Allicio Nutrition Ltd, is a leading UK-based dry powder blending company that had around 35 different flexible connectors used across seven processing lines. They were all clamped connectors in a variety of shapes, sizes and materials.
The nature of a contract blending company means that product runs are changed frequently and, when allergens are involved, equipment must be completely cleaned between each run. These full-cleans required a significant amount of time and maintenance resources removing and refitting the connectors correctly into the appropriate positions.
The clamped connectors also leaked during processing, so Allicio were keen to find a solution that would improve health and safety and reduce the downtime involved in each clean.
Because Allicio regularly switches between different product blends – including allergens such as dairy – full cleans were frequent and time-intensive. On Customer Packed Goods (CPG) lines, cleans took around 4 hours, while Bulk Blending lines could take 12 hours.
Traditional jubilee-clip connectors made the problem worse.
They were slow to remove and reinstall, taking two operators four hours on Bulk lines just for connector handling – and their poor sealing caused dust leaks, increased cleaning times, and product losses.
In fact, batches regularly required an extra 2% product to compensate for leakage.
After a successful initial trial period, the results have been so impressive that Allicio has upgraded over 25 of its connection points to BFM® fittings. One of the original connectors installed around 6 years ago is still going strong!
The consistent length and fast and easy snap-fit of the BFM® means it now takes a quarter of the time to change the connectors and only requires one operator, so staff are freed up to focus on cleaning
which is now a much faster operation overall.
There is also no product leaking out into the plant, which has contributed to staff no longer needing to wear masks, and has meant that they are no longer adding 2% extra product into the batch.
The fast, simple internal snap-fit of the BFM® fitting means connectors can be changed at least 75% faster than previously.
“BFM® fitting has improved health and safety on site. At one point, our staff were required to wear masks due to dust levels. BFM® has directly contributed to masks no longer being required”
- Safety, Health & Environment Coordinator, Allicio Nutrition Ltd
Case Study provided courtesy of BFM® Distributor ProSpare Limited (United Kingdom)
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