Case of Clarification of Southeast Asian Food Extract Solution: Manual Jack Box Type Filter Press
The food processing factory in Southeast Asia has adopted manual hydraulic jack box-type filter press to solve the problem of clarifying plant extract solutions.
Project Background
A medium-sized food processing factory in Southeast Asia that specializes in the production of tropical plant extracts. Its main business is to extract functional concentrates from local characteristic plants and supply them to downstream beverage and health food manufacturers. After the extraction process is completed at this factory, a large amount of mixed slurry containing plant fiber debris, fine particles, and some colloidal substances will be produced. It is necessary to separate the clear extract from the solid residues to obtain high-quality clear concentrated liquid.
Previously, this factory used a simple stainless steel vibrating screen for coarse filtration, which could only intercept large particles of fibers. The fine suspended substances still passed through the screen and entered the subsequent concentration process, resulting in turbid precipitation in the final product and a consistently high customer complaint rate. The factory attempted to introduce a belt vacuum filter, but the equipment was expensive and occupied a large area. Moreover, the factory's production had a distinct seasonal characteristic. During peak production periods, it needed to operate continuously, while during off-peak periods, it had to shut down for a long time. The long idle period of the expensive equipment made it difficult to meet the investment return cycle requirements.
The core requirements of the manufacturer for the alternative equipment are: moderate procurement cost, small floor space, simple operation and maintenance, the ability to adapt to intermittent production rhythms, and all components in contact with the materials must meet food hygiene and safety standards.
Equipment selection and configuration
After a technical assessment, this food processing plant purchased our XMQ2/380 manual hydraulic press box-type filter press, and made special configurations for the food industry application. All the flow components of the entire machine have been upgraded to food-grade standards.
The filtration area is 2 square meters, and the single batch processing capacity precisely matches the discharge volume of each batch extraction tank in this factory. The design of the clear liquid discharge system enables operators to directly observe the clarity of the extraction liquid. Once it is found that the filtrate is turbid, the feeding can be immediately stopped to check the condition of the filter cloth, avoiding the mixing of unqualified filtrate into the finished product tank. The hydraulic press for pressing tightly and the manual pull plate for discharging materials do not require electricity at all, and are even safer and more reliable in the humid environment of the food workshop.
Implementation and operational results
The equipment was installed in a corner of the extraction workshop of the factory, occupying less than two square meters. The operator pumped the extracted mixed slurry into the filter press. The filtration pressure was controlled between 0.15 and 0.25 megapascals, and the single batch filtration lasted for approximately forty minutes. During the filtration process, the operator judged the filtration progress by observing the clarity of the filtrate flowing out from the outlet. When the filtrate changed from initially turbid to completely transparent, it entered the pressing and dehydration stage, and the feeding was stopped when the outlet basically stopped flowing.
After releasing the jack, the operator pulled out the filter plates one by one. The filter cake appeared as dark brown plant fiber blocks with moderate moisture content. It was directly bagged and sold as a by-product to the local organic fertilizer factory, achieving full utilization of the materials. The clear and transparent plant extract solution was collected and directly entered the subsequent evaporation and concentration process. After the product was dissolved, it was clear and transparent, and the customer complaint problems were completely resolved.
The production supervisor of this factory reported that in the past, when using the vibrating screen, the screen mesh needed to be replaced three times a day. The filter cloth was frequently replaced and the cost was not low. Now, one set of filter cloth can be used continuously for two to three weeks before it needs to be cleaned or replaced. The cost of consumables has significantly decreased. The daily maintenance of the entire equipment only requires rinsing the filter plates and the surface of the filter cloth with clean water after each shift, and lubricating and maintaining the screw rod of the jack once a week. Professional technicians are not required for this.
Customer Evaluation and Insights
"The factory's manager stated that this manual hydraulic press box filter has solved the long-standing clarification problems they have been facing. Moreover, the operation method is so intuitive that even new employees with no prior experience can master it after a brief explanation. Previously, they believed that filtering equipment must be automated and large-scale to be considered professional. However, after actual use, they realized that a device that matches the production scale, has a low operational threshold, and is easy to maintain is the most suitable choice."