Processors upgrading production and processing equipment have a significant investment including machines, shipping, installation, and commissioning. To consider an upgrade of controls may also mean a change of procedures and processes. Food manufacturers must weigh their concerns, such as payback, capex budget, downtime, and life cycle costs. Mepaco® has helped customers with manual, entry-level, and advanced controls options. Here are some examples of the rationale why customers choose a which level of controls strategy. Payback The payback for a controls solution depends on the application. Artisan food processors with less production volume may be well-suited for manual controls. Another example of a simple controls package investment could also be testing equipment, R&D equipment, or perhaps short run product lines. In food processing lines with automation as the driving strategy, many processors utilize higher-end controls with computerized recipes and automated controls of integrated equipment to meet goals and return on investment. Capex Budget Financial reservations are a top concern for all sizes of companies to consider in an equipment or system investment. The pros and cons should be carefully considered on the system solution and the equipment and controls partner. Increased production goals drive food processors to invest in automation to sustain growth and competitiveness, with other factors including food safety, personnel safety, and labor utility costs. Downtime In some examples, a capital commitment to a new system with advanced controls are a solution to reduce loss of downtime, specifically downtime related to manual processes such as loading and unloading. Some processors struggle with effective loading times when using non-integrated, manually intensive equipment. New equipment solutions with an integrated recipe and process control package can be engineered to solve automation goals and reduce or redirect labor. Life Cycle Life cycle of equipment is affected by environment, proper use, and hours of operation. Stainless equipment, however, generally lasts a long time. Mepaco® has Mixers that are still in operation after 40 years. From a controls package standpoint, advanced controls packages can be changed and upgraded unless it is a legacy system, which would require a full processor and software upgrade. In a round table discussion of Mepaco® application specialists, engineers, sales and service technicians, the team offered up trends and considerations from component level options to entire system solutions that help solve automation and reduce labor in food manufacturing processes. For more information, read our e-book “Processing Automation Trends”.
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A recent article, “It’s About Labor”, published in Food Engineering magazine, processors were interviewed about the ongoing difficulties finding and retaining workers, even beyond the post pandemic labor levels. Mepaco®’s customers, too, have been driving automation conversations, so we are developing resources to share our application expertise with solutions that are semi- or fully automated.
Some applications lead food manufacturers to consider equipment that allows for versatile functions to reduce labor and manual processes that can either be locally controlled or fully automated.
ThermaBlend®: Cooking/Blending/Chilling
The ThermaBlend® Cooker is a highly efficient cooking/blending solution with a substantial heat transfer area featuring highly efficient agitators and a patented scraper system that proves fast processing times. The ThermaBlend® Cooker is engineered for specific customer goals and is capable of cooking, searing, caramelizing, chilling, sautéing, and blending. Mixers, cookers, and blenders are highly engineered and highly controlled systems for large-scale batch operations up to 1000-gallon capacity.
In one example, Mepaco’s customer, a chicken processor, used manual processes for tenderizing, cooking, and shredding. The labor was nearly eliminated with the introduction of the ThermaBlend® which combined five processes to temper the meat, massage, tenderize, cook, shred and blend with thickening sauce.
Mixer-Blenders and Buffering Mixers: Product Temperature Control
Mixing equipment can be modified for the needs of the application to include direct or in-direct steam options. Cooling jackets, insulation/cladding, or injection systems (CO2 or N2) also add versatility to mixing and blending efficiencies. Mepaco has engineered buffering mixers to streamline operations. In one application, Mepaco engineered heated buffering mixers which kept the particulates in various densities in suspension until downstream operation signaled for more product. In this example, the buffering mixers solve for automation, and maintain the integrity of the product.
Screw Conveyor Systems: Versatile loading while maintaining product temperature
Another application specific solution, screw Conveyors are among the most modifiable equipment solutions to suit the processing layout and versatile loading positions in an automated line. Screw conveyors can have automatic loading based on product weight or downstream signals, as well as automated pivoting between equipment.
To learn more about automation, or upgrades to controls packages, discuss your application and goals with Mepaco.
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