3 in 1 Coffee Batch Manufacturing in IBCs

Chek Hup Sdn Bhd is located in Ipoh, Malaysia and was established in 1960 specialising in rock sugar processing. In the 90’s Chek Hup introduced the manufacturing of 3 in 1 Ipoh White Coffee, a unique recipe developed by Ipoh coffee roasters more than 50 years ago. The Chek Hup brand is in 15 countries and is well known for its quality, robust aroma, smoothness and rich taste. Chek Hup Sdn Bhd is certified with HACCP, ISO 9000 and 14000.

The international market interest has caused an upsurge in the demand in the white coffee. Chek Hup’s production increased to over 80 Tons per month.

This level of demand combined with the increased GMP requirements applied to the food manufacturers meant that Chek Hup was keen to implement newer technology to move them into the next era of business growth.

In November 2006 Matcon were awarded a contract for the supply of the Materials Handling System for Chek Hup.

Matcon used their regional experience in 3 in 1 powder processing to implement a Smart Drum IBC (Intermediate Bulk Container) system of 300 Litre capacity. The Smart Drum system is a closed system in which the batch is contained in a sealed IBC.

Each Smart Drum IBC incorporates Matcon’s cone valve technology, which is used to provide the necessary controlled feed into the packaging lines without the risk of segregation of the 3-1 after blending.

The Smart Drum system is used to transfer batches between the process steps, which include;

  • Bulk and minor Raw Material dispensing to an IBC
  • IBC Blending
  • Discharge of 3-1 Coffee into the Packing lines
  • IBC Cleaning – off line

The IBC system is a modular approach, which can be added to later, which Chek Hup saw as a distinct advantage as this will fulfil their future expansion plans.

Mr Tan Huang Kew the Managing Director at Chek Hup has seen the benefits of the Matcon IBC system: “The With the Matcon system in place, our factory output has increased from 80 tones to 110 tones per month. The factory floor is cleaner with little dust and there is no need to clean the packaging machine’s inlet every day as it is now connected to the chute. So all this helps to cut down the time required for cleaning and mopping”.

The IBC system is a closed transfer system and prevents the risk of contamination i.e. operators exposure to air borne dust, therefore improving the Health & Safety issue (contaminate getting out) considerably. Also the IBC system prevents contamination of product quality which is a GMP issue (contaminate getting in).

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