Case studies show how our products perform in different industries and different material clogging problems.
This time it's about the excretion problem of whey protein concentrate (WPC), which has a very high water and fat content.
The cheese maker was in a very sticky situation. Whey protein concentrate (WPC) tended to bridge upon excretion. Unfortunately, this didn't just slow down production. A fire broke out in one of their baghouses due to caked material. Security bridging had to be resolved urgently.
[problem] Sticky Ingredients, Strict USDA Regulations, Production Shutdowns, No Whey Out!
Many factories use vibrators to remove whey proteins and other sticky substances. However, vibrators can actually exacerbate the bridging problem. By putting the material together and letting the air go down, you are packing the substance. It's like pounding a cup of flour on the table. This might work if you're baking brownies, but it won't work at all if your factory is trying to improve the flow of ingredients.
In addition, FSMA, USDA, and FDA standards and guidelines require food manufacturers to use only equipment designed to meet these stringent standards. A cheese company needed a safe, effective, and USDA-approved solution.
[solution] USDA approved air system cuts blockages and reduces production time
That solution was the Air Sweep USDA 135 . Unlike vibrators, which concentrate wet powders and ultimately damage the container, air sweeps use bursts of compressed air at high pressure and high flow rates. These pulses are like "air knives" that cut through even the thickest and densest material to clear blockages.
The Air Sweep USDA 135 is specifically designed for applications requiring hygienic equipment and frequent cleaning. Used by many food companies around the world, including powdered milk. A cheesemaker originally ordered three USDA 135 air sweeps for a baghouse hopper. These were attached using couplings and placed 120 degrees apart from each other.
Initial tests proved that Air Sweep worked well, with the exception of whey ingredients treated with "lecithin," which was more sticky and more soluble in water. They installed three additional units, including one positioned at the drop tube outlet. This solved the problem immediately and completely.
[results]
Best Whey: Cheese makers have replaced vibrators with air sweeps.
No bridging has occurred in the cheese maker since implementing Air Sweep USDA 135. We are currently implementing an air sweep system in all US factories.