High-end mixing process for ice cream and dessert powders at Colac in Beerse

Due to an increasing potential in ice cream and dessert powders, Colac felt the need to find a partner for a qualitative upgrade of its powder production. It found this partner in AZO, which advised in the installation of an AZO mixing line with 2 amixon mixers and accompanying AZO container filling and unloading stations.

Colac, based in Beerse, is a family-owned company distinguished by its commitment to quality and innovation. In a production environment where hygiene and extensive product knowledge are paramount, the investment in a new production unit for ice cream and dessert powders in 2023 was a logical step.

Quality and hygiene requirements

Quality and requirements to food safety are the basis to realize a sustainable and reliable production unit for the future. The unique AZO solution with wet cleanable bag dumps and the high finishing degree of the machines in combination with 2 amixon mixers provide a state-of-the-art production line. 

In close consultation, it was decided to thoroughly analyze every detail, with the hygienic flexible connections and the Sinconvex mixing ribbons of the amixon mixers as examples. Besides the quality of the installation, the quality stands for the product. The first control sieving step is provided in the AZO bag dumps that exit directly into the mixers. This keeps out foreign elements and makes the process a closed one.

After the homogeneous mixture from the amixon mixer is gravitationally poured into the AZO container, this container is placed on top of the container unloading chair. Below both unloading chairs is the AZO DA eddy current screen machine through which, before entering the filling machines, the product always undergoes a final quality control. Thanks to the pull-out guide on both the motor and rotor sides of the AZO DA sieve machine, the clear choice for quality and cleanability is also present here.

Testing

With amixon, AZO attracts the right partner in this project for mixing the powders. Cleanability, short mixing times, homogeneity and minimal impact on the mixture are the typical characteristics of an amixon VM mixer. Of course, practice is always the best way to really experience this. During pre-performed tests at amixon, these topics were confirmed. Within 3 minutes a homogeneous mixture was achieved, which was fully within Colac's quality requirements.

Flexibility

Colac's choice to work with a 400 and 1,000 liter mixer increases flexibility and reduces cleaning times. Combined with the AZO Batch Containers of 1,000 liters, it allows flexibility in handling different recipes and batch sizes.

Energy Efficiency

At a time when energy efficiency is crucial, a container system is an absolute winner. Colac had an entire space available for a gravity powder production, which was efficiently filled with the entire installation, taking into account necessary ergonomic movement space for operators and containers. A high-performance AZOCOM Graph visualization guides the operator in every step of the process and offers a maximum degree of automation.

Ready for the future

The key to success in this project were Colac's clear requirements and the solutions AZO provided in return. AZO's experience ensures the right solution at the right time to guarantee production quality. Both today and in the future. Or, as Geert Vermeersch (manager of Colac) summarizes it nicely: "To be able to carry out this important project for us with a specialist like AZO was an enriching and pleasant experience. From the concept phase up to and including the final execution, they thought along in terms of flexible and efficient solutions tailored to our SME. The most important thing in such projects always lies in solving the problems experienced in the course of the project. In this aspect, we were able to count not only on AZO's experience and knowledge, but also on the speed of execution. A beautiful project, a quality execution and a handsome result. We are ready for the future!"