When dealing with sensitive products such as Infant Formula and Nutrition and other high containment products, installing the right processing equipment from the outset is vital. From batch consistency to homogeneity, segregation during transfers to validation of equipment washing and drying, from consistent batch ingredients to maintaining hygiene levels.
Infant formula and baby food manufacturers engaged in these sectors have a number of concerns to address. In this article, we share some of the issues we’ve helped our customers solve.
A note before we continue. Every manufacturer experiences a different set of problems. In this piece, we’ve picked the common concerns of infant nutrition manufacturers, but if your specific challenge isn’t addressed here, please contact us so one of our engineers can get in touch.
In addition, we have a free knowledge resource packed with articles, guides and infographics.
Here are some issues that our customers have faced and how we solved them:
Powders must not be exposed to the atmosphere during the manufacturing process.
Solution
In order to overcome this issue, Matcon use ADUs (Auto Docking Units) at every IBC filling position which ensure powders are never exposed to the atmosphere. Once powders are inside the IBC, they remain sealed and contained until the blended product is packaged on the canning line. Many sensitive products are manufactured in ‘high care’ areas with strict filtering requirements and airlocks at production room entrances and exits, however, regardless of the environmental conditioning we ensure that all materials are manufactured in a contained manner with no open transfers.
Moisture is a critical concern to baby food manufacturers as it is the root cause of microbial growth. It breeds potentially lethal bacteria which makes wet washing a real problem and is something that most baby food manufacturers seek to avoid.
Solution
Matcon air washing. In a recent blending trial with a global infant nutrition products manufacturer, we weighed an IBC prior to air washing and again afterwards. The two weights highlighted that only 4g of powder was left in the IBC after air washing. With a tolerance this low the manufacturer deemed these results acceptable for the IBC to go back into production immediately.
What happens when a wet wash cannot be avoided as you need to deep clean? There are times where there is no option but to wet wash, as an example, a company’s SOP may be that after 5 air washes the IBC must be wet cleaned. Matcon’s wet post-washer is capable and shows staggering results:
ATP Swab Test Results After an Air Wash (pre-wash) & Again After a Wet Wash (post-wash) on the Same IBC
The common industry standard in terms of pass/fail for ATP (Adenosine Triphosphate Presence) testing is as follows:
As you can see from the table below, the air wash did a good job at cleaning with only one caution, however, the Matcon wet wash passed on all counts.
| Pre Wash | Area | Post Wash |
| 23 Pass | Outlet | 75 Pass |
| 137 Pass | Cone SS | 70 Pass |
| 167 Caution | Cone seal | 14 Pass |
| 16 Pass | Wield | 34 Pass |
| 8 Pass | Int surface | 17 Pass |
It is vitally important to understand that validated washing systems will offer excellent and repeatable results, however, consideration must be made to the technology being employed. The IBC outlet and Cone Valve are far easier to clean than a butterfly or slide valve, this is due to their simplicity in design with no gaps or traps that can hold water which is difficult to remove.
Raw materials such as milk and grains can carry trace levels of heavy metals, including arsenic and lead, from the soil, and process inputs can also, on occasion, develop heat‑stable toxins.
Solution
To reduce the risk of heavy metals and other toxins in infant nutrition, manufacturers must control the full supply chain. This starts with careful ingredient sourcing; suppliers and soils must be assessed, and higher-risk ingredients such as rice may be limited in favour of alternatives such as oats or quinoa. Testing is equally important throughout production. Raw ingredients should be screened for mycotoxins and heavy metals, finished products checked against strict limits, and sensitive methods such as ICP‑MS used to detect trace metals.
Processing conditions must also be controlled to prevent unwanted substances entering the product. This includes using food-grade stainless steel or glass contact parts and filtered water systems to reduce the risk of introducing particles or other impurities during manufacture. Packaging must also be specified carefully, with BPA-free linings and PVC-free seals used to minimise chemical migration into the product over time.
Finally, infant nutrition manufacturers must operate within strict regulatory frameworks. In Europe, for example, requirements are enforced through EFSA and related legislation, helping to keep infant foods within defined safety limits.
Infant formula contains a number of vitamins and minerals which are added in small quantities. It is essential that these micro and macro additions are distributed evenly throughout the blend. Each company has its own homogenisation thresholds.
The requirement for even distribution of these minor ingredients, becomes apparent during packing. If a 1500kg batch is then split into a number of 1kg or 1.5kg cans, each can must contain the correct proportions of each ingredient.
The Solution
The mass flow created by the Matcon Cone Valve significantly reduces the chances of segregation during transfer to packing. Core flow is a common issue experienced with other discharge devices and are unable to offer a controlled feed to the downstream process. This helps to ensure accurate dosage in the end product.
In addition, Near-Infrared-Spectroscopy (NIR) technology, wirelessly attached to the lid of a Matcon IBC, can precisely identify when a mix is homogenous. This reduces blending time, prevents over-mixing and eradicates the need for invasive sampling.
Having helped manufacturers from food, nutrition and pharmaceutical industries for over 35 years, we understand the importance of working inline with these regulations.
We recognize these needs above all else. Our fully contained, stainless steel IBC systems are designed to help you mitigate these risks while delivering consistent quality batches and the kind of profitability all manufacturers seek.
Find out how we helped baby food manufacturer Hero overcame their manufacturing challenges.
Learn more about Matcon's equipment for infant formula and nutrition products here.