Material Handling System

MAPL's multiple liquid dosing system handles multiple passive liquids used in Foods industry like water, HVO butter, palmolien, HVO & lecithin glucose, milk solution etc. Accurate dosing of each of these liquids is important to achieve product quality and consistency. This is achieved by drawing right quantity of each of them from the respective manifold one by one into a pressure vessel mounted on Load Cell. Finally the liquid mix is dosed into multiple mixers running on different recipe. Accurate dosing and record of liquid used by batch by product is maintained by the system. System offers convenience and pay Back. Accuracy of ±100 grams over 70 kg. is achieved.

Benefits of Liquid Dosing System :-

• Complete automation eliminating human error and human presence.
• Very High dosing accuracy achieved.
• Consistent product quality and better hygiene.

Accurate dosing of minor ingredients in food industry is very essential. All along these operations were done manually batch by batch. PLC controlled MAPL chemical dosing system offers excellent solution with pay back, bringing in consistent quality into the product. 25Kg. of each chemical is loaded into respectively feeders. Each feeder is controlled by a frequency drive. Each chemical is fed into the Foods Grade FRP Pressure tank mounted on load cell one by one. Proper amount of water is added and the chemicals are stirred and dispensed into the cookers or mixer using air pressure or gravity. Chemical Dosing System is catered for multiple products and multiple line system. Dosing accuracy is ±10 grams over 5kg.

Benefits of Chemical Dosing System :-

• Accurate dosing thereby maintaining consistent product quality.
• Saving in manpower and higher productivity.

Accurate dosing of sugar is very essential to get consistent product quality in food industry and MAPL's PLC based sugar handling systems handles sugar & broken biscuit dosing very accurately in multiple product and multiple line running system. Sugar can be taken from bags or silo and transferred into service silo using air blower. Each mixer has a separate electronic tagged trolley. The trolley is placed on flush mounted weighing scale. As per the trolley and corresponding recipe running at the mixer sugar is discharged into trolley. Correct quantity of biscuit dust can also be added simultaneously. Accurate records are maintained batch wise, mixer wise, product wise etc.

Benefits of Sugar Handling System :-

• Accurate and hygienic charging.
• Fully automated hence saving in manpower.

MAPL's butter handling system makes it easier to handle frozen butter. The frozen butter block is lifted and tilted using butter tilter into the butter mixer. The mixer has a knife edge grille which is electrical induction heated. The butter is cut and passes into the butter mixer where it is tempered using circulation of tempered water. The tempered butter is pumped using SS screw pump into a load cell centre. PLC controller is used to cater to multiple demand centre working on different recipes.

Benefits of Automated Butter Handling System :-

• Accurate quantity of butter dispensed.
• Consistent product quality maintained.
• Cost saving due to manpower reduction and handling losses.
• Increased productivity.

Hydrogenated fat and lecithin are required to be mixed together in set quantity and then dosed into the dough mixers. MAPL developed a system called FAT and Lecithin Handling System whereby the HVO in liquid form and lecithin are drawn from the service tank and mixed in mixing tank. A circulation pump is used to continuously circulate the mixture. The mixture is then pumped into lecithin diluted tank. From here the mixture is pneumatically pumped into process demand center. The PLC is programmed to handle multiple process demand centers each of them operating with different recipe. The PLC mixes and pumps out correct quantity as per the recipe running at the process demand center.

Benefits of FAT and Lecithin Handling System :-

• Handling losses and shop floor spillages eliminated.
• FAT and Lecithin Handling System being a closed system excellent hygiene maintained.
• Since accurate quantity of mixture dosed, consistent product quality maintained.
• Increased productivity.
• Human errors avoided in terms of mix or mixing quantity dosing.

Hydrogenated Vegetable Oil (HVO) needs to be mixed with palmoline and then dosed into the dough mixers. MAPL has developed PLC based system whereby correct quantity of HVO and Palmoline are taken by the PLC into the dosing tank. After stirring, the mixture is pneumatically pumped to the process demand center. The PLC is programmed to handle multiple process demand centers each of them operating with different recipes. The PLC mixes and pumps out correct quantity as per tile running recipe at the process demand center.

Benefits of HVO and Palmoline Handling System :-

• Shop floor spillages eliminated.
• Excellent hygiene maintained.
• Consistent product quality.
• Increased productivity.

Customer can buy bulk liquid glucose transported in heated SS tanker and pump glucose directly into Food Grade FRP / SS 316 tanks with internal heating coil. The transfer pump, line and service tank are all heat traced. Through load cell mounted dosing system, liquid glucose is accurately and directly dosed into multiple product operating system's mixers and cookers. The entire operation is PLC automated and works through a completely closed hygienic system. Customer saves glucose buying cost in drums and handling losses with excellent pay back benefits. For small quantity consumption units, economic direct drum unloading tank with transfer system is ideal.

Benefits of Glucose Handling System & Glucose Dosing System :-

• Handling losses and spillages eliminated.
• Dosing accuracy achieved eliminating human error.