For the new facility in Oinofyta, VRAYKOS undertook the engineering and manufacturing of a modern, flexible and highly automated production line covering:
Raw Material Intake – Mixing – Dosing – Bagging
The integrated solution was engineered to meet the strict hygiene and safety requirements of modern food production facilities, providing a maximum production capacity of approximately 4.5 tonnes per eight-hour shift.
Tailor-made engineering for the product and installation
VRAYKOS developed a custom smart mixing system specifically adapted to the:
- The characteristics of the raw materials and protein mixtures
- The requirements of the production process
- The execution of multiple recipes
- The required capacity and weighing accuracy
- The available installation space
A major technical challenge was the integration of the equipment within a narrow and restricted area. The project required specialised engineering, precise layout planning and the coordinated integration of every production stage into a single, fully functional system.
Production line configuration
1. Two bag intake and sieving stations
The line includes two bag intake stations equipped with integrated vibrating sieves for inspecting the raw materials before they enter the mixing process.
This configuration enables rapid feeding and filling of the mixer within five minutes, helping reduce waiting times between production cycles.
2. Series AMK 1,000-litre paddle mixerÂ
At the core of the production line is an AMK paddle mixer with a working capacity of 1,000 litres, engineered for demanding food-industry applications.
The mixer features:
- Four cleaning access doors for easier access to the interior
- Intelligent air-supply systems designed to minimise product losses
- High-performance sealing specifications
- Hygienic design that simplifies cleaning procedures , mirror polishing
- Mixing times of up to five minutes
- A high level of final-product homogeneity
Its design supports the processing of complex recipes and difficult-flow materials, as well as the production of multiple mixes with consistent quality and a high level of repeatability.
3. Dosing, weighing and bagging station
Following the mixing stage, the product is transferred to the automated dosing, weighing and bagging station.
The system provides:
- A weighing deviation of up to ±25 g per 20 kg bag
- A capacity of up to two 25 kg bags per minute
- Controlled and consistent bag filling
- Reduced product losses and spillage
- Flexibility to produce different mixes
The high level of weighing accuracy supports consistent output quantities while reducing deviations and product waste.
4. Semi-automatic bag sewing system
The production line includes a semi-automatic bag sewing system combined with a belt conveyor for the controlled handling of filled bags.
The operator places the bag into the sewing machine, which performs:
- Folding of the upper edge of the bag
- Automatic bag feeding
- Consistent sewing
- Improved sealing
- Reduced product leakage during transportation and storage
The system delivers a capacity of more than two bags per minute and can be adjusted to accommodate different bag sizes, increasing the operational flexibility of the production line.
5. Final-product metal detector
At the final stage of the process, a metal detector has been installed above the belt conveyor to inspect the filled and sewn bags.
The system can detect small metal objects down to 1.5 mm and incorporates a Stop-on-Detect rejection function. When metal contamination is detected, the conveyor stops, allowing the affected bag to be removed and inspected.
This configuration strengthens final-product control before storage or distribution.
Production automation and control
The new production unit is equipped with an integrated PLC automation system and an industrial operator interface for monitoring and controlling the individual production stages.
The system supports:
- Storage & execution of multiple recipes
- Automatic control of production cycles
- Monitoring of key operating parameters
- Production data recording
- Data Analytics functions
- Increased recipe repeatability
- Reduced risk of human error
The automated process improves production stability, enables more effective control of process deviations and allows Kallas Inc. to manage different products through a single, flexible production line.
An integrated Bulk Handling & Process Engineering solution
The new Kallas Inc. mixing unit is an integrated Bulk Handling and Process Engineering application covering all critical production stages:
Intake – Sieving – Feeding – Mixing – Dosing – Weighing – Bagging – Sewing – Final-product Inspection
The project demonstrates VRAYKOS’ capability to engineer and deliver integrated production units for the food industry, combining tailor-made engineering, advanced technology and equipment designed and manufactured in Greece.
