Batch / Blend / Bag

Producing Nutritionals

A small producer of nutrionals had such success that they couldn't keep up with sales orders without adding more labor or more equipment. Either choice seemed also to require more floor space and thus even more capital cost.

The company began looking for a larger blender as the first step toward increasing output. Their preference was for a rotary blender, for gentle mixing of fragile crystalline ingredients with minimum attrition.

Space Restrictions, Budget Restrictions
The existing production plant had very limited floor space, and worse, low headroom of only 13'-6". Alone, adding a larger blender would just make the plant more congested, and the low ceiling seemed to limit the functionality of the blenders they had investigated. However, this existing plant was insulated, humidity controlled, and most important, already operating. Moving to a larger space would be another capital expense, and possible disruption of production.

Expanding Scope to Save Money
Applicon found that the solution to their growth issues was to do more than just buy a larger blender.

Applicon started with a system approach to improve the entire process, and meet these goals:
     • Increase production by 3x, with the same or less labor
     • Handle the raw materials only once
     • Remove lumps from the ingredients
     • Close the potential dust emission points, and capture dust for recycling
     • Blend a batch quickly, and discharge completely without interior buildup
     • Automate bag filling, by weight
     • Provide a net gain in space by eliminating in-process skids and forklift area.
     • Make the system compact, but keep it serviceable

One Vendor, One Builder
Applicon designs and builds batching, blending, handling, and packaging systems. One source of equipment, one responsible vendor.

We specialize in building systems for tight spaces and tight budgets.