制作早餐饼干：案例研究

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BY Edmund Sinnott | 2017年7月25日 | 个案研究 , 链式 工艺系统
 
bulk ingredient case study graphic

Bakery Co.* 是一家市值数十亿美元的食品加工公司，生产一种流行的早餐饼干（和几种变体），由燕麦片、黑麦片、各种面粉和其他成分组成。这些配方虽然不太复杂，但很难通过 Bakery Co. 的现有工艺系统进行扩展，并且在 MPE 参与之前，生产经理就遇到了质量控制问题。

BAKERY CO.’S NEEDS

  1. 最大的问题是，混合干原料后;面粉、甜味剂和添加剂在通过气动管道系统运输到散装袋灌装机的过程中会分离。毋庸置疑，这个问题让生产经理头疼不已
  2. 工厂经理还希望找到一种替代工艺系统，需要更少的维护和降低能源成本，因为他们的气动输送机消耗大量电力，声音很大，并且需要频繁维护

MPE’S SOLUTION

MPE 为 Bakery Co. 设计了一个全新的工艺系统，顺序如下：

  1. 散装（也称为 supersack）卸料机，为管状拖拽输送机供料
  2. 运输到带有主动料仓底部的称重传感器（大型）上的固定缓冲仓，以确保干原料随后一致地流出到失重式给料机
  3. 失重式喂料机确保根据配方精确分配配料
  4. 然后将测量好的原料喂入第二个管状拖式输送机，输送到带式搅拌机
  5. 混合后，（仍然干燥的）混合物送入第三个管状拖式输送机，然后运输到随后的散装袋灌装机进行储存，直到烘焙生产

A PICTURE IS WORTH A THOUSAND WORDS

Bulk bag unloaders for large quantity ingredients feature paddles and spout elongation devices for continuous flow of product exiting bulk bags. Spout seal plates securely fasten for no leakage. Also a dust collector and return line was installed with differential pressure switches that can be monitored from the transport control system (shown below).
MPE batching and transport control system sequences up to four separate batches with zero cross contamination. The conveyor runs automatically when each batch is ready for transport and turns off when not in use, thus saving energy.
3000 lb bulk ingredient storage hoppers are fed from a Chain-Vey above. They have high angle walls and vibrating bin bottoms to ensure consistent outflow of dry ingredients to loss-in-weight feeders with accuracy within 0.1%.
Accurate ingredient amounts are discharged into a Chain-Vey without the need for air-locks.
This second Chain-Vey system is 240 ft in length and carries measured amounts of ingredients to the mixer hopper. The importance here is that unlike many other conveyance systems, Chain-Vey ensures virtually zero product loss even in fine particle applications; an important consideration for adhering to recipes.
The system above the dry mixer hopper utilizes minimal clearance of only 24 inches between the hopper and ceiling. A second scale system records the receipt of each ingredient which is reported to the batching and transport control system.

THE RESULT

散装袋原料被快速卸载，没有浪费 ，并有效地运输到临时仓库;然后 原料被准确测量并运输到混合料斗;在从混合机到最终散装 袋的运输过程中，保持产品的 完整性;所有这些都减少了用电和噪音污染。 与此同时，Bakery Co. 的早餐饼干味道从未如此好过。

*我们将客户的真实姓名替换为虚构的名字 Bakery Co。

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