The SmartMixer

The SmartMixer is an innovative new type of mix system designed for accurate real-time mixing of a wide range of dairy products.  Although primarily geared towards the dairy industry, the system is also likely to have benefits for other industries where mixing and blending is required.

It produces the exact amount of the correct specification end product using three ingredient streams, any of which can contain fat as well as solids.  Uniquely, it achieves this by calculating each batch just prior to manufacture, using the parameters of the ingredients available on the day, then solving a series of simultaneous equations to calculate the precise amount needed of each ingredient.

The SmartMixer will then......

• Produce exactly the right amount in a continuous mode
• to a very tight product specification
• using any specification ingredients
• with greatly minimised wastage
• and no down time

For detailed information about the SmartMixer, please contact us directly using the online form and we will provide a technical PDF document.

SmartMixer Benefits

Accept ingredients of ANY specification that are available 

One of the key benefits of the SmartMixer is the ability to calculate each batch based on the information that is correct at the time.  So, if the cream fat% or concentrate TS% is different from normal, it really is not a problem, as the calculation will adjust all parameters to always produce the correct specification end product.

Calculate the exact amount of ingredients required

As the calculation results are displayed, the operator knows exactly how many litres of each ingredient will be required.  This allows the user to check they have enough of each product before starting the batch and also means that management will know exactly how many litres of each ingredient have been used.

Increase daily volume capacity

By comparison with traditional mix tank systems, the SmartMixer has proven its ability to double the daily volume capacity at one plant at which it was installed. This is due to reducing the delay between finishing one batch and starting another.  In general, while the operator is chasing the previous batch through the pasteuriser with water, the SmartMixer can be filling the buffer tank with product ready for the next batch, so that, when the pasteuriser is ready, the next batch can be immediately started. 

During normal running, the SmartMixer monitors the flow rates and the number of litres produced, and warns the operator if an ingredient tank has run out, if an incubation tank has reached its set number of litres and the overall progress of the batch. There is no need to keep checking the Fat % and TS % of the batch being produced, because the high accuracy of the SmartMixer equations and equipment, ensures that it will always be right.

Save time

Saving time goes "hand in hand" with increasing volume capacity, but it also means that the operator has more time available because the SmartMixer is reducing his workload.  Batch calculations are done in a fraction of a second.

Store recipes and allow alteration by authorised personnel

As standard, up to 16 product recipes can be stored by the PLC, but more can be added if required.  Each recipe consists of only two parameters, namely Fat % and TS %.  The recipe page is password protected so that only authorised personnel can view and alter the product recipes.  

Produce homogenous end products

One of the problems with traditional mix tank systems is that fat in the mixture will tend to rise to the surface of the mix tank while the batch is being processed.  This leads to varying fat contents and varying times during the batch and can lead to inconsistent fat contents in the final end product tanks.  The SmartMixer mixes the ingredients on a "just in time" basis so the fat content in the end product is entirely consistent across the entire batch.

Produce exactly the same amount of end product chosen

Not only does the SmartMixer produce exactly the right amount of the end product, but it also uses exactly the right amount of each ingredient.  A batched is not deemed "finished" until the calculated amount of each ingredient has been delivered to the buffer tank.  It is a tribute to the accuracy of the SmartMixer that, even during runs lasting several hours, the three ingredient flows normally finish within seconds of each other.

No Wastage

During normal running, it is fair to say there is NO wastage.  All the ingredients are delivered in the correct quantities to the buffer tank and all the contents of the buffer tank are delivered to the pasteuriser balance tank.  On the last run of the day, before cleaning, it is possible to arrange it so that all of the ingredient delivery lines are purged to SmartMixer right at the end of the batch, ensuring NO wastage.  Even if not purged, only a small amount of product remains in the pumps and lines of the SmartMixer.

No cleaning problems

All equipment (pumps, lines, valves etc.) are stainless steel and produced to the highest standards.  The buffer tank has sprayballs, and the SmartMixer can either be cleaned as part of the pasteuriser clean or by a separate CIP clean.

More Information

If you are interested in the SmartMixer and would like more information, please call or email MSA so that we can discuss your requirements in further detail.

Click here for MSA contact details.