Introduction
The document discusses the implementation of a bulk handling system at Unilever Ice Cream & Frozen Food's Lowestoft, UK plant, which produces Bird’s Eye® brand products. The system aims to enhance frozen food quality and reduce labor.

Specifications and System Components
The new system includes a low profile feed hopper with flow promotion devices, a 10 ft (3 m) long flexible screw conveyor, and a 2 hp (1.5 kW) gear drive. It is mounted on a mobile base frame with adjustable leveling jacks and includes two 35 cu. ft. (1,000 l) intermediate bins.

Procedures and Improvements
Previously, operators manually transferred dry batter mix using a shovel, which was labor-intensive and resulted in product loss. The new system automates this process, reducing labor from six hours to 1.5 hours. Bulk bags replace pallecons, allowing efficient transfer of dry batter into intermediate bins using a remote-controlled hoist.

Operational Efficiency
The system reduces the number of trips needed to return dry ingredients to storage from 18 to 4 per 12-hour shift. It supports various dry mix recipes with bulk densities ranging from 9.3 to 38.4 lbs/cu ft (118 to 486 kg/cu m).

Benefits and Outcomes
The enclosed system minimizes dust and spillage, enhances operator safety, and maintains ingredient consistency. It has been adopted on additional production lines, including crispy chicken and waffle fries.

Conclusion
The Flexicon bulk handling system significantly improves production efficiency, reduces labor, and enhances product quality at the Lowestoft plant.