Product family: xxxxxxxxxxx
Description: xxxxxxx
Fill Temp: 65-80 F
Volume: 30 to 150 ml
Rate: Up to 120 ppm
Container description: xxxxxxxxx
Materials: xxxxxxxxxxx
Seal Material: Rollstock poly release film
Process
The information below is provided to develop a production line that can run cups xxxxxxxxxxxxxx.
The process will include mixing ingredients with Temperature control units and heated electric kettles.
The mixers are controlled by Temperature Control Units which will be positioned in a space separated by a wall away from the mixers. Appropriate NEMA ratings will be included on the TCU’s based on municipality requirements. Mixing time is not determined at this point so throughout rate available through these tanks needs to be verified. The capacity should be enough to keep the filling line consistently fed with liquid to maximize efficiency.
After mixing, product will move to the 6 lane filling equipment via transfer pump and level control in the filling machine. The filling process will start with a cup indexing unit. Cups index into machined plates that index through the machine. Because the fill level is high on the wall of the cup and the required rate is high, servo controlled operation is required to reduce splashing over the cup edge and impacting sealing film performance. Film will require a removable seal layer. Cups move to a fill station where all 6 cups are filled simultaneously. Filling is followed by a sealing station and finally discharged on to a conveyor. A cup coding system is an option within the filling machine but not included in the scope. The cycle speed of the machine is estimated to produce 120 cups per minute. Additional testing is needed to validate the rate. Product viscosity, fill level etc can impact the speed allowed on the machine to operate with minimum downtime.
The Mixers and Filling Machine require the space to be food grade and designed for liquids. Features of that part of the facility includes washdown walls, epoxy floors, drains, handwash stations, elimination of glass and more.
Below is a typical requirement for food facilities.
Structural & Facility Requirements
- Flooring: Must be durable, slip-resistant, non-absorbent, and easy to clean, such as epoxy coatings or urethane cement.
- Walls & Ceilings: Must be sealed, smooth, light-colored, and, in processing areas, free of crevices, moisture accumulation, or mold.
- Drainage & Plumbing: Adequate drainage systems must prevent standing water; pipes must be designed to avoid contamination.
- Lighting: Must be shatterproof and designed to prevent contamination if broken.
- Ventilation: Properly designed to prevent condensation and air movement from dirty to clean areas.
- Pest Control: Premises must be free of harborage areas (tall grass, standing water) and maintain strict pest control.
Operational & Food Safety Requirements
- Sanitation & Maintenance: A comprehensive, documented sanitation schedule for cleaning, along with preventative maintenance on equipment.
- Personnel Practices: Designated employee changing areas, handwashing stations, and training on food safety.
- Allergen Control: Strict separation techniques and specialized equipment to avoid cross-contact.
- Equipment: Must be made of food-grade, non-toxic, and easily cleanable materials.
- Storage: Ingredients and finished products must be stored off the floor, with proper temperature monitoring (e.g., or less for refrigerated goods).
- Security: Measures to prevent tampering, including restricted access, sealed trailers, and surveillance.
Ingredients in the mix area will include xxxxxxxxx mixed with other ingredients. It is not the intention of the SOW to determine if any Class or Div specifications are required for the room. It is anticipated local codes will dictate those requirements. Additional requirements may be determined by local codes. The equipment being proposed is all rated for food grade production and wash down.
After filling, secondary case packing equipment is an option presented here. It has not been part of the prior discussions. The secondary packaging line does not require the same clean room environment but can be included within it. Another option is to convey cups out of the clean space to handle secondary packaging in a warehouse environment. The secondary packaging equipment starts with a filler takeaway conveyor that has an attached CIJ coder to print lot codes on the cups. A case erector presents opened cases for the operator to insert the filled trays. A hand packing station will require operators to place the cups into molded trays that get inserted into a RSC case which then enters a top and bottom case taper, followed by case coding.
Inspection equipment is not included but available. Inspection may include check weigh, metal detection, X ray and vision. Local code will dictate the scope of inspection equipment required.
A potential line layout is shown in the attached layouts.
A list of equipment is included.
A utility list is included.
Equipment detail below:
Mixing Equipment
The SOW includes two 300 gallon tanks with scraper blades for gentle agitation along with axial turbine blades mounted on a skid. Motors driving the agitation are 7.5 HP and approximately 15 amps each at 230V
As well as compressed air. It is estimated to be 20 CFM at 90 psi
It also includes temperature control unit which will heat and regulate the temperature of the water in the tanks. The location of this unit is unknown given no layout is yet determined within a building space. As a result, additional piping will be required outside of the proposal. The TCU requires two drops at 62 amps at 460 Volts each. Air supply will be required here too.
Additional local utilities for this part of the system include but are not limited to:
- Soft Water supply to the skid
- Air supply to the skid
- Piping from the skid to the drain
- Power drops to the skid
- Soft Water supply to the TCU
- A Compressor for full load air supply
- Possible ventilation pending permit requirements
- Permitting including safety requirements form the local municipality.
Process prep tanks and pumps
- Stainless Products 300 gallon pressure wall processor, 316L. ASME stamp
- 4 mm – ASTM 240 316 Stainless Steel top inverted conical head
- 5 mm – ASTM 240 316 Stainless Steel 15 degree conical bottom
- 4 mm – ASTM 240 316 Stainless Steel straight side liner
- 2 mm – ASTM 240 304 Stainless Steel exterior shell
- 4 mm – ASTM 240 304 Stainless Steel dimple jacket ASME Rated for 75 psi @ 334f (tested @ 150 psi)
- #4 interior finish, welds striped and polished to 180 Grit/32 ra finish
- #4 exterior finish, exterior welds striped and polished to 180 grit finish
- (4) Removable sprayball
- 2″ No Foam Inlet
- (2) 2″ Tri Clamp Inlets
- 4″ Vent
- (1) Thermowell
- 3″ Tri Clamp Outlet – 24″ center from floor
- 20″ Manway
- Counter Rotating Side agitator with scraper blades with center with (4) 4 blade axial turbine blades
- 7.5/HP@58 RPM /7.5 HP scraper blade agitator @ 26-28 RPM 3/60/230-460V
- Mounted on heavy duty stainless steel bridge
- (1) bottom and (2) side code stamped heat exchange zones rated for 90 psi, National Board rated, with U1 certificate
- On stainless legs with adjustable feet. NOTE to be mounted on load cells
- Includes two load cells and two pumps and two heaters/TCU
In Line Filling
Six Lane Inline Filling and Sealing Machine with variable speed drive to fill, seal cups at a rate of 15-25 cycles per minute. Total output 90-150 cups per minute depending on Product Volume and Consistency. Footprint – 144” x 48”.
All materials and construction practices are to NSF / 3A standards, all components are NEMA 4, 4x or IP65 or 67.
Machine will come tooled for one container diameter.
Standard Features:
- Touch Screen PLC control
- Servo Index / Servo film feed /Servo Fill Pistons
- No container No Fill
- Fault Diagnostics
- Pass code protected Maintenance screens
- EWON remote PLC access for online trouble shooting (Wi-Fi connection needed)
- Stainless Leveling Feet
Stations:
Denest Cup Drop: Station will utilize a timed escapement to automatically load the cups. The typical run time is about 2 – 3 minutes with each load in the magazine. This can be loaded while the machine is operating.
Filler 1: Piston style with Shut off Nozzle. Fine adjustment on the piston filler through the HMI assures accuracy. All components are made from Stainless Steel and Acetyl. If no cup is present, it will not fill. A 15 gallon hopper is supplied.
Heat Seal: PID Controlled heater heads w/stainless knife blades to seal and cut film with minimum allowable scrap. Scrap take up is easily accessed and removed. Film feed is servo controlled for either random feed or registered print with optional slot sensor. Film roll diameter not to exceed 10 inches. If no cup is present the station will not operate at that position.
Out Feed: Timed lift and sweep cup discharge will guide the finished cups out the end of the machine onto a discharge conveyor that exits 90 degrees from the machine.
Optional Case Packing Equipment
The secondary packaging line does not require the same clean room environment but can be included within it. The product starts with a case erector to provide RSCs for the operators to load cards in and a case conveyor. A product conveyor from the filler that has an attached CIJ coder to print lot codes on the cups then meets up with the case conveyor at the case packing station. This station requires operators to place the cups into die cut cards then insert filled cards into an RSC. Once filled, the case enters a top and bottom case taper, followed by case labeling on a case conveyor, Markem Image hot wax printer to print on cases.
Inspection equipment has not been included but is available. Inspection may include Check weigh, metal detection, X ray and vision. Local code will dictate the scope of inspection equipment required. Inspection equipment is TBD so it is not included in the drawing but could be included in the clean room area or case packing area.