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Target Volume of Mango juice production problem


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#1 Rol Natty

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Posted 12 April 2020 - 01:16 PM

We prepare 2870 liter mango juice which is calibrated blending tank then goes to small tank -tubular pasteurizer - the product tank then high level storage tank - return tank to pasturizer then filler it is king machinery after final production we get only 305 pack which means 3660 bottle of 0.3 l the reject is 20 packs and 100 liter of juice where the other gone we lose around 1000 liter of juice pls urgent question



#2 Lucas H

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Posted 12 April 2020 - 03:54 PM

How do you make sure, the tanks are empty after you used them and give them to cleaning?

 

Is it a fixed system or do you move the tanks through production?

 

Are your numbers correct because it seems like your losing more than half of your production.

 

And just a questions, happened to production in my old company, did you maybe lose one of the smaller tanks? Did you check your warehouse? (sorry easiest explanaition is sometimes right)



#3 Rol Natty

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Posted 12 April 2020 - 04:32 PM

We clean by hot flush the lines and SIP the pasteurizer, dearator and homogenizer automatically



#4 Rol Natty

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Posted 12 April 2020 - 04:37 PM

We are not moving tanks we hot flush the syrup tank the blending tank after that small tank manual and automatically we make SIP for pasteurizer deartor homogenizer high level tank Return tank and filler



#5 Rol Natty

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Posted 12 April 2020 - 04:38 PM

We are not moving tanks we hot flush the syrup tank the blending tank after that small tank manual and automatically we make SIP for pasteurizer deartor homogenizer high level tank Return tank and filler

yeah we lose half of our production

#6 Lucas H

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Posted 12 April 2020 - 04:55 PM

So it goes like:

 

1 blending tank 2 small tank 3 turbular pastereurizer 4 product tank 5 high level storage tank

inbetween are pipes, the tanks are always stationary.

 

So next thing that comes to mind: do you monitor how much waste water goes down the drain? - meaning are you sure the tanks were empty when you started cleaning?

did you check the piping for leakes - any vast amounts of juice in the building?

Was all product processed in the same shift?



#7 Rol Natty

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Posted 12 April 2020 - 05:07 PM

No when are not checking one tank high level storage tank and the return tank they are beside the filler
And also we re not checking the piping leakes but if it is we will juice on surface Not all any vast amount of juice in buliding
We re on the start up test it is the first trial batch



#8 Lucas H

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Posted 12 April 2020 - 05:29 PM

What quantity goes into the pasteur unit? Did you do a trial with water only first?



#9 Rol Natty

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Posted 12 April 2020 - 05:34 PM

We are not try with water but almost 140 liter



#10 Rol Natty

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Posted 12 April 2020 - 05:35 PM

We are not try with water but almost 140 liter



#11 Rol Natty

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Posted 12 April 2020 - 05:36 PM

It is automatic from small tank ( 120 -140 l tank) pump to pasteurizer



#12 Lucas H

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Posted 12 April 2020 - 05:53 PM

How did you get that product out of your pasteurizer? did I oversee something? you should already lose 140 liters on your pasteurizer, or how is this thing completely emptied?

 

On that note: how long is your piping system?


Edited by Lucas H, 12 April 2020 - 05:53 PM.


#13 Rol Natty

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Posted 12 April 2020 - 05:53 PM

This is the on the pasturizer screen



#14 Rol Natty

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Posted 12 April 2020 - 05:59 PM

The pipe line almost 10 -13 meter
After pumping the small tank on the pasturizer screen it is start to flush water and after sometime mixed juice and water come out from the pasturizer then we take sample and check brix if it is okay he send to the product tank but on this also we lose mor juice on flushing it is automatic time and liter will given on the screen if there is anything u need as photo or video i will provide also



#15 Lucas H

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Posted 12 April 2020 - 05:59 PM

So OK you are already using around 20% of your product theoretically on a batch around 2000 litres. 

 

How long are your pipes in total, what is the inside diameter of your pipes? for the whole system?



#16 Rol Natty

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Posted 12 April 2020 - 06:04 PM

I dont know exactly now i have to ask the chines engineer about the diameter in the mean time ur assumption of the problem i thank u so much for u help



#17 Lucas H

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Posted 12 April 2020 - 06:22 PM

Good luck with your production, take care.



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#18 Rol Natty

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Posted 12 April 2020 - 06:26 PM

[brother i want fo tell me ur assumption today what this problem comes from we re have king machinary thank u



#19 Lucas H

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Posted 12 April 2020 - 06:32 PM

[brother i want fo tell me ur assumption today what this problem comes from we re have king machinary thank u

 

Not too sure what your question is.

My assumption right now is, that a lot of your product is going down the drain by the CIP procedures.

I really hope that this is not the case, but from some experience I made, I think it is possible.


Edited by Lucas H, 12 April 2020 - 06:32 PM.


#20 Rol Natty

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Posted 12 April 2020 - 08:28 PM

The pipe diameter is 7 mm



#21 Lucas H

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Posted 12 April 2020 - 09:01 PM

Any Idea how long the pipes are in total?



#22 Lucas H

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Posted 12 April 2020 - 09:25 PM

Actually it doesnt matter.
I suggest you make a small batch, and measure everything that gets in and out. Including dirty water from cleaning. And mass balance it, if masses in dont equal masses out, you have forgotten something.

If it really is the CIP system you can figure Out the minimum batch size.



#23 Lucas H

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Posted 12 April 2020 - 10:00 PM

Actually it doesnt matter.
I suggest you make a small batch, and measure everything that gets in and out. Including dirty water from cleaning. And mass balance it, if masses in dont equal masses out, you have forgotten something.

If it really is the CIP system you can figure Out the minimum batch size.


If possible please dont use syrup, If you decide to do that.

#24 SQFconsultant

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Posted 13 April 2020 - 02:58 PM

wow, Lucas!

 

What a great analysis and information exchange - great to see this!


Kind regards,

 

Glenn Oster
 
GOC GROUP / +1.800.793.7042 / Food - Food Packaging - Food Storage/DC

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#25 Lucas H

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Posted 13 April 2020 - 05:08 PM

Thank you :-)






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