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
Simplify a critical production component without disrupting the process it supports.
The redesign needed to address inefficiencies in the existing hopper while remaining compatible with the physical conditions of the tortilla production line. Because the hopper represents the first material-handling stage of the process, changes had to improve the system without compromising the flow of masa into the rollers below.
01
EXCESS INTERNAL VOLUME
The existing hopper provided more internal capacity than necessary for the application, creating areas where masa could remain during operation.
02
DUAL DRIVE SYSTEM
Two augers operated with independent motors, increasing the number of powered components required for the same material-transfer stage
03
WIDE DISCHARGE PATH
The existing outlet spread the masa into a wide sheet-like flow before transferring it to the roller system.
04
PRODUCTION DEPENDENCY
As the first material-transfer component in the line, hopper downtime could interrupt the downstream tortilla production process.
05 — FIELD ASSESSMENT
Design development began with the existing machine—not with a blank canvas.
CYAN conducted multiple site visits to document the existing hopper, its relationship to the tortilla machine and the physical conditions that would define the redesign.
Measurements were taken directly from the equipment using field notes, sketches, a measuring tape and ruler. Particular attention was given to the existing auger, available mounting area, hopper geometry, discharge location, roller position and the interfaces required to secure the assembly during operation.
WHAT WE DOCUMENTED
01
EXISTING AUGER
Physical dimensions and position of the existing component intended for reuse.
02
AVAILABLE ENVELOPE
The physical area available for the redesigned hopper within the existing machine.
03
MATERIAL PATH
How nixtamal masa moved from the hopper through the discharge and into the rollers.
04
MOUNTING CONDITIONS
Existing attachment points and the physical relationship between the hopper and machine structure.
05
CLAMPING INTERFACES
Existing plates and locations used for supplemental pressure clamps during operation.
06
DOWNSTREAM ROLLERS
Position and available receiving area of the rollers below the hopper discharge.
Rather than designing the system entirely from new components, the project was constrained around the reuse of an existing auger. Its measured dimensions became one of the primary physical inputs for the new hopper geometry.
06 — DESIGN CRITERIA
Field observations and production requirements were translated into a defined set of design criteria to guide the redesign.
01
FIT AROUND THE EXISTING AUGER
The new hopper had to accommodate the existing auger, including its measured length, diameter, shaft position and relationship to the discharge.
02
SUPPORT THE REQUIRED PRODUCT LOAD
The hopper needed to operate appropriately with approximately 15 to 30 lb of nixtamal masa, providing enough working volume without preserving unnecessary excess capacity.
03
REDUCE PRODUCT RETENTION
Internal geometry had to minimize areas where masa could remain trapped or accumulate during operation.
04
SIMPLIFY MATERIAL DISCHARGE
The redesigned outlet needed to direct masa toward the center of the downstream rollers without relying on the existing wide curtain-forming discharge component.
05
USE A SINGLE-AUGER / SINGLE-MOTOR CONFIGURATION
The redesign was developed from the outset around one auger and one motor, simplifying the original dual-drive arrangement.
06
MAINTAIN STABLE MOUNTING
The hopper had to remain securely supported despite vibration from the production line and the operational forces generated by the rotating auger and material movement.
07
SUPPORT CLEANABILITY
The geometry was developed to reduce difficult-to-clean corners and simplify access to surfaces in contact with masa.
08
DESIGN FOR PRACTICAL FABRICATION
The proposed geometry was kept relatively simple to support fabrication in stainless steel, reduce material use and help control manufacturing cost.
09
USE FOOD-PRODUCTION-COMPATIBLE MATERIAL
The hopper was intended to be fabricated in stainless steel suitable for food-production equipment.
10
PRESERVE PRODUCTION FUNCTION
Above all, the redesigned hopper had to continue receiving, moving and delivering nixtamal masa into the roller system without disrupting the downstream tortilla-forming process.
FIT | FLOW | RELIABILITY
07 — DESIGN DEVELOPMENT
The design was developed iteratively in SketchUp, translating field measurements and functional requirements into a three-dimensional configuration that could be evaluated against the existing production equipment.
Multiple rounds of modeling, client review and on-site verification were used to refine the hopper's proportions, internal geometry, auger integration, motor interface, mounting conditions and dimensional relationships. Changes were incorporated as new measurements and operational considerations were verified throughout the development process.
01
The hopper geometry was developed around both material behavior and production requirements.
GEOMETRY DEVELOPMENT
The upper chamber width was adjusted to accommodate the approximate size of the masa portions loaded by operators, while sloped walls transitioned the material toward a cylindrical lower section surrounding the auger. This geometry was intended to reduce internal areas where masa could remain trapped while directing material toward the conveying mechanism.
02
The existing auger became a fixed reference around which the new assembly was developed.
AUGER + MOTOR INTEGRATION
Its diameter, length, shaft position and connection requirements were measured directly from the existing equipment and incorporated into the digital model. End plates and surrounding geometry were progressively adjusted to accommodate the physical relationship between the auger, shaft and motor connection.
03
Dimensions were continuously checked within the digital model and verified against the physical machine.
DIMENSIONAL REFINEMENT
Key measurements were maintained in SketchUp both as design controls and as a communication tool during client reviews. Multiple site visits were used throughout development to confirm dimensions, available clearances and component relationships before additional refinements were made.
04
Development occurred through an iterative review process with the client team.
ITERATIVE CLIENT REVIEW
Models and dimensional views were reviewed through in-person discussions, screen-based evaluations and shared images. Feedback regarding fit, component relationships, capacity and operational conditions was incorporated into subsequent model revisions, with additional field measurements taken when necessary.
FIELD MEASUREMENTS → 3D MODEL → CLIENT REVIEW → ON-SITE VERIFICATION → REFINEMENT
The final geometry was not developed in isolation—it evolved through repeated comparison between the digital model and the physical production environment.
08 — KEY DESIGN DECISIONS
Simplification became the central strategy of the redesign.
Rather than adding complexity, the redesign focused on removing unnecessary elements, working around existing components and reshaping the hopper around the actual requirements of material flow, operation and fabrication.
REMOVE WHAT ISN'T NEEDED.
RESHAPE WHAT ISN'T WORKING.
RETAIN WHAT STILL WORKS
01
TWO AUGERS → ONE
Simplify the conveying system
The original configuration used two parallel augers powered by independent motors. The redesign was developed around a single existing auger and single-motor configuration, reducing the number of powered components required for the material-transfer stage.
2 AUGERS → 1 AUGER
2 MOTORS → 1 MOTOR
02
WIDE DISCHARGE → DIRECT CENTERED FLOW
Eliminate the intermediate discharge component from the proposed configuration
During the site assessment, the existing curtain-forming discharge was questioned as a necessary part of the material path. Because the downstream rollers provided sufficient receiving area, the proposed redesign eliminates this component and uses a circular outlet positioned to deliver masa directly toward the center of the rollers.
AUGER → CIRCULAR OUTLET → ROLLERS
03
EXCESS VOLUME → FLOW-DIRECTED GEOMETRY
Shape the hopper around the material
The internal geometry was developed to guide masa toward the auger rather than allowing material to remain in unnecessary corners or excess volume. Sloped walls transition toward a cylindrical lower section surrounding the auger, supporting material flow while simplifying the internal form.
The upper chamber was also adjusted to accommodate the approximate size of the masa portions loaded during production.
MATERIAL INPUT ↓
↘ SLOPED WALLS ↙
CYLINDRICAL AUGER HOUSING
↓
OUTLET
04
NEW DESIGN → EXISTING MACHINE
Redesign the component—not the entire production line
The hopper was developed around equipment that would remain in service. The existing auger, available mounting envelope, motor connection, downstream rollers and supplemental clamping method became fixed interfaces that the new design needed to respect.
End plates, mounting geometry and clearances were refined around these existing conditions so the proposed hopper could integrate with the production equipment rather than requiring unnecessary changes to the surrounding line.
EXISTING AUGER
EXISTING MOTOR INTERFACE
EXISTING MACHINE
EXISTING ROLLERS
↓
NEW HOPPER
Together, these decisions defined the proposed single-auger hopper configuration.
09 — FINAL DESIGN PROPOSAL
A simplified single-auger hopper developed around the existing production system.
The final proposal consolidates the project requirements into a compact hopper configuration designed around one existing auger, one motor and a direct material path toward the downstream rollers.
01
SINGLE-AUGER CONFIGURATION
One existing auger integrated within a compact cylindrical lower housing.
02
SLOPED HOPPER GEOMETRY
Inclined walls direct masa toward the auger while reducing unnecessary internal volume and areas of product retention.
03
DIRECT CIRCULAR DISCHARGE
A simplified outlet directs material toward the center of the downstream roller system without the previous wide curtain-forming component.
04
EXISTING-EQUIPMENT INTEGRATION
Motor connection, mounting interfaces and supplemental clamping locations were developed around the existing production equipment.
.jpeg)
Together, these decisions defined the proposed single-auger hopper configuration.
10 — MANUFACTURING HANDOFF & PROJECT STATUS
From design development to manufacturing quotation.
Following completion of the proposed hopper configuration, the design information was prepared for external manufacturing review and quotation.
01
MANUFACTURING HANDOFF
The final design information, including dimensional views and 3D model documentation, was shared with a manufacturing supplier in Mexico for fabrication review and quotation.
This handoff allowed the proposed geometry, material requirements and overall configuration to be submitted for manufacturing and cost review before fabrication.
CYAN DESIGN DEVELOPMENT → CLIENT REVIEW → MANUFACTURER QUOTATION
02
CURRENT PROJECT STATUS
STATUS: MANUFACTURER QUOTATION
The project reached the manufacturing quotation stage. Fabrication was not initiated as project priorities shifted, and the proposed hopper has not yet been manufactured or implemented.
The completed design remains available for future fabrication should the project be resumed.
03
PROJECT OUTCOME
The project produced a fully developed dimensional redesign of the existing hopper based on direct field assessment, existing equipment constraints and iterative client review.
The resulting proposal consolidates the original dual-auger configuration into a simplified single-auger system while retaining compatibility with the existing production environment and providing a documented basis for manufacturing quotation.
REAL EQUIPMENT. REAL CONSTRAINTS. A MORE PURPOSEFUL DESIGN.
Single-Auger Masa Hopper Redesign — CYAN Design Workshop
