Fluids Handling

The Lifecycle of an Ingredient Handling System

By Russell Davies, Principal Consulting Engineer of Systems Solution and Vice Chair of SHAPA

Phil Black - PII Editor 4 weeks ago

114 3 minutes read

Key points

Listen to this article

You might think that once you set up an automated ingredient handling system, you can just flip the switch and let it run forever. But that’s not quite how it works! To keep everything running smoothly and efficiently, you really need to pay attention to every stage of the system's lifecycle—this means design, procurement, installation, and ongoing maintenance.

Taking the time and resources to get things right from the start is crucial. You need to look closely at the characteristics of the materials you’re working with, the environmental conditions, and any physical limitations in your facility. Ignoring these factors can lead to performance issues right from the beginning.

The Importance of Material Characterization

One of the most vital—and often overlooked—parts of system design is material characterization. If you don’t have a solid grasp of how an ingredient behaves and flows, your process design is bound to face challenges. Unfortunately, this step often gets skipped because many end users hesitate to analyze their materials, and suppliers might shy away from extra costs to stay competitive.

As a result, systems often end up using fluidizing pads or vibrators to help discharge materials from vessels, relying on guesswork and general data. While there’s reliable information for common ingredients like flour, salt, and sugar, this method can become much less reliable when it comes to blended products, high-fat ingredients, or materials that absorb moisture easily.

Guessing during the design phase can lead to issues like blockages or lower conveying rates when it comes time to commission the system. At that point, fixing these problems can get pretty pricey. In fact, the costs of making changes after installation often far outweigh the expenses of doing proper material characterization right from the start. In these situations, both sides end up feeling the financial pinch: the end user might find themselves stuck with a system that doesn’t perform as expected, missing out on the return on investment they were counting on, while the supplier could face costs from rework, replacements, or even contractual penalties. So, it’s clear that preventing these issues is not only more effective but also more cost-efficient than trying to fix them later.

Defining Requirements Clearly

It’s crucial to have a detailed User Requirement Specification (URS). This document should clearly lay out the overall system needs, share insights from past experiences with similar setups, and pinpoint any operational limitations—without being too rigid. Over-specifying can stifle a supplier’s ability to come up with creative or optimized solutions. While suppliers usually have the technical know-how, they need to have a solid grasp of the boundaries they’re expected to work within.

Pneumatic Conveying: Vacuum or Blowing?

When it comes to pneumatic conveying systems, deciding between vacuum and blowing should be done on a case-by-case basis. Blowing systems typically provide higher conveying capacities and can cover longer distances, but they might come with challenges like temperature increases, air leaks, or product leaks. A trustworthy supplier should take a good look at the application and suggest a solution based on technical merits rather than personal preference.

Taking a closer look at supplier quotations through an independent assessment is definitely something to think about. Many clients might not be aware of the key questions they should be asking, which can lead to missing out on the best answers. While there’s an initial cost involved, having an independent evaluation can really pay off in the long run by making sure the core system concept is spot on from the get-go.

Maintenance: Safeguarding Performance and Productivity

Once a system is designed, installed, and up and running, it needs ongoing attention to keep it performing well. Preventative maintenance is crucial for ensuring reliable, long-lasting performance. If you skip the planned maintenance, you can bet that unplanned issues will pop up—usually in the form of blockages, breakdowns, and production halts.

A dependable ingredient feed system is vital for the entire production process. When it fails, everything comes to a standstill, leading to lost output and a hit to profitability. The cost of just one hour of downtime often far outweighs what you’d spend on regular maintenance.

Conducting annual inspections can significantly lower the chances of unexpected downtime by catching potential problems before they escalate. System performance can gradually decline without anyone noticing, but regular inspections help spot these changes early on. Once again, being proactive is much more cost-effective than waiting for something to break down.

System Solutions [Midlands] Ltd.
Tel: +44 [0] 7730 518-149
E-mail: rdavies@systsol.co.uk
www.systemsolutionsltd.co.uk