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Robot Laboratory Technology

NIR analysis
Physical analysis

QA reporting software

CheckMaster™

The CheckMaster™ is a robot-operated laboratory that does NIR and physical product quality analyses, among other things, during the manufacturing of feed & food products. The CheckMaster ™ can operate one or two robots depending on the number of sampling points and the number of manufacturing lines. Analysis can take place from raw material intake to packing thus resulting in a full quality overview throughout the process.

The CheckMaster ™ offers a very fast payback due to both savings of operating costs as well as nutrient savings as follows:

  • Reduce protein loss
  • Increase moisture content
  • Eliminate labour costs
  • Reduce repeat work
  • Optimise process equipment
  • Automatic QA reporting

Calculate operating cost savings

Substantial savings can be achieved by implementing the robot laboratory into your process. Use the savings calculator to create specific savings at your site.

 

  • Reduce nutrient give-away
  • Increase moisture level in finish product
  • Reduce rework
  • Reduce recalls
  • Reduce operator resources
  • Reduce laboratory resources

Where to analyse?

Raw material intake

Grinding

Mixing

Pelleting

Drying

Cooling

Coating

Packing

Hazard Analysis Critical Control Points (HACCP)

Install samplers at any critical control point throughout the process flow subject to quality analysis.

  • Automated inline sampling technology installed at all HACCP
  • Integrated vacuum conveying & receiving system
  • Alarms are raised if analytical results do not comply with specifications
  • Quality analysis report continuously created during production

Raw material intake analysis

Analysis at the raw material intake can be entirely automated by means of the robot laboratory. Samplers are placed at preferred locations and will automatically sample and analyse a specific raw material during unloading from either trucks, ships or trains.

 

  • Automated sampling and analysing during unloading
  • Actual accurate nutrient data for formulation systems

Grinding analysis

Inline sampling and analysis of the grinded material will provide information to whether particle sizing will allow for optimal processing. The CheckMaster operates up to six standard sieve screens and uses air sieving technology for sieving. 

 

  • Automated particle distribution curve
  • Information if grinder screen is damaged

Mixing analysis

During mixing a sample is removed and NIR analysed. The NIR analytical data are compared to the formulation requirement so adjustments can be made accordingly.

  • Moisture addition in order to minimising protein loss
  • Moisture addition to ensure that the maximum moisture target is achieved thus resulting in a greater sale volume
  • Dry or liquid addition of micro components such as free amino acids and others

Pelleting analysis

Pellets are sampled after pelleting and analysed with multiple quality parameters in order to optimize the pelleting process on the fly. If a QA parameter is out of specifications, an alarm will go off. 

  • Temperature analysis
  • Product sizing analysis
  • Bulk density analysis
  • NIR analysis

Cooling

Temperature control of the finished feed or food product is important in order to avoid bacteria growth after packing. By sampling and analysing the temperature, the cooler performance can be controlled in terms of retention time and air flow.

  • Minimise bacteria growth due to a too high outgoing temperature
  • Reduce customer complaints

Drying analysis

Accurate moisture control is mandatory in order to ensure optimal operating costs. Both protein loss, final product moisture levels and consequently drying costs can be controlled. By using bench-top NIR technology including sample grinding, the moisture can be controlled accurately.

  • Moisture analysis every 120 sec.
  • Full nutrient analysis (NIR) profile such as moisture, fat, protein, ash, starch….
  • Water activity analysis
  • Bulk density analysis

Coating analysis

Micro and macro coating is important in order to complete the final nutrient mass balance profile of the feed or food product. By accurately analysing the pellets by means of an NIR, an accurate final liquid dosing can be applied.

  • Oil & fat is metered based on the NIR analysis conducted both before and after the coating process
  • Micro dosing in form of free amino acids and others are accurately applied

Packing analysis

Finished products being packed or loaded are analysed, thus ensuring that all essential nutrient and physical parameters are within the QA specifications. 

  •  Automatic development of a QA report
  • 24/7 product release without human interference
  • Reduce customer complaints
  • Minimise recalls

Plug and play technology

Installation is quick and does not interfere with the manufacturing process. As soon as utilities have been connected, the machine will be ready to perform analyses.