Computer-controlled filling machine capable of filling a variety of fat content milk

Dan Soehnlen, owner of Superior Dairy Company (Kenton, Ohio), believes that if something cannot add value, it should be abandoned. He and his son Greg set up a new company, Creative Edge, and the father and son deviated from the family's 80-year business model and adopted a new way to run the new company. Their company has a close-knit team of employees and several trusted vendors who have assembled efficient microemulsion devices on the equipment of the Superior Dairy Factory, eliminating the need for milk tanks. They no longer split the milk of No. 1 and No. 2 components into two processes. They have omitted a lot of unproductive labor and saved the inventory of products at production plants and retail establishments. At the heart of this reform is Creative Edge's new stackable bottle design and Serac, Inc's innovative filling/sealing process.

Today, Superior Dairy ships from its mini-dairy factory to the northeastern retail market at 230,000 gallons per week. These markets have enabled the company's traditional dairy production to increase. The innovative micro milk approach enabled the company to supply more regions and enable their midsize dairy plants to prosper in the environment dominated by giant companies.

The establishment of Creative Edge has brought new business growth points to the family business of Soehnlens. The company has invested considerable funds in technology development. The milk factory has obtained a license and provided technical support to other dairy plants. His other son, Mark Soehnlen, is a partner of Structura Architects, Ltd. He provided Superior with package design, project management methods, and building maintenance services to keep the micro milk factory in order. With only a handful of clients, Structura has made its own expertise confident by designing and starting its own business.

Soehnlen's father and son began to remove all factors that cannot be added. Their first goal was the milk tank. Milk tanks must go through the process of loading, unloading and recycling. Empty containers are returned to the dairy and cleaned, stored, reused or relocated. One of the major customers of the Superior Dairy Factory pointed out another benefit of doing so because of the prolonged working conditions in the frozen condition, the workers raised health complaints, and the use of milk boxes shortened the staff's refrigerated conditions. Working time.

Soehnlen's father and son started using new plastic milk bottles. The strength of these bottles can meet the stacking requirements. In order to use these bottles, they did a lot of experiments and experienced many failures. Those who hold the opposite view think that such an attempt is simply not achievable, and even the blow model that they will produce will not work. In the end, it proved that Creative Edge is correct.

The new type of bottle is flush with the pouring dimple, and the cap of the pour spout is flush with the flat top of the bottle. Bottle walls, bottle tops and bottoms use grooved structures to increase strength. A foil seal was placed under the cap and heat sealed in place. The solid-state seal allows the bottle to withstand pressure effectively, and the plastic milk bottle wall is only slightly heavier than conventional milk bottles. The whole bottle is very strong, milk bottles can be placed into six layers. However, when the four floors were laid, Soehnlen could stack 224 gallons of milk on a pallet. When using traditional milk bottles, a six-layer milk bottle can only hold 216 gallons of milk on a pallet. In this way, the space saved in the milk truck can pile up other light weight debris.

In addition, Creative Edge does a lot of consumer-friendly designs on the bottle. They installed pour spouts on the bottles and installed handles in the opposite corners of the bottle to the pour spout, allowing the bottles to pour milk just like a pitcher and pour tank. A round design is used at the bottom corner of the dump, so that when it is dumped, there is no need to lift the bottle – which greatly facilitates the lack of strength in the arm. To demonstrate this advantage, this milk bottle is called Rock'N Dump Milk Tank. Creative Edge also needs to add white pigments to the plastic to protect the product from light while keeping the bottle transparent so that consumers can see how much milk is in the bottle.

The design of the Rock'N Dump Milk Tank requires a new filling and capping method. Serac’s North American team of engineers performed improvements on standard gallons, half gallons and three litre bottles. Creative Edge and Serac made untiring improvements in filling and capping, and finally they got satisfactory bottles and machines. The final machine can directly reduce labor costs and extend the product's shelf life.
Serac's R16R16V8/1080 ESL net-weight integral filling/capping machine eliminates the need to separately produce and fill the No. 1 component milk and No. 2 component milk. It also eliminates downtime when converting milk fat content. The filling machine has 16 valves that are rotated and filled one after the other. One unit filled 3.25% fat full fat milk, and the other unit filled 0% fat milk, skim milk. When the bottle comes off the conveyor belt, the barcode scanner identifies the label on the bottle and determines what kind of milk should be filled. When the bottle passes through the two filling ports, a precise amount of skimmed milk and/or full fat milk is filled into the bottle, and the filling results are consistent with the fat content on the label.

The filling machine is capable of filling all milk and beverage products, including filling of Creative Edge's patented 1 gallon, 3 liter and half gallon Rock'N pour milk cans.

Serac's filling machine accurately measures the amount of milk flowing into the bottle, avoiding contact with the mouth of the bottle, as touching the mouth of the bottle into the bottle may increase the bacteria in the milk. Serac's contactless, free-flowing, ultra-clean fill spout eliminates the overfilling problems inherent in older technologies, saving the product while ensuring that consumers are value for money. At the same time, Serac's filling machine is easier to maintain and clean because it does not touch the nozzle.

The "micro" of the micro milk factory model lies in three main aspects. It enables large-scale milk production (typically 500,000 gallons per week) to be produced on small equipment. It also reduced the number of direct laborers to 4 per shift. This production model integrates all production equipment into a microprocessor-controlled business system. Creative Edge said that dairy plants can integrate and utilize all software resources and major large-scale business systems.

Using this system allows the device to operate in a fully-immediate mode. The milk factory can produce and package milk according to the order without the need for storage. After the bottled milk is put into the production line, the delivery pallets are directly loaded with the other products of the Superior Milk Factory according to the special order. In a very short time, the pallets will be loaded onto trucks and shipped to retail outlets.

The entire operation of the equipment has almost reached the level of drug-grade cleanliness. During production, it is continuously charged with dry high-efficiency particulate air (ie, filtered air) to maintain positive ion air pressure and prevent the entry of unclean air. The wall of the workshop is made of easy-to-clean stainless steel as a protective layer.

At the same time, Superior uses pasteurization to sterilize milk at 180 degrees Fahrenheit for 25 seconds, which significantly extends the product's shelf life. Tests showed that Superior's milk was not deteriorated within two weeks after the latest print date of printing. In fact, the combination of the company's extended shelf life technology, instant shipping methods, and non-inventory time allowed Superior's products to have a much later sale date than their competitors' counterparts. When consumers see such a latest sales date, they will consider buying more than the original plan.

Only four people are required for each shift in production. One person is responsible for bottle blowing, one is responsible for filling, one is responsible for pallet loading, and one is responsible for forklift operations. Superior therefore minimizes direct labor costs nationwide. There is space in the production equipment to install a second blow molding machine and filler, which will enable them to increase production capacity to 1,000,000 gallons/week in the same area of ​​22,000 square feet.

After the shrink film packaging station is completed, the milk bottles can be packaged in 2, 4 or 8 packages depending on the retailer’s requirements. Milk bottles can also be individually stacked on pallets so that workers at retail locations only need to remove the entire shrink film packaging outside the pallets.

Consumers are very satisfied with this extended shelf life. Compared to traditional packaging, they prefer the Rock `N pour can design because children and seniors have difficulty using traditional packaging. The cost savings in production have enabled retailers to sell the plant's products at a lower price than the products produced by traditional methods, which is to everyone's satisfaction.



Reprinted from: Huayin Media

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