Flexible FFS machine for dairy

WHEN AK Gida decided to expand its production capacity for cream cheese, it chose to invest in equipment made by Oystar Hassia. After all, these companies have been partners for quite a while. AK Gida is one of the leading dairy producers in Turkey, and is a subsidiary of the food group, ülker G?da Sanayi ve Ticaret A.?.  Based in Istanbul, it manufactures 20 products including cheese, butter, homogenised milk, powdered milk, yoghurt and pudding. AK Gida’s brands include ??im, Smartt, Alpella, Dolcia, and Petit Suisse, a cream cheese product made of pasteurised cow’s milk enriched with cream.

Early this year, the company announced its investment in Oystar’s THM 16/48 form, filling and sealing (FFS) machine with an aseptic dosing system, to support its cream cheese segment.  “It was our goal to achieve the very best production for our top seller, Petit Suisse,” said ?mer Murat Gümü?da?, production director at AK Gida. “Oystar Hassia has been supplying us with the highest quality of innovative machinery for years now and that makes them the right partner to help us reach our goal.”

The food manufacturer had already purchased an aseptic machine for its pudding production in 2003. Two additional machines followed in 2007, namely a stick pack machine for chocolate sauce as well as an additional FFS machine for the production of cream cheese.

The THM 16/48 FFS machine is capable of 54,000 45-gram cups per hour at a nominal output of 30 strokes per minute

Reliable efficiency and flexibility

The THM 16/48 is noted for its reliability and high rate of efficiency. This FFS machine produces 54,000 45-gram cups per hour at a nominal output of 30 strokes per minute. “This output has allowed us to increase our production capacity several times over, even as we reduced our downtime,” said Mr Gümü?da?. AK Gida also enjoys improved flexibility. In addition to handling Petit Suisse, the THM 16/48 can switch over to the 35-gram cups used to make the Smartt brand chocolate pudding when necessary.

Both the cream cheese and the pudding cups are manufactured in 6-pack units (30-up format). The 6-pack units are provided with perforated snap-lines to allow the cups to be separated easily. The tool is designed for “low-waste” perforation with trimming and star-shaped punching. “This offers us more than maximum efficiency; it promotes the environmentally friendly manufacture of our products,” said Mr Gümü?da?.

Steam disinfection

To ensure the quality of the product, the THM 16/48 comes in the “Hygienic Active” version for the active disinfection of the bottom web and lid material. In other words, steam is used to disinfect the wrapping materials, which are then passed on in a tunnel with sterile air overpressure until the cups are sealed to prevent re-infection. In addition, a membrane valve dosing system (CIP/SIP-capable) in aseptic design featuring 30 filling nozzles is integrated and a gas flushing of the cup headspace takes place. “This ensures the highest hygienic demands are met and guarantees an optimal product protection with the best-possible quality assurance, said Mr Gümü?da?.

The FFS machine is operated using the TEOs HMI panel, also developed by Oystar. Machinery operation is intuitive, using a modern multi-touch system similar to that of a smartphone. Operators further have the support of a help system integrated into the HMI software: Each time a parameter is entered, the system offers tips on choosing the right settings, and if an error message appears, it displays photos, graphics and tips from the operating manual and the circuit diagrams.

“I believe we’ve really made the best possible choice here,” said Mr Gümü?da?. “We have the ideal setup for our cream cheese production. Once again, further investment in an OYSTAR machine has paid off.”