Mixing and transfer equipment for seeds and crackers

Industrial production line for the gentle transfer, feeding and mixing of seed-based cracker products

Materials: Pumpkin seeds, flax seeds, sesame seeds, corn starch, arrow root, etc.

Project objective: Our client, located in Buffalo, NY, is a small artisanal producer of health foods such as seed-based crackers. Experiencing a steady and reliable increase in demand year over year for their product, the snack manufacturer began work on a new production facility in the downtown Buffalo area to increase production to 6 to 8 million packages per year. The current method was to use small batch 22 kg sacks of ingredients and manually feed and mix the necessary blends by hand. The desire was to scale up to big bag delivery methods with gentle dosing by weight and convey to an industrial mixer that would preserve the ingredients while producing a consistent blend. The daily production rate required is 4 batches per day with each batch totalling 200 kg worth of snack-based product.

Industrial solution: The powder handling experts at Palamatic Process created a solution that would utilize big bag unloading stations with loss in weight technology as the main delivery method for raw ingredients. The gentle dosing action of vibrating feeders would accurately deliver the required amounts of material based on the recipe requirements. A common screw conveyor would then take each ingredient and deliver it to a paddle mixer for gently blending all ingredients together. 

The industrial equipment:

• Big bag unloader - Telescopic tube
• Vibrating feeder - Vibratory feeder
• ECD hygienic screw conveyor
• Paddle mixer - Batch mixing

The EasyFlow® big bag unloading station by Palamatic Process is designed to safely and securely discharge bulk ingredients from 1-ton big bags. The electrical hoist is capable of lifting heavy loads up to 2 tons and securely depositing the FIBC on its resting tray. A clamping head attached to a telescopic discharge tube raises up to meet the discharge spout on the bottom of the flexible tote. The clamp ring provides a dust-tight connection to allow for the safe and fully contained unloading operation of the bulk solids. It also can help provide a mild downward pulling action on the big bag to create a funnelling effect that aids in material flow and prevent arching over the spout. A double-jacketed tube allows for air to volume displacement and connection to a central dust collection system.
Six total stations were provided to allow for constant supply of material by weight for a day’s worth of cracker and snack food production. All contact surfaces are made of 304 stainless steel to respect food industry hygienic standards. The feet of the big bag station incorporate load cells to allow for a controlled feed of material from the big bag by loss in weight functionality.

In order to gently and accurately dose the seeds by weight, and according to the batch recipe to be mixed, an easy clean design (ECD) vibrating feeder was integrated into the discharge outlet of the big bag unloading station. The dosing accuracy required by these units was within a tolerance specification of -/+ 3%. Vibrating dosing equipment is especially suitable for seeds, dried fruits and nuts or bulk materials that are friable or particularly abrasive.

Because of the immediate flow reaction to the start and stop of the electro-magnetic drive, vibrating conveyors can offer greater dosing accuracy over their counterparts, like screw feeders. As the material drains from the big bag discharge station, the PLC can tell the powder feeder to turn on and off. In some instances, a degree of accuracy in the -/+ 20-gram range can even be achieved (depending on the product to be dosed). Furthermore, these food industry machines can be adjusted to increase / decrease accuracy, or, increase / decrease flow rates. This is carried out by utilizing a guillotine gate at the bottom of the hopper where the material feed corridor meets at the exit. By closing off the guillotine valve, the rate is decreased but the dosing accuracy is increased. Vice versa, by opening the powder flow control gate, the flow rate is increased but the accuracy is decreased. A quick connect cover allows for easy access to the internal parts of the feeder for quick cleaning and maintenance. Furthermore, these powder feeding units can even be installed on casters for mobility around the industrial production area.

Mechanical conveyors, or screw conveyors, can be designed by our team at Palamatic Process to enable quick disassembly for cleaning and hygienic purposes. The end bearings are quick connect via thumb screw clamps and detachable flanges. The screw flight ends fit into food-grade bushings that allow for quick removal by hand for full wash down of all internal components. This quick assembly method allows for full decontamination and prevention of cross contamination of food allergens. The continuous material transfer aids in the loading of the paddle mixer at the end of the food production line.

Paddle mixers use paddle-shaped agitators that scoop, lift and flip materials such as powders, granules and pellets in a gentle blending methodology. Paddle Mixers are ideal for blends that have different types of materials with varying bulk densities, shapes, sizes, and flowability characteristics. Paddles blenders excel at applications for food mixes because they are gentle enough to maintain the integrity of the different particulates. The gentle scooping action is ideal for blending fragile ingredients such as nuts, dried fruits and seeds. With the paddle action, the food ingredients travel in in a 3-dimensional figure-8 pattern constantly pulling from both ends of the mixer to the middle. Welded agitators are highly recommended for mixes that require food-grade sanitation. Smooth welds prevent material trap points and cross-contamination with potential allergens. However, industrial paddle mixers can be utilized in any industry requiring blends that need to prevent additional material de-agglomeration or attrition (chemical, building materials, energy, pharmaceutical, cosmetic, etc.).

All equipment contact surfaces are made of 304 stainless steel and PLC communication is driven via an Allen Bradley ethernet connection.

Palamatic Process has been supplying the powder and bulk solids industry with bi bag handling equipment since 1992. In order to determine what solution is best for your project, contact one of our sales engineers. Together, our team of experts can provide the right kind of powder filling equipment that will meet your production goals. Contact one of our experts today for assistance with needed material handling solutions and to request a quote.