Hosokawa Micron Ltd

Hosokawa Micron Ltd is a leading innovator in powder processing technologies pioneering new and unique engineered solutions that deliver product, market and financial advantages for customers.

Hosokawa Micron Ltd provides a renowned single source supply of powder and particle processing equipment and services across pharmaceutical, chemical, food, metals, powder coatings, cosmetics, rubber, soaps and detergents, ceramics, toner, nuclear and plastics industries.

We work closely and in partnership with customers and strive to provide the optimum solution to individual size reduction, mixing, classifying, filling and weighing, screening, containment, nanotechnology and integrated processing and plant performance problems which deliver recognisable and tangible benefits.

Hosokawa Micron Ltd is a member of the worldwide Hosokawa Micron Group which celebrated its centenary in 2016.

Processing industry customers have access to our range of expertise, equipment and engineered solutions in the following technologies and applications:

  1. Unique 5-a-day Processing
    13 November 2018

    Hosokawa Micron’s unique Angle Disintegrator, with 5-a day, streamlined processing options is helping manufacturers of soups, purées, sauces and dressings meet the market demand for increasingly authentic and quality fruit, vegetable purées and demand for the flavours of exotic and often difficult to handle spices and fruits.

    This multi-tasking machine offers 5 different processing options in one machine: pulping or blending; coarse or fine purée; hot or cold ingredients; wet or dry ingredients and rejection of unwanted plant matter or injection of water, steam or inert gas.

    By eliminating peeling and chopping operations and by continuously removing unwanted fibres, skin particles and seeds to produce an homogenous, puréed product processing steps and product handling are reduced to deliver a higher quality, fine textured, end product.

    Garlic, root ginger, tomatoes, onions, oranges and vanilla pods can all be pulped and puréed using the Micron Angle Disintegrator with reject material ejected through a secondary outlet to leave a pristine, homogenous purée. Selection of coarse to fine end product are easily achieved by the changing of removable screens.

    Capable of handling dry or soaked ingredients the Angle Disintegrator is equipped with a water injection system making it suitable for continuous mixing and blending – the option to inject steam or inert gas during operation is also possible.

    With a capacity to handle up to 3000kg/hour of either wet or dry, hot or cold products the hygienic construction enables fast product changeover without cross contamination.

     

    Unique 5-a-day Processing
  2. NEW Hosokawa Viblette VBL-F
    13 November 2018

    The new, Hosokawa Viblette VBL-F, wet sieve analyzer is launched this month and is seen as the modern standard to replace conventional wet sieving methods in dry particle size analysis.

    The simple to use Viblette VBL-F offers sieving times a third less than conventional sieving methods whilst using only 1/6th the liquid to produce accurate and reproducible particle size analysis required in quality control operations. The unit offers a 5 micron, non-filming screen wet sieving capability.

    Wet sieving is an established method where cohesive or highly electrostatic powders are to be analysed and where small amounts of coarse powders are to be isolated – which is difficult to detect by laser diffraction- scattering methods or dry sieving.

    Enhanced vibration allows rapid analysis and unique shower nozzles deliver effective powder wetting with little liquid waste. Liquid is sprayed through shower nozzles onto the powdery sample on the sieve. The sprinkler is rotated by liquid pressure evenly wetting the powder. The problem of fine screen filming that can occur in wet sieving is avoided using enhanced vibration force, allowing both fine particles and liquid to pass through the screen and shortening the measuring time. Manual intervention is not required during sieving.

    Options are available for ultrasonic operation for high cohesive, superfine powders; for organic solvents as well as a series of control options of spray timing, flow volume, rotational speed of sprinkler, process time and vibration on/off timing.

    Typical powder applications include, carbon black, calcium carbonate, graphite, silica, plastic, food, abrasives, ceramic fine powders.

     

  3. Protecting Downflow Booth Performance for Safe Operation
    23 July 2018

    In the pharmaceutical industry the downflow booth is one of the most widely recognised means to protect workers when handling dusty materials or undertaking activities that generate airborne particles. Keeping workers safe from dusts and fumes that can damage their health is a legal requirement under Health and Safety at Work, COSHH regulations across all industries and the user friendly working environment offered by downflow booths as an alternative to cumbersome PPE, combined with the high levels of protection they can afford, has led to the adoption of this clean air technology across chemical, food, healthcare and other industries.

    Matt Wilby, Maintenance and Commissioning Engineer at process containment specialist, Hosokawa Micron Ltd says, ‘However downflow booths can only fully protect those working in them if they are regularly monitored, inspected and maintained to preserve their installation performance levels and comply with safety regulations. 

    Monitor

    Routine monitoring demonstrates the unit is performing to established, safe, commissioned standards. It provides invaluable historical data and enables prompt remedial action if required and forms an inclusive part of a scheduled programme designed to spot and handle deviations that may place operators at risk.

    Daily visual checks such as checking for panel damage and failed lighting are a start point and can be done by the operator, who probably knows the unit better than anyone.

    Further routine checks should be carried out by a trained and competent technicians and include:

    •             Checking manometer readings are in the correct range

    •             Static pressure readings

    •             Checking there is no visible leakage

    •             Filter system check

    Keeping records is crucial in demonstrating that the system performs as it was designed. Failures detected or deviations identified should be logged, reported and acted upon.

    Training of your maintenance team will be offered by your downflow booth manufacturer at equipment handover. Training should be geared to the performance levels, activities undertaken within the booth and tailored to accommodate specialist maintenance operations outside your in-house capability and scope.

    Inspection

    ‘Run to fail’ is not an option with downflow booths and in order to maintain its performance a series of inspections or tests should be carried out by trained engineers at specified intervals determined at commissioning stage and detailed within your service manual for each downflow unit. Matt explains, ‘Qualified external engineers may be required to carry out these test, many of which require local isolation and specialist equipment including the wearing of PPE as Operator Exposure Levels may be compromised.’

     

    Smoke tests verify containment and that airflow in the booth is flowing in the right direction and that it is not compromised by the placement of equipment and that smoke remains within the safe work line and none flows into the outside area which would indicate a risk to those in adjacent work zones and potential product contamination.

    Where cleanroom or controlled area classification verification is required in accordance with BS EN ISO 14644-1:1999 airborne particle count testing is required. This is undertaken using light scattering instruments to determine clean zone cleanliness.

    DOP testing of HEPA filters forms a part of the regulatory requirements and should be carried out by experts to ensure reliability. This test determines if your filters are performing to the standards acceptable for your operations. The test provides assurances for all parts of the filter including the seals and the housing. The statutory requirement for testing intervals is 14 months with the test carried out in accordance with BS EN ISO 14644-3:2005 or PD 6609:2007 by test engineers capable of identifying and resolving leakage problems.

    Service and Maintenance

    ‘A planned maintenance programme prevents equipment failure and production interruption whilst keeping your downflow booth safe to use. We recommend companies look at packages from OEMs which offer scheduled visits to undertake a full range of checks and tests to industry standards as well as full IQ/OQ recertification of your system. Compliance documentation provision is also an advisable option.

     Service intervals should be recommended by manufacturers, take into account HSE guidelines, how your downflow booth is used, how much product passes through it and help determine the framework for a preventative and predictive maintenance schedule to meet your H&S obligations. For example a downflow booth operating on a 24/7, three shift dispensing line will require more frequent servicing than a  booth which handles a few sample tests per week. Any remedial work deemed necessary would be carried out at this point by the service provider – including filter replacement.’ explains Matt.

    Spares, Replacement Parts and Upgrades

    ‘Manufacturers are able to help you manage your stock of spare parts to ensure minimal downtime and optimum performance of your downflow booth. At Hosokawa we offer a range of upgrades to lighting, containment screens, cooling packages etc. that can extend the operational life of your booth as your requirements change.’

    Matt concludes, ‘Whist alarms and reports highlighting abnormal operations will be provided by your booth management system, the responsibility for compliance with regular Health and Safety audits remains with the company operating the booth. If something is not working as it should do not wait for a scheduled service call or H&S audit. Contact your maintenance service provider immediately. Never let the problem escalate.’

    Protecting Downflow Booth Performance for Safe Operation
  4. Safe Drum Handling in a Material World
    23 July 2018

    When speciality fabric manufacturer Vlisco approached Hosokawa Micron Ltd seeking a contained drum handling solution to provide a physical barrier between the operator and product to protect their workforce from contact with airborne, fabric dye particles, they were explicit in the challenges that needed to be met.

    These including the safe handling of drums of various sizes and the de-lidding, opening and emptying of drums into a reactor vessel within a contained environment.

    Hosokawa Micron engineers responded with a bespoke designed drum tipping glovebox, built around the dye reactor vessel, that met all the customer’s requirements including an Operator Exposure Level of <5 µg/m³ to protect operators potentially harmful dusts.

    Drums and kegs of different sizes and weights are presented to the glovebox on a roller track and manually moved into the glovebox before being connected to the drum tipper. Drums are de-lidded and bags opened before special container clamps suitable for handling a range of weights/sizes attach the drums to the lifting/tipping device. The drums are then automatically lifted, rotated and dropped onto the reactor where they are located into position to secure and reduce dust creation on discharge.

    The system is operated under a nitrogen blanket to minimise dust explosion risk and is engineered for ATEX compliance with drum lifting and rotation operated by intrinsically safe air motors.

    As the reactor vessel contains hydrochloric acid, special coatings are applied to the glovebox chamber and plastic parts were used to make up the filter and extraction systems utilising plastic fans, pipework and plastic coated valves and filters.

    As an original and heritage textile design company, Vlisco welcomed Hosokawa’s bespoke approach to providing a purpose designed containment solution that reduced both manual handling of drums and operator risk.

    Michiel Soolsma, Process & Quality Engineer, Vlisco says, ‘From the first contact, Hosokawa made a great impression by understanding our problems and coming up with possible solutions. Although we needed more time before starting the project, Hosokawa showed patience and assisted us when asked.

    From the start to the end of the project Hosokawa showed their experience and engineered a glovebox that is operator friendly and could be integrated in our new installation.

    I personally enjoyed working together with their engineers on this project with Hosokawa.’

    For over 170 years, Vlisco has created more than 350,000 original textile designs. Many of these designs have become cultural treasures, bestowed with special names and meanings by the merchants of Central and West Africa.

    Safe Drum Handling in a Material World
  5. Processors Benefit from Hosokawa’s Smart Manufacturing Journey
    23 July 2018

    The government’s Made Smarter call for increased adoption of industrial digitalisation, to boost UK manufacturing has launched process technology experts, Hosokawa Micron Ltd on an Industry 4 I.R journey that will allow them to deliver advanced solutions to their existing customers and a broader industry base.

    Iain Crosley, MD, Hosokawa Micron Ltd shares details of their journey. ‘Our smart manufacturing journey started in our own contract manufacturing facility in Runcorn, within the dedicated food processing unit, where we support customer requirements for the processing of niche ingredients under food accredited quality control systems. From ultra-small batches for customer R&D projects or for customers lacking appropriate systems to handle certain foodstuffs, such as those containing allergens, to bulk processing to meet peaks in demand, Hosokawa work with a wide range of customers to meet the specific requirements of each.

    Additionally, our contract manufacturing team engage with customers to support the development of bespoke processes or machine acquisition to deliver competitive advantage.

    We have committed to a major digital strategy for contract manufacturing, making significant investment to further optimise production and processing performance through the application of industrial internet of things (IIOT) technologies, always in conjunction with our human knowledge and expertise.’

    This simplified “understand, monitor and control” approach is enabled by Hosokawa combining operational data from smart sensors with machine to machine (M2M) communication and unique process optimisation software.

    ‘The ongoing data analysis will provide important insight into all aspects of the plant’s production performance and the status of production assets and aid strategic decision making, scheduling, predictive maintenance and operational availability. For our contract food processing customers, an immediate benefit has been a reduction in out of specification material, with us now getting it right more than 98% of the time.’

    Building on the operational benefits and knowledge gained from this project, Hosokawa recently launched a new business unit, Hosokawa Gen4, to support companies within the process sector to develop their own digital strategy and realise the potential of IIoT technologies. Hosokawa’s distinctive ability in blending human expertise with data analysis, knowledge capture and its application within the process environment, sets them apart from others in the marketplace.

    Hosokawa Gen4 is now working with production managers across all tiers of the food and wider processing industries to offer a flexible, cost effective way for them to maximise the opportunities of ‘data driven manufacturing’ to enhance continuous improvement techniques to maximise yield, reduce waste and save energy.

     

    Hosokawa Gen4 Global Business Manager, Paul Gilroy says, ‘If you want to find out more about our solutions and how Hosokawa Gen4 can help increase plant availability, maintainability and reliability, I will be happy to speak with you and share our experiences. Download our free Remote Monitoring App and see for yourself how new digital technologies are applied in our own contract processing facility.’

    http://www.hosokawagen4.com/rems-app-for-free-download/

    Processors Benefit from Hosokawa’s Smart Manufacturing Journey
  6. Hosokawa’s Dispensary Booth Design Proves Tipping Point for Pharmaceutical Manufacturer
    23 July 2018

    The investment in new production technology at their North of England, Centre of Excellence led a leading manufacturer of innovative pharmaceutical products to seek supplier support in the provision of a containment system capable of delivering operator protection from hazardous airborne particles generated during manual product transfer.

    The requirement was for a dispensary downflow booth designed to support dispensing and weighing out of active/excipient pharmaceutical powders with the ability to meet low OEL levels during drum tip, invert, dock, mill and IBC transfer, (all fully interlocked with client MES).

    In line with a comprehensive user requirement specification, the pharmaceutical manufacturer requested Hosokawa Micron Ltd to develop a bespoke, GMP design, multi-functional, dispensary weigh booth.

    Hosokawa engineers designed a bespoke, 5m wide, recirculation, dispensing downflow booth suitable for the handling of OEB3 compounds with a time-weighted average less for process operator level (OEL) less than 0.100mg/m3 (<10µg/m3) with the addition of a high containment barrier screen. The booth consistently meets these target OELs over an 8hr period to deliver a high level of operator protection. Full on-site OEL testing was undertaken by Hosokawa Micron’s industrial chemist in accordance with ISPE Guidelines and SAT tests validates these figures.

    The downflow booth is designed with an increased safe working zone of 2m. Customer requirements for all operations to be on one level and with space and height constraints due to location of structural beams and room layout.

    The downflow booth is fitted with a temperature cooling package and attention to handling equipment noise levels helps to provide a more comfortable working environment for operators. The individual units are designed for quiet operation (less than 70dba).

    The two drum inverters will be used for dispensing larger excipients: Each drum inverted equipped with a funnel, butterfly valve and valve outlet chute. The 5d screen is used during the opening of raw material drums to limit operator exposure.

    Raw materials for dispensing into IBCs are presented in a range of multiple drum sizes to be discharged into an IBC using a drum tipper and post hoist inverter.  Space restrictions determined that drums be lifted and inverted using either the drum tipper or post hoist to allow for the 120⁰ or 180⁰ rotation required to invert for discharge. If the raw material requires milling the material enters the IBC via the mill which is part of the dispensing train but which only has the impellor and screen fitted when required.

     

    A vacuum lifter is used to lift a raw material drum off the pallet and place the drum on the inverter where it is clamped into position and fitted with drum discharge cones for easy, dust free discharge of drum contents. Drums are then lifted and lowered onto the mill and docked and locked into position for discharge.

    The drum tipper and inverter provide the ultimate method for safe lifting for reasons of safety, accuracy, repeatability and low maintenance.

    A downward inflating packing head located below the mill outlet inflates against the IBC inlet to ensure closed transfer of materials from mill to IBC. A mill frame with combined IBC guide rails ensures the IBC is perfectly docked for filling prevented product egress which may present a health and safety hazard.

    The customer commented, ‘We have worked with Hosokawa on similar installations and always find them easy to work with, taking time and effort to work closely with our in-house team and other suppliers to ensure an optimum, holistic solution. The input from Hosokawa’s experience engineers is invaluable, not least in the early design stages with physical and visual mock ups that reassure all members of our team including our H & S and maintenance managers, that we have the best design possible for the task.

    Carl Emsley, Hosokawa Micron comments, ‘A complete wooden mock-up of the installation was built in our workshops to enable the internal layout of equipment to be ergonomically assessed for optimum positioning. We also undertook a Computational Fluid Dynamics simulation to show air flow distribution/movement to ensure positioning of both equipment and personnel did not compromise efficiency of the booth. The use of CFD technology allows layout changes to be made at early design stage – not only speeding up the design and build processing but also eliminating costly design errors. This was particularly beneficial when working with several 3rd party equipment suppliers on this challenging project.’

    Hosokawa’s Dispensary Booth Design Proves Tipping Point for Pharmaceutical Manufacturer
  7. Hosokawa Agree Service & Spares Provision for IIT Ltd Equipment
    26 July 2017

     

    Leaders in powder and particle processing, Hosokawa Micron Ltd have today announced it has signed an agreement with Hippisley Ltd to acquire the Intellectual Property Rights of International Innovative Technologies Ltd. (IIT).

    The acquisition assigns Hosokawa Micron Ltd the rights to provide maintenance services and spare parts for the range of comminution/size reduction equipment known as the m-series of mills (M350 and M600), the c-series of classifiers and the s-series of cyclone separators.

    Owners of m-series, c-series and s-series equipment should contact either Dave Lyon dlyon@hmluk.hosokawa.com or Keith Sanderson ksanderson@hmluk.hosokawa.com at Hosokawa Micron Ltd to discuss options for continued equipment after care and spare parts support.

     Hosokawa Agree Service & Spares Provision for IIT Ltd Equipment
  8. Safe Toll Processing Service for Food Allergens
    13 June 2017

    Food processors now have safe processing options for a number of foods containing allergens thanks to Hosokawa Micron’s specialist toll processing service which features segregated hygienic processing suites and a rigorously controlled food safety and quality programme in conjunction with a robust allergen control plan.

    Kathryn Hipkins, Technical Centre Manager, Hosokawa Micron Ltd, explains, ‘We always know what products are arriving at our site. The materials that are processed in our food processing suites are sourced from accredited sites that are free from or control allergens. We regularly retrieve information from our clients regarding allergen policies and assess the accreditation and grade of the raw material supplier.

    We have two food processing areas that are fully segregated and have dedicated PPE and colour coded clothing. One is for the production of allergens and the other is for the production of allergen and gluten free materials. This has been positively received by those companies who do not have the capability or required accreditation for segregation and allergen management which we can provide through a rigorous HACCP programme which involves 3rd party laboratory swab testing and validation of our toll processing suite and its equipment.

    Successful milling of products containing allergens, specifically for use in food supplements containing allergens such as milk calcium, lactose and fish gelatin are testament to our fastidious procedures and validated cleaning regimes, product and process isolation and thorough understanding of procedures in which all our personnel undertake training to prevent cross contamination occurring on our site.’

     Safe Toll Processing Service for Food Allergens
  9. Growing Reputation of Hosokawa’s Agrochemical Agglomerates System
    30 May 2017

    Delivering high speed, continuous production of agrochemicals with good flow properties, long shelf life and good dispersibility and wettability the Hosokawa Micron agglomerator/humidifier system is becoming increasingly popular with producers of agrochemicals.

    At the heart of the system is the Hosokawa Flexomix, mixer agglomerator a high speed, continuous instant mixing unit which ensures very even, homogenous humidification of the particles.

    Pesticides are produced either as dry agglomerates or as dry, extruded product, having the appearance of either small cylindrical shaped pellets or spheronised round particles. The agglomerates are produced by thoroughly mixing a micronized, powdery premix with a liquid binder, such that the particles will stick to each other to form larger particles.

    For both agglomeration and extrusion process, The Hosokawa Flexomix is suitable for agglomeration and extrusion production processes.

    Agglomerated product:

    In case of agglomeration, the homogeneous mixing in the Flexomix ensures efficient formation of agglomerates with uniform quality, resulting in a high process yield. These agglomerates are porous and slightly irregularly shaped ensuring a good wettability and dispersibility.

    The Flexomix has a self-cleaning mixing chamber, which minimizes adherence of moist product to the mixing chamber wall, allowing a relatively high liquid addition ratio as required.

    The agglomerates formed in the Flexomix fall from the Flexomix into a Fluidized Bed Dryer and are dried to the required final moisture content.

    Extruded product:

    In case of extrusion, the feed product is evenly humidified in a Flexomix prior to extrusion. This is carried out using a low-pressure extruder, such as a Bextruder, basket extruder which passes an extrudable mass through a perforated orifice plate. The low pressure in which this extrusion takes place ensures that the extrudates remain relatively porous, maintaining the required good dispersibility. A humidified feed product with very homogeneous moisture content is essential to achieve optimum extrusion results with a maximum yield and minimum of clogging of the extruder.

    In new plants, the Flexomix is the equipment of choice for both a direct agglomeration process as well as the wetting / humidification step in case of an extrusion process to ensure a maximum extrusion performance.

    In a lot of cases, the installation of the Flexomix in existing plants to replace existing (less effective) agglomeration or humidification devices has also proven to be very successful to significantly increase the yield and reduce the down time due to e.g. clogging to a minimum.

    The Flexomix is used for this application by major water dispersible, granular crop protection agent producers, world wide.

     

     

     

    ENDS

     For further information/reader enquiries, please contact:  Hosokawa Micron Ltd, Rivington Road, Whitehouse Industrial Estate, Runcorn, Cheshire, WA7 3DS.   Tel: +44 (0) 1928 755100                                 Fax:+44 (0) 1928 714325 Email: info@hmluk.hosokawa.com  www.hosokawa.co.uk

    For further editorial please contact: Elaine Brooks at B C Marketing Ltd, 7 Eastway Business Village, Olivers Place, Preston, Lancashire.  PR2 9WT. Tel: (01772) 654654 Email: elainebrooks@bcmarketing.co.uk        

     

     

    Growing Reputation of Hosokawa’s Agrochemical Agglomerates System
  10. Removing Residue from Bulk Mixers – Enhanced Dry Cleaning
    12 May 2017

    When mixing bulk solids, residues can pose the threat of cross contamination or introducing product impurities so what are the options for mixer cleaning if these threats are to be avoided.

    As rinsing mixer and screw with water and cleaning agents brings unwanted moisture into the system which can cause creation of lumps in the product, wet spots behind O-rings or gaskets and generate vast quantities of contaminated water or other cleaning fluids that have to be dealt with, here we consider the best dry cleaning approaches to minimise the propagation of bacteria.

    Stewart Bryan, Hosokawa Micron Ltd, suggests, ‘Let us firstly look at the options to reduce the cleaning effort required by reviewing the process design, the vessel used, material transfer steps and any liquid additions. It is often the case that original processes are simply repeated even though the products involved have changed thus generating your own problem. Often it is difficult to review the process without bias and you may find speaking with a powder processing specialist such as Hosokawa can help.

    Secondly look at the mixer design, what are the features that will aid dry cleaning regimes for minimising cross contamination’.

    • Conical mixer designs, with inclined surfaces and gravity discharge leave little opportunity for powders to form residues. In the case of the Hosokawa Vrieco Nauta Conical Mixer there are no horizontal or vertical partitions or sharp corners and as few joints, flanges and seals as possible come into contact with the product eliminating the potential to harbour residue.
    • For restriction free discharge a central bottom outlet offers best options for complete emptying.
    • In a conical screw mixer opt for open screw flights.
    • Powders simply slide off smooth surfaces without seams so a one part mixer is ideal for dry cleaning. With these and other sanitary design features only an extremely low amount of residue (<0.05%) remains when the Vrieco Nauta mixer is emptied, minimising the risk of subsequent batch contamination

    Common deposit collection zones

    Zone 1 is the surfaces above the product level of the filled mixer, mainly caused by dust, dispersed by filling. This can easily be blown away by compressed air.

    Zone 2 is the surface of the vessel below the filling level, in contact with the movement of powders. Addition of liquids to the mixture will increase adhesion to the mixer wall. Cleaning with a cloth may remove such residue.

    Zone 3 the mixing screw and in particular the underside of the blades can be difficult to clean without brushes and friction tools to break the residue from its bond with the blade.

    Whilst CIP dry cleaning of residues is both difficult and time and labour intensive Hosokawa Micron Ltd suggests a number of solutions to enhance the cleaning of conical mixers that can be applied to both dry bulk powder mixing and moist mixtures containing a small percentage of liquid.

     

     

    Enhanced Mixer Dry Cleaning

    A large inspection door in the vessel wall creates an opening through which the operator can easily access all surfaces to be cleaned. Areas for special cleaning consideration include screw flights and the lower surface of the screw blade. The large opening also aids visibility of areas to be cleaned. The full and correct closure of this door is a significant safety factor when the mixer is in operation.

    A semi domed cover, welded to the cone, offering a large radius and no crevices in which bacteria might settle offers enhanced cleanability.

    Hosokawa’s Isem ball segment valve with its rounded interior surfaces reduces the possibility for material deposition to a minimum. An inspection port in the valve is available as standard. In case deposits have to be removed this can be done using special tools.

    ‘Of course there are many, mainly wet or sticky mixing applications where dry cleaning is not an option and wet cleaning is inevitable. In the case of the example, Vrieco Nauta mixer, there are enhanced wet CIP options that are more appropriate,’ explains Stewart Bryan.

     

     Removing Residue from Bulk Mixers – Enhanced Dry Cleaning
  11. Certified Halal, Kosher and Safe Food Toll Processing
    4 May 2017

     

    Increasing numbers of food processors are taking advantage of Hosokawa Micron’s FSSC 22000 food safety management, Halal and Kosher certified toll processing service to meet demands for improved cleanliness, purity and quality in food production.

    Whether companies lack capacity, need access to specific processing technology or are not certified to handle certain ingredients or processes, cleaning regimes or product segregation, Hosokawa Micron can provide the solution.

    Kathryn Hipkins, Technical Centre Manager, Hosokawa Micron Ltd comments, ‘We have over 50 years’ experience and expertise in food processing and can meet one off or on-going requirements in critical and high purity, batch production applications. Kosher and Halal foods is processed in our toll processing facility adhering to strict procedures to deliver a range of traceable, honest and pure goods. Our ability to process goods in accordance with strict procedures is increasingly of interest to those producing goods for those with food sensitivities and is becoming more widely accepted food production practice across a range of goods.’

    With a range of equipment and food technologies to hand, including mixing, milling, separation, granulation, classifying, agglomeration and pack off available Hosokawa can meet a vast range of food processing requirements tailored to meet one off or regular production needs.

    ‘We can work with you to ensure optimum production from choice and design of powder processing and ancillary equipment, product control specifications and cleaning regimes to full batch production documentation, product quality guarantees and validation certificates and secure packaging so you can be confident in outsourcing even critical product production with Hosokawa Micron Ltd.

    Certified Halal, Kosher and Safe Food Toll Processing
  12. Downflow Booth Installation for Leading Cosmetics Company is a Real Beauty
    19 November 2016

    Hosokawa Micron Ltd faced considerable challenges when designing two new downflow booths for the world’s leading cosmetics’ company, due to space limitations in the existing facility and build restrictions cause by structural steelwork, at the Paris site.

    The scope of supply was for one booth suitable for the handling of powders and another, smaller booth suitable for handling solvents.

    It was crucial to the customer that all designs focused particularly on the protection of operational personnel from harmful dusts and fumes and also that products were protected from risk of contamination. In response the booths are designed to offer high levels of operator protection from potentially hazardous dusts and fumes and potential product contamination.

    Before commencement of the project a full risk analysis was undertaken which examined all potential risks from the toxicity and flammability of the materials handled and dust exposure limits to the compatibility of materials handled and the explosion risks. Standard operating procedures and the number of people operating within the booths and production areas were also considered in order to ensure the optimum booth design and configuration. Hosokawa Micron’s use of computational flow dynamic software allows design engineers to see, right at early design concept stage, how airflows can be affected by placement of objects or people and how they can conflict with other directional airflows.

    Said Carl Emsley, Sales Manager, Hosokawa Micron Ltd, ‘In order to future proof and deliver flexibility of operation the booths were designed to accommodate a range of tasks dispensary and sampling tasks plus manual and automated materials handling. Our designs and the finished facility are sympathetic to these demands, offering easy access, well planned and flexible work zones and integrated equipment positioning. The ergonomic design of the booths is enhanced with cooling packages for workplace temperature management to create a more user friendly work environment, ECM filter monitoring, high efficiency fans and LED lighting plus recessed housing for ease of storage and accessibility of tools. The placement of the solvent handling booth also allows for a space saving mezzanine floor above.’

    Powder Handling Booth

    Hosokawa Micron supplied an 8m wide, recirculation downflow booth, which delivers a conditioned downflow of air from the booth’s ceiling inlet plenum pushing any dust downwards and away from the operator’s breathing zone. The air is extracted from the booth via low level exhaust grills and through a series of filters prior to recirculation into the booth’s working area. Safe change filters accessed from the technical zone at the rear of the booth eliminate exposure of operatives to airborne particulates.

    Solvent Handling Booth

    The single pass booth operates a vertical airflow, pushing dusts and vapours downwards and away from the operator’s breathing zone with air discharged through a fume scrubber to atmosphere ensuring that solvent fume laden air will not be recirculated back into the booth and minimising the risk of explosion associated with solvent fumes.

    Hosokawa Micron Ltd engineers worked closely with the customer to establish the optimum system design to ensure the most ergonomic solution capable of delivering operator protection across both booths and the facility. Operations Manager, Mr. Raul, has expressed his satisfaction with both quality and performance of the Hosokawa products.

     ‘Our engineers have worked closely with the customer, listening and responding to the customers’ wishes to create an integrated, ergonomic design  solution that improves the working environment for personnel and meets the demand for an integrated facility. ’ comments Carl Emsley, Hosokawa Micron Ltd.

    Downflow Booth Installation for Leading Cosmetics Company is a Real Beauty
  13. Tea Time in No Time with the Cool Performance New Micron Glacis GC Mill
    19 November 2016

    Hosokawa Micron Ltd announce the development of the high performance cooling type, mechanical mill, the Micron Glacis GC fine grinding mill. Suitable for fine grinding of heat sensitive products, the Micron Glacis GC is ideal for the high volume grinding of green tea which is popular both as a beverage and for use in confectioneries too.

    The fine grinding and low heat generation of the Micron Glacis GC produces a tea with good mouth feel, texture, taste and mellow flavour. The Glacis is able to achieve a high cooling efficiency (7.5 times more than the conventional mechanical mill) by running coolants through the outer liner and grinding rotor. The Glacis can ultra-fine grind low-melting point, heat-sensitive materials that we impossible with conventional units.

    The Micron Glacis GC offers the particle grinding size accuracy of a jet mill (10 - 20µm) but with a higher volume capacity but with a 50% lower energy consumption.

    Material is ground by strong impact and shear force generated at the space between the grinding rotor and the liner. Both the grinding rotor and the mill lining are specially designed with an effective cooling structure which alongside the reduced air volume required by the unit for cooling actively prevents product oxidation and therefore deterioration of the tea quality.

    The Glacis has a low air volume requirement relative to grinding power which means the additional auxiliary equipment such as the blower and bag filer can be scaled down, allowing for a compact installation.

    Tea Time in No Time with the Cool Performance New Micron Glacis GC Mill
  14. Hosokawa Micron Engineers Are Riding High on New Buggy Fill/Weigh Booth
    29 September 2016

    Hosokawa Micron Ltd announce the launch of a new ‘twin, buggy filling and weighing, containment booth’, designed to handle safe, easy and accurate FIBC filling.

    Designed in co-operation with a leading detergent manufacturer, to meet the demands of the high volume product transfer of potentially sensitising powders, the containment system is uniquely configured for automated filling of FIBCs located on a wheeled buggy frame.

    The booth is connected to the customer’s HVAC system to generate a horizontal laminar airflow which captures airborne particulates generated in the filling operations. The contaminated air is then extracted through the combined booth plenum to a remote filtration system.

    Double opening doors at the front of each booth allow easy access for the manual loading of the FIBC buggy. As the buggy is pushed into position the FIBC lid is automatically lifted, eliminating the need for an operative to undertake this procedure by standing on a step ladder. Guide rails ensure accurate positioning beneath the downward sealing filling head. Once the buggy is in position (defined by a sensor) a mechanic clamp device holds the wheeled buggy in place.

    Doors are interlocked to prevent unauthorised entry whilst filling operation takes place.

    On disengagement and removal of the buggy from the filling and weighing system, the FIBC lid is closed.

    Accurate filling and weighing is controlled from outside the booth and once filled the FIBC buggy can be wheeled away with operatives protected from potentially sensitising or hazardous, residual airborne dusts.

    The booth incorporates a single rear, personnel door for safety and ease of all round access and maintenance. The booth is equipped with integrated weigh scale, internal lighting and integral dust monitoring system.

    Hosokawa Micron Engineers Are Riding High on New Buggy Fill/Weigh Booth
  15. The Rising Tide of Super Seaweed
    29 September 2016

    Tipped as one of the superfood trends of 2016, seaweed is packed with minerals, vitamins, fibre, omega 3 and protein, often being added to food as a nutrient boost. Claims that it can prevent colon cancer, control blood glucose level and aid digestion make it of significant dietary and health interest whilst sustainable farming and harvesting methods have led to seaweed’s recognition as a ‘futurefood’ as well as a superfood.

    The fibrous, wet and often sandy or gritty, seaweed is however difficult to process with costly and time consuming drying times. To reduce the drying process seaweed is often chopped to facilitate more rapid, less nutrient destructive drying processes.

    For many years processing experts Hosokawa Micron Ltd have offered processing solutions to alginate producers across the world. To meet the demands for milled, freshly harvested seaweed Hosokawa Micron Ltd has developed a two stage system comprising of a Prebreaker and Vertical Disintegrator. This low energy system offers uniform particle size reduction of wet or moist seaweeds for further processing, which offers higher levels of availability compared to conventional hammer mills.

    Once the friable materials have passed through the initial size reduction (Prebreaker) stage, they are transferred directly to the Hosokawa Micron Vertical Disintegrator to be further reduced to a uniform particle size.

    Designed for the reduction of fine to coarse, wet, moist or dry materials, the Hosokawa Micron Vertical Disintegrator provides automatic and continuous separation of disintegration resistant materials with redirection through the system from the exclusive secondary discharge.

    Uniform particle size is achieved as materials are subjected to repeated impact and attritional force from the high speed rotating hammers, and carried by centrifugal force through a perforated sizing screen. The vertical screen frees itself of product instantaneously during processing, which is ideal for products with a high moisture content.

    Barry Walmsley, Product Manager, Hosokawa Micron Ltd says, ‘The sturdy system, can operate at 12- 20 t/h.  It is low noise and delivers product in a narrow particle size distribution, resulting in higher yields and less effluent. The Disintegrator is designed to withstand corrosion caused by the low pH often involved in the process and erosion caused by the natural inclusions which determines a predominant use of higher abrasion resistant materials of manufacture.'

    The Rising Tide of Super Seaweed

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