Spacious is the most
appropriate word to describe the vanilla powder
factory as one steps into it. The total space
taken up by the cube-tumblers is a mere 1,000
square feet when the total built-in space of the
factory is 8,500 square feet. However, the excess
factory space did not go unutilised. Rows of custom-made
shelves took up almost half of the factory space.
Drums of vanillin and other solvents are stacked
onto these shelves. In addition, the top platform
of this arrangement serves a storage space for
empty drums and yet-to-be used cartons.
Blending is done via two cubetumblers.
These are larger versions of a prototype which
was purchased several years back by Creative.
The original cube-tumbler from Japan can only
produce in batches of 25 kilograms. When Creative's orders started piling up,
it was immediately phased out and a similar machine
with the production capacity of half a tonne was
made to meet its orders. Finding itself up to
its neck with orders, Creativehad another machine with production
capacity of 1 tonne custom-built. Thus, a total
of 4 and a half tonnes may be produced and packed
in 3 hours.
Each of the cube tumbler-mixers has a small
opening at one of its sides where all the necessary
raw materials go in. To make vanilla powder, dextrose
monohydrate, vanillin and other specialties will
undergo a process where they are thoroughly blended.
At a push of a button, the mixers will be rotated
on bars. After the cube tumbler-mixer has rotated
for several minutes, the machine is stopped and
a large tank beneath the mixer will be placed
into position. At another corner of the cube is
an opening where the thoroughly mixed powder will
be allowed to fall into the tank. As soon as the
tank is three - quaters full, one of the workers
will shut the vent to prevent more powder from
exiting and packing of the powder begins.
In scoops, the workers will pack
the white powder into each carton. To ensure that
25 kilograms of vanilla powder are packed into
each carton, these are placed onto a weighing
machine. Once full, the carton is sealed and then
stacked systematically onto a pallet.
The factory space is only under lease and
hence, Creative has
ensured that its tumbler mixers are mobile rather
than secured to the floor. Having to pack the
finished flavour manually is a process which Creative
is dissatisfied with ."We are looking into solving
this kind of production problems," affirmed Victor
Koh. Creative hopes that the factory will
run continuously eventually and that the use of
manual labour will be minimised. Overlooking the
production area is a huge room which will be converted
to an office and a laboratory in future when the
factory is purchased by Creative.
In the other factory which produces
liquid powders,a large mixing tank stood on rollers
in the centre. This mixing tank can hold up to
four and a half tonnes of fluid and has several
different vents to allow for different methods
of packing the finished liquid flavour,i.e. in
drums or in containers. Nearby, two mobile stirrers
stand guard,ready for production anytime. APK
Twin shell dry blender for powder is fixed onto
the factory floor not far from the mixing tank.
This blender can blend up to half a tonne of powder
flavours. On the second storey, there is a fully-furnished
office and a laboratory.
In both factories, the excess factory
space is actually a sign of Creative's commitment to the future.
Said Koh, " The extra space will make it easy
for us to a few more blenders and tumbler-mixers
should the need arise. These two factories are
actually test models, giving us the clues as to
how to run similar factories in other countries."
