Bratney Companies

Popcorn Processing Facility

Design-build popcorn conditioning facility featuring the latest cleaning, optical sorting and packaging technology.
Design-build popcorn conditioning facility featuring the latest cleaning, optical sorting and packaging technology.
Bratney engineers carefully consider operator safety, plant access and lighting for a user friendly processing plant.
Bratney engineers carefully consider operator safety, plant access and lighting for a user friendly processing plant.
Bratney Fabrication manufactures bulk storage bins, equipment stands, platforms, wye valves, slide gates and many other items for processing plants.
Bratney Fabrication manufactures bulk storage bins, equipment stands, platforms, wye valves, slide gates and many other items for processing plants.
Bratney millwrights have decades of experience and understand the requirements of modern food and feed mills.
Bratney millwrights have decades of experience and understand the requirements of modern food and feed mills.
Engineered solutions to your material handling, dust control, electrical and compressed air system challenges.
Engineered solutions to your material handling, dust control, electrical and compressed air system challenges.
Automated popcorn conditioning plant with food safety features and advanced processing technology.
Automated popcorn conditioning plant with food safety features and advanced processing technology.
Electrical and compressed air systems feeding processing equipment throughout the plant.
Electrical and compressed air systems feeding processing equipment throughout the plant.
Advanced cleaning and sorting process with Cimbria pre-cleaner, Cimbria Delta air screen cleaner and Cimbria Chromex color sorter.
Advanced cleaning and sorting process with Cimbria pre-cleaner, Cimbria Delta air screen cleaner and Cimbria Chromex color sorter.
Cimbria SEA Chromex color sorter. Unmatched capacities and multiple camera technologies available on one machine handles the most complex sorting applications.
Cimbria SEA Chromex color sorter. Unmatched capacities and multiple camera technologies available on one machine handles the most complex sorting applications.
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.
Concetti 4-column palletizer, the only robotic palletizer to combine the flexible layer patterns of a robot with layer squaring and layer compression of a high-level palletizer for unmatched versatility and perfect pallet stacks.
Concetti 4-column palletizer, the only robotic palletizer to combine the flexible layer patterns of a robot with layer squaring and layer compression of a high-level palletizer for unmatched versatility and perfect pallet stacks.
Concetti 4-column, robotic palletizing system.
Concetti 4-column, robotic palletizing system.
Continuous cup elevators conveying finished popcorn to the bulk bagging storage bin.
Continuous cup elevators conveying finished popcorn to the bulk bagging storage bin.
Elevator legs and spouting move popcorn through this innovative process flow.
Elevator legs and spouting move popcorn through this innovative process flow.
A combination of vibratory conveyors and continuous cup elevators move raw popcorn through the processing steps in this plant. Dust control at each step ensures a safe and clean plant.
A combination of vibratory conveyors and continuous cup elevators move raw popcorn through the processing steps in this plant. Dust control at each step ensures a safe and clean plant.
The dust control system keeps this plant clean and safe with pickup points at each processing step, transfer point and surge bin.
The dust control system keeps this plant clean and safe with pickup points at each processing step, transfer point and surge bin.
Enclosed receiving and bulk load out lane.
Enclosed receiving and bulk load out 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 42,000  lbs. 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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