MOLASSES I N DU ST RI AL SOLU T I ON BY CH RI STAK I S AGAT H AN - - PowerPoint PPT Presentation

MOLASSES

I N DU ST RI AL SOLU T I ON BY CH RI STAK I S AGAT H AN GELOU LT D

CHRISTAKIS AGATHANGELOU LTD

SINCE 1976, WE HAVE BEEN SUPPLYING THE INDUSTRY WITH INNOVATIVE SOLUTIONS. OUR 40 YEARS PRESENCE IN THE VARIOUS INDUSTRIES AND THE SUPPORT FROM OUR CLIENTS IS OUR GUARANTEE FOR SUCCESS.

ESTABLISHED SINCE 1976 HALLOUMI INDUSTRIAL SOLUTION CYPRUS PRODUCTS 40 YEARS EXPERIANCE GREEK YOGHURT INDUSTRAIL SOLUTION JAMEED – INDUSTRIAL SOLUTION

TRADITIONAL METHOD

Preparation of syrup and Glycerin

• Clean trolley and add pre conditioned tobacco
• Add syrup and glycerin in trolley and prepare for soaking
• Add flavors
• Position trolley in mixing area
• Clean trolley and add pre conditioned tobacco
• Add syrup and glycerin in trolley and prepare for soaking
• Add flavors
• Position trolley in mixing area

Soaking for 1 week

• Daily mix by hand
• Avoid mixing flavors during daily mix
• Close lids to reduce evaporation
• Daily mix by hand
• Avoid mixing flavors during daily mix
• Close lids to reduce evaporation

Empty for filling

• Remove soaked tobacco
• and add it in smaller trolleys,
• to go to the filling stations
• Remove soaked tobacco
• and add it in smaller trolleys,
• to go to the filling stations

TRADITIONAL MOLASSES SOAKING METHOD

TRADITIONAL METHOD MOLASSES MIXING

TRADITIONAL METHOD MOLASSES UNLOADING

TRADITIONAL METHOD SWOT

Strengths Low budget – easy to apply Manual – simplistic operation Low technology Easy to obtain a desired quality on SMALL batch Good for developing new flavors R&D Weaknesses Long soaking time 6-8 days Needs a lot of soaking trolleys Labor intensive Time consuming to mix Mixing consistency Difficult to wash wastes water Need a lot of space Final quality – 100% on human factor Evaporation of flavors Ingredients may vary – depending on process Difficult to control soaking temperature Difficult to control yield of production / batch Difficult to optimize ingredients to reduce cost Opportunities Can start really small Can use soaking trolley as buffer and transport at the same time Threads Quality variation Too much manual handling – contamination Air contamination Very low personnel comfort

DEVELOPING THE INDUSTRIAL SOLUTION

When we set out to industrialized the process we focused on:

• Keeping all strengths and opportunities
• Eliminate the weaknesses and threads

We have tried to maintain all key aspects of the manual process that our clients are comfortable with and enhance the process further to maximize production capacity and minimize time. 1. Soaking / mixing cycle:

i. Our system offers a programmable mixing profile in addition to its unique shape that has revolutionized the soaking time. ii. Soaking time was reduced to 24 hours in our tests iii. It can be related to time, temperature, stage of production, revolutions per minute, start-stop intervals as well as position (around 360°)

2. Batch Size:

i. We addressed the need for batch size based on popular and new flavors. For that reason our system comes with modular compartments of various sizes.

3. Empying:

i. By positioning the vessel at a higher level we can empty the content with minimum efforts reducing the need for extra work and personnel handling ii. Reduced the risk of contamination by personnel iii. Reduce personnel risks of inhaling flavors

DEVELOPING A PROTOTYPE

TEST PROOF PROTOTYPE

SOAKING TIME 24 HOURS - 100% ABSORPTION!

TEST PROOF PROTOTYPE

DRAINING VESSEL – 1 PERSON ONLY – DONE EFFORTLESLY

AVAILABLE MODELS

Model Description Flavours Batch Size Total Batch

SH3T-2 3000 Lt Oval Vessel 2 1500 lt 3000 lt SH3T-3 3000 Lt Oval Vessel 3 1000 lt 3000 lt SH4T-4 3000 Lt Oval Vessel 4 750 lt 3000 lt

SH3T-2

3,000 LT OVAL VESSEL WITH 2 COMPARTMENTS, 1,500 LT EACH

SH3T-3

3,000 LT OVAL VESSEL WITH 2 COMPARTMENTS, 1,000 LT EACH

SH3T-4

3,000 LT OVAL VESSEL WITH 4 COMPARTMENTS 750 LT EACH

SIDE MOLASSES DRAINING CONCEPT

TOP TOBACCO LOADING CONCEPT

POTENTIAL FACTORY LAYOUT

INDUSTRIAL METHOD SWOT

Strengths Very short soaking time 24 hours Limited number of vessels needed No need for many operators Mixing can happen at any interval (day/might) Mixing consistency is constant Easy to wash with CIP Low water consumption during washing No evaporation – need less flavors Constant quality Takes less area in the factory Temperature controlled Monitoring production through software Yield control Accurate ingredients addition Can control stock in hand Weaknesses For fully automatic plant services are needed such as hot water and CIP Need better educated personnel to monitor production Opportunities Maximize production in limited space Need less stagnant capital (7 days less soaking) Increase production Fast investment recovery Threads

TRADITIONAL VS INDUSTRIAL SUMMARY

Process Traditional Industrial Solution

Washing Manual Automatic - CIP Water consumption High Very Low - recirculation Tobacco Loading Manual Manual Molasses addition Manual Automatic - Dosing (stock control) Glycerine Addition Manual Automatic - Dosing (stock control) Flavour Addition Manual Manual Flavour retention Left overs Hygienic design - Clean Flavour Evaporation Open No Evaporation - Closed Mixing Manual Automatic Mixing Cycle 6-8 Days 24 hrs Mixing efficiency Labour dependent Uniform Mixing profile Labour dependent Programmable Quality - Consistency Labour dependent High repeatability Empty into Filling Trolley Manual By gravity Temperature control Not Applicable controlled - programmable Stock control via Software Manual Optional Automatic Production control - Batch history Manual Optional Automatic Production trolleys / vessels (for 50,000 kg) 100X8=800 25 Floor Space (NET SPACE) 1300 m2 340 m2 Personnel per 50,000 kg (Mix & extract only) 40 6-8 people WIP (Capital) 50,000 kg (1.6 JOD/kg) JOD 640,000 JOD 80,000 Equipment Investment (containers only) €800,000 €825,000 Factory environmental condition Very difficult to control Confined in Vessel Personnel comfort Difficult to breath Clean Environment