Matcon Limited

The IBC container is at the centre of Matcon’s powder handling system solution.  Designed for rapid filling and emptying, with washing off-line, the IBC container allows all the manufacturing processes to operate simultaneously for optimum production efficiency. 

The unique Cone Valve technology contained within each IBC prevents the traditional powder handling issues of bridging, blocking and blend segregation.

Sizes range from 150 to 3500 litre capacity, manufactured from Stainless Steel or Polyethylene, with a simple hygienic design.

Mix any recipe any time with a Matcon IBC Blender.  Mixing takes place directly within the IBC which means that recipe changeovers are essentially instantaneous as the blender itself has no product contact parts to clean.  High OEE (Overall Equipment Effectiveness) rates are achieved as filling, emptying and cleaning take place off-line.

The introduction of a High Shear Intensifier to the Matcon IBC Blender has expanded the range of blending capabilities to incorporating liquid additions and being able to process cohesive powders. Near-Infrared (NIR) spectroscopy enables Matcon to prove mix homogeneity and identify accurate recipe blend times, without using invasive sampling.
 

Matcon offer a range of packing solutions for both business to business packing and refilling to FMCG packing systems.

The Powder Packer module is designed to fill B2B sacks directly from Matcon IBCs.  There is no need to use additional feeding equipment and the simple design enables quick changeovers for small campaign runs and ‘make to order’.  Fill bags from 5-30kg at a rate of 1-3 bags/minute with an adjustable and controlled feed, without risk of segregation of the mix.

Alternatively, if you already have a packing machine in mind, the Packing Line Refill module feeds directly to FMCG packing systems (typically FFS equipment) without any secondary refill devices.  The design of the discharge station protects against product segregation enabling a quality product in the final consumer pack.  The refilling is automatic and controlled, producing a consistent feed and allowing the packing lines to maximise their throughput.
 

Matcon IBCs are particularly well suited to pharmaceutical applications, as the Cone Valve technology enables blended powders and granules to feed directly to roller compactors and tablet compression without the risk of segregation.  In fact, this unique technology allows us to supply large-scale IBCs up to 3500L, with the reassurance that the product will not segregate and will be fully discharged. 
Key benefits include:

• Improved product quality
• Improved productivity
• Prevention of segregation during transfer
• Contained materials handling
• Complete, controlled discharge
• IBC range from 150L to 3500L

The Matcon Tablet IBC System enables lean and efficient handling of tablets and capsules whilst maximising the effectiveness of tablet coating and packing.  The Tablet IBC gives our customers the ability to handle coated and uncoated tablets in quantities up to 750kg in one single IBC.  This offers significant benefits including:

• Reduced movements of tablet containers
• Reduced number of connections/disconnections
• Minimal operator handling time
• Less containers required per batch
• Closed and contained transfers
• Fully automatic operation
• Improved inventory control & traceability

Reduce waiting times spent in preparing recipes for batch processing by formulating directly into IBCs. This is done off-line and added into the flow of batch processing as required. Traceability is possible with check weighing capabilities and material tracking.
 
The Sack Tip module provides a quick and efficient method of transferring powdered material from sacks into Matcon IBCs, with minimal dust exposure. The systems easy-to-clean design permits fast changeover of recipes. Optional weigh platforms provide check weighing facilities.

The 'Flexi-Batch' IBC Formulation System offers a fast means of automatically batching ingredients from 10-1000kg with high degrees of accuracy. The contained design means multiple recipes can be handled simultaneously. This system provides full batch traceability and minimises the risk of human error in formulation.