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Overcoming challenging flow characteristics

18 September 2023

Mike Plant suggests a solution to handling difficult plant-based protein powers.

With the production of plant-based products increasing, more food manufacturers are looking for alternative ingredients to help create novel products and plant-based food offerings. Alongside pea and soy proteins, a wider variety of protein sources are now available – such as lentil, mung bean, canola or fava bean – however, the material characteristics of these powders can be challenging. 

Whether transferring soy protein powders for plant-based milks or handling and extruding the various proteins used in plant-based meat production, the material handling requirements of many of these poorly flowing powders requires attention in overall engineering and design. 

To choose the best method for transporting, feeding and weighing, plant-based protein powders, it is critical that several key characteristics be identified to determine each ingredient’s flowability. Most plant protein powders are not free-flowing, and Inconsistent flow can have a negative impact on product quality because the manufacturing process depends on an accurate, continuous supply of raw materials to the process. 

Quick release filters
Raw ingredients for typical plant protein processes can be received in boxes, bags, and bulk bags or supersacks. Bag dump or sack tip stations include a small capacity hopper into which sacks/bags of material are opened. When dealing with blends or powders with a cohesive nature, as is the case with most plant-based protein powders, it is important that the filters used in the devices, as well as other equipment such as the pneumatic receivers, have quick release properties (such as PTFE coatings) to avoid product build-up on the filters which would affect filtration efficiency. 

After exiting the bag dump station, the powders are pulled into a conveying system. The mode of transfer of ingredients is dependent on a variety of process parameters, including material characteristics, distance to be transferred, required rate of transfer, and the type of container in which the ingredient is originally received. 

Pneumatic systems operate in a fully enclosed line, which can improve hygienic operation and also minimises product loss. Vacuum sequencing systems are often also the most economical solution for small to medium rates up to 7,500kg/hr. Typically, pneumatic systems will have inline check sieves or strainers installed to remove packing materials, insects, or hard lumps of agglomerated product, which can help reduce downstream flow problems.

When it comes to batch weighing, the process efficiency and product quality can be improved if the complete batching process is automated. This includes the automated transfer of the raw ingredients to the batching system and the use of Gain-in-Weight (GIW) or Loss-in-Weight (LIW) feeders to accurately and efficiently deliver the individual raw ingredients to the process. Twin screw feeders are a good choice for accurately feeding poorly flowing ingredients such as plant-based protein powders. 

Overcoming challenges
Material transfer and feeding of plant-based proteins can present many manufacturing challenges. Optimised automated systems for weighing and accurate delivery of all the ingredients for the plant-based protein process without manual intervention can result in a number of process ad-vantages, including fewer mistakes, better accuracy, lower bulk costs, improved product quality and savings in manufacturing costs. In addition, systems and components which are specifically designed to handle these difficult flowing materials will reduce downtime and increase operational efficiencies. Operational and product safety are also key elements of design which should be reviewed. 

Mike Plant is Sales Director Coperion K-Tron UK.


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