The Production Process

Mixing

• All ingredients are mixed together.
• Fat is sprayed into the mixer.


Mixing room:
 

• The mixer, together with the fat tank and the dosing tank can be installed in a non air-conditioned room.
• In order to empty easily the content of the mixer into trolleys or bins, it is necessary to install the mixer onto a platform measuring about 4x3 metres.
• Ideal height of the room: 6 meters.

Maturation

• After mixing, the powder must maturate about 24 hours in a room with a temperature of 18 to 20°C and humidity not exceeding 45%.


This allows:
 

• Reduction of the temperature of the mix and solidification of the fat.
• Escaping of the air accumulated (during mixing) between the particles.  The result: more fluid non-sticking powder and more homogeneous mixing.


During maturation, powder can be stored in 60 litre bins, 2/3 filled, or in non-deep trolleys.

It is preferable not to fill totally the bins or trolleys, in order to avoid high compression on the powder situated beneath. This also reduces the 
maturation time.

Forming and wrapping 

Equally to the maturation room, the forming and wrapping room must be set at 18 to 20°C and 45% RH. 

If this isn't followed:
 

Press and wrapping machines will have to be constantly cleaned.

High variation in cube weight will be measured.

Each forming/wrapping line measures:
with open doors ~ 3'150 x 2'635 mm, height ~ 1'750 mm.

In order to increase the precision in weight of the cubes, it is recommended to use an automatic powder infeed system, controlled by the press.  With such a system, the forming/wrapping line will measure 5'023 mm and the height will be 2'410 mm.

Efficiency

• With a good homogeneous mix, 95% efficiency is possible. A part from the temperature and humidity control, the quality and regularity of salt particles is essential. A fat with a low melting point requests frequent cleaning.
• Considering that it takes a certain time to get from your suppliers ingredients with a regular and sufficient quality, efficiency arises with experience

Labour

• Mixer: One or more operators, according to the quantity of batches per hour.
• Press and wrapping machine:  One operator. With a perfect powder, one operator can follow several lines.
• You must of course add the staff for laboratory, maintenance and secondary packing (bags, boxes etc.).

Cleaning and maintenance

• Most of the users run their lines 24 hours per day, 7 days a week and reserve 1 shift for maintenance.
• Machines are to be cleaned with vacuum cleaners and moistured clothes.
• Never use compressed air near the machines!

All the information presented in this page serves as general ideas only.  Before any implementation of the said information, the reader has to verify its contents.  The authors will not be responsible for any consequence due to the use of this information.