AAK plant remodelling increases sauce capacity by 23%
AAK, a Swedish-Danish company, is the world’s leading manufacturer of high value-added vegetable oils and fats. The company’s products are sold throughout the UK and in over 35 countries worldwide. AAK was eager to take a holistic view of its operations to boost product yield and reduce waste when integrating Steam Infusion into its processes, which resulted in a remodelling the plant to boost capacity by 23%.
Challenge
AAK decided to use Steam Infusion at its site in Runcorn, where the company produces ambient sauces and condiments for the UK market as Steam Infusion can more than double the yield in a given time and create higher quality products. In isolation its production rates are incredible, but it takes a holistic approach to truly maximise its value to ensure that the system can be fed and discharged quickly enough, as AAK soon found.
Steam Infusion was used to heat and mix sauces at very high production rates, increasing the output and adding significant value to the production process. However, on inspection, the increase in outputs were in fact so high that bottlenecks in filling were occurring, meaning that the value of the entire sauce production process was not being maximised. The bottleneck was occurring because Intermediate Bulk Containers (IBCs) were being used to transport finished product to local fillers. Although IBCs offer a high degree of flexibility, the sheer number of movements and physical changes was limiting the production rate of the entire process.
IBCs are extremely labour-intensive, and there are a number of associated health and safety risks from their use, so a solution was needed to eliminate the bottlenecks and improve health and safety.
Solution
By taking taking a holistic view of the factory, OAL determined that an automated finished bulk storage system was required to allow for the direct feed of fillers. The previous routing system was expanded linking it to new bulk storage vessels, which were also linked into the CIP system where an additional channel was retrofitted to introduce 50% more cleaning capacity.
“The OAL team’s extensive plant knowledge allowed them to deliver on time and on budget. The project execution was excellent with minimal disruption to production.’ ”
Key results
The fully automated bulk storage system has allowed AAK Foods to realise higher and more effective production as the high-speed Steam Infusion system can be fully utilised. AAK Foods was particularly impressed by the minimal disruption to production during the project, particularly as the routing system was being remodelled. The results in numbers:
23% increase in production rates
Yield improvements
Removal of labour associated with IBC movements / management
50% fewer IBC movements
50% less downtime than planned
Improved health and safety.
Repercussions to all business areas
A holistic approach to new technology isn’t limited to analysis of production areas but considers the repercussions to all functions of a business. The increase in product quality and production capacity offered by Steam Infusion can have implications on other parts of your facility. Working with an experienced partner, like OAL, to review your processes can ensure that you optimise your production line and derive the maximum value from your operations.