www.matconibc.

com

How to get a good Mix

& keep it
Dave Newell

WHO ARE MATCON?

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Suppliers of IBC systems

for efficient & flexible
powder handling

WHERE ARE WE LOCATED?

Worldwide presence
Supported by Agents

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Established offices

Agent representative

MATCON STRUCTURE

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UK based decision centre

90 + employees worldwide
Working across all powder industries with a speciality
focus on Food & Pharma
Dedicated After-Sales support
Sales, Engineering & Factory under one roof
Part of IDEX a $2bn corporation in Illinois

SECTORS OF EXPERIENCE

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OUR EXPERIENCE
Pharma:
High quality
Regulated
Hygiene important
Product integrity

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Pharma
20%
Other
20%

Chem/Ind:
Heavy duty
Durable
Robust

Nutrition
20%

Food
40%

Nutrition:
High volume
High quality
Flexibility
Hygiene important
Product integrity

Food:

High volume
Efficiency
Flowability
Blend homogeneity
Prevent Segregation

OUR CREDENTIALS

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Achieving
Homogeneity

BEVERAGE BLENDS
Bulk Density is varied
Minor additives
Wide % range of ingredients
High sugar content
Segregation is a big issue

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FLEXIBLE MANUFACTURING LAST DECADE

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SOME CHALLENGES OF FIXED MIXERS

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Ability to accommodate a range of batch sizes

How to handle Allergens
Tainting from heavy flavours
Cannot empty it 100% - waste
Amount of cleaning time needed
How can it be validated as clean?
Waiting time is unproductive
How can you grow efficiently?

THINK DIFFERENTLY!

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HOMOGENEITY WHAT AFFECTS IT?

Blending time / speed
Filling volume
Blending machine type
Powder characteristics particle size, density
Order of formulation
Transfer method

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THE CONVENTIONAL WAY

High shear
capabilities

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DEFICIENCY IN THE CONVENTIONAL WAY

1 hour

Lost time in
waiting

10
mins

1 hour

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IBC BLENDING

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Same capacity of up to 5
static mixers
Blend what ordered
Reduce Inventory
3-4 batches per hour
Blend whatever & whenever
Maximise OEE
Building space savings

IBC BLENDER INTENSIFIER

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Extending blending range

Mix liquids & fats
Micro ingredients dispersed
Cleaning off-line

THE PROOF

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Recent example of CV-values

15 min blend
time

18 min blend &

Intensifier

Fe

Vit C

Fe

Vit C

#1

8.42

6.17

1.63

3.54

#3

3.18

1.26

Using the Intensifier for more homogenous blend

HOW CAN YOU PROVE IT

Test facilities around world
Client run trials
Use tracer as reference
Use discharge not thief sampling

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BLENDING DIFFERENT SIZED IBCS

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Segregation of
Beverage Powders

WHAT IS SEGREGATION?

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Segregation = previous uniform particulate ingredients

separate into different concentrations after handling
of a powder blend or material with a varied particle size
Core Flow

Elutriation

Percolation

POOR PROCESS DESIGN

Mixer Emptying

Packer Refill

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Transfer Drop

HANDLING THE FINISHED BLEND

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Cone Valve technology

Prevents segregation
Controlled mass flow
Complete discharge
Handle difficult powders
Automatic operation

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CASE STUDY

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WETRA BACKGROUND

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Formed in 1997 in Malaysia

Originally just marketing coffee produced by others
Wanted to capture more market share & control quality
Brought manufacturing in-house
Supplying locally & exporting to South East Asia

OBJECTIVES

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Provide excellent product quality

Manufacturing flexibility with fast response times
Low levels of inventory or WIP
Dust containment for cleaner environment
& operator safety

WHY MATCON?

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Engineering support
Future-proof allowing for expansion plans
Optimisation of factory layout for maximum efficiency
Agile system for small runs
Ability to switch recipes quickly
Dust control

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THE REWARDS

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Matcon system meets Wetras high requirements

Produce same amount as the old system but in
1/6th of the time
Increased capacity = expansion of the business
Flexibility drives product innovation
Faster response times
Improved hygiene standards have boosted staff
motivation

WHAT DO WETRA SAY?

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Matcons IBC system has enabled Wetra to

reduce costs and blending time, improve
productivity and enhanced food safety &
quality. This has greatly sharpened our
competitive edge to venture into the global
market and spur our business growth
Mr Loh Tak Heng,
Managing Director

DONT FORGET WE OFFER

Flexible powder handling & processing

Matcon IBCs offer product integrity

Worldwide presence for local support
Underpinned by 35 years of experience

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Questions????