DAIRY
IBC Blender, even being able to
change the recipe for each batch
if required, without the need for a
clean down. The IBC blender is able
to accommodate different container
sizes which can be matched to the
batch size. There is no further need
to store excess product and tie-up
cash—the ultimate in manufacturing
flexibility and efficiency.
The amount of manpower they
require has been halved, with
just three people now needed for
filling - one at blending and three at
packing. This new team structure
can produce 20 tonnes in a single
shift, meeting the same capacity as
that of the previous system, whilst
allowing for future sales growth.
They are also able to perform the
cleaning duties during their usual
shift, whereas before, they had to
work overtime.
Small but mighty
The decoupled modular design of
a container-based system means
that Brothers Illong have the ability
to increase production volume
by adding in extra packing lines,
whilst still running with just one
IBC Blender. The upside of using
a container-based production
system is that one blender can
feed to many packing lines—the
containers are simply sent to where
there is a call for product. This is
unlike fixed pneumatic conveying
systems where one mixer is linked
to a single packing machine.
Should demand increase further, a
second IBC Blender can easily be
integrated into the system.
Milk and water
don’t mix
A clearly defined hazard in dairy
installations is the risk of microbial
contamination. If all traces of
moisture are not removed from
the system, there is a danger that
bacteria will grow in these droplets
and contaminate the whole process.
With pneumatic conveying or
continuous mixers this can result
in a very large batch of product
that has to be scrapped. At what
cost to both your reputation and
operations?
Matcon has been working with
leading manufacturers installing
our IBC systems, which overcome
these issues thanks to not only
changing the conceptual solution in
terms of decoupling the system, but
also due to the simple nature of the
IBC design itself. Firstly, because
all blending takes place within the
container itself, there is no timeconsuming
cleaning of a mixer after
each recipe, the blender is simply
ready immediately for change
after change, switching out each
container with no product in contact
with the blender. These dirty IBCs
are then cleaned off-line, away from
the production area.
At the Brothers Illong site, they use
wet washing to clean the IBCs,
but because this takes place offline
there is no risk of waterborne
contamination. There are sufficient
IBCs in the system to ensure there
is plenty of drying time before the
IBCs go back into circulation.
The full benefits
Brothers Illong now have a
fully hygienic yet flexible
manufacturing plant.
Production throughput has doubled,
yet the number of operators has
been reduced by half. This has
resulted in the most efficient and
hygienic dairy facility in China—a
show-piece which satisfies both
their customers and the stringent
Chinese legislators.
16 SEPTEMBER 2019