FoodTech A clean-cut road from constant improvements to everyday food

Transcription

1 FoodTech A clean-cut road from constant improvements to everyday food flexlink.com info@flexlink.com FlexLink EN

2 FOODTECH FoodTech is the intersection of food and technology, aiming to provide applications that improve food production. FlexLink has almost 40 years of experience delivering turn-key solutions to the food industry, and is the perfect partner when facing your production challenges. We are world-class factory automation experts within the food industry. Working closely with customers, we provide innovative, automated solutions to produce goods smarter, safer and at lower operating costs. With a dedicated FoodTech team, we support the industry directly in over 31 countries and are represented in more than 60. We offer a payback time of less than six months compared to other alternatives! FlexLink is part of Coesia, an innovation-based group consisting of 21 companies specialized in automated machinery and industrial process solutions for fast moving consumer goods and food products. Coesia is a group of innovation-based industrial and packaging solutions companies operating globally, headquartered in Bologna Italy, fully owned by Isabella Seràgnoli. Coesia companies are leaders in the sectors of: Advanced automated machinery and packaging materials Industrial process solutions Precision gears Coesia customers are leading players in a broad range of industries, including Aerospace, Consumer Goods, Electronics, Healthcare, Luxury Goods, Pharmaceutical, Racing & Automotive and Tobacco. Coesia Group consists of twentyone companies: ACMA, ATLANTIC ZEISER, CERULEAN, CIMA, CITUS KALIX, COMAS, EMMECI, FLEXLINK, G.D, GDM, GF, HAPA, IPI, MGS, MOLINS, NORDEN, R.A JONES, SACMO, SASIB, TRITRON, VOLPAK. The Group is present in 32 countries with 64 production facilities in 106 operating units, has a turnover of 1,586 million Euro in 2017 and about 7,600 employees. coesia.com

3 WE IMPROVE YOUR PRODUCTION AND PROFIT OEE INCREASE Minimum 1% increased OEE through excellent product and technical solutions CLEANING RESULTS Consistent results and reduced number of re-cleans by up to 90% RAMP-UP TIME Gain 2% higher throughput by minimum 1 week shorter ramp-up time FLOOR SPACE Save 20-40% CLEANING TIME Minimum 25% reduced cleaning time

4 A ROCK SOLID PARTNERSHIP Our knowledge of processes and solutions comes from almost four decades of working closely with machine manufacturers and food producers. Together we identify the true needs, map the value streams and define the optimized flows and solutions. How we work Applying lean principles Focusing on true needs Providing innovative solutions Offering shortest payback time

5 READY MEALS - PANCAKES DOUBLE THE VOLUME WITHOUT COMPROMISING ON HYGIENE OR FLEXIBILITY Customer needs Sensitive product handling Open food environment Good working conditions Short production stop for installation Solution FlexLink solved the lack of space using the entire volume in the factory, by installing conveyors from floor to ceiling. Since the pancakes and crepes were unpacked and delicate it was of high importance that the handling of the products went smooth and friction-free. To ensure a safe transfer of the product from one conveyor to another, careful tests were made at FlexLink s facility. The installation of easy-to-clean conveyors fulfilled the customer s need of excellent hygiene. The short time frame for the installation was a challenge. The target to finish the installation within six weeks was achieved and the production only stood still for ten days. Thanks to close communication and detailed planning, FlexLink managed to fulfill the customer s expectations. Result Compact solution Effective and consistent cleaning results Reduced number of recleans with 90% Gentle handling and transfer of products

6 DAIRY - MILK SAVING UP TO 40% FLOOR SPACE Customer need Free up floor space for new filler Full flexibility between fillers and packers Short installation time Solution To manage the short time plan, FlexLink started assembling the conveyors in the ceiling in advance, to save as much time as possible. When it was time for installation, everything was already in place, and the implementation was done according to schedule. Despite limited space in the ceiling due to ventilation, pipes and pillars, the modular conveyor system could be adapted to these circumstanses. Preparation, planning and communication were crucial for the success of this project. Thanks to the overhead solution, valuable floor space was made available to increase factory capacity. Result Increased floor space, allowing installation of new filler A more open and accessible production floor increased operator efficiency Lowered maintenance costs compared with previous solution The expected outcome of this installation was to gain floor space, and we really did. Elevating the conveyors made a big difference in our narrow premises. The available floor space got much bigger, actually bigger than expected. We have saved a lot of time for the operations since the employees can, in an easy way, move around in the factory. We have also been able to put in additional machines, says the Technical Manager.

7 DAIRY - MILK REDUCING TIME FOR CLEANING WITH 25% Customer need High flexibility between fillers and packers Robust conveyor system with state-of-the-art controls Improve the hygienic conditions in the filling area Low maintenance cost Solution FlexLink designed a conveyor system combined with a washing program, customized for the specific hygienic needs. To secure a short production stop, conveyor sections were pre-assembled in FlexLink s own workshop, and the sections were then lifted into the factory. A technical challenge in this project was the limited space in the factory. FlexLink designed a compact solution, where the conveyors were installed in many different levels. Although the space was limited, the solution was flexible. To decrease back pressure from the packages queuing up on the conveyor FlexLink applied dynamic control of the conveyors speed. In the old system, they used water and soap to reduce friction and back pressure. But with this new solution it was no longer necessary, and in addition, it became more cost effective. Result Automated and effective cleaning process Compact solution Lowered production costs, i.e less water and detergents

8 DAIRY - CHEESE INNOVATIVE SOLUTIONS AND INCREASED AUTOMATION, ENABLED FOUR TIMES HIGHER THROUGHPUT Customer need Increase capacity and volumes Increased automation level Lower production cost Turn-key supplier Solution In this project, where many parameters were being changed at once and with many suppliers involved, excellent communication became a critical factor for success. Discussions covered everything from increased volumes, how the facility was built, how to optimize the production flow, budget constraints and how many operators they could afford. FlexLink s solution met the strict requirements on hygiene, part of which included installing conveyors in a new zone specifically for the handling of opened and unpackaged cheese. Furthermore, in meeting the unique needs of the customer, FlexLink used robots to handle the cheese in trays, a new innovative way to increase productivity. Result Increased capacity from 35 to 140 ppm Increased product quality due to excellent hygiene and cleaning results Reliable automation

9 FOOD PRODUCTION SOLUTIONS Our food production solutions increase your production effectiveness and are designed with food safety and operators in mind. The layouts are compact and the equipment is easy to maintain and relocate. We handle your products gently and the design reduce the contamination risks and support effective and consistent cleaning. Our FoodTech offer includes a toolbox of products and services: Line design Conveyor equipment Product manipulations Line balancing and controls

10 OUR FOODTECH TOOLBOX Chain conveyors Our chain conveyor systems in stainless steel are robust and follow a proactive approach to increase cleanliness, minimize crevices and maximized drainage. 70/85/180/300 mm beam width Up to 120 m/min Operational temp. -20 C to +60 C Chain washer unit CIP unit Line balancers By balancing the flow you can optimize total line effectiveness (OEE) and protect your bottleneck. It can also eliminate unnecessary back pressure and reduce the risk of damaging the products. Dynamic buffers High speed mergers and diverters Modular belt conveyor system The modular wide belt conveyors address important aspects such as quick and easy cleaning, gentle handling of products, operator safety, long service life, and low cost of ownership mm belt width 40 m/min Operational temp. -20 C to +60 C Chain lifter unit 3-A qualified and EHEDG compliant conveyor Elevators By elevating your production flow, valuable floor space is reclaimed. This allows you to add more production capacity or increase the accessibility for your operators. For the food and dairy industries wedge elevators and incline conveyors are available in stainless steel. Line control The standardized controls system is flexible and easy to adapt and expand for new systems or existing lines. This gives you minimal programming of functions which improves your engineering efficiency as well as fast and easy installation. FlexLink controls system supports PackML (Standardized Packaging Machine Language). Cleaning devices Downtime is lost production time. Cleaning must be quick and efficient with the possibility to easily verity the results. FlexLink supplies various cleaning solutions for wet and dry production. Chain washers Chain washer and dryer units Clean In Place (CIP) Chain lifter unit