Manufacturing News

Four Bolts from Disaster

March 27, 2003
/ Print / Reprints /
ShareMore
/ Text Size+
In 1998, Pulakos Chocolates had a problem -- four bolts and shims were missing from a depositing plate on its new chocolate molding line running chocolate almond bars.

"We manufactured 25,000 bars that day," recalls George Pulakos. "The chocolate had already been wrapped, boxed and put in cartons." Finding the missing metal would be like finding a needle in a haystack.

Pulakos turned to Eriez Magnetics for a solution. Eriez brought in a model E-ZX Tec metal detector and began scanning the cartons. Once the case was identified, individual boxes were checked then individual bars. All four pieces of metal were retrieved, and the chocolate was shipped on time.

This experience prompted Pulakos to install Eriez metal detectors throughout the plant.

Three suppliers provide bulk chocolate coming into the plant in 1,500 to 2,000-lb. totes. After blending, the chocolate is pumped to various production areas for conversion into specialty confections.

"We have Eriez rare earth tube magnets in line with the pumps," notes Pulakos. "These help strain out metallic contamination originating either from the tanks, chocolate or other places." The magnets remove ferrous metal from dry and liquid products.

At the molding line, chocolate can be made into one of five different bars -- mixing in almond, rice, peanut butter, caramel or mint as well as plain. Eriez vibratory feeders deliver the mix-ins to the mixing cone accurately, reliably and economically, according to Pulakos. After the deposited chocolate bars set and cool, they are removed from the molds and packaged.

Despite the attentiveness of the personnel operating the molding line, Pulakos installed an E-Z Tec MPC (MicroProcessor Control) metal detector at the end of the line to scan the bars before packaging.

Pulakos also installed MPCTerm monitoring software that allows remote access and real-time diagnostic functions either elsewhere on the plant floor or in a centralized control room. This allows the company to have control and reporting functions directly from the same location as the process controls.

Fortunately, Pulakos averted potential disaster and took advantage of the lesson. "Using magnets and metal detectors helps to identify problems before major damage occurs to downstream equipment," notes Pulakos. "It also protects product quality and maintains productivity of the processing lines, saving time and money."

Eriez Magnetics, 2200 Asbury Rd., Erie, PA 16514-0608 Tel.: (814) 835-5000; Web site: www.eriez.com

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