01_Single-Auger Masa Hopper Redesign
Production equipment redesign developed around existing machinery, dimensional constraints and a simplified single-auger configuration.
CLIENT _ SA Colonial Factory
PROJECT TYPE _ Production Equipment Redesign
STATUS _ Manufacturing Quotation
LOCATION _ San Antonio, Texas
02 — PROJECT OVERVIEW
SA Colonial Tortilla Factory identified an opportunity to redesign the hopper used at the beginning of its industrial tortilla production line. The existing system relied on two independently driven augers within a relatively large hopper, creating unnecessary internal volume, product retention and a wider-than-needed material discharge.
CYAN was asked to develop a more compact hopper configuration around a single existing auger while maintaining compatibility with the production equipment and the material-handling requirements of the process.
The objective was not to redesign the production line—it was to simplify one critical component around the way the existing system actually worked.
03 — EXISTING SYSTEM
Understanding the original equipment configuration and material flow was the starting point for the redesign.
The original hopper was mounted at the beginning of the tortilla production line, directly above the roller system. Fresh nixtamal masa was loaded into the upper chamber, where two augers—each powered by an independent motor—moved the material toward the discharge.
From there, the masa was forced through a wide outlet that formed a continuous sheet-like flow before dropping into the rollers below. Because the hopper controlled the first material-transfer stage of the line, its operation directly affected the continuity of the downstream production process.
01 — DUAL AUGERS
Two parallel augers moved the masa toward the discharge.
02 — LARGE HOPPER VOLUME
The original chamber extended beyond the volume required by the redesigned configuration.
03 — MATERIAL RETENTION
Masa could remain within portions of the hopper during operation.
04 — WIDE MATERIAL DISCHARGE
The existing outlet distributed the masa across a relatively wide area before it entered the roller system.
04 — THE DESIGN CHALLENGE
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05 — FIELD ASSESSMENT
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06 — DESIGN CRITERIA
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07 — DESIGN DEVELOPMENT
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08 — KEY DESIGN DECISIONS
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09 — FINAL DESIGN PROPOSAL
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10 — MANUFACTURING HANDOFF
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11 — PROJECT STATUS
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12 — NEXT PROJECT / CTA
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