To meet the evolving market trends towards single-portion packages, the food processing industry needs packaging machines with advanced features such as flexible materials, variable sizes, high speeds, and low reject rates. However, this shift towards smaller packaging sizes also demands adjustments in processing technology to maintain efficient production.
Therefore, food processors, especially those dealing with high-value snacks, must invest in adaptable transfer systems that guarantee gentle and sanitary movement of specific quantities through various production stages. With the demand for single-serving portions on the rise, the food processing industry has adapted by implementing advanced features in packaging machines. These machines offer flexible materials, variable sizes, high speeds, and low reject rates, ensuring efficient production.
This requires food processors, especially those handling high-value snacks, to invest in adaptable transfer systems that guarantee gentle and sanitary movement of specific quantities through various production stages.
When it comes to sensitive products like nuts, chips, and small packages of coffee, cereal, and dry pet food, packaging and processing companies face the costly issue of material damage and loss. Even a small difference of 1% in waste compared to 5% can greatly impact the bottom line. To prevent such losses, packagers, and processors need to avoid using conveyors that may put the fragile products through stressful phases during transport, risking their integrity.
This has led many companies to consider alternative methods such as using high-velocity air power through tubes, bends, or sweeps to convey delicate and valuable products before dumping them into bins or containers. For instance, in the coffee industry, where whole beans are carefully roasted, processors spare no expense to ensure product quality. Using high-velocity air power to transport delicate products like nuts, chips, coffee, cereal, and dry pet food offers packagers and processors a cost-effective solution to prevent material damage and loss.
With potential savings of up to 4%, this method avoids the use of conveyors that may put fragile products at risk during transport. By choosing this alternative method, companies can maintain the integrity of their products and ensure the highest level of quality for their customers.
When a macadamia nut is cracked, its value may decrease by half. Instead of being sold at a premium price, damaged nuts are often sold at a significant discount and used in cooking or further processing in the food packaging industry. Many high-value foods are delicate and require careful handling to avoid breakage or pulverization. This can severely decrease the value of the product, and damaged portions may need to be removed to prevent customers from switching to other brands due to perceived quality issues.
In some cases, high-speed air-powered systems can damage over 10% of delicate products. This adds to the packaging industry’s costs, as this damage often occurs after substantial value has been added and is compounded by the poor selection of transfer equipment. Increase your product’s value and protect your brand using delicate, high-quality ingredients. Our expertly crafted macadamia nuts ensure that you get the best flavor and quality without any damage or waste.
With our advanced handling systems, we guarantee that only a small percentage of delicate products are lost during processing, saving you money and preserving your product’s value. Trust us to give you the best ingredients and packaging solutions for your business.
The Limitations of Air Conveyors
Food packagers and processors should be aware that pneumatic and aeromechanical systems, while efficient for conveying food products at high speeds, can damage fragile and valuable goods. Whether using dilute phase or dense phase conveyors, which differ in speed and pressure, it is important to regularly replace filters and minimize bends and sweeps in the system. While aeromechanical conveyors have a unique method of transport, their high-capacity mechanical design can also degrade delicate products.
Therefore, all fragile and friable foods should be carefully handled during high-speed conveyance to prevent damage. Protect your fragile food products during high-speed conveyance with our carefully designed, high-efficiency conveyors. Whether using dilute phase or dense phase conveyors, our systems are equipped with regular filter replacements and minimal bends and sweeps to ensure the safe transport of your valuable goods. Trust our expertise to keep your products intact during transportation.
A Gentler Approach Boosts Profitability
For the safe transportation of delicate, high-value packaged food items, tubular cable conveyors are a recommended alternative. These conveyors use a sealed tube and a coated, flexible stainless-steel drag cable to move products at low speeds without the use of air. This prevents damage and waste, making them suitable for use in the packaged food industry for items like snacks, nuts, cereal, coffee, pet food, beans, and seeds.
These systems can handle up to 2,000 cubic feet per hour (56m3/hr.) of various product types, such as flakes, pellets, shavings, crumbles, granules, regrind, chunks, parts, prills, and powders. Unlike air-powered conveying systems, tubular cable conveyors can safely transport sticky or easily compacted materials without causing blockages. Their modular design also allows for easy customization and expansion, making them an ideal choice for packaging lines. Safe, efficient, and versatile transportation for delicate and high-value food products.
With a design specifically meant for the packaged food industry, these conveyors can handle a range of items such as snacks, nuts, cereal, coffee, and more. Able to move up to 2,000 cubic feet per hour at low speeds, these systems prevent damage and waste. Their unique tubular cable design allows for the transportation of sticky or easily compacted materials without the risk of blockages. Plus, the modular design makes them customizable and expandable to fit the needs of any packaging line.
Less Energy Use, Less Noise
When implementing pneumatic conveying systems in food packaging and process lines, larger and power-hungry motors are often required to run fans, blowers, and rotary valves due to the high velocity at which products are conveyed. Additionally, compressed air is necessary for the operation of the pressure tank, resulting in even more power consumption.
Furthermore, pneumatic systems generate significant noise, especially aeromechanical systems that run at high speeds. In comparison, tubular cable systems utilize smaller motors and are much quieter, making them more suitable for having conversations around them while in use. These systems also consume less energy, utilizing only about one-tenth of the energy used by pneumatic systems.
Switching to a tubular conveyor can result in significant electricity savings, with some cases seeing a return on investment within a year in terms of energy efficiency. Compared to traditional pneumatic conveying systems, highly efficient tubular cable systems offer a lower energy consumption rate, generate minimal noise, and utilize smaller motors. This results in not only quieter operation for a more comfortable working environment but also significant savings in electricity costs.
In some cases, the system can pay for itself in just one year due to its superior energy efficiency. With a tubular conveyor system, you can benefit from a quieter, more energy-efficient solution for your food packaging and process lines, without sacrificing performance.