In preparation for an event coming up it was asked what is your list of to do items to start production of a product?
To start there are questions, is the plant cold, shut down for the weekend, or simply stopped to change to a new product? Was the system cleaned or what was the last product made? There are different approaches based on the above questions. If it’s a cold clean plant, then it is different than if simply changing die with a warm system, which starts easier.
Basically, there are just a few differences in every plant or system but here is a possible list to follow.
Power up the plant, turn lights on and devices that need preheating like the boiler, dryer, liquid supply tanks etc. Historical data can assist in times needed for each so it can be managed so as to not start too soon and waste energy. At this point following the four basic areas of extrusion, raw materials, system configuration, operation specs and final product specs seem to be a good start. A possible plant or specific production area walk around will help to visually see condition and readiness with these thoughts in mind.
Raw Material Area:
Make sure all ingredients are to spec and available. System is calibrated for correct flows of liquid and dry ingredients or the periodic calibrations on a computer-controlled system are believed to still be accurate and functioning including flow meters or devices. The grinding system is correctly configured and yielding the grind desired. Batches made and prepared and placed in bin to feed system at a volume to keep pace with production rates. Possibly do a test by NIR to see that in line or in lab the dry ingredients meet the nutritional specs on the bag. Same applies for liquids if needed.
System configuration:
The above as needed in raw material area as mentioned. Extrusion verification of steam and water and other liquid pressures is required. Is the extruder barrel and gear before this point correctly set up for that product and clean enough to avoid a quick shutdown? Die most importantly and end of barrel adjustments to knives and possible flow/cook controlling restriction devices. Set the conveyors and by passes. The dryer is heated up and all is running down stream or ready to go as needed. Dryer louvers and exhausts settings are set correctly, doors shut, and system is clean to start. Once started the dryer bed depth and evenness must be checked.
Operational specifications:
On a known product the parameters should be documented to achieve the desired product. OK, slight adjustments might be made to hit the end point but having a good starting point reduces waste. Any system will have some waste at start up and shut down based on the nature of these systems. Knowing how to handle using by-passes or timers etc. until judged perfect and reworking the non-perfect product is necessary. Computers and sensors greatly decrease these events, but systems are making product where all of this is by hand. In either situation once the system is set, barring any event, it will simply run itself when in harmony, all balanced. Down-stream system all started as the perfect flow continues its path, dryer, coolers, coaters weighers and bagging.
Final product specifications
For final product specifications, you have the measurements and devices needed near the extruder to do the preliminary tests, such as density, quick moisture meters, measuring rules or calipers etc. Usually, systems have bagging bins, so you have a chance at the end pre-bagging to test the final product for any and all aspects. If all went well in the first three areas you most likely will not have any situations in the final review.
