Case Study: Biggest Flour Manufacturer Shifts from Vibro to Centrifugal Sifter

Introduction

The flour milling industry is amongst the most competitive industries in the global food processing sectors. Even the slightest efficiency improvements have a bigger effect on fulfilment of demand from the consumer end. A world-renowned flour manufacturer who prides themselves on providing high quality wheat flour to local and export markets suddenly experienced a challenge in their screening process.

For generations, they relied on standard vibro sifters to ensure the quality and consistency of their flour, however as production demands continued to grow the vibro sifter’s efficiency limitations became apparent. In order to be ahead of the increasing consumer demand and operational objectives the manufacturer sought the services of Galaxy Sivtek to provide a modern, space saving, and high performing solution.

Challenges with Vibro Sifters

The vibro sifter had long been a workhorse piece of equipment, but the design of the equipment brought forward concerns for a large-scale flour manufacturer:

• Space Utilization: Conventional vibro sifters required significant floor space in the production area. This space turned out to be a high-value resource, where there is no possibility of expansion or further processes as the plant was growing.
• Output Limitations: The vibro sifter was able to offer 6.4 tons per hour. This was sufficient in the past but was not sufficient enough to meet the current production needs of the company, which has produced bottlenecks in the process of fulfilling bulk orders.
• Complex Integration: Vibro sifters needed more connections and independent handling lines which were inefficient in a modern streamlined production.

The challenges did not only reduce the rate of production but also limited the manufacturer to maximizing the rate of production in addition to the layout of their plant.

The Sivtek Solution: Centrifugal Sifter

Recognizing these challenges, Galaxy Sivtek proposed the Sivtek Centrifugal Sifter—a highly efficient screening machine for the heavy-duty plant with the compound aim of small-sized integration. The centrifugal sifter is the alternative to the vibro sifter and utilizes a rotating paddle style of pushing the material through a fixed cylindrical screen that ensures quicker, more efficient and clog free screening.

Key Advantages for the Flour Manufacturer

1. Compact Design: The centrifugal sifter occupies only one-third of the space that a vibro sifter occupies. This freed up tons of precious production floor space, which, in turn, could be better utilized for other important processes.
2. Inline Installation: The centrifugal sifter could be in-lined with the process in place unlike vibro sifters. This also removed the additional connecting lines and made it easy to install and simplified the operations.
3. Boosted Output: The centrifugal sifter gave an output of 10 tons per hour, which was 56% capacity increase compared to 6.4 tons/hr with the vibro sifter. This improvement directly addressed the manufacturer’s production bottlenecks.
4. Consistent Quality: The centrifugal sifter applied high-efficiency screening to guarantee high-quality standards for the flour, free of lumps and impurities.

Results & Impact

Switching from vibro to centrifugal sifter was a transformational decision for the milling manufacturer.

• Production Efficiency: With the rating of 10 tons/hr, the plant could dramatically enlarge production volumes daily, meeting increasing customer demands.
• Optimized Space: Being only one-third in terms of footprint, the manufacture had been able to free up valuable floor space for other uses, thereby improving overall efficiency of the plant.
• Seamless Integration: The inline installation improved operational efficiency by limiting downtime and unnecessarily restricting workflow of ingredients.
• Cost Savings: Greater production and a simpler installation rendered lower operating costs in the long term, thereby improving returns.

This transformation not only addressed immediate operational issues but also set the company up for long-term growth and scalability.

Why Galaxy Sivtek?

The choice of partnering with Galaxy Sivtek was more than just an upgrade in equipment; it was an assurance that the company specialized in sieving and filtration solutions would expert in the implementation. Galaxy Sivtek’s capability to offer customized solutions and guarantee on-site performance facilitated the transition to be smooth and successful.

Sivtek Centrifugal Sifter has become a part of the process of the manufacturer, and it has proven to be reliable and has excellent performance daily.

Conclusion

This case study exemplifies how India’s largest flour manufacturer achieved new efficiencies and greater productivity by moving from a standard vibro sifter to the Sivtek Centrifugal Sifter. The transformation was concerned with space issues, improved throughput and simplified integration- all without compromised quality of the products.

At Galaxy Sivtek, we pride ourselves on helping our manufacturers to modernize their processes with innovative solutions that boost efficiencies, scalability, and potential for long-term success.

Ready to take your flour production to the next level? Unlock higher throughput and smarter space utilization with the Sivtek Centrifugal Sifter.