Processes

Precise mixing and blending is paramount for consistent product quality for a wide variety of liquid products. Batch or inline mixing is typically achieved by agitating the product through a shear pump, a static mixer or an impeller style mixer installed in a tank or other process vessel. Rotary jet spray nozzles typically associated with clean-in-place also can be used in a mixing capacity for processing.

Statco-DSI has extensive experience in mixing and dissolving dry ingredients into a liquid stream utilizing a shear blender and liquid ring pump. Our MixSys table mounted system provides thorough mixing while ensuring operator safety and optimal sanitation standards. Accurate metering helps you blend various products or ingredients into one stream at maximum production capacities.

Our BlenZer inline blend and cleanse system set the standard in beverage processing and is now used in a wide variety of industries. Continuous blending of multiple streams ensures faster changeovers, reduces product loss and maximizes production capacities. BlenZer is skid mounted in a modular layout to conserve floor space in the production area. We can customize each system to meet your specific product and processing needs.

Product packaging is more than just a container for your product. It also is a barrier to contaminants, often including some level of product security with heat seals and other tamper-evident devices. And packaging has become a key marketing tool.

Various packaging sizes offer convenience, economies of scale in production and portion control. These options dictate a variety of product changeover requirements and material handling complexities.

Statco-DSI is your material handling partners. We can take your container from the beginning of your production line all the way to the truck at the loading bay. Along the way, we integrate specialized material handling components and quality control equipment from leading manufacturers to make your line as efficient as possible.

Multiple product SKU’s are not a problem. We can design new systems or update existing ones to cover a full range of product options, production flexibility, packaging variances and filler options.

If your process involves dissolving powders into a liquid stream homogenously, shear blending is a proven process. Utilizing centrifugal pump technology, shear blending replaces the traditional impeller with a rotor-stator to deliver consistent and repeatable product emulsification. The rotor-stator combination is customized to your products and the amount of shear required.

Working in unison with a vacuum pump, Statco-DSI’s MixSys technology facilitates the flow of both liquid and dry products. Dry ingredients are pulled from an ergonomically safe, table-based funnel into the liquid flow and the rotor-stator homogeneously mixes the two streams. MixSys is CIP-able and easily transportable to other production lines.

From dairy products to cosmetics, MixSys delivers consistent quality and cost-effective processing.

Managing the heating and cooling process of food and beverage manufacturing efficiently is critical to consistent product characteristics such as taste, texture and shelf life.

Statco-DSI can help with a wide variety of manufacturing parameters including:

Properly heating food and beverage products is critical to food safety.  From thick highly viscous slurries with particulates running thru a tubular or a scraped surface heat exchanger to an HTST system running fluid milk through a plate heat exchanger to our industry leading Therma-Stat ESL/Aseptic system, Statco-DSI has the experience you need to ensure product quality and improve processing efficiencies.

If your application requires cooling, we can build or specify a chiller to provide an optimal cooling media.  Keep a cool head when it comes to heat transfer.  Contact our engineering team to help make the most of your heat transfer efficiencies.

Typical milk production includes homogenization to prevent the cream (high fat) and milk (low fat) from separating. Prior to homogenization, fat globules, which weigh less than milk, rise to the top. Product is pumped at extremely high pressure through small valves to pulverize the fat globules. This emulsification results in a smoother product and helps prevent future product separation to extend shelf life.

Homogenization technology is used in the pharmaceutical, food and beverage, and cosmetics industries as well to provide a smoother product that is less likely to separate over time. Many products used by consumers every day are homogenized — beauty products such as creams and lotions, beverages such as fruit juice, edibles such as baby food and even your daily vitamins and supplements.

Whether your application parameters and product lines require a standard or aseptic homogenizer, Statco-DSI will specify the best model for your needs.

Using centrifugal force, mechanical clarifiers and separators are designed for liquid based applications by separating two or more phases of different densities, liquid from liquid or liquid from solid. We help our customers achieve optimal clarification and separation in dairy and beverage applications including:

Cleaning and sanitizing is a critical practice in any processing facility to ensure food safety, increase product integrity and minimize maintenance issues.  Product ingredients and processes may dictate specific sanitation schedules, based upon allergens and pathogens or equipment availability can dictate when sanitation can occur.

Statco-DSI regularly designs and installs clean-in-place (CIP) systems.  From standalone CIP systems to modular CIP skids and clean-out-of-place (COP) systems for smaller equipment and parts, we work with you to find the optimal solution to properly clean and sanitize your equipment.

A proper mix of time, temperature, sanitizers and agitation is optimal.  If your timeline for sanitation is short, a higher level of impingement can help reduce the time involved, as does using the proper temperature and sanitizers for the application.  All of this can be programmed in to the systems controls, for one button operation.

We offer spray balls that tie into your CIP system to clean silos, tanks, totes and vessels. To increase the impingement of the “static” spray ball, a rotary jet spray head will generally reduce time and save considerable water and sanitizers.

Some equipment is CIP’able, and the equipment that isn’t, typically must be broken down to clean properly.  Portable COP tanks can be equipped with jets, for a higher level of cleaning than a simple soak and scrub can provide.  Tell us your goals, and we can assist in offering the best solution.

In addition to sanitizing process equipment, specialty components can be used to clean and sanitize cases, tubs, totes, pans, pallets and trays.  These types of components are designed for higher quantities of the same or similar items.

Alternatives to standard sanitizers, such as ozone and ultraviolet technologies, can be used for sanitation but also for sterilizing product/ingredients, equipment, and effluent going to drain.

Statco-DSI can help clean up your sanitation process.