This plan is aimed at powdered or granular seasonings such as chicken essence, mushroom essence, compound spices, sauces, etc. It provides a complete turnkey project from raw material storage to finished product stacking, achieving "land acquisition and production". The production line design follows GMP and HACCP standards, with a modular layout and a production capacity ranging from 300 kg/h to 3000 kg/h. It can flexibly switch between at least 200 SKUs.
1、 Process path
1. Automatic bag removal and feeding → 2 Dust free negative pressure conveying → 3 Accurate measurement of ingredients → 4 Efficient mixing (≤ 60 s/CV ≤ 3%) → 5 Wet granulation/extrusion granulation → 6 Continuous fluidized drying → 7 Online cooling → 8 Multi level screening → 9 Vacuum feeding packaging → 10 Gold inspection/re inspection → 11 Robot palletizing → 12 Automatic film wrapping and storage.
The entire process adopts industrial Ethernet, and the MES system collects key data such as batch, temperature, moisture, vibration in real time, achieving one click traceability.
2、 Core equipment and technological highlights
1. Raw material processing system
The dust-free feeding station of Benyou Machinery is equipped with PTFE coated filter cartridges, pulse blowback and negative pressure balance valves, with bag removal dust ≤ 1 mg/m ³ and material replacement time<2 minutes.
Adopting our independently developed double helix weight loss scale, with a dynamic accuracy of ± 0.2%, it supports stable measurement of trace additives (≤ 5 g).
3. Mixing and granulation
The BYSY dual axis blade mixer with a capacity of 200-3000 L is available, and the blades are made of detachable hard alloy blades with an integrated CIP/SIP design.
The wet granulation machine adopts the Benyou BYZL series, with adjustable particle size of 0.8-2.0 mm; The whole machine adopts dual safety measures of gas seal and labyrinth seal, with no risk of cross contamination.
4. Drying and cooling
The continuous vibration fluidized bed dryer is jointly optimized by Benyou and Jiangsu Bohong
Adopting segmented constant temperature and pulse blowing technology, the drying efficiency is increased by 40% and energy saving is reduced by 30%;
- The bed body is made of 316L stainless steel with integrated stretching, Ra ≤ 0.4 µ m, and food grade without dead corners;
- Closed loop control of online moisture meter, with finished product moisture fluctuation ≤ ± 0.3%.
After drying, the material is cooled by a BYFL fluidized bed cooler and quickly cooled to room temperature using clean air at ≤ 35 ℃ to prevent clumping.
5. Screening and packaging
Double layer straight screening+ultrasonic anti blocking system, increasing the lifespan of the screen by three times;
Our vacuum feeding packaging machine is equipped with servo screw measurement, high packaging accuracy, integrated metal detection, weight selection, and automatic rejection of non-conforming products.
6. Robot palletizing
By applying advanced international technology and combining it with our independently developed stacking algorithm, we can simultaneously process three packaging forms: cardboard boxes, bags, and barrels, with extremely high stacking efficiency and a 25% reduction in floor space.
7、 Automation and informatization
• Adopting our own MES system:
Batch management: scanning and binding of raw materials, equipment, personnel, and process parameters throughout the process;
- Electronic signature: compliant with FDA 21 CFR Part 11;
Cloud OEE dashboard: Real time display of utilization rate, failure rate, and energy consumption.
Reserve ERP and WMS interfaces to support later digital twin and AI optimization.
Turnkey Engineering Service Process
1. Pre consultation: process testing, capacity planning, investment return analysis (ROI ≤ 2.5 years).
2. Engineering design: 3D factory modeling, clean area airflow simulation, HAZOP safety assessment.
3. Equipment manufacturing: Our two major bases in Shanghai and Xuzhou offer modular pre installation with a one-time pass rate of over 98% for FAT testing.
4. On site installation: Professional project managers are stationed on site, and the accumulated service mileage of this excellent service has reached 150000 kilometers.
5. Debugging training: IOQ/PQ full set of validation documents, providing SOP, maintenance manual, spare parts list; Operator training should be no less than 16 hours.
6. Warranty and after-sales service: The entire machine is covered by a 24 month warranty, with 7 × 24-hour remote diagnosis and spare parts arriving within 48 hours.
Typical case
A large seasoning group in Shandong province: Two 3000 kg/h chicken essence turnkey production lines were put into operation in March 2024, with a 60% increase in production capacity and a 45% decrease in labor costs that year.
A foreign-funded sauce factory in Guangdong: One 1500 kg/h composite sauce production line, using our superior CIP/SIP system, has shortened the cleaning time from 4 hours to 45 minutes and reduced water consumption by 35%.
Conclusion
Based on our 20 years of experience in food engineering, 386000 sets of equipment operation data, and over 350 patented technologies, we not only deliver production lines, but also provide sustainable competitive advantages. Choosing our premium seasoning turnkey project means choosing a future that is safe, efficient, intelligent, and green.
