Simultaneous Batching System
Processes Multiple Recipes at High Speeds
January 30, 2008. Ingredient Masters, Inc. has introduced a system
that simultaneously processes up to 20 batches per hour, each with
up to 24 components. The system is well-suited to a broad range
of food processing requirements, as well as many industrial applications.
The Ingredient Masters system is engineered for recipe sizes of 10 to
200 lbs. each, and maintains ingredient accuracy of +.02 lbs. per
ingredient with the use of screw (spiral-type) feeders. Systems
engineered to handle very high ingredient volumes, or very large
batches, can be specified for auto valve release. The transfer
conveyor can be scaled for gain-in-weight, (which provides
slightly higher accuracy) or loss-in-weight, (which is faster)
at customer option.
The batching systems are customized to the application, and can
often be engineered to incorporate existing powder handling devices.
They use as few as four, and as many as 30 dispensers, which are
each 28 to 105 cu. ft. in capacity. Dispensers are rotationally molded
polyethylene, for best-possible material flow, and are USDA, 3A, FDA
and EPA approved. They are also exceptionally durable, and,
unlike conventional dispensers, remain “sweat-free” when
temperatures fluctuate.
Like other Ingredient Masters equipment, this batching system will flow
virtually all powdered, flaked and granular ingredients – even compacted
or hygroscopic ingredients – without the addition of a Bulk Bag
Conditioner or other “helper” device.
System operation is controlled via an Allen Bradley PLC and a PC.
Software is typically Allen-Bradley RSLogic 5000 for the PLC logic and
RSView for operator graphics. A Microsoft Access database stores
recipe and ingredient information, and records batch data.
Recipe storage is virtually unlimited and each recipe is date-stamped
with the most recent revision or approval. A master list of ingredients,
including operating parameters for each, is maintained in the database.
The system maintains a deductive inventory for each dispensing hopper
and tracks ingredient lot numbers for archiving in the batch data.
New System Batches Wet and Dry Material
with Exceptional Accuracy
October 22, 2007. Ingredient Masters has introduced an innovative system
for sequentially introducing dry and liquid materials to a mixer.
The heart of the system is a “Super Sack” bulk material handling system,
which incorporates multiple air-actuated dispensing hoppers, a robotic scale
cart which moves between them, and an innovative, space-saving support
structure. Dispensers are polyethylene, with capacities between 3.5 cu. ft.
and 105 cu. ft. There are ten standard dispenser sizes.
Other components include a vacuum transfer system, a fiber handling
(“loss-in-weight”) scale hopper, and a 50-lb. bag handling system with
multiple hoppers. The hoppers are agitated, and are equipped with
screw feeders; they discharge above a common platform scale.
The liquid handling portion of the system discharges three to seven ingredients;
surge tanks feed continuously and are refilled via gravity flow each time a full
tote is connected to the system.
Centralized computer control is via an Allen Bradley PLC and a PC.
Software is Allen-Bradley RSLogic 5000 for the PLC logic and RSView for
operator graphics. A Microsoft Access database stores recipe and ingredient
information, and records batch data.
An unlimited number of recipes can be stored; each is date-stamped with the
most recent revision or approval. A master list of ingredients, including operating
parameters for each, is maintained in the database. The system maintains a
deductive inventory for each dispensing hopper and tracks ingredient lot
numbers for recording in the batch data.
The scale cart discharge accuracy depends on batch size, and is generally
0.002 lb. to 1 lb. per batch, a tolerance which makes the system well-suited
for the broadest range of applications.
Internet-Based System Combines Flexibility,
Precision for Dry Ingredient Batching
January, 2007. Ingredient Masters has introduced a batching system with
internet-based programming, monitoring and diagnostics capabilities.
This fully automated, self-contained system uses an Allen-Bradley PLC for
the input of up to 100 recurring process recipes, and numerous QC functions.
Weighing accuracy is +.02 lb. per ingredient on a 1000-lb. recipe.
Systems use three or more FDA-USDA polyethylene dispensers, each with
capacities between 3.5 and 100 cu. ft. The new system is particularly beneficial
for applications where space is at a premium. (The footprint for a 5-dispenser
system is just 8’X 30’.) In addition to the in-line dispenser configuration,
the system can be set up with modular dispensers to accommodate
non-recurring recipes.
The Ingredient Masters System is JIT-compatible system and well-suited to the
precision batching of dry product of all types, including abrasive and “high-drag”
ingredients. Its integral, high-efficiency dust collection simplifies air
quality management and plant housekeeping.
Ingredient Masters specializes in precision batching equipment for the food
and pharmaceutical industries, also chemicals, ceramics, minerals,
gypsum and other products.
Manufacturers Announce Strategic Partnership
July 31, 2006. Mettler Toledo, the world’s largest manufacturer of weighing
solutions for laboratory, industrial and food retailing applications, and Ingredient
Masters, a leader in custom powder handling systems that reduce the costs of
processing and batching dry ingredients of all types, have formed a strategic
alliance. The alliance, announced today, will involve the engineering and
marketing functions of both companies and will operate throughout
North America.
Speaking jointly, Roger Jeffrey, Mettler Toledo Global Business Development
Manager, and Scott Culshaw, President and CEO of Ingredient Masters, explain
that the primary mission of the alliance is to pair Mettler Toledo’s expertise with
proprietary technologies such as Q.i (Quantum Impact), with Ingredient Masters’
expertise in the specialized field of “micro ingredient” batching and handling.
Explains Jeffery, “Q.i is a material feed measurement, management and cut-off
control technology, initially developed & productized for manufacturing operations
within Procter & Gamble, and since made available to any manufacturing company.
“In any manufacturing operation that involves batching, Q.i substantially simplifies
the engineering effort and simultaneously enhances production speed and feed
accuracy,” adds Jeffery. “Mettler Toledo was was highly successful in applying the
Q.i technology within P&G’s global business units, and elsewhere, and, with this
new alliance, will bring its benefits to a far greater number of producers –
both regional and global."
Adds Ingredient Masters’ Culshaw, “Our experience in food, pharma and chemical
processing, and Mettler Toledo’s strengths in precision measurement instruments,
allow our two companies to bring truly innovative, cost-effective solutions to market
sectors that have not yet been well-served by traditional control systems suppliers.”
Both companies currently invest approximately 6% annually on R&D; both
have representation in all major US regions.
For further information, contact:
Mettler-Toledo, Inc.,
1900 Polaris Parkway, Columbus, OH, 43240
614-438-4412 • www.mt.com
Ingredient Masters, Inc.
1080 Nimitzview Drive Cincinnati, Ohio 45230
513-231-7432 or 888-345-4729
www.ingredientmasters.com
Minor Ingredient Batching System
Offers Flexibility, Precision
June 20, 2006, Ingredient Masters, a manufacturer of precision batching systems
for powdered, flaked and granular ingredients of all types, has introduced a minor
ingredient batching system for continuous production facilities that use minor
ingredients in their product recipes. MORE
Powder Batching Technology Prevents Dust Release
September 15, 2005, a new Ingredient Masters technology contains all dusts inside
the dispenser, regardless of type or micron size.
Marketed as the Ventable Bulk Bag Dispenser, this new batching concept prevents
fugitive emissions, while virtually eliminating IAQ and housekeeping issues. This
technology also allows many materials to be re-captured and used. It is ideal for
powders such as talc and carbon black, which create special challenges when
released, and are difficult to re-capture.
Ingredient Masters systems are custom to the user. Ventable Bulk Bag
Dispensers are configured using USDA grade polyethylene dispensers,
each with an integral dust port.
The patented dispensers are manufactured in ten standard sizes, from 3.5 cu. ft.
to 105 cu. ft. All have a distinctive design feature which eliminates “bridging” –
a common phenomena which hampers the flow of powdered material.
The system is shipped skid-mounted, or single or double lowboy, or wide load.
Ingredient Masters systems are engineered for compatibility with existing plant
equipment and FIFO (first-in, first-out) protocols.
Whether a facility uses bulk bags, totes or paper bags, this batching system
provides an efficient, ergonomic, and material-saving way to process powders
and dry bulk ingredients.
Systems produce substantial savings in reduced labor, simplified dunnage
and landfilling, and now, optimum confinement of fine powder material.
Installation assistance provided nationwide.
Manual Batching Systems Offer Maximum Flexibility,
Lowest Capital Cost
January 25, 2005 Ingredient Masters, a manufacturer of equipment and
systems for companies who use (or process) dry, flaked or powdered ingredients,
has introduced customizable manual batching and weighing systems.
Ingredient Masters (“IM”) manual batching systems are tailored to the customer’s
production requirements. They are engineered to adapt readily to future
expansions and automation.
System components include dispensers, unloaders, and dust collection.
Dispensers are USDA approved polyethylene and have a patented design feature
which eliminates “bridging” – a phenomena which works against the efficient flow
of powdered material.
Many IM systems include user interface, feeder conveyors and precision
metering and weighing devices. Ingredient Masters batching systems are
engineered for compatibility with existing equipment and FIFO (first-in, first-out)
processing protocols.
Whether a facility uses bulk bags, totes or paper bags, “IM” manual batching
systems provide an efficient, ergonomic, and consistent way to process powders
and dry bulk ingredients. Systems are designed to meet a specific ROI objective –
generally two years or less. They produce substantial savings in reduced labor,
simplified dunnage and landfilling, and improved confinement of fine
powder material.
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