Production of food supplements

The product is fed from big bags and sacks and comprises up to 15 different raw materials, depending on the formulation. Despite this complexity, the system requires only two operators, who are responsible for replenishing the raw materials and changing the packaging materials.

All other process steps, including the operation of the HECHT systems and the mixer, are fully automated. A dedicated recipe management system is directly connected to the existing ERP system. The total throughput is up to 2.25 tonnes per hour.

Following goods receipt, the big bags containing the different raw materials are transported to two production rooms, where they are emptied using HECHT big bag discharge stations. These essentially consist of four main components:

• Connection system: Enables low-dust or dust-free emptying of the big bag.

• Support table: Supports the weight of the big bags and secures the load.

• Massage paddles: Assist the discharge of poorly flowing products through a massaging action.

• Frame with tensioning device: Ensures that the big bag outlet spout is securely fastened and tensioned.

Additional options can be incorporated depending on the installation conditions and specific requirements. A runway beam with a chain hoist and a loading harness are used to safely lift and position the big bags. Due to the high volume of raw materials, this project requires discharge stations equipped with an outlet spout connection system, massage paddles and a HECHT ball suction shoe with an integrated lump breaker function.

Minor ingredients and flavourings are added via two semi-open combined sack and drum charging hoppers. One hopper is used to screen crystalline products, while the other breaks up lumps. The raw materials are then transferred to the next process stage by vacuum conveying through two HECHT ProClean Conveyor PCC700 units into a 6,000-litre mixer manufactured by Gebrüder Lödige.

The HECHT  PCC700 conveyor system is specifically designed for use between value-adding machines, such as mixers and filling lines, in high-volume production environments. The PCC700 meets all GMP and FDA requirements, ensures a dust- and contamination-free environment and, thanks to its modular design, offers a high degree of spatial flexibility.

The operating principle is similar to that of conventional vacuum conveying systems: the bulk material is drawn in from the feeding station via pipework by means of negative pressure. The conveying characteristics can be flexibly adjusted – from free-flow conveying to plug flow and dense-phase conveying. Plunger conveying, in particular, prevents segregation right from the conveying process.

The high conveying capacity (up to 10 tonnes per hour, depending on the product) is achieved through:

• four large filter elements,
• a generously sized collection hopper,
• the parallel operation of suction and filter cleaning (with two filters in use alternately),
• and a total filter area of up to 3.6 m².

This design ensures a low pressure differential, which in turn allows even very fine-grained products (

The downstream Pflugschar® mixer operates using a centrifugal and vortex process that generates three-dimensional movement of the material being mixed. The Pflugschar® blades are arranged in such a way as to ensure complete coverage of the material. This results in rapid, homogeneous mixing without any dead zones. To meet specific requirements, rotating blade heads can also be integrated to break up agglomerates and enable targeted granulation.

To prevent metallic contamination, the conveyor lines for big bag raw materials and small components are fitted with horizontal metal separators.

Once the mixing process is complete, the mixer’s discharge flap opens automatically. The product is transferred into another suction shoe and then conveyed in cycles to the filling line via an additional PCC700 conveying system. Depending on requirements, either drums or big bags can be filled with the finished product.

To ensure a homogeneous, lump-free mixture, a centrifugal screening machine is installed below the PCC700 to remove oversized particles. In addition, a gravimetric metal separator ensures maximum product safety.

A filling head with an integrated back-trickle protection flap prevents product loss and dust formation when the system is at a standstill or the packaging materials are being changed. This keeps the process hygienic and clean during these phases.

Further key functions at a glance:

• A diverter allows raw materials to bypass the mixing system and be conveyed directly to the filling line. This enables the process to be run empty when containers have only been partially emptied or when packaging materials need to be changed.

• The entire production process is digitally monitored, documented and traceable. Raw materials are scanned and only released if they match the specified recipe. An automatic error-prevention system is integrated.

• The entire process requires only two operators to supply raw materials and packaging materials. All other operations are fully automated.

• The system has no idle periods as long as the supply of raw materials and the filling process continue without interruption. Sophisticated recipe and time management ensures semi-continuous operation.