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The right ingredients
Solids & Bulk Handling
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Ingredient transfer and weighing can be made easy, says Sharon Nowak, K-Tron Process Group’s business development manager for food and pharmaceutical equipment. The manufacture of baked snack foods often involves the material transfer of several ingredients to mixing and extrusion processes. Dependent upon the percentage of these ingredients in the blend, materials are usually categorised as majors, minors and micros. In many cases, the transfer and weighment of these majors, minors, and micros can be a manual and tedious process. When increased production demand and lack of overall process efficiency caused a manufacturer of baked snack foods in Mexico to switch from a manual to a more automated process, they approached the K-Tron Process Group for help. Read article for more information.
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Rat holes stand no chance
Device for bulk material activation provides optimal feeding, by Dr. Manuel Spoerri
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Many bulk materials, especially fine powder, do not flow consistently out of the supply hopper during feeding. This can lead to the formation of rat holes, or in extreme cases material bridges. Until now, K-Tron has used a vertical agitator to prevent the occurrence of such problems. Although this system is dependable, it is also difficult to clean and requires additional headroom. These disadvantages can now be avoided with the ActiFlow system.
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Clean conveyors: More frequent changeovers mean cleanability is king when it comes to conveyor design
The Snacks Magazine
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Ther concept of ‘on-machine’ or ‘on-time seasoning - where seasoning is delivered to product via a drum prior to entering the weigh scale - is nothing new but it is only recently that it has really come into its own as numerous flavour changeovers and shorter seasoning runs become the norm. “Processors need the ability to run smaller batches of seasonings, thus meeting individual market demands in terms of quantity and variety more efficiently; they also need to perform flavour/seasoning changeovers, with less disruption of the line flow, while preventing a line slow-down,” explains Heat & Control product manager Francois Cousin. While on-machine seasoning systems improve efficiency overall, they also create their own problems, particularly where sanitation is concerned, as there is a much greater danger of cross-contamination.
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Loss-in-Weight Feeding and Continuous Extrusion: New Options in Pharmaceutical Processing, BY SHARON NOWAK AND CHARLIE MARTIN
Pharmaceutical Online The Magazine
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The combination of twin-screw extruders and loss-in-weight feeding and pneumatic refill systems is quickly becoming the manufacturing process of choice when developing pharmaceutical solid dosage forms. The application of continuous extrusion via twin-screw extruders (TSEs) for pharmaceutical solid dosage-form production is growing in popularity as a preferred option to more traditional and costly granulation and dosage-form fabrication techniques. Two methods in which the extruder is used for solid dosage-form production are wet granulation and hot-melt extrusion (HME). During extrusion in both of these methods, pellets, granules, liquids, and powders must be fed accurately and continuously throughout the run and refill operations in order to ensure consistency of formulation, constant throughput, proper order of mixing ingredients, and regulated mass transfer.
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Trail mix on spec every time: Weigh belt feeders improve ingredient weighing accuracy
Food Engineering Magazine
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Kar Nuts Products Company, located in Madison Heights, MI, produces salted nuts, snack food and trail mix blends in flexible 10-16 oz. packages. When growth and expansion caused the company to move to a new facility, the design objective was to produce a state-of-theart operation with a focus on increased efficiency and product quality. As a result, a completely automated roasting, metering, blending, conveying and packaging process was installed. Every product has a different combination of ingredients, each with its own bulk densities and material handling characteristics, which presented a challenge to Kar Nuts when selecting a metering and feeding device. Due to the wide variety of feed rates, as well as the fragile and costly nature of products such as coated chocolate, dried fruits and roasted nuts, it was imperative for the feed device to be versatile, gentle and highly accurate.
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Dry Processing Technology: Focus on Powder & Bulk Operations
Keeping potato chips flavorful: Snack maker finds a better way to control ingredient flow
Food Engineering Magazine, 1 page
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For more than 50 years, Zweifel Pomy-Chips, AG, (Spreitenbach, Switzerland) has been one of the largest snack food manufacturers in Europe. The company produces about 5,000 tons of potato chips annually, and another 1,200 tons of snacks are produced from grain and corn. Known for innovative chip flavors and recipes such as Nature, Paprika, Provençale, Curry and Mexican, Zweifel strives for quality coating and consistent delivery of the seasoning blend to the potato chip manufacturing process. The problem was that existing equipment wasn’t delivering consistent quantities and perfectly repeatable blends to the coating process. This not only affected flavor but also wasted expensive ingredients when greater-than-needed amounts were delivered. Zweifel needed a better way to meter the ingredients to the coating process.
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Choosing The Right Refill Design For Pharmaceutical Loss-In-Weight Feeders
Pharma Solutions Update - a publication of Pharmaceuticalonline
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As the pharmaceutical industry continues to investigate and utilize continuous manufacturing practices, the roles of loss-in-weight (LIW) feeders and the subsequent accurate and consistent refill of these feeders are critical to the overall process. The method of refill, reaction time of the refill device, and also the size of the refill hopper are all critical variables in ensuring an accurate and consistent flow of material to the LIW feeder. Several pharmaceutical operations are dependent upon this refill of feed principle. These operations include continuous extrusion (both hot-melt and wet granulation extrusion), continuous direct compression or blending, and continuous wet granulation.
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Jedes Detail zählt: Mikrodosiertechnologie verspricht mehr Effizienz und einen höheren Automatisierungsgrad (German Only)
CAV CHEMIE-ANLAGEN + VERFAHREN
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Den Wunsch nach kontinuierlichen Pulverdosierern mit geringem Durchsatz, die stündlich mitunter nur einen Teelöffel Material verarbeiten, die Genauigkeit jedoch
in Milligramm messen, äußerten zuerst Pharmaunternehmen. Heute jedoch bietet die Entwicklung der Präzisionsmikrodosiertechnologie Anwendern
vieler Branchen neue und effizientere Betriebsmöglichkeiten. Um das gesamte Potenzial dieser Technologie auszunutzen, ist jeder Aspekt der Dosiererkonstruktion
und -anwendung eingehend zu beachten.
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Pharmaceutical Design: K-Tron Process Group ensures highly accurate feeding of continuous pharmaceutical extrusion
Solids & Bulk Handling - March 2008 - 2 Pages
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Continuous processing for the pharmaceutical and health care product manufacturer is quickly becoming a viable processing option. At the heart of each of these continuous operations is the component or ingredient twin-screw feeder. The availability of high accuracy feeding, reliable refill devices as well as on line PAT technology has helped to open the door to the continuous concept, thus allowing the availability of choice in moving from traditional batch processing techniques. Manufacturing operations such as milling/micronisation, granulation, direct compression, coating and extrusion are all being renovated with this innovative process design
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Feeder Accuracy And Design:
Critical Parameters In Continuous Pharmaceutical Operations
Pharmaceutical Solutions Update - a publication of Pharmaceutical Online
3 Pages - Download PDF
The manufacturing sector of the pharmaceutical industry is currently undergoing a radical change. The need to improve process and product quality while controlling overall process costs is growing. Continuous processing offers a chance to achieve these goals. The implementation of PAT (Process Analytical Technology) tools further aids in the support of the continuous operation, as the tools give real-time indication and assurance of product quality throughout the process. A variety of batch processes in the industry are currently undergoing continuous evaluation, including continuous direct compression or blending, continuous wet and dry granulation, and continuous granulation via hot-melt extrusion. At the heart of each of these continuous operations is the feeder which is used to proportion raw ingredients into the process. Feeder technology and accuracy is paramount in the overall continuous process.
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A Gentle Method: Vacuum Conveying Systems for Pharmaceutical Operations
CPP - 2 Pages
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Vacuum conveying for tabletting operations offers special advantages for material transfer including cleaner, dust free and contained operation with minimal product exposure. It also offers a gentle method to move a large volume of bulks especially in areas with height limitations, where gravity discharge from a large bin or tote may not be an option. Finally, the option to use either dense or dilute phase vacuum transfer offers much more versatility in powder transfer.
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Kontinuierlich gravimetrische Extrusionsregelung (German Only)
WDM - Download PDF
Einleitung: Produkte, die eine gravimetrische Extrusionsregelung unterstützen, sind seit Mitte der 80er Jahre auf dem Markt. Seit der Einführung der ersten Systeme haben sich die Erfahrung, die Genauigkeit und der Grad der Integration dieser Produkte dank des inzwischen weit verbreiteten Einsatzes von Computer- und Netzwerktechnologien enorm verbessert. Die Aufgabe dieser Produkte besteht darin, die Extruderdrehzahl so zu regeln, dass der Extruder einen geregelten, reproduzierbaren Massenstrom ausstößt. Dies ist vor allem aus drei Gründen wünschenswert. Erstens: Ohne gravimetrische Extrusionsregelung ist mit dem betreffenden Produkt keine wirtschaftliche Produktion möglich. Zweitens soll die Produktqualität gehalten oder gar verbessert werden. Und schließlich lassen sich mit gravimetrischer Extrusionsregelung trotz des möglicherweise beträchtlichen Investitionsaufwands signifikante Kosteneinsparungen erzielen.
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Die schonende Methode:
Vakuumfördersysteme in der Pharmaproduktion (German Only)
Chemie-Anlagen + Verfahren 3/2007
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Die Vakuumförderung bietet bei der Kapsel- und Tablettenherstellung echten Nutzen bezüglich Sauberkeit, staubfreiem Handling und Produktberührungen. Große Schüttgutmengen können sehr schonend gefördert werden, besonders wenn Höhenrestriktionen eine Schwerkraftförderung verhindern. Die Wahl des Fördersystems, Dünnstrom- oder Dichtstromförderung, ermöglicht optimierte Lösungen.
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Feintuning für Tablettenpressen: Exakte Schmiermitteldosierung erhöht die Leistung und senkt den Verbrauch (German Only)
Chemie-Anlagen + Verfahren 8/2007 - 2 Zeite
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Um die Leistung und die Qualität zu steigern, können Tablettenpressen ohne großen Aufwand auch nachträglich mit einer präzisen Schmiermitteldosierung und einem Injektor von K-Tron ausgerüstet werden. Für die Pharma- und Food-Industrie stellen die Hygienevorschriften dabei kein Problem dar. Mit einer automatisierten Schüttgutförderung lässt sich die Wirtschaftlichkeit weiter verbessern.
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Creative Conveyors: Design Considerations for
Pneumatic Conveying of Coal
Solids & Bulk Handling - 2 Pages - Download PDF
If you ask six different engineers for a pneumatic conveying system, you will likely get at least six different designs. This case study shows how a few of the applied concepts worked in an actual installation and the reasoning for the approach. The overview includes helpful hints and insights behind the decisionmaking process concerning convey line construction, filtration, storage, and temperature as it affects a dilute phase conveying system. Although the material being handled in this case is coal, the principles can be applied to many other materials. The story began with a coal processor who incorporated a dilute phase pneumatic conveying system into its production. A wide variety of coal is delivered via railcar, crushed and dried before it is introduced into the pneumatic conveying system at ambient temperatures. The material is then stored, processed and pneumatically conveyed once again, but at elevated temperatures. The final product is formed into billets.
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External Lubrication: One Remedy for Tabletting Finicky Formulations
Tablets & Capsules - 4 Pages - Download PDF
Pharmaceutical formulators traditionally blend lubricants like magnesium stearate into tablet formulations to aid flowability and lubricate tablet press tooling. Depending on the formulation, however, internal lubrication can be problematic. Magnesium stearate is typically the lubricant, though not always, and it has a tendency to coat the particles,” said James Mossop, technical products manager, Fette America, Rockaway, NJ. “If you blend too much, you can over-blend, which means you’re over-coating the particles. That has an effect on dissolution, and sometimes on content uniformity. It also hinders the ability for the particles to adhere to each other during compression. Typically, it takes more compression force to make them bind so you can form the tablets to the right thickness and the right hardness.
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Addition Directly into the Process:
Feeding Systems for the Production of Hot Melt Adhesives
CPP - 2 Pages - Download PDF
The production of solvent-free hot melt adhesives is a continuous process. In most cases a twin-screw compounder or co-kneader is used to obtain a homogenous melt. To achieve the required product quality, it is necessary to guarantee high feeding accuracy of the additives. K-Tron offers various feeding systems for precise addition of components into the extrusion process. Hot melt adhesives are solvent-free. They are characteristically solid at temperatures below 82 °C, melt into low-viscosity fluids above this point and set rapidly upon cooling. The development of hot melt adhesive technology was inspired by the previous use of molten wax for bonding. When this method no longer satisfied performance needs, 100 % thermoplastic systems were introduced. Today, there are many different hot melt adhesives available in the marketplace, the most common being those used for hot melt, pressure-sensitive adhesive applications.
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Smart Feeding Technology Improves Quality in Textile Fiber Production
Chemical Fibers International - 2 Pages - Download PDF
Typically the production of man-made colored textile and carpet fibers involves the feeding of two or more components into a single screw extruder, where they are blended and extruded as a filament. Filament pumps, nozzles and further processing equipment ensure the fibers have the correct form and thickness. The key concern of the manufacturer is that the color of the fiber is uniform and consistent, with no visible variations in color. In order to ensure consistent coloration of the fibers modern processes generally use gravimetric feeding systems, which can feed the highly concentrated masterbatches in various granulate forms with high accuracy.
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Bulk Solids Pump (BSP) Technology Reduces Downtime for PolyOne
Plastics, Additives and Compounding - 4 Pages - Download PDF
PolyOne is a leading global compounding company, providing customers with a single source for polymer, elastomer, colorant and additive products. The company offers a diverse product portfolio and a complete range of technical services. PolyOne's business includes color and additive masterbatches, engineering materials, vinyl compounding, polymer coatings and thermoplastic resin distribution. This article examines how the K-Tron Bulk Solids Pump integrated into the K4G Gravimetric Blender reduced downtime for PolyOne.
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Mit Präzision dosieren - (German Only)
DEI - Die Ernährungsindustrie -2 Pages - - Download PDF
Optimierung von Produktionsabläufen und Kosten bei der Herstellung von Frühstückscerealien - Sharon Nowak
Moderne Lebensmittelhersteller sind ständig bemüht, den hohen Produktionsstandard zu halten und gleichzeitig die Produktionskosten zu minimieren. Bei der Herstellung von Frühstückscerealien leisten hochgenaue, gravimetrische Differenzial- und Banddosiergeräte dazu einen wesentlichen Beitrag. Mit diesen Geräten lassen sich bei Vormischungen wie auch bei Individualkomponenten signifikante Einsparungen erzielen, speziell bei teuren Zutaten.
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Feeders in Milling and Micronization of Pharmaceutical Powders
Chem. info - 2 Pages - Download PDF
Operations often involve the size reduction of highly potent API's. As the potency of the dry compounds increases, so do the complexities of the application. This article offers advice in feeder selection and how it influences the process. Size reduction mills are used widely throughout the pharmaceutical industry for the reduction of active pharmaceutical ingredients (API's) as well as bulk pharmaceuticals and excipients such as lactose and hydroxypropylmethyl cellulose. Size reduction is used to increase surface area, improve formulation dissolution properties and maintain a consistent average particle size distribution (PSD) for the formulation, allowing for a better quality mixture when creating solid dosage forms suce as tablets and capsules.
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Zum Wohle des Geschmacks (German only)
P&A Spezial : Lebensmittel Produktion Application - 3 pages
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Dosier- und Materialverarbeitungslösungen für Softdrink-Konzentrate Die Erweiterung einer Lebensmittel-oder Getränkeproduktlinie bedeutet häufig nicht nur eine Vergrößerung der Kapazität, sondern auch eine stärkere Automation des Prozesses. Dies war auch der Fall, als ein großer Softdrinkhersteller sich auf der Suche nach einer Gesamtlösung für Materialverarbeitung, Transport, Dosieren, Wägen und Verpacken seines Softdrink-Konzen trats an einen Spezialisten für Dosiertechnik wandte.
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Vacuum Conveying of Powder (In sanitary and non-sanitary applicaitons)
Solids & Bulk Handling - 2 Pages - Download PDF
Moving powders from one place to another can be a tricky business with all the regulations regarding hygiene, hazardous locations, cleanliness and safety to be adhered to. If the transfer process can be combined with a secondary process, then savings can be enormous in both manpower and wastage. Vacuum conveying allows powders to be moved with the addition of other crucial process steps. Roger Burgess of K-Tron PCS GB, Stockport UK, looks at the flexible, hygienic and economic benefits of vacuum conveying.
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Massenstrom-Messgerät bewährt sich in PE-Produktion (German only)
Chemie Technik - 1 Page - Download PDF
Polyethylen-Pellets werden heute auf Hochleistungs-Compoundern produziert. Um eine hohe Dosiergenauigkeit sicher zu stellen sind schnell messende Waagen gefragt. Kombinierte Massenstrom-Messgeräte für Schüttgüter haben sich hier bewährt, da diese verhältnismäßig kompakt bauen und der Produktverlust beim Hoch- und Ru
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