The SmartMixer has been designed to achieve the objectives that, after much research, we believe the Customer requires from a system of this type, namely.
Accept ingredients of any specification that are available.
One of the key points of the SmartMixer is the ability to calculate each batch based on the information that is correct at the time. So, if the cream fat% or the
concentrate TS% is different from normal, it really is not a problem, as the calculation will adjust all parameters to always produce the correct specification end product. This means that skim concentrate can be produced by re-hydrating
skim powder and also that separated cream washings can be used
Calculate the exact amounts of each required.
As the calculation results are displayed, the operator now knows exactly how many litres of each ingredient will be required. This allows him to check that he has enough of each
product before starting the batch, and also means that management will know exactly how many litres of each ingredient have been used.
Increase daily volume capacity.
By comparison with traditional mix tank systems, the SmartMixer has been proved to have doubled the daily volume capacity at one plant at which it was installed. The reason is that there is only a
few minutes time delay between finishing one batch and starting another. In general, while the operator is chasing the previous batch through the pasteuriser with water, the SmartMixer can be priming the buffer tank ready for the next
batch to be pasteurised. The buffer tank may need to be rinsed with a hose if following a "fat based" batch with a "skim only" batch, but apart from that, there is nothing else to do.
Save time.
Saving time goes "hand in hand" with increasing volume capacity, but it also means that the operator has more time available because the SmartMixer is taking so much of the workload off of him. Batch Calculations are
done in a fraction of a second. The SmartMixer monitors the flow rates and the number of litres produced, and warns the operator if an ingredient tank has run out, if a finished product tank has reached its set number of litres and the
progress of the batch. There is no need to keep checking the Fat% and TS% of the batch being produced, because the system is so accurate.
Store recipes and allow alteration by authorised personnel
As standard, up to 16 product recipes can be stored by the PLC, but more can be added if required. Each recipe consists of only two parameters, namely Fat % and TS % The
recipe page is password protected so that only authorised personnel can view and alter the recipes.
Produce homogeneous end products
One of the problems with traditional mix tank systems is that fat in the mixture will tend to rise to the surface of the mix tank while the batch is being processed. This leads to varying fat
contents at varying times during the batch, and can lead to inconsistent fat contents in the final end product tanks. The SmartMixer mixes the ingredients on a "just in time" basis, so the fat content of the end product is entirely
consistent across the entire batch.
Produce exactly the right amount of the end product chosen
Not only does the SmartMixer produce exactly the right amount of the end product, but it also uses exactly the right amount of each ingredient. A batch is not deemed
"finished" until the calculated amount of each ingredient has been delivered to the buffer tank.It is a tribute to the accuracy of the SmartMixer that, even during runs lasting several hours, the three ingredient flows normally finish
within seconds of each other.
Produce exactly the right specification end product.
The SmartMixer has been proved to be
so accurate (when given the right ingredient specifications) that it has been found that recipe fat contents can be reduced and still meet the customers specifications. With increased accuracy, less "safety margin" is required
With no wastage,
During normal running during the day, it is fair to say that there is NO wastage.
All the ingredients are delivered in the correct quantities to the buffer tank, and all the contents of the buffer tank are
emptied to the pasteuriser balance tank. On the last run of the day, before cleaning, it is possible to arrange it so that all of the ingredient delivery lines are purged to SmartMixer right at the end of the batch, ensuring NO wastage.
Even if not purged, only a small amount of product remains in the pumps and lines of the SmartMixer.
With no cleaning problems.
All equipment (pumps, lines, valves) are stainless steel and produced to the highest standards. The buffer tank has sprayballs, and the SmartMixer can either be cleaned as part of the pasteuriser clean
or by a separate CIP system
It must also be:
Robust and reliable
Simple for operators to understand and operate
Simple for maintenance and fault finding.
Cost effective
Built from the highest quality components to the highest specification.