Custom Automated Protein Ball Production Line Solutions by Seny Machinery
For food manufacturers seeking precision and scalability, Seny Machinery offers tailored automated protein ball production lines designed for peak efficiency. Our turnkey solutions integrate FDA-compliant stainless steel equipment, HACCP-certified processes, and modular customization to produce 2-5 tons of protein balls daily—from mixing to packaging. Backed by 24/7 multilingual engineering support, we ensure rapid deployment and compliance with global food safety standards like ISO 22000.
Video of protein ball production in action
How Full Automation Enhances Protein Ball Production Efficiency
Seny Machinery’s fully automated protein ball production line streamlines operations across four integrated stages:
| Process Stage | Automated Features | Traditional Manual Line | Seny Automated Line |
|---|---|---|---|
| Mixing & Formulation | Precision ingredient dosing (±0.5% accuracy) | 3-4 workers required | Zero manual intervention |
| Shaping & Molding | Dual-axis servo molding (200-500 balls/minute) | 120-150 balls/minute | 300% speed increase |
| Baking & Cooling | Multi-zone infrared baking (±1°C control) | Inconsistent heat distribution | 99% shape uniformity |
| Packaging | AI vision-guided pouch sealing | 50-70 packs/minute | 120 packs/minute |
Key Advantages:
- 60% labor cost reduction: Eliminates 8-12 workers per shift.
- Scalable output: Daily production ranges from 2 tons (small batches) to 5 tons (24/7 operation) via PLC-controlled parameter adjustments.
- Real-time quality assurance: The PLC system monitors critical metrics (e.g., moisture content ≤8%, ball diameter 25±2mm) and auto-adjusts settings, minimizing waste by 18%.
A live dashboard screenshot (Fig.1) from a Seny client in Germany demonstrates 94% OEE (Overall Equipment Effectiveness), with error alerts resolving 85% of issues remotely within 15 minutes.
What Product Variations Can Customized Lines Accommodate?
Seny Machinery’s modular production system enables rapid adaptation to diverse protein-based products through three key mechanisms:
1. Interchangeable Mold Kits for Size & Shape Flexibility
| Mold Type | Specifications | Output Examples |
|---|---|---|
| Spherical (Standard) | Diameter: 20-45mm Weight: 10-50g/unit |
Classic protein balls |
| Cubic | Edge: 15-30mm Weight: 15-40g/unit |
Textured energy cubes |
| Cylindrical | Ø12-25mm × 30-60mm Weight: 20-50g/unit |
Protein bites for cereal mixes |
A 3D schematic (Fig.2) demonstrates how molds snap into the forming module within 7 minutes, supported by laser-aligned guides (±0.1mm precision).
2. Multi-Product Compatibility
The line’s adjustable parameters (temperature: 50-200°C, pressure: 0.2-1.5MPa) allow production of:
- Nutrition Bars: 60-100g compressed slabs (moisture ≤12%)
- Plant-Based Snacks: Pea/soy protein blends with 30-second mold cleaning cycles
- Coated Products: Chocolate-enrobed balls via add-on tempering module
3. Case Study: Seamless Line Conversion
A Thai manufacturer switched from 25g round whey protein balls to 35g square plant-based units in 4 hours by:
- Installing cubic molds (Edge: 28mm)
- Adjusting baking zones to 85°C (from 110°C) for heat-sensitive ingredients
- Reprogramming packaging weights via HMI touchscreen
Technical Guarantee: All modular components meet ISO 22000 hygiene protocols, with <0.5% cross-contamination risk in product transitions.
Key Technical Parameters of the SY-800 Filling and Forming Production Line
1. SY-800 Filling and Forming Machine
| Parameter | Specification | Certification |
|---|---|---|
| Forming Capacity | 20-120 units/minute (adjustable via PLC for 10-50g portions) | FDA-compliant design |
| Material | 304 stainless steel (corrosion-resistant, non-reactive surface) | ISO 22000 hygiene grade |
| Power Consumption | 2.2 kW | CE-marked electricals |
| Filling Accuracy | ±1.5% weight deviation (dual-frequency control for dough and filling) |
2. Rounding Machine
| Parameter | Specification |
|---|---|
| Rotation Speed | 200-400 RPM (adaptable to sticky or dry dough textures) |
| Output Consistency | 99% sphericity tolerance (±1mm diameter) |
| Material | 304 stainless steel contact parts |
3. Coating Machine
| Parameter | Specification |
|---|---|
| Coating Uniformity | 95% powder adhesion rate (adjustable nozzle pressure: 0.1-0.5MPa) |
| Capacity | Synchronized with forming speed (20-120 units/minute) |
| Cleaning Cycle | CIP (Clean-in-Place) system reduces downtime to 10 minutes |
Operational Workflow:
1.Forming: The SY-800 shapes dough and filling into preset weights (e.g., 25g dough + 15g filling) using servo-driven extrusion. 2.Rounding: A spiral conveyor transfers formed units to the rounding module, which eliminates seams via centrifugal force. 3.Coating: Particles pass through a misting chamber and rotating powder bed for even coating (e.g., sesame, coconut flakes).
Compliance Highlights:
- 304 stainless steel construction ensures compatibility with acidic/alkaline ingredients (e.g., fruit-filled or fermented dough).
- FDA-certified lubricants and seals prevent contamination in high-moisture environments.
- HMI-controlled parameter presets enable rapid shifts between products like glutinous rice balls (sticky texture) and plant-based snacks (crumbly fillings).
Key Quality Certifications: How Production Lines Achieve Compliance
To meet global market demands and ensure product safety, Seny Machinery’s protein ball production lines are rigorously designed to comply with HACCP, ISO 22000, CE, and GB 14881 standards. Below is a detailed breakdown of how these certifications align with production processes:
1. HACCP (Hazard Analysis Critical Control Point)
Seny’s automation integrates HACCP principles through:
- Hazard Analysis: AI-powered sensors detect biological, chemical, and physical risks (e.g., allergen cross-contact, metal fragments) at raw material intake and mixing stages.
- Critical Control Points (CCPs):
CCP Stage Control Measure Monitoring Tool Baking Zone Infrared temperature control (±1°C accuracy) PLC dashboard with real-time logs Cooling Conveyor Airflow sanitation to prevent microbial growth Particle counters (≤100 CFU/g) Packaging Seal Heat seal integrity testing (180-200°C, 0.2-0.5MPa) Vision inspection system - Corrective Actions: Deviations trigger auto-stop protocols (e.g., undercooked batches diverted to rework)
2. ISO 22000 (Food Safety Management)
The production line aligns with ISO 22000’s holistic framework:
- Risk Assessment: Digital twin simulations validate process stability for new recipes (e.g., plant-based vs. whey protein).
- Documentation: Traceability systems log batch-specific data (moisture, pH, weight) for 3+ years, meeting audit requirements.
- Verification: Quarterly third-party audits and internal microbiological swab tests (e.g., Listeria spp. <10 CFU/cm²).
- Continuous Improvement: Machine learning optimizes energy use (e.g., 15% reduction in baking zone gas consumption)
3. CE Marking (EU Machinery Directive)
Seny’s equipment adheres to CE safety and hygiene mandates:
- Mechanical Safety: Interlocked guards prevent access to moving parts (e.g., molding rollers) during operation.
- Material Compliance: 304 stainless steel surfaces resist corrosion and chemical reactions (per EN 10088-2).
- Electrical Safety: CE-certified motors and wiring (IP65-rated) prevent short circuits in high-moisture environments.
- Testing: Noise emissions (<70 dB) and vibration levels (<2.5 mm/s) validated by TÜV SÜD.
4. GB 14881 (China Food Hygiene Code)
The production line addresses China’s stringent hygiene protocols:
- Facility Design:
- Cleanroom zoning (Class 100,000) with positive air pressure.
- Floor slopes (1-2°) and stainless steel drains prevent water pooling.
- Sanitation:
- CIP (Clean-in-Place) systems clean conveyors with 85°C alkaline solutions.
- UV tunnels sterilize packaging materials (99.9% pathogen reduction).
- Personnel Hygiene: RFID-controlled access to high-risk zones (e.g., filling modules) with mandatory air showers.
Stage After-Sales Support: From Trial to Mass Production
Phase 1: Free Raw Material Testing & Trial Run
| Service | Details | Outcome |
|---|---|---|
| Lab-Scale Simulation | 50kg sample production test (moisture, texture, and flavor validation) | Recipe optimization report |
| Trial Run (3-5 days) | On-site or factory testing with client’s raw materials | Confirmed throughput (e.g., 3T/day) |
| Data Analysis | AI-driven performance report highlighting adjustments for scaling | Risk mitigation plan |
Deployment Timeline:
- Day 1-3: Equipment assembly and calibration (e.g., torque settings for dough consistency).
- Day 4-5: Test runs with client’s staff (5-8 operators).
- Day 6-7: HMI programming workshops and maintenance drills.
Training Modules:
- Troubleshooting 101: Resolving common issues (e.g., conveyor jams, sensor errors).
- Sanitation SOPs: CIP system operation and allergen control protocols.
- Output Optimization: Adjusting PLC parameters for energy/raw material savings.
Phase 3: Lifetime Remote O&M Support
24/7 Multilingual Hotline: +86-21-57751165 (Chinese/English/Arabic)
- Smart Diagnostics: IoT-enabled machines send real-time alerts for proactive maintenance (e.g., bearing wear detection).
- Remote Updates: Annual software upgrades for new recipes or regulatory compliance.
- Spare Parts Guarantee: Global warehouse network delivers critical components (e.g., molding belts) within 72 hours.
Why Choose Seny’s Service Model?
- Zero Hidden Costs: Transparent pricing covers installation, training, and 1-year warranty.
- Proactive Maintenance: Predictive analytics cut unplanned downtime by 35%.
