Upgraded Conical Mixer Design to Eliminate Oversea Maintenance Concerns

04-06-2016

Mr Rafael Padrosa is having a quite tough decision to make for the Conical Mixer their factory plans to get for the upcoming expansion. As the purchase manager, Rafael has been working in Junca Gelatines for over 10 years. Junca Gelatines is a family-owned business dedicated to the manufacture of gelatines and collagen hydrolysates since 1947. He has witnessed the fast development of the largest Spanish producer of gelatines. His number one priority is to find an ideal Conical Mixer within his tight budget.

conical screw mixer wholeview

He sent out some inquiries to different companies all over the world. European factories are his first choice as they are close and it is easy to get problem solved whenever there is a problem. However, the price is way too high for him. Among all the inquires, one factory does stand out: Vortex Machinery Company located in Shanghai, China. Their price offer is quite good. What is more important, they have the experience of working with other gelatines companies such as Rousselot and Gelita who are both the leading companies in Gelatines industry. What is more, they really care about their clients by keeping in touch via emails, phones to ensure all problems get well solved. Rafael is tempted, however, his concern over the conical mixer is not eliminated until all the problems have appropriate solutions.

To understand the concerns of Rafael, it is necessary for us to get to know more about gelatines and what problems he is facing during the operation of mixing. Gelatine is a natural and healthy foodstuff with a long tradition. The pure protein offers a large number of as yet unbeaten advantages and plays a major role in the modern food industry. Gelatine is suitable for gelling, thickening and stabilizing dishes and gives them their creamy consistency. That is why Gelatine is a real all-rounder and is used in the most varied sectors of industry for the most diverse products. In particular, gelatine is indispensable for the food, pharmaceuticals and photographic industries. You may find them in sweets. desserts,dairy products, beverages, cosmetics, pet food and many other industries such as meat industry, diet and nutrition industry.
gelatin

The first problem with Rafael’s current conical mixer is that it is way too hard for them to fix the mixer. All the mixers have to work 24/7 non-stop to maintain the daily operation. The repair hole of the current mixer is not big enough for a person to get inside. They have to open the entire top cover which is very heavy and takes up too much spare. The whole product line would have to wait for a long time to resume the production. Vortex Machinery technical director Jerry helps them solve this problem by designing two repair holes: one big repair hole on the top cover to ensure that one worker can get inside, the other small repair hole near the bottom of the conical mixer to repair spirals easily. The bottom of conical mixer requires regular and thorough cleaning and maintenance as materials get blocked and bacterial contaminated easily. A small hole near the bottom of conical is a perfect solution to their maintenance problem.
clean & maintenance hole
The second problem they are facing is the long period of transmission parts repair. It is quite a challenge for them to fix the transmission parts. First of them, it takes up a lot of manpower to change the gears and bearings. Second, it takes way too long for them to get the replacement parts. Once the mixer stops working, it affects both the product quality and delivery. Jerry suggests a segmented design for the internal transmission structure. We use flange connection parts to minimize the manpower. All you need is to replace the faulty part easily. All the gears and bearings Vortex manufactured for the conical mixer are international standard parts. We have all of them in stock to reduce the long delivery time.
internal conical screw mixer
clean hatch

Another problem that hangs over Rafael’s head is that it is very difficult for them to clean up the entire mixer thoroughly. As the conical vessel is very big, an incomplete clean can result in a secondary pollution. Bacterial contamination has a huge impact on the quality of the product. With the clean mouths Jerry has designed at the top and bottom of the conical mixer, the clean worker can use a water gun to clean the device. The service port at the bottom of the conical mixer plays a key part in clearing the residual materials. In addition, Jerry has designed an automatic CIP spray ball on the top cover which helps to clean during the production process. There is a hot air vent to help shorten the time for drying the water.

Last but not least, there has been oil spill and noise problem with the Motor reducer as their current conical mixer uses belt for the transmission part. It would be great if Jerry can help solve this problem. Jerry designs a dual-motor reducer which increases transmission efficiency and reduces the chance of malfunction.
Dual motor reducer

Rafael is very grateful to Vortex for the careful consideration of all the current concerns he addressed. Now his decision is made up pretty easily. Partner with Vortex Machinery Company is just the first step for their global expansion. “We are now living in a global community which means we have to get used to do business across the world. There is no reason to limit yourself anymore.” Said Rafael.

Jerry, technical director of Vortex Machinery Company, shares his opinion of how Vortex copes with the challenges. “The biggest challenge for our oversea clients is the after-sale service. With more and more inquiries from overseas, we solve this problem with upgraded design and professional devotion to guarantee the quality of both our mixer and after-sale service.”
globalized vortex