Fortunately, the manufacturer's sister facility was not experiencing these same processing challenges. It turns out, the sister facility was using the high shear Rotosolver on their 100-gallon tanks. These mixers reduced batch time to 10 minutes or less and the powders were fully hydrated with no clumps. The weekly inspections of the screens and strainers found them clean. Also, production yields were 100% because the recipe was not altered by lost powders on the screens. No more wasted ingredients or out-of-spec product!
Bottom line? No more long mix times for batches, no more clogged filters, no more off-spec product, no more wasted ingredients. In addition, there is no more holding up production with downtime for cleaning screens or strainers. Yields improved to the same levels for both plants. The payback was less than three months!