Client application
Automation, safety and versatility: Bags / Crates – High-hygiene bagging of yeast
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Background & client requirements
A leading player in the Food & Feed (agri-food) sector, our client specialises in the production of dried yeast. This sector demands the highest standards of food safety and the preservation of the physical quality of the products (flake integrity).
Objectives
- Modernise the client’s current process.
- Ensure operator safety: The previous equipment posed mechanical risks that had led to incidents. Ensuring operator safety was the number one priority.
- Produce with precision: Achieve a throughput of 120 units per hour with an accuracy of +/- 30g, whilst controlling dust emissions.
The BM1030 bagging machine, proven on sensitive products, ensures a smooth transition between bag and
“Bag-in-Box” formats without human intervention, whilst guaranteeing optimal cleanability.
Customer product
Yeast flakes
Yeast flakes (or flakes) are produced through a rigorous pasteurisation and drying process, ensuring benchmark microbiological and nutritional stability. Rich in protein and B vitamins, they are highly sought after in the food, nutraceutical and pharmaceutical sectors.
Proven performance in real-world conditions
To meet these specifications, Halpaq has developed a solution whose effectiveness has been demonstrated through extensive laboratory testing, confirming that the particle size distribution is maintained.
The solution implemented includes:
- HBM 1030 bagging machine : The heart of the proposed system, designed to automatically switch between the two types of packaging.
- ATEX compliance: Given the nature of yeast dust, the solution incorporates specific ATEX certification to ensure safe operation.
- Dedicated dosing unit: A successfully tested technology to ensure a consistent flow of powder without breaking the fragile (flakes).
- Secure transfer system: Full automation designed to eliminate all manual handling near the filling areas to ensure total operator safety.
Performance demonstrated during testing
- Complete workstation safety: The ‘zero-contact’ design and full automation eliminate hazard zones, ensuring optimal protection for future operators (a direct response to injury issues with the old system).
- Optimised cleanability: Product changeover tests confirmed that the hygienic design reduces retention areas, ensuring rapid cleaning without complex dismantling.
- Reliability and dosing accuracy: Tests have validated compliance with weight tolerances (+/- 30g) at a rate of 120 bags per hour, whilst preserving the visual integrity of the flakes (flakes).
- Bag-in-Box flexibility validated: The automatic transition between bag mode and carton mode was successfully carried out via the PLC, confirming that no physical intervention was required.
Benefits for the customer
- “Zero Accident” safety guarantee: Operator safety is an integral part of the process
- Preservation of the product’s added value: The dosing unit maintains the product’s integrity
- Flexibility without line stoppages: 100% automated versatility ensures agility without the need for mechanical adjustments
- Hygiene and quick cleaning: The hygienic design drastically reduces retention areas
The equipment used for this project
Equipment
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Marc S.
Powder processing solutions expert