Kasus Produksi Bubuk Rempah-rempah di Afrika | 200 kg / jam Jalur Penggilingan & Pencampuran

From material testing to factory layout — a complete turnkey solution for consistent spice blending.

Quick summary:
A mid-size food company needed a 200 kg/h grinding + mixing line to produce uniform spice blends (target particle size: 80 mesh; mixing uniformity: ±2%). We performed on-site inspection, ran free lab trials on their samples, delivered CAD/3D layouts, and supplied two complete grinding-and-mixing lines — avoiding costly design mistakes and ensuring product quality.

Client Need

• Throughput: 200 kg/h continuous operation
• Ukuran partikel akhir: 80 mesh (customer spec)
• Mixing uniformity: within ±2% of target concentration
• Materials: chili, black pepper, powdered spices with varying oil content and fibers
• Constraints: limited factory floor space and existing utilities (single-phase compressed air, max ceiling height 4.2 m)

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⚙️ Technical Requirements (summary)

• Feed moisture range tolerated: ≤ 10% (wet samples pre-dried)
• Hardness / particle input: whole dried pods, seeds, coarse flakes
• Dust control: Pulse-jet dust collector integrated for OSHA / local workplace safety compliance
• Cleaning & cross-contamination control: quick-release sieves, CIP accessible areas for food safety
• Control: PLC with HMI, recipe memory, and remote monitoring option

Our solutions（Our Action — step by step）

1) On-site inspection & sample collection

• Engineering team visited the factory to review raw material handling, utilities, and space constraints.
• Collected representative samples for lab tests and noted potential issues (high oil → risk of agglomeration; coarse fibers → wear).

2) Free laboratory testing (client samples)

• Performed test grinding, sieving, and mixing trials in our lab using the client’s spice batches.
• Measured mixing uniformity using a salt tracer method (10 grab samples across mixer discharge).
• Results (measured): Sample # Marker (%) 1 2.02 2 1.98 3 1.99 4 2.03 5 2.01 6 1.97 7 2.00 8 2.04 9 1.96 10 2.00
• Sum = 20.00; Mean = 20.00 / 10 = 2.00%.
• Range = min 1.96 → max 2.04 → ±0.04 absolute, which is ±2% relative of the 2.00% target → passes spec.
• Particle size distribution (PSD) — test run (example): Sieve (mesh) Approx. opening % Passing 60 ~250 µm 99% 80 ~180 µm 95% 100 ~150 µm 80% Pan — 1% Conclusion: single-stage high-speed pin-mill + integral cyclone + air-classification met the 80-mesh target with stable PSD.

3) Customized equipment selection & design

• Recommended equipment set (tailored to samples and space):
• Feeding & pre-cleaner (vibratory feeder + destoner)
• High-efficiency spice grinder (pin mill) with variable rotor speed (capacity 200 kg/h)
• Inline air classifier / vibrating screen to ensure 80 mesh cut-off and recirculate oversize
• Ribbon mixer (forced type) sized for batch / continuous blending to achieve ±2% uniformity
• Pulse jet dust collector with HEPA option and food-grade ducting
• Bagging/weighing station with check-weigher and CIP access
• Supplied CAD drawings dan 3D layout showing machine footprints, utility runs, and maintenance clearances.

4) Factory Acceptance & Delivery

• Conducted FAT (Factory Acceptance Test) with client samples to reproduce lab results on full-scale equipment.
• Delivered transparent FOB/CIF quotation and lead-time schedule.
• Packaged equipment for safe export and provided pre-shipment checklists.

5) Installation, commissioning & training

• On-site installation supervision and commissioning (mechanical, electrical, PLC tuning).
• Operator training (SOPs for start/stop, cleaning, troubleshooting).
• Delivered QA checklist templates and preventive maintenance schedule.

Result / Project Outcome

• Design errors avoided: 3D layout prevented equipment interferences and allowed efficient material flow.
• Quality achieved: Final product met 80 mesh PSD and mixing uniformity within ±2%.
• Order placed: Client ordered 2 complete grinding + mixing lines after FAT.
• Operational benefit: Reduced rework and packaging rejects; improved batch-to-batch consistency.
• Follow-up: Ongoing spare parts plan and annual performance review.

Deliverables

• Complete equipment set (grinder, classifier, mixer, dust collector, feeders, controls)
• CAD & 3D factory layout (DWG / STEP / PDF)
• Lab test report (PSD charts, mixing uniformity data, processing recommendations)
• FAT report and acceptance certificate
• Operation & maintenance manual, SOPs, and training record
• 12-month warranty & spare parts list