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PLP Systems pilot plant for continuous coating
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2+ MIN

PLP Systems pilot plant for continuous coating

There was a key change once a continuous coating test plant was developed in our company that can reproduce the full capacity of the industry demands, to minimize the difference in results between a laboratory test compared to actual production. This internal continuous coating test plant is used for: Technological innovation of PLP and know-how to compete in the market with the application of pellet coating. Customers looking for creative applications are available to perform testing and developing new products for your pet food by coating them with powders or flakes such as spices, vegetables, cheese, flavors, nutritional agents, etc. Too to coat semi-moist or baked pet food. Customers who want to test PLP technology before purchasing the system can perform the test of the complete coating line.     The pilot plant can be adapted for different products with a production capacity from 300 kg / h to 15 ton / h, managing different densities. It is equipped with a precise gravimetric continuous dosing of the main product (croquettes) carried out by means of a weighing tape or a weighing thread. Dosing of liquids by pump and flow meter and dosing of powders by weight loss feeders. All controlled by the automation and proportional dosing adjusted by frequency control drives. The test plant can be integrated with 3 different PLP coating technologies: DRUM ROTARY; COVER WITH DOUBLE AXLE BLADES; MASS SPIN COATER.   ROTARY DRUM       The latest development over the more traditional rotary drum, this machine is specially recommended for semi-wet products, small extruded or granulated pellets and lower production capacity. The special corrugated shape of the drum increases the rotation of the product, at the same time protects it from damage and reduces waste inside the machine, making it a perfect machine to be used in food application or with special kibbles for pet food.   CONTINUOUS COVER WITH DOUBLE AXLE PADDLES     It is our most widely used machine for standard pet food production and has received the majority of R&D improvements during the last years. There are different models that can cover all required production ranges with high liquid inclusion rates or fats. The focus of the machine is the retention time and this is achieved by regulations of speed independent of the axles, internal dampers and automatic check valve in the output of the product. The retention time in standard pet food production it can reach up to 200 seconds.   MASS SPIN COATER     Compact continuous cover used to add micro liquids up to 1%. The MSC integrates a continuous precision weighing technology, based on Coriolis forces. Thanks to a nozzle special is able to obtain a perfect homogeneity even when the inclusion rates are less than 0.1%.   Source: PLP Systems

KSE Process Technology  - Measures in Relation to the COVID19 virus
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2+ MIN

KSE Process Technology - Measures in Relation to the COVID19 virus

In relation to the COVID-19 virus, we try to support everyone who copes with these challenging circumstances and do our very best to service our customers as normal, while protecting the health of everyone involved. KSE highly values its continued 24/7 support to customers around the world. Our service employees remain available to provide remote assistance and advice as usual. However, current travel restrictions and regulations make it difficult to provide on-site support. That is why we only carry out work on location in case of emergency and only when it is possible to travel to – and work at – the plant safely. These measures will be in effect at least until April 6th, 2020; following the guidelines of the Dutch authorities. Please be informed that: We take responsibility for the health of our employees and will follow all regulations and guidelines to the best of our ability while we continue to service our clients. KSE works with local agents around the world who are often able to provide local support. These restrictions do not apply to cargo therefore, shipments will be carried out as planned. Our sales and service department will remain available by telephone, e-mail and social media. Where possible, we recommend the use of video call apps, as a temporary alternative to in-person meetings. We are always available for advice and support and aim to provide the best possible solutions and service, with the health and safety of all people as our highest priority. In case you have any questions, please do not hesitate to contact our representatives. With kind regards, Adriaan Smulders, CEO. KSE Process Technology B.V.

Protecting Pet Food ingredients with durable, accurate ingredient handling systems
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6+ MIN

Protecting Pet Food ingredients with durable, accurate ingredient handling systems

Many processing applications in the pet food and treat industry can be particularly harsh with high rates of very abrasive products, so equipment must be designed with tougher standards in mind from the ground up. In addition to being durable, equipment must be accurate, easy to clean and efficient to operate, and support food safety. Dave Carney, area sales manager at Bühler Aeroglide, Cary, NC, notes the increased sanitation requirements of today's equipment have driven changes in how they are designed. 'This requires more modularity and ease-of-access to enable customers to adhere to these demands,' he said. Jessica Stank, marketing manager for Lake Odessa, Mich.-based Automated Process Equipment Corporation (APEC), said the biggest trends she is seeing in material handling equipment are related to improvements in the level of efficiency they can provide. '[End users] are looking at ways to automate their process and are looking for equipment that is highly accurate and requires little human intervention to achieve the desired result,' she said. 'Thus, equipment manufacturers are making design improvements to help meet this demand for increased efficiency in processing facilities.' Improvements include specialty components such as capacitive load cell technology on weighing equipment, special bin designs and bulk bag unloaders with massagers or added vibration to assist with product flow. The biggest challenges stem from the types of ingredients used in pet food processing. Stank said certain common dry ingredients are prone to flow issues due to density or other characteristics, and liquids that contain fats and suspended solids can be challenging as well. Tanks that hold fats and oils often heat the liquids. Sensors designed to monitor ingredient levels must withstand harsh environments including a wide range of temperatures. 'Things like stainless steel contact surfaces, equipment that is fully enclosed with locking lids and automation programs that include track and trace technology have addressed concerns regarding safety and sanitation,' she said. Due to Food Safety Modernization Act (FSMA) requirements, pet food processing facilities have moved to food-grade equipment and components that have increased the level of sanitation in plants tremendously. Keeping ingredients contained inside fully enclosed equipment prevents fugitive particles from making their way into the air and onto the floor, which also improves worker safety. Steve Sawyer, factory sales, Dynatrol Division of Automation Products, Inc., Houston, said equipment needs to stand up to the harsh environments found in pet food and treat applications. 'Our customers handle large and small amounts of bulk ingredients and are requesting equipment to operate successfully on products having wider ranges of bulk densities and consistencies,' he said. Sawyer's company manufactures the Dynatrol DJT Level Detectors, which are sensors that provide information on product levels within hoppers, offering high-, intermediate- or low-level detection in temperatures exceeding 300 F. 'We have added a line of specialty coatings for detectors to protect components from steam cleaning and aid in decreasing build-up while not affecting sensitivity,' Sawyer said. This maintains the product's accuracy, decreases down time and increases productivity and product life. Joseph Cross, engineering and process manager, Zeppelin Systems USA, Inc., Odessa, Fla., said producers are demanding increased automation that reduces human interaction to provide labor savings and improves employee engagement by eliminating repetitive tasks. 'This has led Zeppelin to develop our Kokeisl dosing system, a way to dose ingredients in large and small amounts both very quickly and extremely accurately,' Cross said. Equipment manufacturers are challenged to deliver accurate amounts of ingredients quickly. One innovation to address this is a new valve design from Zeppelin.The Kokeisl system offers a unique discharge aid in combination with a large port and a fast-acting discharge valve that can be opened and closed from a 0 to 100% aperture in milliseconds, allowing a large flow of ingredients during the initial delivery followed by a very small trickle-feed to complete the batch with extreme accuracy and repeatability. 'By automating an increasing number of ingredients, many processes may be completed simultaneously, reducing the overall batching time and increasing the throughput of the line,' Cross said. 'Furthermore, increased automation allows for more accurate lot tracking of all major and minor ingredients, allowing for better inventory control and decreased reaction time in the rare case of recalls.' Batching systems Don Goshert, vice president and general manager, Sterling Systems & Controls, Inc., Sterling, Ill., noted the latest trends he is seeing are automatic and semi-automatic minor ingredient weighing/batching systems that dispense raw ingredients while tracking lot information and validating batched ingredient weights. 'Lot tracking with total ingredient material traceability is a requirement in many industries, particularly in the pet food, feed and agriculture, and food industries,' he said. Data collection and management of ingredients and batches from the feed processing batching control system has improved processors' ability to meet product safety requirements. For example, Sterling Systems engineers and produces customized batching control systems that can include as little or as much ingredient lot tracking and traceability as the customer wants to implement. It just depends on the customer's ability to fund and implement the tracking system, as several inventory strategies are available. Utilizing batching controls and automatic dispensing/dosing systems to handle minor ingredients can reduce or eliminate the need for reliance on personnel to manually track or document ingredient lots and weights. Automation streamlining improvements Processors are under pressure to maximize both throughput and accuracy. 'Increasing demand, custom ingredients and pet food quality enhancements have all driven the demand for increasing efficiency in the process controls and automation process systems that produce pet food, such as the minor ingredient batching systems,' Goshert said. The addition of both automation and highly accurate weighing technology can contribute to a major increase in accuracy in a pet food processing facility. 'By replacing a worker with a scoop and a scale with a computer and scale, it virtually eliminates the cost of human error,' Stank said. 'The addition of highly accurate load cells into the ingredient handling portion of the process ensures that costly ingredients are not wasted, and that the recipe is followed to the exact specifications time after time.' A mistake many pet food and feed processing plants make is attempting to justify the automation of all ingredients. Goshert said most successful operations justify ingredient batching automation by applying the 80/20 rule, as the quantity of ingredients is important, but the frequency of an ingredient's use also needs to be considered. 'If you use small doses of an ingredient in almost every formula, that ingredient may be a good candidate for automation too,' he said. When automatic systems are combined with semi-automatic ingredient processing — adding some ingredients by hand when instructed by the control system — justification can be achieved, Goshert added. Cross said equipment providers have been pushed by end users 'like never before' to provide systems that guarantee employee and food safety. 'Increasing levels of automation translates to reduced human interaction with individual ingredients and potentially hazardous equipment, reducing overall workplace injuries and improving batch accuracy and traceability,' he said. 'Also, as allergen concerns grow across the industry, fast and efficient CIP (clean-in-place) systems and the ability to fully sanitize and certify cleanliness has become more important to guarantee consumer satisfaction as well as product quality.' Heading to the future The need to design and maintain ingredient handling equipment for efficient sanitization is one challenge. Another is the evolution of the ingredients being used and how to convey them. These are both areas in which companies believe more innovation is needed. 'I could foresee being able to monitor surfaces for microbials and alert operators that a cleaning is recommended as a market request,' Carney said. Managing all possible data sources from one primary platform is becoming a priority in the pet food and treat industry. Goshert said integrating preventative maintenance planning software with ingredient batching and process controls is an important improvement. 'The demand for keeping the increasingly sophisticated and automated process systems and equipment running at optimal performance has never been greater,' he said. Localizing access to the preventative maintenance planning software from the shop floor or the corporate office area is key. 'Data tracking on the production floor integrated with ERP (enterprise resource planning) systems is essential to maximize benefits,' Goshert said. 'Processors should be sure to work with equipment and control and automation vendors that are on the forefront of data management and can provide complete data tracking with ERP integration.' Source: ADM & Pet Food Processing  

KSE to further Establish Presence in US market
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KSE to further Establish Presence in US market

The push for pet food and feed manufacturers to modernize their processing facilities is behind The Netherlands-based KSE Process Technology's plans to expand the company's presence in the US. KSE anticipates corporate mergers and acquisitions along with major technological innovations and automation will contribute to demand for the company's expertise in the North American markets.   ''Many of the [US] factories date back to the 1950s and 1960s and are primarily designed for bulk production. In the meantime, KSE is seeing an increasing demand in the US for specific animal feeds that can be produced in small series,' said Dennis van Lankeren, head of North American sales at KSE. 'The company therefore expects the American market to professionalize and innovate at an accelerated pace in the coming years. Large agrofood groups such as Nutreco are also becoming increasingly active in the US. This is a sign for us that substantial investments are in the pipeline.'' KSE is a technology company with a wide range of dosing and weighing machines, automation solutions and services for the global pet food and feed industry. To date, KSE's four projects in North America — three in the US and one in Canada — illuminated regulatory hurdles and unique challenges such as requirements differing from state to state, but Van Lankeren said KSE is establishing a presence in the US and getting to know the market better. 'We have already stationed a service employee in Ohio and the St. Louis region may follow soon. We are also considering setting up a local sales office so that we are even closer to the market. And in the longer term, we may have to set up a local production facility,' Lankeren said. KSE credits support from the Brabant Development Agency (BOM) in successfully making the step to North America. BOM has assisted KSE with establishing its American legal identity, meeting key business partners and developing a meaningful network in the US. Founded in 1973, KSE Process Technology is a global player in the field of dosing and weighing systems for the animal feed industry. From flour to maize, salt, vitamins and minerals, animal feed can contain up to 50 raw materials. According to the company, KSE's equipment, process lines and smart, future-proof software ensure that all ingredients end up in the finished product quickly and in the right dosage. The family business in Bladel, The Netherlands, employs around 160 people, including 20 R&D specialists. By Jennifer Semple

Is your factory up to the task?
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3+ MIN

Is your factory up to the task?

How demand for greater flexibility in pet food formulation requires us to improve our production process Growing complexity How do you cope with the countless changes in formulation driven by market demands, FDA regulations and marketing gurus? This ever-changing landscape of powders, meat inclusions and spices to feed our beloved four-footed friends? When talking about pet food formulation, we often focus on nutrition and optimisation. But what about the factories that manufacture these foods? Are they even up to the task?
Sadly, the answer is often no. While the possibilities and demands have increased
dramatically over the last decade, our factories are lagging behind. Recipes are complicated, and many ingredients must be added by hand, resulting in hard labour in dusty areas. To guarantee quality is always up to the highest standard, everything must be track and traceable, so we can know exactly where the food is produced, what went into it and when.
In short, our factories have changed from making a simple set of diets in long runs to a high complexity of formulations and processes in shorter runs, resulting in a
battle between our needs and production capabilities. How to cope? However, there is light at the end of the tunnel. As a specialist in dosing and weighing technology for pet food, KSE has a unique perspective on this dynamic and changing landscape and first-hand experience with developing solutions to cope with the challenges.
The company offers a robust portfolio of dosing and weighing technology, including its unique dosing slide, weigher in weigher systems, containerised systems and automation, together with a specialty blend of knowledge for the pet food, premix and feed industry, built on over 80 years of experience.
It is one of a handful of pioneering premium suppliers that have invested in new technology, building production facilities all over the world with a higher level of sanitation, track and traceability, accuracy and transparency, which it refers to as the "Factory of the Future". Make it future-proof Future-proof designs are here to enable the greater flexibility that is expected of a modern-day factory. For example, a dosing slide has major advantages over its well-known competitor: the dosing screw. With a much higher accuracy, higher dosing speed and larger dosing range it can easily outperform traditional systems. Furthermore, the movement of the dosing slide activates the product and reduces bridging and rat-holing.
The use of gravity, in turn, reduces power consumption, making it a greener solution and, combined with driving weighers, it achieves higher flexibility. Unique weigher-in-weigher solutions provide single gram accuracies, making it possible to dose grams up to hundreds of kilograms using the same systems.
Another major trend is containerised systems to use as a silo or to move product around the entire factory. This eliminates contamination during
transport or when exchanging ingredients and provides the ability to have multitype products for multiple species in the same lines. All this, combined with highend technology for data analysis and optimisation, enables you to process pet food like never before. Up to the task Look at your own process and ask yourself this: "Am I able to produce everything nutritionists think up in their
lab, accurately and traceably without contamination?" If the answer is no, you know you will have to act.
Getting your factory up to this task is not just a need, but mandatory to help your brand survive. The future truly is now. Source: KSE Process Technology B.V.

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