BACK-TO-BASICS APPROACH
Advanced Powder Solutions (APS) specializes in transforming challenges into triumphs through creative drying and mixing solutions. This case study explores their journey, where a seemingly simple task – creating brown sugar – led to a valuable discovery.
The Challenge: Efficient Coating & Extraction
APS was approached by a client seeking to develop a single-machine method for coating sugar crystals with flavor extract while simultaneously handling drying and extraction. The initial experiment yielded promising results: APS’s advanced drying technology efficiently dehydrated spent beans, removing solvents and concentrating trapped flavor compounds. By reintroducing the dried beans into a fresh ethanol-water solution, APS helped the client increase flavor extraction efficiency from 50–60% to an impressive 90%—a testament to the precision and effectiveness of GEMCO drying technology.
However, achieving uniform coating proved challenging. Traditional spraying techniques resulted in inconsistencies and excessive stickiness, making the process impractical for large-scale production.
The Aha Moment: Simplifying the Coating Process
A future project sparked an unexpected revelation—creating brown sugar by coating sugar crystals with molasses. The complexity of traditional spraying methods seemed to hinder success, so APS proposed a simpler approach: directly pouring the flavor extract onto sugar crystals within GEMCO’s tumble mixing system.
This straightforward technique transformed the process. While the initial flavor extract project presented hurdles, the insight gained led to a breakthrough for another client seeking an efficient method for producing brown sugar. By pouring cold molasses onto sugar crystals within the dryer and utilizing gentle mixing and drying technology, APS achieved perfectly homogenous and flavorful brown sugar with remarkable ease.
Key Benefits of APS’s Approach
Process Simplification: Eliminates the need for complex spraying equipment.
Enhanced Efficiency: Streamlines production while reducing waste.
Consistent Results: Ensures uniform coating and reliable product quality.
Beyond the Technique: The Power of Learning
This project underscores the importance of drawing insights from seemingly unrelated experiences. Sometimes, the simplest solutions unlock the greatest innovations. At APS, continuous learning and collaborative problem-solving drive the development of smarter, more effective processing techniques.
APS is ready to help you optimize efficiency and enhance product quality. Contact us today to explore tailored solutions for your manufacturing needs.