Efficient cleaning will make you win time
Shutting down an installation for cleaning and maintenance purposes is inefficient. Therefore, it is essential to minimize the number of cleanings and optimize the cleaning times. As a process partner, J-Tec goes beyond designing and building installations. For the food industry specifically, the operational cost of the installation is already taken into account at the design phase.
How? Our engineers examined actual cleaning times in existing installations, analyzed how the process can be optimized and how these optimisations can be processed in new installations. Based on our findings, we defined three key-points that will ultimately reduce the OPEX of the food installation.
J-Tec designs a combined sieve and magnetic system according to the latest hygienic standards
For over 40 years J-Tec is designing, installing and maintaining complete process installations in as well the chemical and the food industry. This acquired experience brings along the necessary know-how needed to provide tailor-made solutions for our customers. However every process challenge requires a customized approach, we dispose of a wide variety of standard developments which we can apply.
Thanks to our numerous references in the food industry we understand that hygiene is a crucial element in every food installation. That is why J-Tec is continually looking for new technologies and innovative solutions in order to exclude any form of contamination.
J-Tec designed a multifunctional mixing installation taking the EHEDG guidelines into account. This vertically build blending line does not need any pneumatic transport and works fully gravitational. Another advantage is that the discharging, mixing, sieving, dosing and bag filling activities can take place on a small surface (ca. 2,5x3x10 wxdxh), meaning that this J-Tec solution fits almost everywhere.
On the top floor big bags® can be discharged using an easy controllable hoist. Thanks to a J-Tec discharge unit, equipped with an hygienic and 100 % dust free discharging clamp, your big bags® can be emptied in a clean and optimal way. (J-Tec hygienic dirt valve is optional)
We’ve engineered a bag and liquid discharging unit in combination with the big bag® discharging unit. The liquid system allows us to add Max. 5% of warm/cold/ viscous or less viscous fluids into the mixer in a homogeneous way without the possibility of clot agglomeration. The raw materials can be discharged into just one access point of an underneath mixer. This mixing unit is equipped with air nozzles which automatically remove the product residues for up to 99.9% after each batch. The mixer is also engineered with a large door in order to enhance the cleanability.
When your products are mixed into a homogenous substance, a rotating dosing sieve in connection with a continuous weighing scale doses the mixture into bags. The bag filling process itself is manually controlled. Afterwards the bags can be easily sealed.
All frames used in this installation are especially designed conform the EHEDG guidelines in order to optimise the hygienic aspect of the installation. It is furthermore very easy to upgrade this installation with a complete CIP cleaning system.
J-Tec skid solutions
Being part of Katoen Natie, a world leader when it comes to port activities, logistics and semi-industrial services, has its advantages. Katoen Natie has over 4.8 million m² of warehouses located throughout 25 countries, worldwide. As a member of this international player, we’re able to use its facilities for the benefit of our projects.
A manufacturer asked us to engineer and build a blending line in a North-African country. The installation consists out of 4 main parts: dry material handling, CIP, kneading and bagging. Our know-how about how to treat the given product, combined with our experience in international projects, was decisive for awarding us this contract.
The dry material handling level consists out of a bag discharging station, a mixer and a pneumatic conveying line equipped with a metal detection system. The conveying line feeds a loss in weight feeder installed above a kneader. Next to the dry handling application we also engineered a liquids installation which doses water and oils into the kneader. The whole process is CIP-able thanks to an automated CIP installation designed by our liquids department.
Because the installation is to be built in a North-African country, specific concerns like administrational issues, local regulations and special bank regulations need to be taken into account. The administrative burden is a big issue. Whenever a single piece of equipment needs to be imported, an overload of paperwork is assured. In order to avoid this and guarantee that the agreed delivery time will be respected, J-Tec came up with a clever solution.
We used a Katoen Natie warehouse near our headquarters in Belgium, were we build and even pre-wire the entire installation. Doing this gave us the advantage of thoroughly testing the installation without and with product, to obtain a vertical start-up. The installation was also engineered in specific modules and skids in order to simplify the transportation. This should reduce the time needed for dismounting and mounting the complete blending line. Another advantage is that the complete installation will be sent to North-Africa in one shipment, reducing the administrative delays to a minimum. This project is yet another example of the powerful formula J-Tec and Katoen Natie represents.
J-Tec Complete cacao blending line
Two years ago J-Tec opened its Asian headquarter in Bangkok, Thailand, and the investment is paying off. An exquisite example proving our success in Asia, is a recent project we’ve realized for a well-known producer of cacao products. This client asked us to engineer and build a complete blending line in a production facility in Samutprakan, Thailand, near to Bangkok. J-Tec provided an innovative solution for their process challenges and got the project.
The blending line mainly consists out of 4 different levels.
- On the upper level several receiving hoppers (on weighing cells, with integrated filters) are fed by different pneumatic conveying lines. We’ve connected the first line to an existing dosing premix installation for the transportation of one specific premix. This line will be foreseen of product by additionally installed screw conveyors. In order to install these conveyors we needed to lift up the complete existing structure.
- The second line is connected to an existing screw conveyor underneath an existing silo.
- The 3rd line is responsible for the supply of sugar and milk powder, discharged from 4 FIBC discharging stations. These stations were already in use for an existing blending line. In order to use the same systems for the new installation, additional screw conveyors needed to be installed. This was quite a challenge, considering the limited available space underneath these stations.
On the second level, the products get dosed into a double shafted paddle mixer. Such a mixer generates two movements at once, providing a homogeneous mixture. The blender is also equipped with a trapdoor which ensures a quick discharge of the mixed product in an underneath receiving hopper.
At the penultimate level, a vibrating sifter is installed to exclude all irregularities out of the mixed product. An extra metal separator makes sure no metal comes into the end product.
In the last step of the process, the finished product gets collected into 4 receiving hoppers. The product gets equally distributed due to a clever setup of 3 screw conveyors, which ensures a continuous product flow.
In order to save costs and meet delivery times, we’ve decided to work with a local supplier for the manufacturing of the hoppers. All other equipment was built and shipped in from Europe.
A satisfied client and a smooth completion of the project made this a successful story.