From concept to reality: hygienic solution for liquid egg product

Perfect Automation has recently installed a solution for Sunny Queen’s concept of liquid egg mixture in side spout pouches. The project presented many challenges as it required an intricate balance between elevated contamination risks and the delicate heat sensitivity of the product. The final user-friendly design allows for the content to be reused while also achieving extended shelf life for the product.

Before implementing this solution, a Sunny Queen spokesperson said the company was grappling with a couple of significant challenges. “Our existing CIP (clean-in-place) system was lacking in efficiency and effectiveness and the process of managing the cartridge feeler was predominantly manual, which resulted in operational inefficiencies and inconsistencies. We recognised the need for an automated system to streamline this aspect of our operations and enhance overall accuracy and speed.”

Perfect Automation supplied and installed a new 10-station Rotary Leepack Pouch Machine line that was designed to manage two distinct products. In addition, a HEPA Air System was integrated to establish an ultra-clean environment before the product is introduced into the pouches, thus contributing to the overall accomplishment of complete sterilisation.

Furthermore, the integration of Herrmann Ultrasonic Sealing achieved a good seal for this heat-sensitive product. This advanced ultrasonic technology introduces a cold sealing method for the pouches, combined with an inspection system. This integration is designed to ensure that each pouch obtains an airtight seal, particularly critical for these highly sensitive products. This innovation achieved good product integrity and also resulted in reduced energy costs and minimised production downtime, which helped improve operational effectiveness.

According to Sunny Queen, the solution has yielded “measurable and impactful outcomes”, and the equipment is more compact, which has helped the company manage the space at its factory.

“Through the efficient operation of the CIP system, we have been able to recycle and reuse chemicals, leading to substantial cost savings in our chemical consumption. This not only aligns with our sustainability goals but also directly contributes to reducing operational expenses,” the Sunny Queen spokesperson said.

Sunny Queen’s liquid egg mixture has now made its way onto the shelves of Australian supermarkets. According to the company, the technology employed in producing these pouches has notably extended the shelf life of the product and “the inclusion of a resealable lid has significantly improved the product’s convenience”.