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 JAMEED – HALLOUMI INDUSTRIAL INDUSTRIAL SOLUTION SOLUTION GREEK YOGHURT CYPRUS INDUSTRAIL PRODUCTS SOLUTION 40 YEARS EXPERIANCE
TRADITIONAL METHOD • Clean trolley and add pre conditioned tobacco • Clean trolley and add pre conditioned tobacco • Add syrup and glycerin in trolley and prepare for soaking • Add syrup and glycerin in trolley and prepare for soaking • Add flavors • Add flavors Preparation of syrup and • Position trolley in mixing area • Position trolley in mixing area Glycerin • Daily mix by hand • Daily mix by hand • Avoid mixing flavors during daily mix • Avoid mixing flavors during daily mix • Close lids to reduce evaporation • Close lids to reduce evaporation Soaking for 1 week • Remove soaked tobacco • Remove soaked tobacco • and add it in smaller trolleys, • and add it in smaller trolleys, • to go to the filling stations • to go to the filling stations Empty for filling
TRADITIONAL MOLASSES SOAKING METHOD
TRADITIONAL METHOD MOLASSES MIXING
TRADITIONAL METHOD MOLASSES UNLOADING
TRADITIONAL METHOD SWOT Strengths Weaknesses Low budget – easy to apply Long soaking time 6-8 days Manual – simplistic operation Needs a lot of soaking trolleys Low technology Labor intensive Easy to obtain a desired quality on SMALL Time consuming to mix batch Mixing consistency Good for developing new flavors R&D 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 Threads Can start really small Quality variation Can use soaking trolley as buffer and Too much manual handling – contamination transport at the same time 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. Soaking time was reduced to 24 hours in our tests ii. 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 Weaknesses Very short soaking time 24 hours For fully automatic plant services are needed Limited number of vessels needed such as hot water and CIP No need for many operators Need better educated personnel to monitor Mixing can happen at any interval (day/might) production 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 Opportunities Threads Maximize production in limited space Need less stagnant capital (7 days less soaking) Increase production Fast investment recovery
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 m 2 340 m 2 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 cn=Marios Christou, o=Chr. Agathangelou Ltd, ou=G.M., email=mchristou@agathang elou.com, c=CY 2016.02.02 10:08:36 +02'00'
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