A leading Japanese manufacturer of nutritional therapy foods specializes in powdered formulations designed for patients with swallowing disorders and those requiring tube feeding. Hygiene is paramount in their production facility, where the sensitive nature of their products demands rigorous cleanliness and control.
Despite their dedication to quality, the company faced significant challenges with their existing setup, which hampered their ability to monitor and contain product flow and maintain an optimal cleaning process. Their main problem areas were their large, steel buffer tanks and a gravity-fed transition between a vacuum conveyor and hopper.
To address the issues they were facing, the manufacturer sought a solution that would not only optimize their processes but also eliminate powder leaks. Their search led them to the BFM® fitting connector system.
The plant used large 840L, stainless steel buffer tanks, which frequently encountered clogging, bridging, and ratholing issues. These blockages disrupted production and were notoriously difficult to clear.
Maintenance of these large tanks was another pain point.
Monthly cleaning required the tanks to be disassembled, relocated, and replaced—a process that demanded multiple staff members and spanned four days. This significant downtime strained both resources and productivity.
Additionally, the facility faced persistent dust leakage from a hopper connection positioned under a Piab vacuum conveyor (shown far right).
The powdered product entered the hopper through a free-fall mechanism, with only a short, one-ended clamped connector enclosing the flow. This setup failed to fully contain the powder, allowing dust to escape into the production area.
The leakage not only posed health and safety risks but also compromised hygiene standards in the plant.
The new system offered continuous visibility of product flow, a game-changing feature for monitoring and quality control. The transparency of Seeflex 040E allowed staff to detect blockages or quality issues in real-time.
Moreover, the anti-static properties of the material significantly reduced powder adherence to the hopper walls, minimizing disruptions caused by clogs. Any blockages that do occur can be easily remedied.
Maintenance processes were also transformed. Unlike the cumbersome steel tanks, the flexible connectors could be easily removed and transported by a single staff member. Cleaning time was drastically reduced, streamlining the overall workflow and minimizing production downtime.
To address the dust leakage issue at the hopper connection, a BLUEBAND™ connector system was installed. This solution fully encased the gravity-fed powder, creating a 100% sealed system that effectively prevented leaks.
By ensuring complete containment, the BFM® fitting solution has provided enhanced hygiene for both the product and the factory environment.
Improved Product Visibility: The transparent Seeflex material enabled constant monitoring, allowing staff to promptly identify and resolve any blockages or quality issues.
“We undertook lots of product tests on various options before deciding on changing to the BFM® fitting system,” shared the Maintenance Manager. “The transparency of the new hopper system lets us visually see the product and detect any issues before they become a problem. The ease of removal and refitting has made our regular cleaning processes much more efficient.”
By adopting the BFM® fitting connector system, the manufacturer achieved significant advancements in hygiene, monitoring, and efficiency. Their investment in innovative solutions not only resolved longstanding challenges but also set a new standard for operational excellence in the production of therapeutic nutrition products.
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