Semi-Bulk Systems

Charles S. Alack, CEO & COO

The collaborative genius and pioneering spirit of the engineers led to the birth of Semi-Bulk Systems (SBS), a company committed to harnessing scientific insights to enhance efficiency across a myriad of sectors including food and beverage, healthcare and pharmaceuticals.

Although Vacucam^® is the heart of the mixing system, to greatly increase the efficiency of a powder/liquid mixing process, it was necessary to design efficient options for powder handling and delivery to always couple to the inlet of the ejector mixer for optimum automation, labor savings, speed, environmental control and quality control. The birth of the Air-Cone^® hopper provides the most efficient pre-conditioning and delivery for a broad range of powders to feed the Vacucam^®. The Air-Cone^® Hopper is adapted to a number of different feed hoppers, paper bag dump hoppers, bulk bag and other powder delivery options to deliver pre-conditioned powder flow to the mixer.

Although the very unique Vacucam^® is the most efficient powder/liquid mixing device in the food and beverage industry, as well as the many other industries processing powders and liquids, it is but the heart of the total system and process. It is one technology that couples with a second very unique technology (the Air-Cone^®hopper) to provide the total system.

The company's dedicated team of professionals works diligently to deliver bespoke solutions that align with the unique demands of each customer. The company has developed a line of Pre-Engineered, Standardized, Modular, Skidded processes to accommodate a broad range of process options for different capacities, applications, and industries.

“SBS has dedicated itself to the continuous development and refinement of our technology," Alack, CEO and COO says, reflecting on nearly half a century of innovation and service. “This commitment has enabled us to introduce multiple mixer sizes for the last 49 years, catering to a vast spectrum of markets and applications.”

Advanced Mixing Made Simple

Its Vacucam^® represents a paradigm shift in powder-liquid mixing technology, offering remarkable efficiency and performance. It harnesses the power of a near-perfect vacuum and adds conditioned powder to the mixer with precision and speed. This innovative approach ensures that powders are thoroughly wetted and dispersed to liquids without clumping, which is frequent in traditional mixing methods.

The hallmark of the Vacucam^® is its ability to achieve instantaneous and complete wetting; a significant leap forward in mixing efficiency. Through careful engineering and design, this system guarantees batch-to-batch consistency and superior product quality. SBS also seamlessly integrates the Vacucam^® in-line system into existing processes, giving industries greater flexibility and centralized control to optimize production operations.
Another key advantage is its minimal maintenance requirements and absence of moving parts, reducing downtime and operational costs. Its energy-efficient design leads to substantial savings, with up to a 90 percent reduction in energy costs and a significant increase in production rates.
Complementing this system is the Air-Cone^® Hopper, which plays a crucial role in conditioning difficult powders for dependable flow and optimal discharge. Its ability to eliminate batch-to-batch variations caused by material holdback makes it ideal for applications requiring reliable flow and total discharge. This makes it an excellent feed source for vacuum conveyors and for integrating with the Vacucam^®.

The Air-Cone^®hopper has an inner membrane that completely covers the area where the product comes into contact with the lower cone. Low-pressure "conditioning" air or inert gas, distributed by an air supply manifold and diffused through the membrane wall, effectively conditions the dry ingredients. Subsequently, these ingredients assume the properties of a liquid, allowing for smooth and accurate flow into the manufacturing process. This aeration process eliminates typical production problems associated with difficult powders, such as bridging and rat holes, ensuring uninterrupted and efficient operations.
The Vacucam^®, along with the Air-Cone^® Hopper, form an integrated system that redefines powder-liquid mixing processes. By combining the former’s precision and efficiency with the latter’s reliability and conditioning capabilities, SBS offers industries a comprehensive solution that redefines performance, reliability and quality in mixing technology.

Today, there is a critical need for efficient and innovative solutions in the manufacturing sector. SBS addresses this demand, presenting a suite of modular process options that meet the needs of contemporary manufacturing. This innovative range includes single-pass systems, batch recycle methods, and dynamic continuous steady-state (DCSS) approaches, offering unmatched flexibility.

The core of SBS's philosophy extends beyond providing advanced technology. It is committed to fostering long-term value for its clientele by conducting rigorous pilot plant testing and continuous process refinement. This ensures that the implemented solutions meet and exceed client expectations. It is through this meticulous approach that the industry’s leading voices have designated SBS's offerings as the Best Available-Technologies (BAT).

SBS's journey towards excellence is further augmented by its embrace of automation, which significantly reduces labor dependency and helps optimize energy consumption. This helps clients navigate market complexities, setting new standards for efficiency, sustainability and profitability, as well as strengthening the competitive edge for their customers.

Transforming Industries, One Solution at a Time

The impact of the solutions reverberates far beyond the confines of a laboratory or a production floor. This was evident when SBS collaborated with a prominent cheese manufacturing facility to enhance their production processes. Faced with challenges in their existing method of producing non-fat dry milk (NFDM) solutions, which involved arduous manual labor and prolonged processing times, the client sought a solution to enhance efficiency and reduce operational costs.
SBS conducted a comprehensive assessment of the facility's requirements and swiftly deployed a customized solution. This involved replacing cumbersome, 50-pound paper bags with 2,000-pound bulk bags and introducing a standardized EJM2000 in-line mixer. A dual bulk bag unloading hopper was installed to help expedite the powder delivery process.

The results were remarkable. The cycle time for liquefying the NFDM solution was drastically reduced from 23 to just seven hours per silo. SBS also identified that the milk’s lengthy 12-hour hold time was not required to maintain product quality, enabling the facility to transition to a more efficient one-hour hold time. This led the facility to significantly save money, reducing their operational shifts from three to just one daily.

Since the implementation of the solution, the cheese production industry has embraced the solution in numerous facilities.

SBS transcends the conventional role of a technology provider to emerge as an indispensable partner in the pursuit of progress. Offering comprehensive solutions that redefine the standards of efficiency, reliability and sustainability within the food and beverage manufacturing sector, the firm has empowered its clientele to navigate and excel in the dynamic industrial landscape.

An unwavering commitment to innovation and delivery of immediate value enables Semi-Bulk Systems to be a catalyst for shaping the future of manufacturing. Anchored in a legacy of excellence spanning decades, it continues to push the boundaries of engineering and technology, heralding a new era of manufacturing and industrial automation with determination and visionary foresight.