Baking & Snack - March 2021 - 70

INGREDIENT HANDLING

Super sack unloaders
provide bakers with
greater versatility to add
new ingredients and
enhance the capacity of
the overall system.
Shick Esteve

plained. " This can drastically reduce batch time if a particular ingredient has been a bottleneck. The same thing can be
done for liquids. Large totes can be used in lieu of a bulk
tank. A good control and automation system for ingredient handling batching will ensure efficiency of the overall
system by performing material handling traffic control so
mixers are not waiting on ingredients. "
Older systems also can benefit from new digital options.
" Control system upgrades are arguably the best single
investment that you can make to improve a legacy system, "
Mr. Goshert observed. " A control system can automate a lot
of ingredient transfer issues and streamline the delivery. In
addition, it can provide valuable notifications of ingredient
levels and for reordering them. It can also send notifications of system operation abnormalities to prevent downtime and adjust system operations to maximize efficiency. "
To improve the bulk ingredient capacity, always make
sure to monitor the amount of ingredients in the silos, advised John Hunter, sales account manager, bakery and ingredient handling, B├╝hler Inc.
" Having inventory controls directly linked to your bulk
ingredient supplier, so that they can schedule deliveries
without needing to be advised by the baker, is a big plus, "
he said. " Also, it can be helpful to share production schedules with vendors so that they have an additional tool to do
proactive planning of their deliveries. This type of approach
enables the bulk silo capacity to be used more optimally. "

Running out of room
Expanding in restricted spaces poses several challenges,
particularly in older facilities. To solve these issues, companies need to look at their bakeries in a different way.
" Think about this problem in 3D to determine whether
there are options to install solutions on multiple levels to
achieve expansion, " Mr. Hunter advised. " Sometimes a
small penthouse extension can give real flexibility. When
developing an expansion solution with these types of

70 Baking & Snack March 2021 / www.bakingbusiness.com

constraints, having a multi-skilled team, process and mechanical engineers working together can provide another perspective. "
Mr. Adams suggested redesigning the system layout to
maximize the space available. Even then, it may require
some sacrifices.
" An example would be if you need to add sugar, salt and
flour to a mix, " he said. " If there is only room for two ingredient handling systems, then perhaps we can add a
pre-blend station above or elsewhere to combine the sugar
and salt beforehand to eliminate the need for space for this
specific equipment. We have also worked a lot on stacking
equipment vertically by building storage frames for blowers
and other equipment to maximize floor space. "
Mr. Schwartz recommended using an online monitoring system that comes with email or text message alerts
when flour, sugar or other ingredients reach a critical point.
Additionally, an internet-based connection to outside suppliers can signal when to refill silos automatically like a justin-time operation.
Day bins and other add-ons should also be considered as
an option to boost storage in the plant if space allows.
" Capacity of Gemini/KB Systems' indoor bins can also
be increased through the addition of a bolted bin tier extension, providing additional ceiling clearance is available in
the facility, " Mr. Schwartz said. " These KB bins lend themselves to 'starting small and growing with the business.' "
During the pandemic, there are other near-term ways to
avoid a major renovation.
" You could switch to bulk bag unloading with a 2,000-lb
bulk bag and have a direct or separate line going up into the
same hopper above the mixer, " Mr. Leach said. " You have
two lines. Hopper A is being filled with product A, and
hopper B is filling at the same time, so you're increasing
your capacity requirements by having not a bulk storage
silo system but a semi-bulk bag loading system. "
He added that variable-speed drives can fine-tune the ef-


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Baking & Snack - March 2021

Table of Contents for the Digital Edition of Baking & Snack - March 2021

Baking & Snack - March 2021 - Intro
Baking & Snack - March 2021 - 1
Baking & Snack - March 2021 - 2
Baking & Snack - March 2021 - 3
Baking & Snack - March 2021 - 4
Baking & Snack - March 2021 - 5
Baking & Snack - March 2021 - 6
Baking & Snack - March 2021 - 7
Baking & Snack - March 2021 - 8
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