a dust-free and contamination-free environment and, thanks to its modular design, offers great spatial flexibility.

The operating principle is similar to that of classic vacuum conveying systems: the bulk material is drawn in by negative pressure through pipes from the feed station. The conveying characteristics can be set flexibly – from dilute-phase through plug conveying to dense-phase conveying. Plug conveying in particular prevents segregation during transport.

The high conveying capacity (up to 10 tonnes per hour, depending on the product) is the result of:

• four large filter elements,
• a generously sized separator vessel,
• parallel suction and filter cleaning (two filters alternately in use)
• and a total filter area of up to 3.6 m².

This architecture keeps the pressure difference low, so even very fine products (< 1 μm) can be conveyed. The low filter load also extends the service life of the filter elements. The filters can be changed quickly and without tools.

The downstream Ploughshare® mixer uses a centrifugal and whirling process that creates a three-dimensional movement of the mixture. The ploughshare blades are positioned so that all the material is picked up. This produces fast, homogeneous mixtures without dead zones. To meet special requirements, rotating choppers can also be integrated to break up agglomerates and enable targeted granulation.

To prevent metal contamination, the conveying lines for big bag raw materials and minor components are fitted with horizontal metal separators.

When the mixing process is complete, the mixer's discharge valve opens automatically.
The product is conveyed to another suction shoe and then transported cyclically to the filling line via another PCC700 conveying system. Depending on requirements, drums or big bags can be filled with the end product.

To guarantee a homogeneous mixture without lumps, an eddy-current sieve below the PCC700 removes oversized particles. A gravimetric metal detector also ensures maximum product safety.

A filling head with an integrated anti-kink valve prevents product loss and dust formation during standstill or when changing packaging material. This keeps the process hygienic and clean in these phases too.

Overview of other important functions:

A diverter makes it possible to convey raw materials past the mixing system directly to the filling system, for example to empty the process with partly empty packaging or to change packaging material.
The entire production is digitally monitored, documented and traceable. Raw materials are scanned and released when they match the recipe – automatic error prevention is built in.
The whole process requires only two operators for supplying raw materials and packaging materials – all other processes run fully automatically.
The installation has no downtime as long as raw material supply and filling run continuously. Well-designed recipe and time management ensures a semi-continuous process.