case study
Candy Manufacturer Reduces Scrap and Saves US$25,000 with AutoJet® Spray System
Five month payback achieved by reducing scrap and decreasing release agent consumption.
Problem:
A leading manufacturer of candy mints was using employees equipped with handheld spray bottles to apply release agent to a 36" (0.9 meter) cooling wheel. When too little release agent was applied, the candy stuck to the wheel and had to be scrapped. Over-application of the release agent was costly and messy. Workers were unable to apply the proper volume of release agent consistently.
Solution:
After testing different spray pressures and spray set-ups, we identified which of our nozzles could deliver the desired performance without misting. Our solution included two PulsaJet® air atomizing nozzles and an AutoJet 1550+ Modular Spray System. One nozzle is positioned above the cable, and the other is below to provide complete coverage of the cable. The spray controller cycles the nozzles on and off very quickly to control the flow rate and ensure the proper volume of lubricant is applied. Flow rate adjustments are automatic and made nearly instantly when operating conditions, such as line speed, change.
Results:
The candy manufacturer has experienced many benefits since the installation of the AutoJet Spray System. Manual spraying has been eliminated and workers have been deployed to other tasks. The proper volume of release agent is now consistently applied on the cooling wheel resulting in an improvement in mint quality and a reduction in scrap. Other benefits include a 10% decrease in release agent use and a 10% increase in production. The manufacturer reports the system cost was offset in just five months and reduced operating costs by US$25,000 annually.
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