Innovative Products requireInnovative Technologies Hygiene Compatible Productionof Milk and Dairy Products

T H E S O L U T I O N

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Innovative Technologies for Innovative Products

Additional Benefits Needed

Cultures throughout the world have been producing some of their most important foods from milk for thousands of years. Because milk is naturally healthy. The demand for milk and milk products, which promise further functional properties in addition to their fundamental positive effect on health, has been increasing recently. This has been seen with productssuch as probiotic yoghurts, milk enriched with vitaminsand other nutrients, fermented milk drinks and manymore ‘wellness products’.

High Demands on Plant Systems

The demands on plant systemsand processing technology are growing as a result of the desired product diversity and legal regulations. The choice of the right partner is today competitively decisive. Whetherbulk goods, small quantities or liquid components: combined

with innovative process controltechnology from our processing IT subsidiary hsh-systeme für prozess-IT gmbh, our automaticfeeding systems introduce all rawmaterials into the production process at exactly the right timeand in exactly the right quantity.

Barcode logging delivers production safety Central provision of sacks and ‘big bags’

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AZO Solutions for theMilk Processing Industry.

Your AZO advantages

• Overall system and processcontrol technology for theproduction of milk andwellness products from one source

• Many years experience with GMP, qualification and validation

• Reliable traceability anddocumentation of the production processes

• The most up to date hygiene standards for maximum production safety

Complete tri-blender loading system. The milk flow absorbs the dry product as a result of injector action

The entire process at a glance: Optimum process control from a central process leading and visualization system

Automation solutions by thetechnological and quality leaderare convincing thanks to:

• Maximum flexibility with regardto the variety of raw materialsand types as well as the reliabledosing of small quantities

• The most up to date hygienestandards, utilization of adequatematerials and special designs forsensitive areas such as sanitaryimplementations

• Ease of cleaning thanks to quick release fasteners

• Clean line disconnection and prevention of product displacement

• High throughputs

• Gentle conveying technology for difficult products such as powdered milk with a fat content of 70 – 80 %

• Reliable batch identification

• Supporting documents for materials, for instance seals in accordance with GMP andFDA guidelines

• Safe explosion prevention, in particular compliance withATEX guidelines

Outdoor silos

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Powdered Milk Production – Gentle Suction Impulse Conveyance

Reliable Conveyance of Powdered Milk

The subsequent processing of sprayed powdered milkplaces very specific demands on the plant system.

AZO is the right contact partner for you if you want to convey powdered milk gently into internal silos afterextraction in spray towers, subject it to screening stagesand load filling systems for sacks, big bags and silo vehicles.

Gentle Conveyor Technology

The principle of suction impulseconveyance is optimally adaptedfor transporting powdered milk.Product infiltration is very simpleand is dust-free as it works withnegative pressure. The negativepressure compressor is located at the end of the system. AZOtechnology also enables high fatcontent powdered milk to be reliably and gently conveyedthrough the lines.

Advantages of AZO SuctionImpulse Conveyance

Suction impulse conveyance has proved itself in numeroussystems for the production andextraction of spray products suchas powdered milk. It provides technical and cost advantages,particularly in the silo sector. The powdered milk is collected in strainers above the silo and fed continuously to the silo viaeasy-to-clean bucket wheels.

Product receipt after the spray tower into the gentle suction impulse conveyor system Precipitator above internal silo at the end of the suction impulse conveyor

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Only minor vorticities are createdin the silo by depressurized fillingin free fall. This has a positive effect on thedust exatmosphere and the safetymeasures thereby made necessary.

Gentle ConveyorTechnology for Powdered Milk.

Your AZO advantages

• Even difficult products such as powdered milk with a fat content of 70 – 80 % are conveyed as gently as possible andwith ease of cleaning

• AZO suction conveyancepermits economical concepts for dust exprotection measures

Internal silos with vibration bottom discharge anddistribution into different conveyor lines via dosingscrews

Depending on the customer requirement either the suction impulse conveyor or the pressure impulse conveyor systems are used for powdered milk production. The pressure impulse process is particularly suitable for very high conveyor capacities and long conveyor paths

»The AZO suction impulse conveyance principle has proveditself many times for bulk goods with difficult conveying characteristics. Producers of milk and wellness productsbenefit from our experience in the pharmaceutical field, particularly in the areas of HACCP, GMP and validation.«

Precipitator for the continuous conveyance

of powdered milk

Easy-to-clean sluice design

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Powdered Milk Processing – Continuous Mixer Processes

Process Continuity in Powdered Milk Processing

In powdered milk processing, continuity is particularlyimportant in mixing process loading. This applies, forexample, to the production of milk specialities for the confectionery and bakery products industry as well as to the production of special blends that impart yoghurtand other end products with health-promoting properties. In numerous production facilities the innovativeAZODOS® dosing systems have proved that they feed these production processes with a continuous mass flow and provide exceptionally convenient controland maximum flexibility thanks to intelligent processingtechnology. This means that the production processescan be economically automated in the continuous process for both very large and small production batches.

Safe Loading of Continuous Mix Processes

In addition to powdered milk, further raw materials are fed continuously from large silos orbig bags via differential dosingscales according to preset recipes.Product and quantity fluctuationsof the powdered milk from thespray tower are detected andadapted according to all other recipe components. Due to thelarge number of raw material components and to structuralrequirements, gravimetric dosing

units are mostly accommodateddirectly below the silo. The dosedquantities fall into a common conveyor line and are gently transported to the continuousmixer by a suction system. Thewell-tried AZO suction conveyancesaves space and height during the process, thus supporting the economic efficiency of this solution by reducing instrument-based expenditure. After the mixprocess the special blends arescreened and either bagged in big bags or sacks, or temporarilystored in loading silos.

Channelling through fall sluices in pneumaticconveyor systems

Newly developed slide deflector for the distribution and consolidation of conveyor flows with minimum product direction change. There are no housings in which product residues can be deposited

Fill stations for big bags with dosed filling and exact determination offilling weight

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Innovative Dosing Systems

AZO dosing systems with intelli-gent process control are madeconvincing by a large number of advantages:

• Differential dosing scale principle

• Precise online adjustment control and quick correction incase of any deviations from target values

• Absolute weight calculation

• No distortion resulting frompowdered milk quantity fluctuations. The powdered milk quantities extracted in thespray tower are used as controlcomponents. In the same way,fat content and pH value areused as control variables

• Recipe change within the shortest possible time

• Easy calibration

• Calculation of measured valueswith high resolution

• Easy-to-clean systems for quickproduct change

• Upgradeability thanks to modulardesign

Continuous Mix ProcessLoading.

Your AZO advantages

• Process continuity evenwith low fluidity powderedmilk with high fat content

• Entire feeding technologyand intelligent processing IT from one source

• Reliable compliance withhygiene standards

• Exceptionally convenientoperation and control

• Flexible, contamination-freeproduction processes withhigh process safety

• Very high throughputs

Filling facilities for silo vehicles Gravimetric loading of continuous mix processes

AZODOS® stations for gravimetric continuous dosing

in pneumatic conveyance

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Flexible supply

In the production of yoghurt, milk-based desserts and any products based on fresh milk orother liquids, the use of daily andintermediate silos for medium-sized solid components in additionto large silos has proved its value. It means that operating personnelcan be employed more flexiblyand, for example, can also prepare small components, carryout weighing and apply the mainrecipe using the Just-in-Time procedure. Supply can also bedesigned in such a way that, for

pipes and weighed in their own container scales. The main scales with the light product lines work in parallel sothat both lines are emptied intothe mixer simultaneously.

Economical Mixer Loading

The AZO pneumatic suction weighing systems have provedthemselves outstandingly for automatic mixer loading in theprocessing of bulk goods. This

example, no filling activities take place during the night shift. Feed hoppers and safe big bagemptying systems permit theautomatic conveyance of rawmaterials from sacks and big bagsinto daily or intermediate silos.

Reliable Batch Separation

In order to be more flexible and tolimit cleaning expenditure, a lineseparation of light and dark rawmaterials is effected as far as themixer. Dark ingredients such ascocoa are transported in separate

Loading of three liquid lines, two of which have central cocoa scales Pneumatic loading of agitator containers

Fresh Milk Processing – Economical Mixer Loading

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system also offers decisive advantages in belated switchingfrom manual to automatic feed:

• Horizontal material flow savingheight and space

• Efficient process engineeringcomplexity making it possible to convey large numbers ofcomponents on one or moreblending lines

• Dust-free, flexible processes

• High weighing and dosing precision

• Constant quality

• Quick recipe change

Complete Documentation of the Smallest Quantities

The ManDos operator controlledmanual weighing system is suitable for processing raw materials that cannot be automated economically because of their physical properties. ManDos is also convincing in cases of low

batch frequency, small raw material requirements and frequent ingredient changes. In these cases, the manual weighing system permits thecomplete documentation of the smallest quantities such as flavourings, decisively increasesrecipe precision and creates stockkeeping transparency.

Weighing individual raw materials by batch with homogenization before addition to the liquid flow Continuous feeding process: Large components from silos, medium-sized components from big bags

An AZO speciality: suction weighing systems with valve deflector for the fully automatic batch preparation of

large and medium-sized components

Newly developed operation terminal

Fresh Milk ProcessingSolutions.

Your AZO advantages

• All raw materials, large, medium and small components can be automatically dosed, weighed and fed to the dissolving and blending process

• Reliable batch identification and traceability; all big bags or sacks are identified by means of a barcodesystem before they reach the process

• High flexibility of operatingpersonnel through the useof daily or intermediatesilos for the night shift

• Clean separation of lines for light and dark raw materials through to the end of the process minimizes cleaning expenditure

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The Patented Solution

When dry products are added to liquids, gentle work processes and lump-free solutions are needed. AZO’spatented auto-suction initial mixing and weighingcontainer is optimally suited to this requirement.

Unlike other systems, with the AZO initial mixing and weighing containers the addition of dry products takes place below floor

The intensive agitator supports the particularly fine and regular distribution of dry products into the liquid

Auto-suction initial mixing and weighing container. It can also cater for small preparations thanks to its shape, which is tapered downwards

Fresh Milk Processing – Adding Dry Products to Liquids

Unlike other systems, the additionof solids to milk and other liquidcomponents takes place belowthe liquid level, i.e. below floor,and can be done using excesspressure with air/protective gas or with a vacuum as desired.Supported by an intensive agitator,

the dry products are distributedinto the liquid particularly regularlyand finely. The special construction of thecontainers allows even small preparations to be produced very efficiently.

The Auto-Suction InitialMixing and WeighingContainer from AZO.

Your AZO advantages

• Dosing, mixing and weighing in a single unit

• Optimal binding of dry products with liquids

• Short initial mixing times

• High concentrations possible

• No separate filter required

• Absolute wet/dry separation

• Weighing of both liquidsand dry products

• O2 reduction through the use of N2 during conveyance provides for the increased shelf-life of preparations

• The preparation of smallblend quantities can beachieved without problem

• CIP compatible

11Loading a high-performance precision mixer for the production of homogenous blends and subsequent big bag filling

Mixer loading with ingredients, medium and large components

Gentle Technologies forSensitive Products

Instant products are sensitive. The raw materials are sensitive to mixture decomposition becausethe structure and apparent weightsof the individual ingredients can bevery different. The agglomeratedfinished product must also be conveyed gently so that the structure responsible for goodsolubility is maintained. An increase in bulk density during the conveyance and blending processes must be avoided inorder to prevent the possibility of so-called ‘deceptive packaging’.

cyclone screening machines have proved their value in initialchecking, intermediate screeningand final checking.

Entire system and process control technology from onesource: Upon request, AZO will handle the entire system construction including mixers.More than 50 years experience in automatic bulk goods handlingis your guarantee of safe and innovative solutions.

conveys instant products verygently while maintaining theirstructure, preventing mixturedecomposition.

Safe mixer loading: Whethercomponents are large, medium-sized or small, AZO has the optimum automation solution. For instance, suction weighingsystems for large components,the versatile AZO Componenter®

for medium-sized and small quantities, and ManDos for theexact provision of the smallestquantities.

Reliable screening: The AZO

Flexible production processes are also needed for large typevarieties. Ease of cleaning andcomplete residue evacuation arealso on the list of requirements.

Economical Automation for All Requirements

Your production is safe under all circumstances with provenAZO system and process control technology:

Innovative slow conveyorsystems: The AZO suction impulse conveyance system

Instant Drink Production – Gentle and Economical Automated Solutions

Automation solutions for instant product manufacturing

Your AZO advantages

• Complete system and process control technologyfrom one source

• Easy to clean systems withreliable residue evacuation

• Absolutely gentle conveyortechnology with no mixturedecomposition

• Reliable screening and safemetal separation

Tap the full automation potential!In addition to complete solutions for the milk processingindustry, AZO also delivers partial systems and machinesthat open up new rationalization potential for you andincrease your competitiveness.

Product Feeding Systems for SacksComplete series of filling funnelswith corresponding suction filtersand empty sack compactors forcarrying bulk goods into closedsystems with low levels of dust.

AZO GmbH + Co. KGD-74706 Osterburken Tel. +49 6291 92-0Fax +49 6291 92-9500info@azo.de, www.azo.de

Big Bag Emptying SystemsModular design optimally suited to your individual requirements.Efficient solutions for all commonbig bag types, also with sleeve,with the proven AZO connectingsystems.

Big Bag Filling SystemsDifferent variants with floor orhanging scales, individually suitedto filling performance and to yourrequirements.

Gentle Conveyor SystemsFor conveying sensitive bulkgoods in the milk industry such asfull-cream milk or fatty powderedmilk. The innovative AZO solutionconsists of slow conveyorsystems with suction and pressure conveyance and thecompletely new slide deflectorprogram, with which only minimum product direction change is necessary during switching operations. The AZOimpulse conveyor systems with extensive pressure vesselprogram are ideally suited to high conveyor performances and long conveyor paths.

Screening Machines for InitialCheck Screening, IntermediateScreening and Final Checking The proven and tested cyclonescreening machine in its latestdesign: Screen changing with few movements, easy inspectionand cleaning. The liquid screening machine for screening dry products andagglomerates from liquids, e.g.cheese elements from whey.

AZO Dosing System withIntelligent Process ControlFor exact, gravimetric differentialdosing in the continuous process.Easy to clean thanks to modularfeatures that can be added to atany time and with exceptionallyconvenient operation and control.

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