1. Production line

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    Production line
  2. Product line

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    Products
  3. Logistics

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    Logistics
  4. Laboratory «BioLab»

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    Laboratory «BioLab»
  5. Foreign affairs

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    Foreign affairs
  6. Exhibitions

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    Exhibitions
Production Line
FUNCTIONAL DESCRIPTION OF PREMIX PLANT WORK.
Scheme and principle of work:
  • This scheme provides a complete view of Premix Plant principle work and capabilities.
  • Next step by step description of the process line sections


1. SECTION OF ACCEPTANCE AND STORAGE OF RAW MATERIALS
Acceptance and debagging of raw materials set through receiving Hopper TH01. Under raw materials understood fillers for premixes. Air supply system (BL01) fills 4 dosing bunkers of volume of 25 m3 each (total volume of storage/dispensing is about 100 m3) from the receiving hopper. Production of acceptance section is 20 m3 / h
Raw materials/fillers downloaded through the receiving hopper are able to pass through the magnet and cleaning shaker VS01. Raw materials stored in bags and «big bags» in warehouse.

2. DOSING SECTION (MACRO-INGREDIENTS)
This dosing section includes 4 dosing bunkers of 25 m3 each, feed raw materials contained in Article 1 (Section of acceptance and storage of raw materials). So 4x25 m3, total storage volume is about 100 m3.
Each bunker is equipped with a discharge hopper, made of reinforced steel sheet. Two bunkers unloading bunker unloading discharging activators for the products with poorly flowing. All four dischargers connected with unloading dosing screw conveyors.
Unloading screw conveyors connected with hopper of weigher DW01, productivity of 1000 kg.
The weighter is located directly under the dosing bunkers, equipped with discharge gate and a filling valve to deliver a prepared plumb/lot in an Air Conveying System PV01 with a following feed to the mixing section.
Control of dosing system and weighing system is carried out with weight control automatically. In case of force majeure it can be controlled manually.

3. DOSING SECTION (MESO-INGREDIENTS)
This dosing section includes 6 dosing bunkers of 9 m3 each. So 6x9 m3, total storage volume is about 54 m3.
Feed and filling of ingredients in these bunkers are carried out with mobile receiver TH02, equipped with its own filter system and dust control.
Each bunker is equipped with a discharge hopper, made of reinforced steel sheet. All 6 dischargers connected with unloading dosing screw conveyors which connected with weighter DW01, productivity of 1000 kg.
The weighter is located directly under the dosing bunkers, equipped with discharge gate and a filling valve to deliver a prepared plumb/lot in an Air Conveying System PV01 with a following feed to the mixing section.
Control of dosing system and weighing system is carried out with weight control automatically. In case of force majeure it can be controlled manually.

4. DOSING SECTION (MICRO-INGREDIENTS)
This dosing section includes 20 dosing bunkers of 0.45 m3 each. So 20x0.45 m3, total storage volume is about 9 m3.
Each bunker is equipped with a discharge hopper, made of reinforced steel sheet. 10 bunkers equipped with bunker unloading discharging activators for the products with poorly flowing. All 20 dischargers connected with unloading dosing screw conveyors.
First of ten unloading dosing screw conveyors connected with hopper of weighter DW02 – productivity of 10 kg and DW03 – productivity of 100 kg. Second of ten unloading dosing screw conveyors connected with hopper of weighter DW04, productivity of 10 kg and DW05, productivity of 100 kg.
The weighter is located directly under the dosing bunkers, equipped with discharge gate and a filling valve to deliver a prepared plumb/lot in an Air Conveying System PV02 with a following feed to the mixing section.
Management of dosing system and weighing system is carried out with weight control automatically. In case of force majeure it can be controlled manually.

5. MIXING SECTION
Complete plumb/portions come into the bunker over mixer MB01. This buffer weighing hopper is for storing plumbs/portions. Once finished the full portion, and there is no raw material in the mixer (empty), the monitoring sensor sends a signal to open the valve over the mixer. Ready portion arrives ( «falls» ) to the mixer for the following mixing.
Receiving hopper TH03 is provided for flexibility of the production process. It's used if necessary to add a small amount of components which are «lost» in bunkers of micro-dosing or if high accuracy in weighing these components on weighter of Dosing Section of micro-ingredients.
Mixer PM01 is a single shaft, blade, horizontal type with maximum efficiency. Volume mixer is 2000 l or 1000 kg; mixing time is 4 minutes or less. If necessary, the liquid components (technical fat or vegetable oil) are added when mixing. The injection of the liquid components is carried out through spray nozzles which are in the upper part of the mixer. Liquids feed is carried by dosing pump through the flow meter.
After the mixing process is over, the finished product (premix) enters the hopper below the mixer MB02.

6. PACKAGE SECTION (SACKING OF FINISHED PRODUCT)
From Hopper MB02 product arrives in a weighing storage bunker BU01 of half-automatic sacking section through an inclined screw conveyor.
Weighing and sacking machine operates in accordance with the «net weighing system» allowing to sack of 25 kg and 50 kg.
Under the weight hopper of Package section is chute with a clip for bags. The bag is sewn with Sewing machine SM01 after filling.

7. CENTRAL ASPIRATION SYSTEM (OPTIONAL)
Aspiration system of the whole Premix plant is one separate aspiration device with a fan CYF01-Fi.
This aspiration device removes a dust from the air through the automatically cleaned air filter. Dust collection is carried out in a storage bag, thereby minimizing the possibility of contamination and pollution.

CENTRAL MANAGMENT SYSTEM

Management of Premix Plant from Dosing Section to Section of finished products is carried out through program and logistics controller (PLC), inbuilt in the MCC. Acceptance of raw materials from bags and «big bags» conditionally controlled by a separate control panel with built-in buttons and indicator lights to indicate the position of valves (open or closed) and bunkers (empty or full), etc. Transportation systems are equipped with locking devices for maximum damage and prevent failure of the overflow or in cases of emergencies.
From Dosing Section PLC takes over and automatically manages portions through the transport system to the storage bunker of Sacking Section.
If necessary the liquid inlet (according to a predetermined recipe), all necessary processes are performed automatically.
Software is created based on Windows, which allows you to control the Plant through the computer.
In the production process, there is a possibility to view the updates of raw materials stock in the warehouse or diagrams of following portions process during production. In case of accidents, they are always displayed on the bottom line. Also generated on the computer:
  • production reports
  • reports of portions
  • consumer Reports (theoretical and practical)
  • Etc

It is possible to organize the production on the Plant.

If necessary, Management system can be expanded in the future. There is following panel of management on the Plant:
  • Acceptance of raw materials
  • Dosing/Mixing/transport to Package section
  • Sacking Section

This system allows one person to operate the Plant as efficiently as possible under any circumstances.