How to Improve Food Processing Without Overhauling Your Entire Plant

Start With the Actual Process

When throughput falls short, the immediate reaction may be to add equipment or increase batch capacity. That may be the right decision, but first determine whether the plant has a true capacity limitation or a process-flow problem.

Follow a typical batch from ingredient loading through processing, discharge, cleaning and downstream filling or packaging. Look for points where:

• Product regularly waits between operations
• Operators must intervene to keep a batch on specification
• Heating or cooling takes longer than expected
• Cleaning or changeovers disrupt the schedule
• Downstream equipment limits upstream production

This review can identify the actual constraint before time and capital are committed to a solution.

Evaluate the Complete Batch Cycle

Batch time includes more than mixing. Loading, heating, cooling, ingredient incorporation, holding, discharge and cleaning all affect the number of batches a plant can complete during a shift.

Reducing time in one step provides limited value if the vessel still waits for a filler, or cleaning remains the longest part of the cycle. In some applications, improving heat transfer, discharge or production sequencing can create more usable capacity without increasing vessel size.

The goal is not simply to make one piece of equipment operate faster. It is to improve the flow and consistency of the entire process.

Match the Equipment to the Product

Mixing performance depends on a number of key variables, including product viscosity, particulates, vessel geometry, agitator design, scraper coverage and heat-transfer area. Increasing batch volume without accounting for these variables can result in longer cycle times, inconsistent mixing or changes in product quality.

If operators routinely extend mixing time, adjust ingredients or manually correct temperature and texture, the process may not be properly matched to the product.

An equipment review should consider:

• Product viscosity throughout the batch
• Size and fragility of particulates
• Required heating and cooling rates
• Agitator type, speed and flow pattern
• Working volume and discharge characteristics

The best solution is not necessarily the largest vessel. It is the system that repeatedly achieves the required product result while supporting production goals.

Focus Improvement on the Real Constraint

Once the primary constraint is identified, compare potential improvements using measurable operating data such as:

• Total cycle time
• Labor per batch
• Cleaning duration
• Yield
• Downtime
• Overall line throughput

Using measurable operating data provides a stronger basis for deciding whether the plant needs a procedural change, equipment modification, additional vessel or larger process-system investment.

For a more in-depth look at practical ways to improve your food processing operation, download Lee Industries’ How to Improve Food Processing: A Practical Playbook.

And feel free to contact us to discuss your specific challenges with one of our Applications Engineers.