Semi-Bulk Systems

Semi-Bulk Systems is a world-class provider of modular engineered process solutions involving dry ingredient handling and dry/liquid mixing systems. For nearly 50 years, it has designed and developed process solutions for manufacturers of beverage, dairy, food, and industrial products.

In today’s market, most companies do not provide equipment for both the dry and wet sides of the mixing process, leaving manufacturers reliant on multiple companies for a single process. As a result, aligning the wet and dry sides to function concurrently becomes a tedious task.

Semi-Bulk Systems addresses this challenge with its Total Solution for both dry side and dry/liquid mixing, revolutionizing the floors of global food manufacturers. The solution optimizes process efficiencies and provides the lowest manufacturing costs, enabling clients to be highly competitive.

“Our Total Solution offers process and mixing benefits that address both powder handling and powder/liquid mixing, previously unavailable to food and beverage manufacturers,” says Charles Alack, founder, CEO, and COO of Semi-Bulk Systems.

At the heart of the system is the VACUCAM^®Ejector Mixer (VACUUM Convey and Mix) Slurry Processes, designed by taking Bernoulli’s principle into consideration. The vacuum and mixer performance is designed around the hydraulic pressure and flow of liquid through the orifice. The mixer does not have any moving parts and is based on the proper sizing of the liquid supply pump to the mixer. This product is offered in a broad range of sizes and capacities.

Semi-Bulk Systems’ processes can be configured as a single pass process or a batch process. Utilizing the two technologies, automated dry side handling and powder delivery feeding, it offers the most efficient, standard, and modular processes for the food and beverage industry. It calls this versatile approach the Dynamic Continuous Steady State (DCSS) process.

In addition to its DCSS process, Semi-Bulk Systems develops pre-engineered, pre-assembled, modular skids with finished wiring and pneumatic installation. These skids are equipped for total automation and very high production capacities.

Semi-Bulk Systems also designs and supplies specialized dry side components, like hygienic bulk bag unloaders and hygienic bulk bag and small bag surge hoppers to automate the delivery of dry ingredients. This allows users to supply the VACUCAM^® Ejector Mixer from single or multiple dry ingredient sources with total automation and high capacity. Through these features, labor and operational costs are reduced while production capacity is increased.

The dry side powder delivery incorporates hygienic spray balls in the tanks and hoppers, air-cone hoppers (fluidized discharge cone) for conditioned flow of the dry side, vibrators on the cone of hopper, the ‘Hugger’ to support bulk bag agitation and free flow from bulk bag into a hopper, load cells on hopper for loss-in-weight dry delivery to Ejector Mixer, bin vents on top of hoppers for dust control, and totally enclosed bulk bag discharge into surge hoppers for vent control.

Numerous VACUCAM^® Ejector Mixer processes have been designed for the dairy industry, including frozen desserts, ice cream, and sugar liquefication. The latter highlights the effectiveness of the product and Semi-Bulk Systems’ dual technology solution. The skids can be sized for different volume requirements, and the dry side can be designed for the most favorable supply process, whether bulk truck, rail car, silo, or a combination.

Semi-Bulk Systems has applied its technology and experience in powder handling and powder/liquid mixing to provide the most efficient sugar liquefication process. The technology delivers numerous benefits over conventional processes, like reduced inbound syrup transportation and raw material costs, minimal maintenance requirements, higher capacity, and totally automated process options.

Its VACUCAM^® DCSS process offers major benefits and cost savings to starch, flour, calcium carbonates, limestone, and dairy products-related businesses.

Semi-Bulk Systems demonstrated the unrivaled potential of its solutions when a sanitizer manufacturing client faced a significant challenge in handling Carbopol. A sales representative recommended a Semi-Bulk Systems mixer to solve its issue with the hours it took to make the thickener.

“We finally got their plant manager to try our system, and he just couldn’t believe it,” Alack says. “It did a phenomenal job with the thickening agent. The client affectionately called the system the ‘Carbo Cannon’ as it ended their woes in handling Carbopol.”

“Carbo Cannon” enabled the client to reduce the amount of thickening agent, as it allowed the product to maintain the same viscosity with less Carbopol. The product also helped triple the amount of daily hand sanitizer production and paid for itself within just a few days.

By partnering with Semi-Bulk Systems, customers get the opportunity to witness their product being produced in its pilot plant or at their facility. The team then presents them with a written process performance guarantee. Proposals include a description of the many benefits they will realize by making the change to Dynamic Mix-Making Technology. Semi-Bulk Systems calls this Process XstreamLining.

Founders Avrom R. Handleman and Alack established Semi-Bulk Systems in 1975, bringing an abundance of engineering and process experience relating to both dry-side processing and powder/liquid mixing. With the achievement of ISO 9001 and 3A Certification, it scaled its operations to serve customers across the globe. The team now serves smaller operations as well as Fortune 50 manufacturers.

Semi-Bulk Systems plans to continue its R&D to obtain higher levels of Process XstreamLining while helping clients increase their capacities, process efficiencies, product yields, worker safety, and manufacturing accuracy.