The Floveyor Hygienic Conveyor. It s perfect with food

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1 The Floveyor Hygienic Conveyor It s perfect with food

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3 About Floveyor Who we are Floveyor is an award winning third-generation family business. We design, manufacture and support materials handling solutions for powders and granules. In 1958, we invented and patented the aero-mechanical conveyor (AMC), commonly known as the Floveyor. Today 70% of our matchless AMCs are integral to high end food applications everywhere. What we do We simplify conveying by: > > finding ideal material handling solutions for powders and granules > > excelling in getting your raw materials into the process > > focusing on transferring your materials between processes Above all, we provide safe, globally compliant equipment that protects your product, your brand and reputation. Why food industry clients choose us They value their peace of mind. So, they rely on us to: > > apply our 60 years of relentless R&D to protect their competitive edge > > provide impeccable service and support in any situation at any time > > deliver what we promise - top quality equipment that surpasses industry best practice AFFORDABLE INNOVATION SERVICE EXCELLENCE SPECIALIST KNOWLEDGE 3

4 Meet the world s most efficient, food safe conveying system The Hygienic Aero-Mechanical Conveyor (AMC) is a fully enclosed conveying system. It is designed to pneumatically suspend and transfer bulk materials from a fixed inlet to a fixed discharge through a fully enclosed tubular conveying element. The product is suspended in air pockets generated behind the conveying element, or rope assembly discs. With the product suspended within this air pocket, there is no need for fans, compressors or high-flow filters, all of which require significant maintenance and create hygiene hazards. Due to its fully enclosed design, it effortlessly conveys dusty powdered products such as flour or milk power without contaminating the environment. In fact, the same Hygienic AMC system can convey products from the finest of powders up to large granules without any adjustments or issues. 4 The Floveyor Hygienic Conveyor

5 The Hygienic AMC s key capabilities Gentle Essential Conveys all kinds of materials from 20nm to 6mm particle size including granules, flakes, chips, and other fragile materials with little or no degradation Maintains crucial batch and blend integrity regardless of material properties, bulk density, particle size distribution, flow characteristics or moisture content Complete Rapid Conveys materials in total batch transfers, with negligible residue left in the system Achieves high throughputs while being small, mobile and devoid of large filtration requirements Modular Versatile Integrates seamlessly with existing plant and equipment, reducing installation requirements and minimising maintenance Operates at any angle without diminishing maximum throughputs Green Safe Operates as one of the most cost effective and energy efficient methods of dry bulk elevation and conveying Handles potentially explosive materials, with optional Zone 21/22 upgrades to suit environments as per ATEX 2014/34/EU High speed footage of material movement within the AMC The Floveyor Hygienic Conveyor 5

6 Elevate thousands of materials with one system Spice Mix Chocolate Powder Custard Powder Egg Powder Flour Desiccated Coconut Chocolate Pieces Muesli Salt Lactose Grains Teas 6 The Floveyor Hygienic Conveyor

7 This table shows nominal AMC throughput capacity for bulk materials frequently handled by Floveyor s F3 Hygienic AMCs. BULK MATERIAL CAPACITY BULK DENSITY CAPACITY BRAN 5 tph 300 kg/m3 16.7m3/hr 589 ft3/hr COCOA BEANS 12 tph 500 kg/m3 24.0m3/hr 848 ft3/hr COCOA POWDER 8 tph 520 kg/m3 15.4m3/hr 543 ft3/hr COFFEE BEANS 12 tph 400 kg/m3 30.0m3/hr 1,059 ft3/hr COFFEE POWDER 8 tph 300 kg/m3 26.7m3/hr 942 ft3/hr CORN (MAIZE) 12 tph 720 kg/m3 16.7m3/hr 589 ft3/hr FLOUR PRODUCTS 8 tph 363 kg/m3 20.7m3/hr 730 ft3/hr MALT 15 tph 650 kg/m3 23.1m3/hr 815 ft3/hr MILK POWDER (WHOLE) 5 tph 320 kg/m3 15.6m3/hr 552 ft3/hr OATS 12 tph 416 kg/m3 28.8m3/hr 1,019 ft3/hr PEAS DRIED 12 tph 760 kg/m3 15.8m3/hr 558 ft3/hr POPPY SEED 15 tph 500 kg/m3 30.0m3/hr 1,059 ft3/hr RICE 20 tph 720 kg/m3 27.8m3/hr 981 ft3/hr SALT 15 tph 1,200 kg/m3 12.5m3/hr 441 ft3/hr SOYA BEANS 12 tph 760 kg/m3 15.8m3/hr 558 ft3/hr SUGAR 12 tph 800 kg/m3 15.0m3/hr 530 ft3/hr TAPIOCA STARCH 7 tph 520 kg/m3 13.5m3/hr 475 ft3/hr TEA (LEAF) 7 tph 380 kg/m3 18.4m3/hr 651 ft3/hr WHEAT (DRY 12% CLEAN) 30 tph 750 kg/m3 40.0m3/hr 1,413 ft3/hr Bulk handling throughput is mostly determined by volume, and the flow characteristics of individual materials. As with any system, the Hygienic AMC s throughput is highly dependent on how the machine is fed. The Floveyor Hygienic Conveyor 7

8 The Hygienic Aero-Mechanical Conveyor (AMC) meets the most stringent food safety standards Due to its fully-enclosed, dust-proof design, the AMC is inherently suited to hygienic applications. Its modularity enables it to integrate seamlessly with existing plant and equipment, simplifying installation requirements. Floveyor s Hygienic AMC is designed, engineered and manufactured utilising the best of GMP, AMI and 3-A, recommendations and standards, and in accordance with the European Hygienic Engineering & Design Group (EHEDG) guidelines. Ensuring the utmost peace of mind for our users. The Hygienic AMC is one of only five accepted mechanical transfer systems for food products listed in The European Hygienic Engineering & Design Group s (EHEDG) Guideline No. 36 Transfer Systems. As the inventors and ongoing developers of AMC technology, we are gratified by this significant industry endorsement. Floveyor is also the sole global supplier of dairy suitable hygienic and metal detectable polymer rope assemblies for the use in Aero-Mechanical Conveyors. These ropes are designed to remove wire contamination risks and bacterial susceptible surfaces. AVAILABLE SIZES 3in / 76mm KEY DIFFERENTIATORS Specific for Critical Hygiene GMP + EHEDG Designs TYPICAL APPLICATION Hygienic Food Processes Frequent Cleaning Required CONSTRUCTION MATERIALS AISI 304 or 316 Structural Parts AISI 304L or AISI 316L Contact Parts CONTACT SURFACE FINISH N6 (Ra 0.8μm) Contact Surfaces N7 (Ra 1.6μm) Non-Contact Surfaces ROPES AVAILABLE Polymer Coated PolyMag, AISI 329 Moulded PolyMag ENERGY CONSUMPTION kW CONVEYING DISTANCE 45 0 / 13.7m THROUGHPUT From a trickle feed up to 30,000kg/hour 8 The Floveyor Hygienic Conveyor

9 The Hygienic AMC Design Innovations 1. FDA & EC compliant, PU sleeved metallic conveying element (the Rope) 2. Conveying element detectable by x-ray or tramp metal detector 3. Complete batch transfer, with negligible residue 4. Tri-clamp connections 5. Sanitary air purged bearings 6. Free of welling points, flat surfaces, or internal catch points within the product contact zone 7. Spaced off frame components for complete cleanability 8. ATEX or IEC Ex zoning suitability (optional inclusion) 9. Tool-less quick-release access to maintenance areas 10. Suitable for both Clean In-Place (CIP) and Clean-Out-of-Place (COP) Systems The Floveyor Hygienic Conveyor 9

10 Find a complete solution We provide complete tailored solutions for high grade bulk food handling. Every design and construction detail reflects our commitment to creating the ultimate in contamination free, sanitary, and low maintenance conveying. This includes our top quality complementary equipment. Decanting equipment The Transition Hopper The Transition Hopper is designed for infeed from fixed plant or third-party equipment. The transition hopper mounts rigidly to the feed housing. It directs material towards the feed sprocket, and then it is drawn into the contact tubes. The Manual Bag Dump Station The Manual Bag Dump Station allows the operator to pour material directly into the AMC inlet via an ergonomically sized loading hopper. The loading hopper is equipped with a rigid ledge to stabilise the bag(s) before dumping. It is also fitted with an interlocked, quick-release safety grid, knife storage hooks and securing chain. These features minimise the risk of operators dropping knives into the AMC when they empty bags above the inlet. The dump station is enclosed and fitted with a quick-release dust-extraction plenum to minimise environmental contamination during dumping operations. The bag dump station connects to plant dust extraction via a tri-clamp connection point at the rear of the enclosure. The bag dump station can also be fitted with a secondary material inlet to connect to an upstream process such as FIBCs 10 The Floveyor Hygienic Conveyor

11 The Floveyor FIBC Unloader The Floveyor FIBC Unloader can support, seal and agitate material in FIBCs (Bulk Bags) during unloading operations. It is available in forklift loaded or hoist loaded models. It is manufactured from AISI 304 or 316 stainless steel and is designed, fabricated and certified in accordance with Australian Standards. All structural members are fully-sealed SHS rotated at 45 to shed spillage and wash down solutions. Bag Massaging Paddles The Floveyor FIBC Unloader is fitted with pneumatically actuated Bag Massaging Paddles. The paddles crush the FIBC during unloading to collapse bridges and rat-holes, promoting material flow. The Floveyor Hygienic Conveyor 11

12 The FIBC Unloader + Manual Bag Dump Station The FIBC Unloader + Manual Bag Dump Station is an integrated solution that allows the operator to load materials from both FIBCs and smaller manually loaded bags. This combined function is ideal where operators mix a large amount of base material with small amounts of additives. It s particularly efficient for contract food manufacturers and packers who manage continuously changing requirements. The Screw Feeder The Screw Feeder receives material from the FIBC Unloader, Manual Bag Dump Station, or other process equipment and feeds the material directly into the AMC inlet, via a VFD driven Archimedes screw supplied with ribbon flighting. The Screw Feeder allows a controlled material feed, stop/start functionality, and connection to high/low level sensors for automated material supply as needed by the process. 12 The Floveyor Hygienic Conveyor

13 The Loss-in-Weight Dosing Auger The Loss-in-Weight Dosing Auger accurately controls batch weight and mass flow rates. It is useful where precise batching/dosing operations are needed. The Dosing Auger is typically included as part of a Floveyor FIBC unloader. It mounts to a rigid frame supported by four shear-beam load cells. The signal from the load cells is totalised and transmitted to a nearby control panel for processing. A touch-screen HMI panel enables the operator to save current product/batch configurations for quick re-use. Once initiated, the dosing auger operates automatically, alerting the operator when batching is complete, additional raw materials is required or if a fault is detected. Mobile Conveyors All Floveyor s Aero-Mechanical Conveyors are famous for their small footprints and versatility. Our effortless Mobile Conveyors take these qualities to the next level to deliver portability for a vast range of applications. The Floveyor Hygienic Conveyor 13

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15 Revolutionary rope assemblies Our technologically advanced food grade rope assemblies are engineered to protect your product against contamination. An AMC is only as strong as its rope assembly. It s the conveyor s arterial system essential to maintaining an effortless flow of diverse and often challenging materials. A Floveyor Polymer Food Grade Rope Assembly is fully sealed, FDA & EC compliant and detectable with x-ray or eddy current metal detectors. The Rope is safe for direct contact food products and typical CIP wash down and sterilisation solutions. The assembled rope is endless, forming a continuous conveying element. A single joining disc enables assembly, disassembly, and replacement. The Floveyor hygienic joining disc is a sealed, fastener-free connection that conforms to EHEDG guidelines for food handling and is suitable for CIP cleaning systems. Exploded view Outer Joining Disc Captive Anti-Rotation Pin Rope Rope Inner Joining Disc The Floveyor Hygienic Conveyor 15

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17 Minimal maintenance The Floveyor Hygienic AMC is an extremely simple conveyor. However, its effortless performance is backed by three generations of research and design ingenuity. You told us you needed a flawlessly hygienic system with classic AMC simplicity, so we created it. Once installed and run in, the Hygienic AMC needs very little maintenance beyond the following scheduled checks: > > checking bearings and seals for wear and replacing them as needed > > inspecting the rope for wear and stretch and adjusting it accordingly Hygienic AMCs come equipped with an electric tensioning mechanism so operators can complete this vital piece of maintenance at ground level and in seconds. Constructed without welling points The Floveyor Hygienic Conveyor 17

18 Effortless cleaning The Floveyor Hygienic AMC is designed for wet or dry cleaning. It comes standard with all the features for Clean-In Place (CIP) processes. Optional Clean Out-of-Place (COP) functionality to remove liquids from the process area can also be provided. CIP - dry cleaning A dry-cleaning system may be appropriate where the bulk material handled is not typically adhesive, hygroscopic, bacterially sensitive or allergenic. To facilitate CIP Dry Cleaning, the Floveyor Hygienic AMC is fitted with pneumatic fittings in the feed and discharge housings suitable for connection to site process air. The fittings are orientated towards potential build up areas within the housings, ensuring that pressurised air applied while the AMC is running propels any residual material back into the main product stream. Thereby eliminating any small amounts of residual material not carried away by the actual conveying process. CIP - inert purging Inert material purging is another effective method of dry cleaning the AMC. This method is especially effective when light internal build up arises from slightly adhesive or hygroscopic materials. An inert coarse, dry material such as crushed rice or rock salt is introduced and conveyed through the AMC. This scours and purges the internals by dry cleaning and flushing the internal contact surfaces. Typically, a couple of bags of inert material are all that is required. Planning your material loading sequence can also be beneficial. Conveying minor ingredients or residue sensitive materials first, followed by neutral materials flushes the minor ingredients, or adhesive materials from the conveyor. 18 The Floveyor Hygienic Conveyor

19 CIP - wet cleaning The Floveyor Hygienic AMC comes standard with everything required for CIP wet washing, including: > > a blanking plate for the feed housing, supplied with a BSP fitting (optional NPT fitting) for connection to plant CIP systems > > a manual blanking plate for the discharge chute > > a 2 triclover fitting for connection to plant drainage. > > air fittings for connection to compressed air for drying For CIP Wet Cleaning, the feed and discharge points of the conveyor are blanked off. Then the AMC is run in cleaning mode, and the conveyor is injected with washing solutions through the feed housing plate. The washing solution is then recirculated within the AMC at high speed, similar to a washing machine. Once the cleaning cycle is complete, the solution is drained through the bottom feed housing drainage fitting. The cycle can be repeated as required. Once washing is complete the AMC is rinsed and flushed of all cleaning solutions using a similar process. After draining, the AMC can be run empty and dried by injecting cool compressed air through the housing pneumatic fittings. This aids and accelerates the drying process. Similar processes are available for steam or foam cleaning regimens. For difficult to access discharge housings, the manual washing plate may be replaced with Floveyor s permanently installed, pneumatically actuated washing plate. This is typically controlled from a pushbutton station at ground level. To further simplify the operation, the pneumatic washing plate can also be controlled by the PLC for an automatic CIP procedure. COP - cleaning For Clean Out-of-Place (COP) systems we fit the Hygienic AMC and associated equipment with mobile frames. This makes it easy to move the equipment from the processing plant to a wet washing area. Disassemble and clean each part of the equipment as per your cleaning and sterilisation procedure. Note: If your equipment and plant layout are not suitable for COP cleaning, we ll advise you on the most appropriate alternatives. The Floveyor Hygienic Conveyor 19

20 SIMPLICITY IN CONVEYING T +61 (8) E enquiries@floveyor.com hygienic.floveyor.com