Manufacturing News

Blender Reduces Waste by 80 Percent

March 26, 2003
/ Print / Reprints /
ShareMore
/ Text Size+
Bringing production lines up to full speed after a shutdown can cause off-spec product until processing parameters level off. Purina Mills' St. Joseph, MO, plant produces more than 150,000 tons per year of cattle, horse, chicken, hog and dairy feed. In an adjacent building, it also produces 4,000 tons per month of dairy pre-mix nuggets.

"We ship the 'nuggets,' or pellets, to other plants where they are used as part of a more complex feed," says Ed Cooper, maintenance manager at the plant.

While the nugget plant runs on a 24 hour, seven day a week schedule, processing lines periodically shut down for maintenance or changeover. "Restarting the processing lines invariably produces off-spec product until the hoppers and extrusion dies are full, and the dryers equilibrate at the appropriate temperature," notes Cooper. "During production some of the high fat/high protein product clings to the sides of the extruder, and comes off the fluidized dryer or cooler beds. The product is not contaminated, it is just not the right consistency or proper finished moisture." Under-processed product has the consistency of peanut butter, while semi-dried pellets are as low as 8 percent moisture.

Purina Mills was discarding almost five tons of product a day, sending it directly to a landfill, according to Cooper. "Our waste collection costs, reaching $4,000 per month, along with the lost product cost -- in excess of $100,000 -- was just unacceptable," Cooper says. The plant needed a way to liquefy the unusable product before portioning it back into the process. Cooper turned to Breddo-Likwifier for a solution.

A 300-gal. steam-jacketed mixer was installed on load cells and tied into the plant's PLC (programmable logic controller) system. "We start with 1,000 lb. of water in the mixer, heat it with steam then add about one ton of the off-spec batter and pellets," says Cooper.

Process-line PLCs were reprogrammed to automatically reduce water being added into a new batch, adjusting for addition of a portion of the reconstituted mass. Normal water quantities resume when rework addition is complete.

"We have had total success with the new system," says Cooper. "It is low maintenance, simple to operate and easily tied into current automation systems. As a result, we are reclaiming 80 percent of our waste as well as reducing landfill use."

Breddo-Likwifier Div., American Ingredients Co., 3947 Broadway, Kansas City, MO 64111. Tel.: (816) 561-9050; Fax: (816) 561-7778.

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

Fabulous Food Plant: Paramount Citrus

Learn more about this fabulous food plant in Food Engineering's article, found here.

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

What was your favorite part of FA&M 2014?

View Results Poll Archive

THE MAGAZINE

Food Engineering Magazine

Food engineering magazine 2014 april cover

2014 April

Catch a preview of the Powder and Bulk Show in this April 2014 edition of Food Engineering. Also, be sure to check out a coffee stick making a real stir and a major advancement in the the pet food industry.
Table Of Contents Subscribe

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.

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.

STAY CONNECTED

FE recent tweets

facebook_40.pngtwitter_40px.pngyoutube_40px.pnglinkedin_40px.png