In the ever-evolving landscape of food manufacturing, companies face a myriad of unique challenges that demand innovative solutions such as integration with existing machinery, compliance with set standards and designs based around factory constraints. From handling delicate ingredients to meeting strict safety and hygiene standards, each production line presents its own set of complexities. Off-the-shelf equipment often falls short in addressing these specific needs, leading to inefficiencies and compromised product quality. That’s where customised equipment solutions come into play, offering tailored approaches that consider these aspects.
At KMG Systems, we recognize that every food manufacturing process is unique. We specialize in designing and manufacturing bespoke conveying, seasoning, and processing equipment tailored to your production line’s precise needs. Our custom solutions are engineered to seamlessly integrate with existing systems, from the initial process stages to downstream packaging. Each system is designed with your plant’s specific layout in mind, factoring in the building’s size and shape, as well as compliance with local laws and regulations. Every component is built with safety and hygiene in focus, from machine guarding to handrails on the steelwork.
The Importance of Customisation in Food Manufacturing
Every product in the food industry has distinct characteristics that influence how it should be processed and handled. Here are some common challenges that necessitate customised equipment and how we handle them:
- Delicate Product Handling: Fragile items like crisps, biscuits, or puffed snacks require gentle conveying systems to prevent breakage and maintain product integrity. KMG provides systems that can gently convey products whether it is a belt conveyor or one of our electromagnetically driven conveyors
- Bulk Material Management: Ingredients such as nuts, seeds, or grains need robust equipment capable of handling large volumes without causing bottlenecks or spillage. At KMG each machine is custom designed to convey the required throughput with no product stack up or breakage.
- Strict Hygiene Requirements: Ready-to-eat foods and allergen-sensitive products demand equipment designed for easy cleaning and sanitisation to meet food safety regulations. At KMG we take pride in designing systems that adhere to strict hygiene standards with no dirt traps and every edge and corner being made easy to clean.
- Limited Space Constraints: Facilities with spatial limitations require compact and efficient equipment layouts that maximise productivity without expanding the footprint. With a team of in-house designers, KMG analyse each production plant individually to find the best layout of machines for your needs.
- Complex Production Processes: Multi-stage manufacturing or products requiring precise seasoning and coating need equipment that can be finely tuned to exact specifications. Each one of our machines at KMG from our Powder Dosing Unit to our Electromagnetic Conveyors are set up and tuned to suit your needs.
How KMG Systems Delivers Custom Solutions
Our approach to providing customised equipment involves close collaboration with our customers to understand their specific needs and challenges. Here’s how we tailor our solutions:
1. Comprehensive Consultation
We begin by conducting a thorough analysis of your production processes, identifying key aspects such as unique transfers from existing systems, specific throughputs and safety standards where off-the-shelf equipment may fall short. This involves site visits and surveys to check overall dimensions as well as limitations on site access along with discussions with your engineering teams, and a detailed review of your product such as and bulk densities, product temperature and general characteristics.
2. Innovative Design and Engineering
Our team of experienced design engineers then use advanced design software to create equipment that fits your exact specifications. Whether it’s modifying an existing design or developing a completely new system. This is laid out as a General Arrangement drawing that is analysed with every customer, making any modifications if required based on ongoing feedback we focus on innovation and practicality to ensure the solution meets your operational goals. Every project is allocated a Project Manager who will be in constant contact with your teams to ensure full support throughout the project from design to delivery.
3. Material and Component Selection
Choosing the right materials is crucial, especially when dealing with food products. We select food-grade 304 stainless steel and other appropriate materials that offer durability, hygiene, and compliance with industry standards. Along with our seamless designs that ensure there are no corners or edges that are difficult to clean. Machines can be designed for washing down or dry areas based on your needs.
4. Seamless Integration
Custom equipment must integrate smoothly with your existing production line. We design our machines and steelwork to be compatible with your current systems, considering transfers from process to downstream packaging, existing steelwork and factory limitations, minimising downtime during installation and ensuring a cohesive operation. All our steelwork is tailor made to suit the factory shape and size with flexibility on the platform and handrail design.
5. Testing and Validation
Before deployment, we rigorously test the equipment to validate its performance against your requirements. This includes pre-delivery inspections, active running of each machine and trial runs with your actual products to fine-tune the system for optimal efficiency. Customers are invited to come and see their machinery on site at KMG before dispatch to understand the level of testing we provide.
6. Ongoing Support and Maintenance
Our relationship doesn’t end with the delivery of the equipment. We provide comprehensive after-sales support, including training for your staff, maintenance services, and readily available spare parts to keep your production line running smoothly.
Benefits of Customised Equipment Solutions
- Enhanced Productivity: Tailored equipment optimises workflow, reduces bottlenecks, and increases throughput. From the spread of the seasoning on the product to the distribution in the packing area.
- Improved Product Quality: Equipment designed for your specific products ensures gentle handling and consistency, leading to higher quality outcomes.
- Regulatory Compliance: Custom solutions can be designed to meet specific hygiene and safety standards relevant to your products and processes.
- Cost Efficiency and Sustainability: By addressing inefficiencies and reducing waste, customised equipment can lead to significant cost savings over time. With each machine being designed exactly to the required size.
- Flexibility and Scalability: Custom equipment can be designed with future expansion in mind, allowing you to scale operations as needed and split large upgrades into smaller projects
At KMG Systems, we recognise that the challenges you face are unique. Our commitment is to provide equipment solutions that are as individual as your business.