The Challenge: Inefficient and Labor-Intensive Batching
In the fast-paced world of beverage manufacturing, efficiency and precision are paramount. Yet, many processors grapple with outdated and labor-intensive batching processes that hinder productivity and increase operational costs. One such beverage manufacturer faced significant challenges in their batching protocol, which required operators to carry and dump hundreds of pounds of powders from 50-pound bags into a conventional “premix” tank batch mixer on an elevated batch deck. This cumbersome process not only slowed down production but also posed serious ergonomic risks to the operators.
The manufacturer needed a solution that would allow them to produce products faster, use less energy, and improve operator safety, all while maintaining the high quality of their beverages. Furthermore, they sought to reduce product loss across diverse batches ranging from 100 to 30,000 gallons, which included a wide array of ingredients such as gums, stabilizers, plant proteins, vitamins, minerals, sweeteners, and more. The operational hurdles were mounting, and they needed an innovative solution to streamline their processes.
Introducing the Admix Fastfeed System
Enter the Admix Fastfeed® system, a revolutionary inline powder induction and dispersion system designed to tackle the most demanding batching challenges. Our team of experts conducted a thorough batching audit and identified the Fastfeed system as the ideal solution for the beverage manufacturer's needs. The Fastfeed system is a fully integrated solution that features a two-stage rotor/stator high-speed disperser coupled with a powerful powder suction pump.
This unique combination enables high liquid flow and controlled vacuum induction, ensuring that powders are instantly and completely wetted and dispersed at the particulate level. The result? No unmixed ingredients reach the downstream blend tank, and emulsions in the 3-5 micron range are routinely produced. The Fastfeed system is not just an upgrade; it’s a game-changer for any manufacturer looking to enhance their batching processes.
Streamlining Operations: How Fastfeed Addressed Key Pain Points
The installation of the Fastfeed system brought immediate and noticeable improvements to the beverage manufacturer’s operations. Operators could now induct, wet, disperse, and hydrate all powdered ingredients in a single pass, with induction rates exceeding 450 pounds per minute. This efficiency allowed highly used powders to be inducted from bulk sacks, while other powders could still be added from 50-pound bags—all from the safety and convenience of floor level.
Moreover, the Fastfeed system enabled the induction of liquid flavor concentrates and purees from pails, drums, and totes without needing additional pumps. This versatility not only streamlined the process but also significantly reduced the physical strain on operators, enhancing workplace safety and ergonomics.
Unparalleled Efficiency and Energy Savings
One of the standout benefits of the Fastfeed system is its ability to drastically reduce energy consumption. By eliminating the need for time-consuming recirculation loops and delivering smooth, lump-free products with each batch, the system ensures that no energy is wasted on inefficient mixing processes. In fact, the beverage manufacturer observed a 70% reduction in energy usage after implementing the Fastfeed system.
Furthermore, batch times were cut in half, allowing the manufacturer to meet increasing demand without compromising on quality. The elimination of dusting from dumping powders into open-top mix tanks also contributed to a cleaner and safer working environment, reducing the risk of contamination and improving overall product integrity.
Enhanced Product Quality and Consistency
Consistency is key in beverage manufacturing, and the Fastfeed system excels in delivering uniform product quality across all batch sizes. By ensuring that all ingredients are thoroughly mixed and dispersed at the particulate level, the system eliminates batch-to-batch inconsistencies that can arise from manual powder dumping.
The manufacturer no longer needed downstream strainers and filters, as the Fastfeed system consistently produced smooth, lump-free products. This level of precision not only enhanced the quality of the beverages but also reduced the need for costly rework and product loss. The reduction in air entrainment further improved the texture and stability of the final product, ensuring that each batch met the highest standards of quality.
Achieving Rapid ROI and Long-Term Benefits
Investing in the Fastfeed system proved to be a financially savvy decision for the beverage manufacturer. The system delivered a return on investment in less than one year, thanks to the significant savings in energy, reduced batch times, and minimized product loss. The long-term benefits of the Fastfeed system extend beyond immediate cost savings, offering a sustainable solution that supports ongoing operational improvements and growth.
With the Fastfeed system, the manufacturer can now produce any batch size required with unparalleled efficiency and consistency. The system’s versatility and reliability ensure that they can continue to innovate and expand their product offerings without being constrained by outdated batching processes.
Conclusion
The Admix Fastfeed® system has revolutionized the beverage manufacturing process for countless processors, delivering unmatched efficiency, energy savings, and product quality. By addressing key operational pain points and providing a comprehensive solution, the Fastfeed system empowers manufacturers to achieve their production goals with confidence and ease.
Is the Fastfeed system right for your process? Discover how this innovative solution can transform your operations by contacting us for a quote or learning more about our trial program today. Let us help you take your manufacturing efficiency to the next level.