Systematic juice production – How Flottweg’s belt press increased Frankly Juice’s production capacity and efficiency

Organic, cold-pressed, fresh, and natural – these are the values of Frankly Juice from Denmark, a manufacturer of cold-pressed juices, smoothies, and ginger shots. Initially launched as a startup, Frankly Juice reached the maximum capacity of its old production plant in 2022. By working with separation technology specialist Flottweg and investing in a new plant with a belt press, the company has increased its efficiency and thus ensured its long-term competitiveness. 

The story behind the juice: Frankly Juice

Frankly Juice was founded as a startup in 2014 by Christian Seiersen and Christian Bowall. Guided by their passion for health and sustainability, the two developed a new juice concept, where all the nutrients and minerals from the fruit and vegetables are retained in the juice – without any additives or preservatives. In addition, Frankly Juice uses exclusively organic ingredients. “We produce a natural, very fresh, and high-quality product based on regional ingredients such as apples, carrots, and ginger,” explains founder Christian Bowall. 

The production process at Frankly Juice

To ensure the freshness of their juices and smoothies and to maintain consistently high product quality, the raw materials need to be processed quickly. The key metrics include throughflow and efficiency. A continuous and efficient production plant plays a central role in processing the raw materials. First, the fruit and vegetables are washed thoroughly and then crushed in a mill. Then comes the key step: The juice is pressed continuously and with maximum yield using a Flottweg belt press. The juice is temporarily stored in storage tanks and then filled into returnable bottles in the filling plant.

Frankly’s secret: the HPP method

A special aspect in the production of their juices and smoothies is the HPP (high pressure processing) method. This method ensures that the products have a long shelf life while retaining all the flavor and nutrients. The high-pressure method ensures the stability of the juices without the need for high temperatures and serves to retain the maximum amount of nutrients. 

“To ensure consistent product quality, having an optimal pH value is essential for our end product. This is how we achieve top quality and natural taste for our customers,” explains Anders Thoby, manager at Frankly Juice. The pH value is a decisive criterion for the quality and taste of the juice.

Frankly’s key to efficiency: Flottweg belt press

After Frankly’s old production plant reached its capacity limits, the company decided to invest in a new plant with a belt press. “Our problem in the past was capacity. Our old plant could not produce the number of liters per hour we needed. That’s why we had to upgrade our plant,” says plant manager Thoby. Only by increasing capacity could the company secure its long-term competitiveness. Christian Bowall explains: “If we had not invested in a larger belt press from Flottweg, we would not have been efficient enough and cost-effective enough in our production to be able to sell to retailers.”

Flottweg supplied Frankly Juice with an entire production line, with the belt press as its centerpiece. “Flottweg delivered the complete production plant, including the box receiving station, the fruit and vegetable washing machine, the milling station, the belt press with in-place cleaning of the circulating belt, the purification unit, all the way to the raw juice. The belt press is the center of the production line,” says Anders Thoby. 

Flottweg’s belt press is characterized above all by its efficiency and maximum yield. Thanks to the precise automatic control of the product feed, the special belt alignment, the L-profiled roller, and the arrangement of the press rollers (alternating pressing and shear forces), the product is pressed gently yet optimally to achieve maximum output. This ensures that Frankly obtains optimal yield. The fruit and vegetable pomace produced during production is fully utilized - for example, in the production of animal feed but also for food ingredients - thereby closing the cycle and improving sustainability.

In the automatic and sensor-controlled feeding process, the fruit mash is placed on the belt and partially juiced under a first roller. Depending on the quality of the raw material, the width and height of the mash cake can be adjusted to ensure optimal processing. The L-profiled roller then applies increased pressure to the mash, followed by other rollers which further increase the pressure. 

Frankly has significantly expanded its capacity by choosing Flottweg. “With the old plant, we were able to press about 300 liters of juice per hour with a single operator. Now we can produce 1500 liters per hour. This is a considerable increase – thanks to the high-quality system,” says Anders Thoby, describing the changes. “In addition, there is no more downtime. This makes us more efficient, because we can operate the system continuously without stopping. Flottweg’s belt press is a reliable machine.” Christian Bowall also adds: “Not only can we produce more per hour, but we also have 10 to 15% more yield in total. This was very important for us to be able to compete in the market.” By investing in Flottweg’s technology, Frankly Juice has significantly increased production capacity and yield. This strategic decision has enabled the company to meet their growing demand while at the same time strengthening its competitiveness in the long term.

After production: CIP cleaning of the belt press

Another significant advantage of Flottweg’s belt press is the significantly simplified cleaning of the machine. Compared to previous labor-intensive cleaning procedures, the CIP (clean-in-place) system requires significantly less time and resources. CIP cleaning of the belt press can be started during or at the end of a production day. This further reduces the time and effort required. 

“The crucial difference between the new and the old plant is the cleaning technology. The previous cleaning process was mostly manual and there wasn’t a proper CIP system. The new plant offers a much easier solution, because we can run the CIP and see what the machine is doing and just monitor the process. This makes our daily work much easier, with minimal input from the staff,” says Thoby. 

This simplification of the cleaning process not only improves the staff’s daily work but also saves significant amounts of time. The new system ensures high hygiene standards and ensures that the machine remains in perfect condition without interrupting the production flow. This optimization of the cleaning processes is a decisive factor in Frankly Juice’s increased productivity and product quality, as well as the company’s steady growth.

Frankly’s conclusion: “Efficient machines and plants that deliver excellent yield”

By investing in a modern production plant with a Flottweg belt press, Frankly Juice has taken a decisive step towards increased efficiency and competitiveness. The increase in production capacity from 300 to 1500 liters per hour and the 10 to 15% increase in yield have enabled the company to meet market demand and strengthen its position as a supplier of high-quality, certified organic juices and smoothies. “The belt press and the entire production plant from Flottweg are reliable and have fully met our expectations and needs. We are very happy and satisfied with this choice” says Thoby. 

Thanks to the improved efficiency and the near-continuous operation of the plant, Frankly Juice was able to reduce production costs while also further optimizing the quality and taste of its products. In addition, the optimized CIP cleaning has provided significant hygiene and workload benefits. Overall, Frankly’s choice of a Flottweg plant shows how targeted investment in advanced technology and efficient production facilities can ensure the long-term success and growth of a company.

Author:

Julia Deliano, PR and Content Manager, Flottweg SE