Process / Product quality benefits
- Uniform and consistent sugar dissolution
- Stable syrup concentration across batches
- Reduced batch cycle times
- Improved repeatability and process control
Previously unsuccessful methods
The existing top-entry mixing process created multiple operational and safety challenges:
- Operators were required to climb ladders while handling heavy loads
- Manual pouring increased the risk of slips, falls, and overexertion injuries
- Batch cycle times were extended due to slow manual addition
- Ergonomic strain increased fatigue and reduced productivity
These limitations highlighted the need for a floor-level, mechanically assisted powder induction system.
Fristam’s solution
Fristam recommended installing an inline Powder Mixer system as a direct replacement for top-entry powder addition. The solution utilised a high-capacity Liquid Ring Pump to generate vacuum suction for powder induction, combined with inline mixing elements to rapidly disperse sugar into the liquid stream.
The Powder Mixer’s waist-height induction funnel allowed operators to load sugar bags safely at floor level, completely eliminating ladder use. The system was installed adjacent to the existing batch tank and integrated into the circulation loop to maintain continuous, controlled mixing.
For this application, the customer selected a 40-00 USA Powder Mixer, configured to handle high-volume sugar induction while maintaining consistent dispersion and hygienic operation.
Process set-up
1. Floor-level installation
The Powder Mixer was installed beside the batch tank, allowing operators to add sugar safely at ground level.
2. Powder induction operation
Sugar was fed into the Powder Mixer funnel, where vacuum generated by the pump pulled solids directly into the liquid stream.
3. Inline dispersion
As sugar entered the system, inline mixing ensured rapid wet-out and uniform dissolution before returning product to the batch tank.
4. Continuous operation monitoring
Production staff monitored flow rate, induction speed, and operator ergonomics during routine operation to confirm performance improvements.
A successful outcome with the Fristam Powder Mixer
The Powder Mixer immediately transformed the plant’s sugar mixing operation by eliminating the primary safety risk associated with ladder climbing and manual overhead lifting.
Operators were able to load sugar bags at waist height while remaining on the factory floor, significantly improving ergonomics and reducing the risk of workplace injury.
In addition to safety improvements, the Powder Mixer increased sugar induction capacity to approximately 600 lb / 272 kg per minute, reducing batch processing time by around 30 minutes per cycle. This improved overall plant throughput and freed operator time for other production tasks.
More than 15 years after installation, the same Powder Mixer remains in continuous operation — demonstrating long-term reliability and sustained safety benefits.
Sustainability benefits
- Reduced energy consumption through shorter mixing cycles
- Less material waste from controlled powder induction
- Improved resource efficiency through streamlined operations
Financial benefits
- Reduced labour requirements per batch
- Lower indirect costs associated with workplace injury risk
- Increased production output through faster processing
- Long equipment service life with minimal maintenance
Other benefits
- Floor-level ergonomic operation improves health and safety compliance
- Compact inline installation minimises space requirements
- Reliable, low-maintenance operation over extended service life