Movable Emulsifier Equipment Application Case Study
In the production of diversified viscous food condiments, such as salad dressing, fruit jam, and spicy sauce, the need for flexible switching between multiple production stations and compatibility with different tank specifications directly affects production flexibility and operational efficiency. A manufacturer engaged in multi-variety condiment processing once faced bottlenecks caused by fixed emulsifier equipment, which restricted the optimization of multi-batch, multi-specification production lines. The introduction of movable emulsifier equipment effectively addressed these challenges, achieving a comprehensive upgrade in production flexibility, equipment utilization, and processing consistency.
Background: Mobility-Related Dilemmas in Multi-Station Production
The manufacturer’s production line involved simultaneous processing of six types of condiments, with each product assigned to an independent mixing tank and processing station. In the traditional production process, each station was equipped with a fixed emulsifier, leading to multiple operational bottlenecks centered on equipment mobility and utilization.
Firstly, low equipment utilization and high investment costs. Fixed emulsifiers were dedicated to specific stations, while some low-yield products (such as special-flavor salad dressing) only occupied the equipment for 3-4 hours a day, resulting in idle capacity of nearly 60% for some devices. To meet production needs, the manufacturer had to invest in multiple fixed emulsifiers, increasing initial equipment investment and subsequent maintenance costs.
Secondly, limited production flexibility and long batch switching time. When adjusting production plans (e.g., increasing the output of fruit jam and reducing spicy sauce), fixed equipment could not be rearranged between stations. Workers had to transfer materials between different stations, which took 40-50 minutes per batch and increased the risk of material contamination and loss. Moreover, the mismatch between fixed equipment parameters and new product specifications often led to inconsistent emulsification effects during trial production of new condiments.
Thirdly, cumbersome equipment maintenance and site constraints. Fixed emulsifiers were installed in fixed positions, making it difficult for maintenance personnel to access the bottom and side parts for inspection and repair. The layout of pipelines and wires of fixed equipment also restricted the adjustment of production line layout, hindering subsequent process upgrading. Additionally, the fixed structure made cleaning between different products time-consuming, as residues in dead corners of pipelines were hard to remove, prolonging the interval between batches.
Furthermore, the production workshop had limited space, and the occupation of multiple fixed emulsifiers led to crowded operating areas, increasing the risk of operational safety hazards and reducing worker efficiency.
Solution: Introduction and Application of Movable Emulsifier Equipment
To solve the above problems, the manufacturer selected a movable high-shear emulsifier equipment with customized specifications, integrating mobility, high-efficiency emulsification, and flexible docking functions. The core design of the equipment focuses on multi-station adaptation and operational flexibility, perfectly matching the needs of multi-variety, multi-batch condiment production.
The mobility system of the equipment is equipped with heavy-duty universal wheels with locking devices, which can bear the weight of the whole machine (including the emulsification head and control cabinet) and move smoothly on the workshop ground. The wheels are equipped with shock-absorbing pads to avoid vibration affecting emulsification effect during movement and ensure stable positioning after locking, with no displacement during operation. The equipment height is steplessly adjustable (800-1500mm), enabling quick docking with mixing tanks of different heights (50L-500L) at various stations without additional adapter parts.
In terms of emulsification performance, the equipment retains the high-shear stator-rotor structure (adjustable gap 0.2-0.3mm) and 360° scraping wall stirring function, generating strong shear force to ensure uniform dispersion of materials and avoid residue on the tank wall. The control cabinet is integrated with the main machine, equipped with a touch-screen operation panel that can store parameter settings for different products, enabling quick parameter switching when moving between stations. The equipment adopts a detachable emulsification head, which facilitates cleaning and avoids cross-contamination between different condiments.
Before formal commissioning, the manufacturer conducted on-site tests at multiple stations, optimizing the moving route, docking time, and operation parameters. For high-viscosity fruit jam, the optimal parameters were determined as: high-shear speed 6500rpm, stirring time 45 minutes, and equipment height adjusted to 1200mm. For low-viscosity salad dressing, the parameters were adjusted to: high-shear speed 5500rpm, stirring time 30 minutes, and equipment height adjusted to 900mm. The test results showed that the equipment could complete station switching within 5 minutes and achieve stable emulsification effect consistent with fixed equipment. Based on these data, the equipment was officially put into production.
Results: Comprehensive Improvement in Production Performance
After the movable emulsifier equipment was put into operation, the manufacturer’s production process achieved significant improvements in flexibility, equipment utilization, production efficiency, and cost control, with measurable data verifying the application effect.
In terms of flexibility and equipment utilization, the movable design enabled the equipment to cover 6 production stations, replacing 4 fixed emulsifiers. The equipment utilization rate increased from 40% (for fixed devices) to 85%, as it could be quickly transferred to different stations according to production needs. For low-yield products, the equipment could be shared between stations, eliminating idle capacity. During new product trial production, the equipment could be flexibly docked with small test tanks and large production tanks, reducing the time for parameter adaptation by 60% and ensuring consistent trial production and mass production effects.
In terms of production efficiency, the station switching time was shortened from 40-50 minutes (material transfer between fixed stations) to 5 minutes, a reduction of nearly 90%. The detachable emulsification head and integrated cleaning design reduced cleaning time per batch by 35%, shortening the interval between different product batches. The parameter storage function avoided repeated adjustment when switching products, saving 10-15 minutes per batch. Overall, the daily production capacity increased by 1.8 times compared with the traditional process, while the number of equipment in use decreased by 60%.
In terms of cost control, the reduction in fixed equipment investment saved initial capital expenditure by 45%. The shared use of a single movable emulsifier reduced maintenance costs by 50% (compared with maintaining multiple fixed devices), as only one set of equipment required regular inspection and wearing parts replacement. The reduction in material transfer and cleaning time lowered labor costs by 30%, and the avoidance of material loss during transfer reduced raw material waste by about 12%.
In terms of product consistency and safety, the stable positioning and uniform emulsification effect of the equipment ensured that the viscosity fluctuation range of each batch of products was controlled within ±3%, solving the problem of inconsistent quality caused by parameter differences between fixed equipment. The detachable and easy-to-clean structure eliminated cross-contamination between products, and the mobile design optimized the workshop layout, reducing operational safety hazards.
Long-Term Operation and Experience Summary
As of the current statistical period, the movable emulsifier equipment has been in continuous stable operation for more than 8,500 hours, with a failure rate of less than 1%. The heavy-duty universal wheels show no obvious wear, and the locking device maintains stable positioning performance. The detachable emulsification head and modular design facilitate maintenance, and the wearing parts (stator-rotor, sealing ring) can be replaced on-site within 30 minutes, ensuring production continuity.
The application practice shows that movable emulsifier equipment, with its flexible mobility, multi-station adaptation, and integrated operational functions, can effectively solve the problems of low utilization, poor flexibility, and high cost of fixed emulsifiers in multi-variety condiment production. By optimizing equipment allocation, shortening switching time, and improving utilization rate, it enhances production flexibility and efficiency, while reducing investment and operational costs.
For manufacturers engaged in multi-batch, multi-specification viscous food processing, the selection of movable emulsifier equipment should focus on load-bearing capacity, positioning stability, and docking adaptability. Customized height adjustment range and parameter storage functions, as well as strict on-site mobility tests, are key to ensuring the matching between equipment and production lines. The stable operation of this equipment not only provides a reliable guarantee for product quality and production flexibility but also lays a solid foundation for subsequent production line layout optimization and product category expansion.
Your message must be between 20-3,000 characters!