Marion’s Custom Mixing Solution Transforms Coffee Company's Production Process

Due to increasing demand for its products, a well-known company in the coffee industry, known for offering high-quality and diverse coffee blends, needed to upgrade its production process to maintain its reputation for premium quality.

The company had been facing several production inefficiencies, such as harsh mixing processes that damaged whole beans, uneven addition of flavors leading to inconsistent batches, extended mixing times and labor-intensive cleaning processes that hindered productivity and scalability.

Additionally, the company was increasingly conscious of its environmental footprint, seeking a mixer solution that promised energy efficiency and minimized waste. A critical area of concern was the traditional mixing equipment's design flaws, notably the presence of a few centimeters of dead space at the bottom of the unit where the product exits after mixing. This space became a collection point for materials that never entered the mix when the machine was first loaded. Consequently, at the end of the mixing process, the valve would be opened briefly to purge this unmixed portion. Not only did this add an extra step to the process, but it also led to unnecessary waste and further complicated the production cycle.

Summary of challenges:

• Preserving bean integrity: The primary challenge was processing delicate coffee beans without causing breakage or loss of essential flavors and aromas, a common issue with standard mixers.

• Consistency and efficiency in mixing: Achieving a consistently high-quality blend in a shorter time was imperative for increasing production without sacrificing the signature quality of their coffee.

• Environmental concerns and waste reduction: Increasingly aware of its environmental footprint, the company sought a mixer solution that was energy-efficient and minimized waste.

• Customization for unique requirements: The customer's specific demands for scale, quality and particular processing requirements called for a highly customized mixer solution. For our range of customization options, go to our Marion customization page. 

The opportunity - customized excellence

To address these challenges, Marion developed a solution focused on enhancing product quality and operational efficiency. This approach involved a thorough examination of the customer's existing practices and the introduction of an innovative paddle mixer, tailor-made for gentle handling of delicate whole beans. To demonstrate its effectiveness, the cutting-edge solution was rigorously tested at the newly upgraded Marion Test Center.

The innovative design of the mixer featured a semi-cylindrical trough, a significant improvement over the conventional U-shaped model. This design effectively minimized pinch points, thereby reducing the risk of bean breakage. To further enhance product consistency across batches, sanitary liquid spray bar manifolds were integrated for precise and uniform flavor dosing.

The new mixer's design significantly promoted cleaning efficiency by integrating flush gate valves and sanitary seals, marking a substantial advancement in mixing technology. Introducing the flush gate valve was a critical improvement, addressing the issue of dead space at the mixer's bottom that previously led to material waste and process inefficiencies. By ensuring complete product engagement in the mixing process, this innovation not only helped streamline operations but also supported the company's environmental sustainability goals by minimizing waste.

Furthermore, the mixer’s spray bar manifold was removable, thereby facilitating easy maintenance and cleaning. Its washdown-rated specification underscores the mixer's suitability for environments requiring rigorous cleanliness, thereby guaranteeing product safety and quality while simplifying maintenance routines. This comprehensive approach to design not only enhances operational efficiency, but also aligns with the company's commitment to sustainability and quality assurance.

For enhanced operator safety and ease of access, the mixer was equipped with counterweighted doors and safety grates. These features are indicative of Marion's commitment to both operational efficiency and workplace safety.

Comprehensive training sessions were provided to ensure that staff could operate the new equipment effectively, with ongoing support and maintenance services arranged to ensure the mixer’s long-term performance and reliability. 

Results

The introduction of Marion's custom solution led to several significant improvements, including:

• Elevated product quality: The mixer’s ‘figure 8’ mixing pattern, provides a gentle scoop and fold approach, preserving the coffee beans' integrity, resulting in a product of superior quality that resonated well with the customer's brand reputation.

• Significant boost in production efficiency: With reduced mixing times, the customer experienced a substantial increase in production volume, enabling them to meet the growing market demand more efficiently.

• Waste reduction and enhanced sustainability: The flush gate valve directly addressed the company's environmental concerns by minimizing waste and ensuring a more sustainable mixing process. This advancement not only optimized the use of resources but also aligned with the company's commitment to reducing its environmental footprint.

• Heightened customer satisfaction: The tailor-made solution effectively tackled the customer's specific processing challenges, significantly contributing to their business expansion and leading to high levels of satisfaction.

• Strengthened market position: This case study underscores Marion's capability to deliver innovative and customer-specific solutions, reinforcing its standing as an industry leader in coffee processing technology.

Further optimizing operations

For a comprehensive solution, the combination of Marion's flavor dosing system and an HVH Cablevey Conveyor offers an impressive turnkey option. By incorporating these two systems, businesses can streamline their operations and achieve optimal efficiency.

Conclusion 

In conclusion, this case study demonstrates Marion’s unique expertise in providing specialized, efficient and sustainable solutions in the coffee processing industry. By understanding and addressing the unique challenges of its customer, Marion reinforced its position as a leader in innovative mixing technology, contributing significantly to the company’s continued success and growth in the competitive coffee market.

The collaboration between both parties serves as an inspiring example of how targeted solutions can bring about significant advancements in both processing efficiency and product quality, ultimately contributing to the customer’s success in a highly competitive market.

“Our collaboration with Marion not only enhanced our production efficiency but also elevated the quality of our coffee, reaffirming our commitment to excellence. This customized solution has been a game-changer for us, enabling us to meet our growth objectives while staying true to our values of sustainability and quality.” Company representative

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