Renovation leaves candy manufacturer with sweet taste

March 30, 2003
/ Print / Reprints /
ShareMore
/ Text Size+


Favorite Brands International moves from manual to automated as plant personnel test the input/output on a newly installed PLC at one of its Chicago plants.
Candy manufacturer Favorite Brands International of Bannockburn, Ill., needed to add capabilities to three production lines at one of its Chicago plants. Each line only allowed FBI to produce one product, one color, and one flavor at a time, store it off, move on to the next line, then manually blend everything back in prior to packaging. "To produce one packet of product, we would have to change over the whole processing system as many as six times," stated Pat McEvoy, former head of engineering at FBI. "Many times, that changeover would lead to lost production time."

FBI manufactures non-chocolate candies and snacks, including drops and mints, fruit roll-ups and gummi-type candies, as well as caramel-based candies and ingredient supplies. As a co-packer, FBI packages the majority of its non-chocolate candy products.

Looking to expand and automate their processing capability, FBI selected equipment that required a lot of design and utility work. "When you put in a complex processing system, if you don't have the proper utilities for it, it's not going to function properly," commented McEvoy. They turned to an old friend, Shambaugh & Son, L.P., Fort Wayne, Ind., for help. "We've done a half a dozen multi-million dollar projects over the last five years with Shambaugh, but this was more complicated due to the technology we were installing."

The project focused on phasing the installation of three types of equipment: color blending systems, cooking systems, and packaging systems. Each system was installed at separate times in an attempt to keep production up, according to McEvoy. "We couldn't take down any of the systems for extended periods of time, so we had to have each of the three basic components individually scheduled. It required a lot of integration of production scheduling, and demand planning." For Shambaugh, it required pre-fabrication.

A roof-mounted air-handling system constructed by Shambaugh & Son, L.P., controls the new air-conditioned cooling conveyors that send the product directly from the processing area into packaging.
"We pre-fabricated a lot of the piping, pumping and heat exchangers," said Mark Shambaugh, president of Shambaugh. "So rather than having the guys on-site, we did it in our fab shop, shipped it, and plugged it in." According to Shambaugh, pre-fabrication reduces the need to perform field engineering, which can add costs and downtime, as well as result in increased errors and poor quality workmanship.

Start-up of the new equipment was accomplished in a phased approach that met plant operations requirements established in the planning stage. The expanded processing system was implemented by the addition of more packaging machines and automated cartoning and case packing equipment. The new systems added more capability and flexibility to the equipment, improved the amount of rework because of the addition of more dosing and weighing systems, as well as freed up 40,000 square feet in the facility for future expansions. "What we basically ended up with was fundamentally a state-of-the-art processing system all the way through packaging," stated McEvoy.

Did you enjoy this article? Click here to subscribe to Food Engineering Magazine.

You must login or register in order to post a comment.

Multimedia

Videos

Image Galleries

Plant of the Year 2014

Blue Diamond Growers was chosen as Food Engineering's 2014 Plant of the Year. The Sacramento-based company is the world’s largest producer of almonds and almond ingredients.

Podcasts

Burns & McDonnell project manager RJ Hope and senior project engineer Justin Hamilton discuss the distinctions between Food Safety and Food Defense as well as the implications for food manufacturers of the Food Safety Modernization Act.
More Podcasts

Food Engineering

FE November 2014 Cover

2014 November

In the November 2014 issue of Food Engineering read about the Sustainable Plant of the Year, Smithfield Foods. Also, discover good reasons to consider a plant renovation project.

Table Of Contents Subscribe

FSMA Audit

What is the is most important step you have taken to become ready for a FSMA audit?
View Results Poll Archive

THE FOOD ENGINEERING STORE

Food-Authentication-Flyer-(.gif
Food Authentication Using Bioorganic Molecules

This text provides critical tools and data needed to augment routine food analysis and enhance food safety by aiding in the detection of counterfeit, and potentially deleterious, foods.

More Products

Clear Seas Research

Clear Seas ResearchWith access to over one million professionals and more than 60 industry-specific publications,Clear Seas Research offers relevant insights from those who know your industry best. Let us customize a market research solution that exceeds your marketing goals.

STAY CONNECTED

FE recent tweets

facebook_40.pngtwitter_40px.pngyoutube_40px.png linkedin_40px.pngGoogle +

Food Master

Food Master Cover 2014Food Master 2014 is now available!

Where the buying process begins in the food and beverage manufacturing market. 

Visit www.foodmaster.com to learn more.