FastRead Newsletter (Vol. 4, Iss. 2)

Money Talks

Written by: George Nikolopoulos, Regional Sales Manager

A customer recently contacted Admix for help with a new process. We had solved process issues for them in the past so they were confident we would provide a solution to their newest challenge.

The processor had a new recipe that used a large amount of starch. So much so, that it was clogging the strainers. This would shut down the line and seriously hold up production.

Needless to say, it was costing them a lot of money: wasted product, down time, low productivity, disgruntled operators and maintenance personnel.  In addition, whatever product did make it through did not have the correct amount of starch and required more energy to drive off the excess water.

Admix identified a potential solution: an inline high shear mixer after the tank and agitator. The new product being produced had a high solids content, as well as higher density, and significantly higher viscosity. An inline high shear mixer from our trial equipment pool was installed. Then - life changed!

The product was being produced with no down time. The strainers were not clogging. There was no change in pressure across these strainers. The product being produced did not require longer cooking times to reduce the water content.

The customer reported to Admix that this change, the simple addition of a Boston Shearmill inline high shear mixer, will save $70,000.00 per month.

Ex Nihilo (Make Something Out of Nothing)

Written by: George Nikolopoulos, Regional Sales Manager

A manufacturer of private label food products contacted Admix looking for an in-tank high shear mixer. We conducted an on-site demo, scaled up the mixer and supplied the customer with a high shear mixer. Two years later, the same manufacturer needed to kick it up a notch. There was a new product to be made from a new contract.

Although the new product could be made on the original Admix mixer, the tank was too small for the required volume necessary to fill the new contract. What was needed was a system that could handle a larger batch as well as minimize dusting. Essentially, they needed the combination of high shear and powder induction.

The manufacturer visited the Admix Applications Lab for a witnessed test. The Admix Fastfeed powder induction system was able to make the desired product, hydrating a fairly high concentration of gum and starch in a single pass. It was also able to recirculate this viscous product so that other ingredients could be added after the gum hydration step. The visit was a success. A process solution was presented to the manufacturer so that the contract could be secured and product could be made to fulfill that contract.

Admix can help save you money and we can help you make products that you may not have been able to make before.  Contact us today at 800-466-2369.

Reduce Your Energy Consumption

Written by: Rick Earley, Beverage & Dairy Market Manager

Reducing energy in our customers’ processes has long been a focus for Admix.  Many batching applications utilize a bottom impeller tank mixer to prepare product.

• A Rotosolver high speed in-tank disperser typically uses 7.5 HP for a 300 gallon batch of 300 cps product. This compares to 25-40 HP for conventional bottom impeller square tank mixers. (The Rotosolver high shear mixer meets or exceeds 3-A sanitary standards while no bottom impeller mixer does).
• Not only does the Rotosolver use much less horsepower, but it processes a completely homogeneous batch faster with less entrained air.
• The Admix Fastfeed inline powder (and liquid) induction and dispersion skid only uses 12.5 HP. All powders and liquids can be added via the Fastfeed and transferred directly to the downstream batch tank on a single pass. We have reduced customers’ batch times from 6 hours down to 30 minutes with the Fastfeed. When you compare 40 HP vs. 12.5 HP, 6 hours vs. 30 minutes, the answer is simple = time and energy savings!
• Pre-milling of some products with our Boston Shearmill (BSM) prior to your high pressure homogenizer allows the homogenizer to run at less pressure. In addition, the BSM may eliminate the need for your homogenizer all together. There goes a 100 HP homogenizer, replaced with a 50 HP BSM. And just think about the water and maintenance savings compared to the cost of operating the homogenizer.