Automated Weigh Batching Increases Output, Saves Labor at Goya Florida

Each of the batching systems combines a bulk bag discharger and a flexible screw conveyor that feeds the ingredient into a pneumatic conveying line 55 ft long. The result of adding Flexicon’s efficient, labor-saving equipment has been an increase of 12.5% in production of blends per shift.

Powder processing simplified through automation

The process begins when one-ton bulk bags of seasoning are delivered by forklift to the bulk bag discharger, which is mounted on load cells. The operator connects the bag loops to a lifting frame at floor level and, using a pendant controller, loads the bag into the discharger frame by means of a hoist and trolley travelling on a cantilevered I-beam.

The operator then makes a dust-tight connection to a clamp ring atop a telescoping tube, and unties the spout drawstring. The telescoping tube applies continuous downward tension on the bag as it empties and elongates, promoting flow and evacuation of the seasoning.

Here are three of the five bulk weighing and batching systems at Sazón’s Miami-area plant, each comprised of a bulk bag discharger on load cells, that move seasoning from bulk bags through a pneumatic conveying line to five blenders.Flexicon

The seasoning, comprised of fine white crystals, flows into a 5-cu-ft floor hopper charging an integral 5 ft long, 3.5 in. diameter flexible screw conveyor. The conveyor propels the product at an incline, discharging through flexible downspouting into a pickup adapter feeding a 2.5 in. diameter pneumatic conveying line.

Load cells supporting the bulk bag discharger transmit loss-of-weight signals to a PLC that controls the batch weight of the seasoning. “We just input the information into the panel, say 2,000 pounds, and that’s it,” Carlo says.

Upon receiving the signal, the inclined flexible screw conveyor feeds the seasoning into the pickup adapter. From there, the material travels 55 ft horizontally and 15 ft vertically to a 24 in. diameter filter-receiver that discharges into a 2.5 cu ft hopper.

Here, an operator at Sazón uses a pendant to hoist a bulk bag and roll it into position.Flexicon

Delivery of the seasoning slows and stops automatically when the weight lost from the bulk bag reaches the target batch weight. A rotary airlock valve simultaneously discharges the batch into the blender through downspouting, as minor ingredients are added manually.

After 30-minute blending cycles, the batch gravity discharges through a slide gate and passes through a check-sifter before flowing into a hopper from which a flexible screw conveyor feeds a packaging line. Foil-lined packets of seasoning and bouillon are formed and filled with 5 to 10 g of material, and heat-sealed at rates of 1,000 to 1,500 per minute.

The packets are inserted into a carton that passes through a checkweigher, is coded, and moves to an accumulator for placement into a master case. In the final step, two palletizers consolidate the master cases for shipment.

Less labor, higher output

By adding five Flexicon weighing and batching systems, Sazón can operate two shifts that process 35 seasoning and bouillon batches per shift—compared to 21 batches previously—with only five operators needed for batching, blending, packaging, and shipping.

Blended batches of seasoning and bouillon powder are gravity discharged into a polymer surge hopper and flexible screw conveyor that feeds a packaging machine. The fully enclosed system prevents contamination of the product and facility environment.Flexicon

“We package more than a billion [seasoning and bouillon] packets a year now, and we’re much more comfortable,” notes Carlo. “No worker fatigue, and far less time dumping bags manually. It’s a more efficient way to make our products and it’s making our lives easier.”

Looking ahead, Carlo says Goya has identified a satellite facility near the Miami-area plant, where Sazón can add production capacity, “and build on the automation work done with Flexicon to test new procedures that will reduce material handling and enhance food safety and quality control initiatives.”