Client application
Optimising hygiene and automating cleaning: towards a ‘dust-free’ production area
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Background & client requirements
The client is a leading international player in the spice sector. Its business involves the preparation of complex aromatic blends with varying physical properties (density, fat content, particle size). The systematic presence of allergens necessitates a strict hygiene protocol to prevent any cross-contamination.
Objectives
- Eliminate environmental pollution at source: Ensure the production line is airtight to put an end to the constant dispersion of dust and improve hygiene in the production workshop.
- Move from general cleaning to localised cleaning: Replace manual foam jet washing of the entire room with a rapid, automated, internal Clean-in-Place (CIP) cycle.
- Secure the process (Allergens and ATEX): Eliminate retention zones to guarantee total decontamination between batches and ensure strict compliance with ATEX standards (flammable dusts).
- Controlling the dosing of complex mixtures: Ensuring reliable flow of powders prone to “rathole” (arching) to guarantee a steady flow without blockages.
- Optimising versatility and productivity: Achieving a throughput of 150 units per hour with an accuracy of +/- 30g, whilst automating the switch from bag to bag-in-box format.
The BM1030 bagging machine combines industrial output rates with the highest standards of hygiene, transforming the burden of manual cleaning into an automated, secure and ATEX-certified process.
Produit client
Spice powder
Spice powder is a dehydrated plant-based powder that guarantees long-term, stable storage. Used in the food, nutraceutical and chemical industries, it ensures the uniform incorporation of active ingredients and flavourings. Its powdery nature requires airtight packaging and precise dosing to comply with ATEX standards and allergen management requirements.
Performance validation under operational conditions
In order to meet the specifications, Halpaq has developed a configuration whose effectiveness has been tested in the workshop. These preliminary tests have confirmed that the product fully complies with the specifications.
Halpaq’s solution:
- Dosing unit with integrated agitator : To prevent the “rathole” effect, Halpaq has incorporated a specialised mechanical agitator into the hopper. This system continuously breaks up the product to ensure even filling.
- Specific ATEX certification : Given the explosive nature of spice dust, the entire line has been designed and certified in accordance with current ATEX standards to ensure the safety of the site and operators.
- Clean-in-Place (CIP) cycle : The stainless steel design with no dead zones allows for automated internal washing via strategically placed nozzles, guaranteeing ‘zero allergen’ safety without the need for dismantling.
- Total containment : The hermetic filling system prevents any dispersion of particles, thereby protecting the working environment.
Measures validated during trials
- Elimination of the need for a full clean of the production area: Controlling emissions at source thanks to the airtight design of the BM 1030, as well as its total containment, has made it possible to confirm the permanent discontinuation of intensive cleaning protocols. Previously, the customer had to clean the entire room with a foam jet (floors, walls and structures) between batches. With the Halpaq bagging machine, cleaning is restricted to the machine’s internal circuit, improving workshop hygiene and line availability.
- Dosing accuracy and maintaining production rates: The productivity target of 150 bags per hour has been consistently achieved. Despite the complexity of the spice blends, the dynamic agitator ensured constant flow, guaranteeing a precision of +/- 30g. This performance safeguards the client’s margins by preventing over-dosing whilst maintaining industrial production rates.
- Elimination of retention zones (Allergen Safety): The thorough inspection carried out after the Clean-in-Place (CIP) cycle demonstrated decontamination. The absence of residues in the dosing and bagging circuits validates the “zero cross-contamination” strategy, an essential guarantee for this site handling various allergens.
Benefits for the customer
- No need for a full clean of the premises: Containing the process at source eliminates dust dispersion
- “Zero Allergen” safety guarantee: The automated Clean-in-Place (CIP) cycle eradicates retention zones
- Consistent productivity on complex products: The integrated agitator prevents “rathole” phenomena (vaulting)
- Automated “Bag and Bag-in-Box” versatility: The line ensures the transition between different packaging formats without operator intervention
- ATEX compliance and safety: The specific design protects operators and the production site from ignition risks associated with fine dust.
The equipment used for this project
Equipment
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Marc S.
Powder processing solutions expert