Founded in 1912, Henry P. Thomson, Inc. is one of the largest tea importers in the US. Although it began on Wall Street (center of the tea trade back then), HPT now warehouses its products in Augusta, GA and sells primarily to tea packagers, who sell to restaurants, food chains and supermarkets in southern states.
"Many coffee roasters based in the South have complementary iced tea lines," explains Eugene Amici, president, Henry P. Thomson. "During the 1920s and 30s, HPT became the tea department for those coffee roasters, who have scaled up nationally since that time."
"Approximately 85 percent of HPT blends are for iced tea, which Americans increasingly choose as an alternative to carbonated beverages with less or no sugar," says John Smith, VP and managing director. "Iced tea is consumed in restaurants, made at home, and bought in the refrigerated sections of grocery stores and convenience stores," he adds.
A key to HPT's 100-year success is maintaining tea blend consistency — a difficult task due to sack-to-sack variations in imported tea. For example, says Smith: "We receive 400 sacks of an African tea, and from sack to sack the tea may be lighter or darker in color or vary in quality due to seasonal variations. Yet the customer expects blends that have no variation in quality from batch to batch."
To deliver this consistency, HTP relies on a Munson 140 cu ft (3.9 cu m) capacity Rotary Batch Mixer.
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Dr. Harvey's Ups Output Of Natural Pet Foods with Rotary Batch Mixer
Dr. Harvey’s produces all-natural food products for dogs and birds, each of which is a blend of 15 to 30 dry ingredients ranging from seeds, dried vegetables, fruits and organic grains, to protein powder and freeze-dried meat.
The company's previous 9000 sq ft (836 m2) plant and 2 cu ft (57 liter) ribbon blender limited growth, prompting Dr. Harvey’s to move to a 30,000 sq ft (2787 m2) facility in Eatontown, New Jersey, and install a 20 cu ft (566 liter) Munson Rotary Batch Mixer, which is "the central and fastest part of the process," says General Manager Cesar Salazar.
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Ribbon Blender Keeps Essential Oils of Spices Intact
Paul Murphy, a Culinary Institute of America graduate who has worked with notable chefs across the U.S., turned his attention to custom spice blends and opened Al Dentes' Provisions. Initially focused on custom seasoning for chefs in the Las Vegas area, Al Dentes' has since become the largest supplier of dried spices, herbs, and seasonings in the Las Vegas metro area and has branched out to Hawaii and the western United States with custom and private label products.
Las Vegas accounts for approximately 65 percent of Al Dentes' business. In all, Al Dentes' uses 175 different ingredients — dried, granulated and powdered ingredients along with liquid and encapsulated oils — to create 80 to 100 custom blends.
"Chefs come to us with a particular flavor profile; we conduct R&D and create a spice blend to meet their needs," explains Matthew McClure, Al Dentes' general manager. "We can also take any existing blend and adjust it to suit a chef's liking or convert a blend to purer raw materials. Because of the volume of spices we use, we can also convert raw materials to ones with better price points," he adds.
Proper mixing of each spice blend is critical to Al Dentes' success. "We tried a few blenders, but found that they would physically puncture the cells of the spices, allowing the oil to seep out, resulting in loss of the blend's flavor and aroma — the essence of the spice," explains McClure.
In the end, Al Dentes' purchased a Munson Model HD-2-1/2-5-SS Horizontal Ribbon Blender with a capacity of 25 cu ft (0.71 cu m). "We selected the ribbon blender from Munson because it allows for a nice, almost folding action," says McClure. "In the end, we achieve a fully incorporated, homogenous mix that is loose and almost fluffy — exactly we want in our seasonings."
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Munson Machinery Company, Inc.
Jewel Date Company grows, processes, packages and ships approximately 8 million lb (3.6 million kg) of dates and date products a year. In addition to selling whole and diced dates, the company grinds dates into flours, granules and powders it sells as ingredients to food manufacturers, and directly to consumers through its online store.
The company utilizes a Munson Screen Classifying Cutter to reduce dates into granules and powders within narrow size ranges.
Harvested dates are air-dried for two days to reduce moisture content from 50% to 7%, causing the dates to harden. "Anything greater than 7% and the dates will clump during processing," explains John Ortiz, sales manager. The dates are then cooled, loaded into a hopper and forklifted to a conveyor that transports them to the 11 in. (28 cm) wide throat of the cutter.
The company previously utilized a hammer mill which offered less capacity and particle size control.
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Film Producer Enhances Recycling Program with Rotary Batch Mixers
OMNOVA Solutions significantly improved recycling capabilities at its plant in Auburn, Pennsylvania by investing in rotary batch mixers from Munson Machinery Co. Inc., NY.
OMNOVA supplies printed flexible and rigid films to commercial and residential product makers for flat and three-dimensional (3D) lamination to wood, metal, particle board and substrates used in high-end and commodity products. Applications include cabinets for kitchens, bath and healthcare; home and office hospitality furniture; retail displays; wall and floor coverings; and interiors of recreational vehicles.
The plant compounds, calenders, prints, embosses, and coats primarily PVC films. Despite significant reductions in waste through LEAN SixSigma and other continuous improvement programs, OMNOVA's calendering process still generated process waste material that could be recycled. In an effort to effectively re-utilize this material and improve the plant's environmental footprint, OMNOVA invested in its recycling program.
OMNOVA's options to recycle material were initially limited. To improve the recycling process, OMNOVA invested in a Munson 700-TSC-300 rotary batch mixer with capacity of 18,000 lb. (8,165 kg) and 300 cu ft (8.5 cu m). The company granulated its start-up and process waste material, reducing its particle size and then blended it in the mixer. Plant process engineer Steve Reed says, "The homogeneous mixing action of the Munson machine produced high-quality recycled blends that could be added back into compound formulations in-house or sold outside to brokers." One benefit of the machine's mixing efficiency was to reduce variations in particle size distribution. This prevents particle segregation and problems arising from different melt temperatures during re-processing.
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Animal Vitamin and Mineral Producer Relies on Rotary Batch Mixers
ADM Alliance Nutrition, Inc. is a leading manufacturer and distributor of vitamin and trace mineral pre-mixes, ingredients and food additives used in manufacturing pet food products. In addition, about 10 per cent of the company's output is mixes for bovine and swine feed.
"We run about 1100 pre-mixes from 400 different powdered ingredients largely for pet food producers," notes Alliance Nutrition Location Manager Kyle Taylor. The ingredient list is vast — zinc sulphate, zinc oxide, manganese, L-pheronine, riboflavin, lysine, assorted vitamins and minerals, and a host of other nutritional compounds, to name a few. "The mixers we use to produce our blends are critical to the success of our business," adds Taylor.
Three of the company's mixers are Munson Rotary Batch machines, that are over 30 years old and run 20/7.
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Mixer Keeps Hot-Melt Adhesives Cool
HMT Manufacturing produces hot-melt adhesives and laminating systems that join almost any material, such as fabric, wood, melamine, foil, and cork, to virtually any substrate including plywood, polystyrene, rubber, steel, and foam. Customers range from makers of building materials and RVs to woodworkers and retailers.
Most of HMT's adhesives are cast as films, which the customer places on the substrate and then covers with the laminate. HMT's Advantage Laminating System then applies infrared heat to melt the adhesive immediately before the materials pass between rollers that compress them. With no cure time required, the composite can be cut or machined immediately, maximizing productivity.
The company blends heat-sensitive hot melt adhesive ingredients using a Rotary Batch Mixer that imparts no shear or heat into the material and produces uniform blends quickly, while requiring minimal maintenance.
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Biron Teas Brings Blending In-House with Rotary Batch Mixer
Founded in 2015, Biron Teas sells organic artisanal teas through retail epicurean grocers, the hospitality industry, and ecommerce.
Owners Andi and Roland Biron first relied on a Seattle-based co-packer to blend their tea varieties, but with cross country shipping fees, delays, and growing demand, the company needed to expand capacity and bring blending in-house.
Mixing teas requires gentle handling. "Because our co-packer used a V-cone mixer, I looked at this equipment first," said Andi Biron, but its swinging operation consumed too much floor space.
Biron ultimately specified a Rotary Batch MX-3-SS Mini Mixer from Munson Machinery for its smaller footprint, and ability to produce uniform blends without product degradation or cross contamination.
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Nutraceutical Blending Cycles Cut 90 Percent with Switch to Rotary Batch Mixing
With increasing demand for its health and wellness nutraceutical supplements, A&Z Pharmaceutical built a 26,700 sq ft (2483 sq m) wing and production line here dedicated to nutraceutical products that were previously produced at another site. The company cut blending times on a new production line over 90 percent by opting for Rotary Batch Mixing over the V-cone blending employed on other lines.
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Tumbling Blends Herbal Supplements Five-Times Faster Than Agitating
Systemic Formulas, manufacturer of herbal blends and powdered vitamins, sells directly to homeopaths, naturopaths, nutritional consultants, and other healthcare professionals. "Our products are complicated," says production manager Spencer Hansen, "with multiple ingredients and more than 150 different SKUs." The company offers capsules, powders, liquids, and sachet daily-dose packaging.
As its product line has grown, Systemic Formulas has streamlined production to meet demand, replacing its Paddle Mixer with a Rotary Batch Mixer that cuts mixing and cleaning time by 80 percent.
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Uniform Iced Tea Blends Achieved Using Rotary Batch Mixer
Founded in 1912, Henry P. Thomson, Inc. is one of the largest tea importers in the US. Although it began on Wall Street (center of the tea trade back then), HPT now warehouses its products in Augusta, GA and sells primarily to tea packagers, who sell to restaurants, food chains and supermarkets in southern states.
"Many coffee roasters based in the South have complementary iced tea lines," explains Eugene Amici, president, Henry P. Thomson. "During the 1920s and 30s, HPT became the tea department for those coffee roasters, who have scaled up nationally since that time."
"Approximately 85 percent of HPT blends are for iced tea, which Americans increasingly choose as an alternative to carbonated beverages with less or no sugar," says John Smith, VP and managing director. "Iced tea is consumed in restaurants, made at home, and bought in the refrigerated sections of grocery stores and convenience stores," he adds.
A key to HPT's 100-year success is maintaining tea blend consistency — a difficult task due to sack-to-sack variations in imported tea. For example, says Smith: "We receive 400 sacks of an African tea, and from sack to sack the tea may be lighter or darker in color or vary in quality due to seasonal variations. Yet the customer expects blends that have no variation in quality from batch to batch."
To deliver this consistency, HTP relies on a Munson 140 cu ft (3.9 cu m) capacity Rotary Batch Mixer.
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https://www.munsonmachinery.com/Articles/article.php?ID=CC-0592
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Animal Feed Producer Ups Uniformity, Cuts Cycle Times with Fluidized Bed Mixing
Country Junction Feeds has produced animal feed products in Alberta, Canada for over 100 years. Today it offers a full line of organic wet and dry feeds for cattle, hogs, poultry, horses, bison, elk, goats and sheep. To improve batch consistency and prevent damage when adding liquids to fragile ingredients, the company installed a fluidized-bed type mixer on its "wet feed" production line.
Dry feed in raw or pelletized form is typically pre-blended in a 4400 lb (2000 kg) capacity mixer. The wet blending process adds oils and/or molasses to rolled oats, barley, pellets and "bull ration" calf feed for nutrition and palatability as well as dust control.
To blend dry ingredients with liquid additions in batches up to 660 lb (300 kg), the company installed a Munson model MF-18-SS fluidized bed mixer.
"Fluidized bed mixing brought more batch-to-batch consistency than the previous auger mixer," explains Mark Shantz, Country Junction’s maintenance manager, adding that it imparts less shear than the auger mixer, reducing product degradation, particularly with fragile materials.
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Contract Manufacturer of Powdered Cleaning Products Boosts Capacity with Two Ribbon Blenders
Webco Chemical Corporation is a fully integrated, custom contract manufacturer and packager of liquid and powder chemical products. Founded by Charles Puliafico in 1956 and now in its third generation of private ownership, the company employs 75 in its modern, 200,000 sq ft (18,581 sq m) facility.
Webco offers both liquid and powder blending and filling services. Powder products are blended in quantities from small batches to multi-batch production runs and packed in containers ranging from 4 oz (118 cc) bottles to 55 gal (208 liter) fiberboard drums. "We blend primarily industrial, agricultural and household cleaning products," says Mark Puliafico, President of Webco. "Some examples include metal cleaning and finishing products, household and commercial laundry powders, and cleaning products for dairy farms including egg washing cleaners and even a powdered teat dip for cows."
To meet increased demand, Webco recently replaced its aging blenders with two Munson Model HD-36 stainless steel heavy duty ribbon blenders, each with a blending capacity of 40 cu ft (1.13 cu m). "This gives us a total blending capacity of about 90,000 to 100,000 lb (41,000 to 45,000 kg) per shift," says Puliafico. "One blender discharges into the fiberboard drums while the other feeds a semi-automatic filling machine. Both blenders run pretty muc
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Supplement Producer Ups Uniformity, Cuts Cycle Times with Rotary Batch Mini Mixer
Tailwind Nutrition in Durango Colorado produces nutritional energy supplements containing blends of dextrose, sucrose, fructose, electrolytes, amino acids, caffeine, coconut milk proteins and other ingredients.
To boost capacity and cut cleaning time between changeovers, the company replaced its previous blender with a Munson Rotary Batch Mini Mixer, which rotates on external roller bearing assemblies, eliminating the need for an internal shaft and shaft seals.
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Cal-Chlor Reduces Calcium Chloride with Screen Classifying Cutters
Cal-Chlor Corporation of Lafayette Louisiana is the world’s largest distributor of calcium chloride, a two-part chloride salt in high demand for drilling of oil and gas. Using four Screen Classifying Cutters from Munson Machinery, the Cal-Chlor plant reduces 200 to 400 tons of calcium chloride pellets per day into a powder comprised of uniformly sized particles.
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Rotary Continuous Mixer - Munson Machinery
Slash capital and operational costs when blending long runs of dry bulk solids with or without liquid additions, quickly, uniformly and gently
The MUNSON® Rotary Continuous Mixer cuts labor and operational costs dramatically when mixing dry bulk solids, with or without liquid additions, in-line over long product runs. Delivers uniform blends — typically in one to two minutes residence time — gently and with low energy use.
A money-saving machine for mixing of bulk materials in large volumes, the MUNSON Rotary Continuous Mixer blends primary bulk ingredients, minor ingredients down to 0.1 percent, and/or liquid additions and coatings — uniformly, gently, rapidly and dust-free.
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Rotary Batch Mixer - Munson Machinery
Blend dry bulk solids with or without liquid additions quickly, uniformly and gently, with total discharge and no cross-contamination
The MUNSON® Rotary Batch Mixer delivers uniform particle distribution, uniform liquid additions, cycle times under 3 minutes, gentle product handling, the lowest energy consumption, and complete discharge with no segregation. It also cleans and sanitizes quickly and easily preventing cross-contamination.
Munson's unique, four-way mixing action gently folds, tumbles, cuts and turns the material, producing a thorough blend in only 1 to 3 minutes, while imparting minimal energy and intensity to the product.
The same blending action prevents segregation regardless of particle sizes, shapes or bulk densities, and provides an ideal fluid bed for liquid additions.
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Rotary Batch Mixers Help Concrete Producer Solve Color Problems
Concrete Texturing Tool & Supply (DBA Kingdom Products) began receiving customer complaints when ownership of its original manufacturer of decorative concrete materials changed hands.
"We were in a situation beyond our control, with colors fluctuating dramatically," says Bart Sacco, president of CTTS, which has been specializing in decorative concrete products for more than 16 years. "Formula changes in products like hardeners affected their workability and coverage rates and our installers experienced color shifts in the hardeners." In response to these problems, Sacco founded Kingdom Products (www.kingdom-products.com) to make its own materials.
"We constructed a state-of-the-art blending facility that allows us to create color hardeners and other decorative concrete products free of color drifts from batch to batch."
Today, three years since installing its first 50 cu ft (1.4 cu m) Munson Rotary Batch Mixer, Kingdom Products is manufacturing a variety of products for the decorative concrete and general masonry market, including high-performance countertop mixes, color hardeners, release agents, overlays, micro toppings and lightweight vertical stamp mixes. The company recently added a second stainless steel 40 cu ft (1 cu m) Munson Rotary Batch Mixer to support the operation and offer toll manufacturing services.
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Mini Rotary Batch Mixer Helps Producer of Nutritional Supplements
Managers at Daily Manufacturing, Inc. discuss why they replaced a ribbon blender with a Munson Mini Rotary Batch Mixer to blend ingredients for the firm's high quality nutritional products. The mixer gently but thoroughly mixes ingredients having different bulk densities, and is easy to clean between batches. Daily Manufacturing produces more than 50 blended products in batch sizes ranging from 33 to 440 lb (15 to 200 kg). The mini mixer thoroughly blends a batch in less than half the time required by the ribbon blender, greatly increasing productivity, and is flexible enough to meet current and future needs.
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Rotary Batch Mixer Helps Company Produce Award Winning Coffee Blends
Canadian firm Kicking Horse Coffee produces blended coffee varieties including as many as seven different beans. A Munson rotary batch mixer blends the beans quickly but gently and is easy to clean out between batches. Mixing time is two minutes regardless of the size of the batch or the number of different types of beans being blended or their bulk densities. The blender's "tumble, cut, turn and fold" mixing action assures thorough blending without damage to the relatively fragile beans. Once mixing is complete, the drum continues to rotate and the lifters direct its contents toward the discharge spout, preventing stratification and promoting complete emptying of its contents.
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Why Harney and Sons Blends Teas with Munson Rotary Batch Mixer
Harney & Sons buys fine teas from all over the world which are blended and packaged in the company's plant. Demand for Harney's teas had grown to the point where the plant's two blending machines were barely able to keep up, so the company installed a Munson rotary mixer that has proved more than adequate for its needs. Productivity is much higher, since the new machine has a batch cycle time of only about two hours, including cleaning. The new machine is not only bigger and faster, but gets a better mix of the flavors and is consistent from batch to batch.
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How Harney and Sons Blends 250 Varieties of Teas
Harney & Sons buys fine teas from all over the world which are blended and packaged in the company's plant. Demand for Harney's teas had grown to the point where the plant's two blending machines were barely able to keep up, so the company installed a Munson rotary mixer that has proved more than adequate for its needs. Productivity is much higher, since the new machine has a batch cycle time of only about two hours, including cleaning. The new machine is not only bigger and faster, but gets a better mix of the flavors and is consistent from batch to batch.
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Why Kopp Glass Batches Glass with Munson Abrasion Resistant Rotary Mixer
Kopp Glass, a world leading producer of precision molded borosilicate glass, relies on a rotary batch mixer from Munson Machinery to blend more than 300 glass compositions in unlimited colors. Kopp produces its glass in small batches, typically in the range of 100 to 1,000 pieces. The powdered ingredients are mixed, melted in a pot furnace, then molded by skilled craftsmen. The mixer is a vital part of Kopp's operation. A batch may contain anywhere from five to 15 ingredients that must be mixed thoroughly in order to guarantee product quality. Sand accounts for 60-75% of a formulation and the rest of the ingredients include borax, metal oxides and various other minerals.
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How Kopp Glass Batches Glass Rapidly with Abrasion Resistant Rotary Mixer
Kopp Glass, a world leading producer of precision molded borosilicate glass, relies on a rotary batch mixer from Munson Machinery to blend more than 300 glass compositions in unlimited colors. Kopp produces its glass in small batches, typically in the range of 100 to 1,000 pieces. The powdered ingredients are mixed, melted in a pot furnace, then molded by skilled craftsmen. The mixer is a vital part of Kopp's operation. A batch may contain anywhere from five to 15 ingredients that must be mixed thoroughly in order to guarantee product quality. Sand accounts for 60-75% of a formulation and the rest of the ingredients include borax, metal oxides and various other minerals.
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