Forbes has been growing quickly, so much so that a new manufacturing facility was required to meet the demand for chocolate mixes. As a formulator and packager of chocolate powder mixes, Forbes needed to be able to convey and process a large amount of cocoa and other ingredients in a reliable, accurate and efficient manner.

To accomplish this task Forbes turned to Hapman, the leading manufacturer of Tubular Drag Conveyor, Feeding and Bulk Handling Systems. Initial testing was performed at Hapman’s facilities in Kalamazoo, MI. Upon completion of testing carried out under Forbes’ observation, the project turned to the design stages.

The advantage for Forbes in using the Tubular Drag Conveyors is that they are heavy duty, handle a large capacity, and are totally enclosed.  Perhaps most important is that they can also accomplish the conveying of material on several levels and planes with one conveyor.

Working with the Forbes’ engineering department, Hapman designed a complete material handling system within the facilities physical constraints that integrated both new and existing equipment. Also factored into the design was the ability to accommodate future capacity increases, as well as maintaining a polished, food-quality appearance.

 The Chocolate Powder Blending System utilizes two Bulk Bag Unloaders that handle cocoa and cornstarch. From the Bulk Bag Unloaders the material is meter-fed via screw feeders into an 8” stainless steel “Square Loop” Tubular Drag Conveyor. Also feeding the Tubular Drag Conveyor is a Sack Tip Station with integral dust collection which keeps all of the collected material dust in the product stream. The Sack Tip Station is used for putting other raw materials, delivered in various bag sizes, into the process. Each batch has a specific raw ingredient requirement. After the pre-measured ingredients are added to the conveyor, screw-feeders then convey specified amounts of cocoa and cornstarch from the Bulk Bag Unloaders into the Tubular Drag Conveyors utilizing the batch controls.

Once the ingredients are elevated, the material is discharged into a centrifugal sifter and then into a diverter to be directed to one of the two blenders. The blenders, purchased separately form Hayes & Stolz but integrated into the system by Hapman, mix each batch. From the blenders the powder is then fed into another Hapman stainless steel 8” Tubular Drag Conveyor which elevates the completed batch to a hopper above the packaging machinery.