Hoang Tam – Installation of HOPPER & BAG TIPPING STATION for the NESTLÉ SHIMADA-JAPAN-POWDER HD Project of GEA PROCESS ENGINEERING Partner 08/2020. This project required not only strict compliance with Nestlé’s rigorous international food safety standards but also the world-class quality management and installation techniques of the general contractor, GEA Process Engineering. Through practical experience and core competencies in sanitary stainless steel fabrication, our team of engineers and technicians successfully handed over the system on schedule, meeting the highest operational technical criteria.
Context and Significance of the Nestlé Shimada-Japan-Powder HD Project
The powdered food production industry, particularly for products exported to the Japanese market like the Nestlé Shimada-Japan-Powder HD project, requires extremely strict control over impurities, microorganisms, and fine dust. Every piece of equipment in direct contact with powder materials must comply with prestigious international certifications such as the FDA (U.S. Food and Drug Administration) and EHEDG (European Hygienic Engineering & Design Group).
Our partner, GEA Process Engineering, is one of the world's largest process technology suppliers for the food, dairy, and pharmaceutical industries. Given this stature, GEA established highly detailed and stringent Technical Specifications for subcontractors involved in fabrication and on-site installation. Passing the rigorous capability assessment rounds to become the direct contractor for the Hopper and Bag Tipping Station components has solidified the reputation of the Hoang Tam brand on the industrial stainless steel fabrication map.
The powder feeding system is the starting point of the entire production process. If dust leaks, metal cross-contamination, or microbial accumulation in "dead legs" occur at this initial point, an entire batch worth millions of USD could be rejected. Therefore, the precision of every weld, the surface smoothness of the stainless steel, and the dust control solution at the Bag Tipping Station are the deciding factors for the project's quality.
Equipment Details: Hopper and Bag Tipping Station in the powder processing system
Bag Tipping Station
The Bag Tipping Station is designed to allow operators to safely and cleanly load powdered materials from paper, plastic, or woven bags (weighing from 15kg to 50kg) into a closed production system. This equipment integrates the following core components:
- Feeding Hood: Ergonomically designed for easy operation, featuring a flip door to keep dust contained when not in use.
- Safety Grating: Prevents packaging debris and large impurities from falling into the hopper below. The grating is manufactured from precision laser-cut stainless steel and is easily removable for cleaning.
- Integrated Dust Collector: Uses a centrifugal fan combined with automatic reverse pulse-jet cartridge filters. When an operator pours powder, airborne fine dust is sucked back into the filter, keeping the working environment safe and preventing material loss.
- Magnetic Separator: A high-intensity magnet placed directly under the grating to thoroughly remove accidental magnetic metal particles from the material before it proceeds into the next process.
Hopper
The Hopper receives material directly from the Bag Tipping Station and transfers it into the pneumatic conveying system or mixer.
The design of the Hopper must carefully calculate the hopper wall angle to avoid bridging or rat-holing of fine powder.
The entire hopper body is fabricated from premium SUS316L stainless steel for product contact surfaces, and SUS304 for external structural support components.
The Hopper is integrated with Clean-In-Place (CIP) spray balls to completely flush out material after each production batch without requiring equipment disassembly.
Hoang Tam’s Project Execution Process: From Design Drawings to On-site Installation
Technical Consultation and Design Optimization
Immediately after receiving the Basic Engineering Drawings from GEA Process Engineering, Hoang Tam’s design engineering team conducted in-depth analysis using 3D CAD/SolidWorks software.
The goal was to detect potential spatial conflicts during actual installation at the Nestlé Shimada factory early on, while optimizing mechanical details to align with fabrication capabilities while maintaining the functional integrity of the original design.
We proposed refining the Hopper's support leg structure to enhance load-bearing capacity during pneumatic pulse-jet dust removal, and rounding internal weld corners with a minimum radius of R = 3mm to completely eliminate microbial dead legs.
These technical proposals were reviewed and highly appreciated by GEA experts before moving to mass production.
Precision Mechanical Fabrication at Hoang Tam Workshop
The fabrication process was carried out at Hoang Tam’s modern facility under the strict supervision of the QA/QC department. Fabrication steps included:
- CNC Laser Cutting: Ensures dimensional accuracy below 0.1mm for SUS316L and SUS304 stainless steel sheets with thicknesses from 2mm to 5mm.
2. Forming and Rolling: Utilizing modern hydraulic rolling machines to create perfectly even conical and cylindrical shapes without deformation or surface cracks.
3. Specialized TIG (GTAW) Welding for Food Industry: This is the most crucial stage. All food-contact welds are performed using TIG welding with 99.99% pure Argon gas shielding on both the internal and external sides (back-shielding). Back-shielding with Argon completely eliminates oxidation (weld burn, "cauliflower" slag) inside the pipes and hoppers, ensuring smooth and fully penetrated welds.
4. Surface Finishing: Internal welds are ground flush and polished to a roughness of Ra < 0.4 µm (sanitary grade). The external surfaces are bead blasted to create uniform texture, enhancing aesthetics and ease of cleaning.
On-site Installation and Construction (August 2020)
On-site installation at the Nestlé factory in August 2020 took place amidst very strict labor safety and pandemic prevention regulations. Hoang Tam developed a detailed daily execution plan, logically distributing personnel to ensure no overlap with other contractors on-site.
Installation followed standard procedures:
- Positioning and Installing the Support Frame: Precise alignment of connection flanges using laser leveling equipment, ensuring a total installation tolerance of under 2mm.
- Hoisting Hopper and Bag Tipping Station into Position: Utilizing certified specialized lifting equipment to position heavy components in the factory area with limited clearance height.
- Connecting Process Piping and Dust Extraction Systems: Welding ductwork, pneumatic lines, and CIP pipes using 6G-certified sanitary welders.
- Electrical and Pneumatic Connection: Connecting pneumatic solenoid valves controlling the cartridge dust removal system and proximity sensors for the tipping station doors to the central control panel provided by GEA.
QA/QC, Testing, and Commissioning
The quality of a sanitary stainless steel system cannot just be seen with the naked eye; it must be proven with actual measured data. Hoang Tam worked with GEA and Nestlé quality teams to perform rigorous tests:
- Roughness Testing: Using calibrated handheld Mitutoyo surface roughness testers on random points inside the hopper. Actual results reached Ra 0.32 µm to 0.38 µm, exceeding the requirement of Ra < 0.4 µm.
- Dye Penetrant Testing (PT): Performed on 100% of structural and critical sanitary welds to ensure no cracks, pores, or surface pitting.
- Leak Testing: Pressure testing with nitrogen gas on the Bag Tipping Station's filter chamber to ensure no fine dust leakage occurs when the fan is running.
- As-Built Documentation Handover: Includes Mill Test Certificates (MTC) for SUS316L/SUS304, Weld Logs, welder certificates, roughness reports, and PT reports.
Leading Technical Standards Applied in the Project
The success of this hopper and bag tipping station installation project lies in the absolute adherence to international technical standards for high-quality instant food manufacturing:
Rigorous Requirements for Sanitary Stainless Steel
Stainless steel for the food industry is not merely ordinary stainless steel. The low carbon content in SUS316L helps minimize chromium carbide precipitation in the heat-affected zones of welds, preventing intergranular corrosion. Additionally, stainless steel surfaces must undergo Passivation with specialized acid solutions to regenerate the ultra-thin protective chromium oxide layer, making the surface inert to the harsh chemical detergents used during CIP processes.
Fine Dust Control and Workplace Protection Techniques
Food dust (such as milk or coffee powder) not only affects the respiratory health of operators but also poses a dangerous Dust Explosion Hazard when reaching critical concentrations in closed spaces. The Bag Tipping Station system installed by Hoang Tam fully complies with ATEX fire and explosion safety standards. The fan system is calculated for optimal airflow to create negative pressure inside the tipping booth, effectively preventing dust-laden air from escaping into the operator room.
Overcoming Dual Challenges During the 2020 Pandemic Peak
August 2020 was a challenging time for all manufacturing and construction businesses in Vietnam due to the Covid-19 pandemic outbreak. Supply chains for mechanical materials were interrupted, and worker mobility was severely restricted by social distancing orders.
To ensure the delivery schedule for Nestlé Shimada was met, Hoang Tam’s management board activated an emergency response plan:
- Organizing a centralized working plan, strictly following site-wide epidemic prevention principles to protect the health of all engineers and workers.
- Negotiating with strategic suppliers to stockpile stainless steel sheets, Argon gas, and filter components weeks in advance, preventing material shortages from delaying construction.
- Applying online daily progress reporting technology using high-resolution photos and videos sent to GEA experts abroad, keeping technical oversight running smoothly even though experts could not fly to the site due to international flight restrictions.
Resilience, flexibility, and extreme professionalism during this period helped Hoang Tam complete the project on time, receiving a letter of appreciation from the GEA Process Engineering project management board.
Hoang Tam’s Core Competencies in Industrial Stainless Steel Mechanics
The Hopper & Bag Tipping Station project for Nestlé Shimada is just one of many typical proofs of Hoang Tam’s mechanical construction capabilities. We are proud to possess a closed-loop service value chain from design consultation to operational maintenance, meeting the most rigorous market requirements:
Technical Consultation & Solution Design
We don’t just fabricate according to existing drawings; we partner with customers to find the most cost-effective and operationally efficient solutions. Our experienced engineering team stays updated with the latest sanitary industrial design trends worldwide to apply to specific projects.
Fabrication & Manufacturing
We own a large-scale workshop equipped with modern machinery such as high-capacity fiber laser cutters, CNC press brakes, automatic rolling machines, and high-quality TIG/MIG welding systems. We strictly control material inputs (only using products from reputable global steel corporations) through to every finished product detail before leaving the factory.
On-site Installation & Construction
Hoang Tam’s on-site engineering team is well-trained in project management, HSE (Health, Safety, and Environment), and sanitary mechanical installation standards. We have the capability to manage and coordinate large-scale, complex technical projects requiring multi-party collaboration.
Maintenance, Service, and Post-Project Technical Support
Understanding the importance of maintaining continuous production, we provide periodic maintenance, 24/7 emergency troubleshooting, and genuine replacement parts for sanitary stainless steel piping systems, tanks, and charging/discharging systems.
The successful handover of the project is a golden milestone, proving that the technical capabilities of a Vietnamese enterprise can fully meet the most rigorous food manufacturing standards of the Japanese and global markets.
Hoang Tam is committed to continuous investment in fabrication technology, enhancing workforce expertise, and optimizing quality management processes. We are confident in continuing as a trusted partner for multinational corporations and leading EPC contractors in large-scale food, pharmaceutical, chemical, and industrial storage tank factory projects in Vietnam and the region.
Customer satisfaction and the durability and safety of every project over the years are the greatest metrics of value for the Hoang Tam brand.
Detailed Contact Information
For in-depth consultation on design, fabrication, and installation solutions for industrial sanitary stainless steel equipment, please contact:
Hoang Tam
Address: Lot L1, Street No. 8, Le Minh Xuan Industrial Park, Tan Nhut Commune, Ho Chi Minh City, Vietnam
Hotline: +84933049069
Phone: +84933049069
Email: contact@hoangtamsse.com
Website: hoangtamsse.com
