Optima Consumer has developed a new solution concept for evacuating, gassing and sealing baby milk powder containers. Uwe Bedau, Managing Director of Elb-Milch, explains how they worked together on this project.
22 May 2020
The functional lids ensure maximum production reliability. (Image: Optima)
Optima Consumer has developed an innovative solution concept for the fully automatic evacuation, gassing and sealing of baby milk powder containers. It is the result of an extensive market study and fulfils the requirements of the infant formula market. An initial project together with Milchwerke Mittelelbe has been successfully completed.
The Chinese baby milk powder scandal caused an uproar among experts and heightened awareness of the risks involved. Product safety in production. Optima Consumer took this as an opportunity to reassess requirements. A detailed product market study showed that the industry has adapted and, above all, tightened its requirements.
The focus is on product and production safety, product quality, resources and sustainability, as well as the desire for a Machine solution for evacuation, gassing and sealing functions for the high-care sector from a single source. Turnkey expertise is also in demand.
Christoph Held, Managing Director of Optima Consumer (Image: Optima)
„With the OPTIMA EGS and the OPTIMA FS filling machine, we are able to offer the centrepiece of baby milk powder production lines from a single source.“ Christoph Held, Managing Director of Optima Consumer
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Safety and traceability are crucial
The goal of the Optima development team was therefore clear: a safe and efficient solution for the high-care sector that is Can be integrated into turnkey lines is. In order to maximise the use of our own technological many production experiences into the development process of the OPTIMA EGS The company was able to win over a long-standing partner for this project: Milchwerke Mittelelbe, also known as Elb-Milch. The machine for the fully automatic evacuation, gassing and sealing of baby milk powder containers enables up to 250 cans per minute safely and efficiently.
The OPTIMA EGS (right) - the centrepiece of every baby milk powder production line - harmonises perfectly with the high speed of the OPTIMA FS. (Image: Optima)
Track and trace increases production reliability
With the OPTIMA EGS, it is possible to clearly and traceably assign important production data to each container throughout the manufacturing processes. This also includes the Documentation of all process parameters such as the residual oxygen values of the cans at all process steps. This is possible because Each can is individually evacuated, gassed and sealed becomes.
The production data can be saved using the manufacturing intelligence solutions developed by Optima, and important key figures are clearly displayed. In addition, entire production lines can be networked with machines from different manufacturers to optimise the production process. Optimise overall system effectiveness.
In combination with software tools for preventive maintenance, for example, which increase machine availability, Optima Smart Services make production processes even safer and more efficient.
Foreign bodies in the product could lead to product recalls in the past. Protecting the unsealed can is therefore a must. The patented functional lid fulfils this requirement. The cans are not transported open with product, but are closed with a functional lid during evacuation and gassing.
The elaborate additional function, No need to clinch each can in advance. Clinching (also known as clinching) is a process for joining sheet metal without the use of a filler material. The can lid is pressed on from above.
Container transport with clear allocation of all cans. Format changeover is carried out without tools. (Image: Optima)
Low space requirement, low residual oxygen content
The unique combination of functionalities is also a clear response to the market demand for a Footprint-optimised high-care room. This means lower investment costs due to the elimination of the clincher, but also lower production costs due to a space-saving high-care room with increased safety and efficiency.
Sophisticated products, some with new ingredients, require increased product protection. Reduced residual oxygen values are the goal.
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The requirements for production and product safety will be increasingly orientated towards pharmaceutical standards in the future. The experience within the Optima Pharma group of companies was utilised here.
This requirement was met with an evacuation process specially developed for baby food powder. Depending on the product, a residual oxygen content of 0.6 per cent is achieved at an output of up to 250 cans per minute. Product-carrying parts are particularly easy to clean as they are easily accessible. Some of these can also be removed for cleaning and wet-cleaned in an area separate from the production area.
Win-win partnership
Elb-Milch supported Optima Consumer throughout the entire period of development of the innovative system: e.g. with the comparison of identified market requirements, the coordination of initial concepts in the virtual reality centre, the comparison of test results at the test station and on the prototype as well as with initial field tests on site in Stendal.
The conclusion of this joint project for the future was the validation and approval of the OPTIMA EGS as a Elb-Milch production plant.
Standing still would be a step backwards
The Optima Consumer development team is already working on further key systems to offer even greater safety and efficiency in the production of infant formula powder. One Non-destructive 100 per cent leakage check is the next goal on the development roadmap.
At the same time, the machine portfolio in the area of filling technology is being revised and expanded. A Vacuum filler, which is also consistently aligned with market requirements, is to be developed by 2021.
[infotext]The first OPTIMA EGS was put into operation at Milchwerke Mittelelbe. Managing Director Uwe Bedau explains why they worked with Optima on this innovation project.
pj: Your company has been working with Optima for over 20 years. What experiences have you had?
Uwe Bedau: Optimum customisation and individual solutions for sensitive products like ours are only possible with the Expertise in all areas possible. The design solutions always take into account our wishes as a manufacturer and those of our end customers. In addition, the comprehensive Service from product development to technical changes in the design phase and after-sales service.
pj: In your opinion, what are the technical advantages of the OPTIMA EGS?
Uwe Bedau: The optimised machine concept combines high speed with maximum safety and quality. The residual oxygen values are officially below one per cent and therefore in a range that meets all the requirements for modern infant formula. In production reality, the values are usually far lower. Also worth emphasising is the Compact design. The system can also be integrated into any line, which makes it extremely flexible. These points and the commitment of the Optima employees persuaded us to purchase the OPTIMA EGS after the pilot phase.
pj: In the past two years, you have commissioned a filling machine, a Rotocap capping machine and the EGS from Optima. How did the projects go?
Uwe Bedau: From the first meeting to the customisation of the existing Optima equipment, the Optima employees delivered an absolutely flawless performance. And that under not so easy conditions in terms of Hygiene standards and production processes. A large number of optimisations were made during the on-site production monitoring by Optima and Elb-Milch specialists.
On the baby milk powder production line, for which Optima supplied the centrepiece, we have been able to significantly increase output, with fantastic residual oxygen levels and a very high level of safety for all our products. [/infotext]
[infotext icon]Optima has been a successful technology partner for filling and weighing technology in the food industry for many years. Infant formula area. More than 30 filling systems have been sold in recent years and over 60 Optima filling systems are in production worldwide. EGS stands for evacuation, gassing and seaming and has now been successfully launched on the market[/infotext].
