Bratney Companies

Popcorn Processing Facility


 

 

Image of the Bratney Agricultural Processing design-build popcorn conditioning facility.
Image of the Bratney Agricultural Processing design-build popcorn conditioning facility.
Image of the Bratney edible corn processing facility.
Image of the Bratney edible corn processing facility.
Image of the Bratney fabrication manufacturing bulk storage bins.
Image of the Bratney fabrication manufacturing bulk storage bins.
Image of Bratney millwright fabrication for modern food and feed mills.
Image of Bratney millwright fabrication for modern food and feed mills.
Image of Bratney Process Design facility for material handling, dust control, and more.
Image of Bratney Process Design facility for material handling, dust control, and more.
Photo of the Bratney process engineering popcorn conditioning plant.
Photo of the Bratney process engineering popcorn conditioning plant.
Photo of Bratney Turn Key Construction Plant.
Photo of Bratney Turn Key Construction Plant.
Image of the Cimbria Chromex Color Sorter at Bratney.
Image of the Cimbria Chromex Color Sorter at Bratney.
Image of the Cimbria SEA Chromex color sorter.
Image of the Cimbria SEA Chromex color sorter.
Concetti automatic packaging system with bagging scale, bagger, metal detection, check weighing, robot palletizer and stretch wrapper.
Concetti automatic packaging system with bagging scale, bagger, metal detection, check weighing, robot palletizer and stretch wrapper.
Image of the Concetti 4-column palletizer.
Image of the Concetti 4-column palletizer.
Image of the Concetti 4-column, robotic palletizing system.
Image of the Concetti 4-column, robotic palletizing system.
Image of continuous cup elevators conveying finished popcorn to the bulk bagging storage bin.
Image of continuous cup elevators conveying finished popcorn to the bulk bagging storage bin.
Image of an edible corn conditioning plant.
Image of an edible corn conditioning plant.
Image of material handling systems with dust control to stay safe.
Image of material handling systems with dust control to stay safe.
Image of a plant dust control system to keep the plant clean and safe.
Image of a plant dust control system to keep the plant clean and safe.
Image of a popcorn processing plant receiving lane.
Image of a popcorn processing plant receiving lane.
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Bratney Companies was asked to deliver a turn key popcorn conditioning facility for a premier global supplier of premium quality popcorn. The client’s primary concerns included; a safe and healthy finished product surpassing the industry standard for quality and foreign materials, peak efficiency, advanced technology, operator safety, plant automation and budget.

Through a collaborative effort between Bratney’s project development team and our client, an innovative process flow and plant design was conceived. From that point, Bratney design staff began detailed engineering to not only eliminate antiquated steps in the process, but to carefully place the equipment, structures and platforms in the most efficient manner providing for optimum performance and accessibility.

All of this was done being ever mindful of the client’s budget and their desire to incorporate the latest processing and packaging equipment from Cimbria and Concetti. This technology allowed them to beat the industry standard of 1-2% foreign material by nearly 2 full percentage points, producing 99.9% perfect popcorn.

The automated plant safely processes 42,000 lbs. / hour with only three operators. And, more importantly at a quality level not achievable without the advanced technology Bratney process engineers incorporated in the design.

Food processing plants require not only a quality design, but attention to details. Bratney millwrights are experienced in the proper installation of conditioning equipment, material handling systems, storage systems, dust control systems and compressed air systems. Those skills combined with those of our start up and service technicians, allowed us to commission each system, train the plant operators and successfully bring this plant online.

Project Scope – Turn Key Popcorn Conditioning Plant
  • process engineering developing a unique process flow

  • facility design

  • project management

  • construction management

  • millwright services

  • equipment selection

  • equipment installation

  • facility startup and commissioning

  • operator training

Project Details
  • 3,000 bushels per hour receiving line

  • Pre-cleaning, precision cleaning and optical sorting line with 42,000lbs. per hour capacity

  • Flexible material handling systems to transfer raw or finished popcorn to a variety of storage and processing stages, including an automated open mouth packaging system from Concetti, bulk sack filling and truck loading systems

  • Food plant options including, in-line magnets, in-line metal detectors, stainless steel contact parts in the packaging system, bagged product metal detection and NTEP certified check weighing

  • Ease of access to all equipment for cleanout between varieties

  • Dust control tied to each piece of equipment, surge bin and transfer point for safety and good housekeeping;

  • Finished product storage

  • Electrical control room

  • Office and warehouse

Equipment Solutions
  • Cimbria pre-cleaners and precision cleaners

  • Cimbria color sorters

  • Concetti Automated Packaging System capable of running both pre-made, open-mouth paper bags and polyethylene FFS (form fill and seal) bags on the same machine

  • Wulftec automated pallet wrapping system integrated to the Concetti packaging line

  • Anex continuous cup elevators

  • Bratney Fabrication – surge bins, equipment platforms, stairs, transitions, valves

  • Plant automation and control system

  • Dust control systems

  • Compressed air system

 

 

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