Overview
A large-scale cocoa processing operation supplying ingredients to multiple food and confectionery markets needed to adapt its production line to support new customer requirements. While the facility already operated advanced sifting equipment, evolving packaging demands exposed inefficiencies in the existing process.
To maintain product quality, reduce handling complexity, and improve workplace safety, the operation sought a permanent system redesign that would eliminate frequent reconfiguration and support multiple packaging formats simultaneously.
Challenges
The cocoa processing line faced several operational challenges:
- Frequent changes to bagging and measuring requirements
- Production downtime caused by repeated system reconfiguration
- Labor-intensive changeovers involving heavy equipment movement
- Excessive cocoa dust during packaging operations
- Loss of valuable product during bulk bag filling
- Safety risks associated with manual handling and cleanup
The lack of a purpose-built bulk packaging solution made it difficult to meet customer needs efficiently and consistently.
Solutions
An integrated sifting and bulk packaging system was engineered to permanently reconfigure the production line for flexibility and efficiency.
Key elements of the solution included:
- A rotary sifting system to maintain consistent cocoa powder quality
- A heavy-duty airlock to control product flow between processing stages
- Dual bulk bag filling stations to support multiple packaging formats
- Automated controls to streamline operation and reduce manual intervention
- A system layout designed to eliminate frequent changeovers and equipment movement
The solution consolidated previously separate processes into a unified, purpose-built system.
Results
The redesigned sifting and packaging system delivered significant operational improvements:
- Streamlined production with fewer process interruptions
- Improved efficiency through simultaneous sifting and bagging operations
- Reduced labor requirements and lower cleanup effort
- Elimination of product loss during bulk packaging
- A safer, cleaner, and dust-controlled work environment
- Increased overall profitability through improved process control
The operation gained the flexibility to meet diverse customer requirements without sacrificing efficiency or product quality.
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