INNOVATOR magazine issue 2014
SPRAY DYNAMICS速 has you covered
achieving production efficiency get more out of food
The latest from FASTBACK速
NAMKEEN Hot Spot
achieving
SUCCESS
Heat and Control has always measured its success by the success of its customers. When we celebrated our first 60 years in business in 2010, we renewed our commitment to provide innovative machinery and technology that will process and package products better for our valued customers.
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PIONEERING FOOD PRODUCTION SINCE 1950 R&D + TESTING DESIGN, ENGINEERING + MANUFACTURE INSTALLATION, COMMISSIONING + OPERATOR TRAINING POST SALES SERVICE + SPARE PARTS
CONTENTS About Us
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Development To Production Reality
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Fastback OMS Reality: Pretzels Inc
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First Choice For OMS
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Mid-Gate / FDX
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The Latest From FastBack
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Comparing Conveyors
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FastBack Success: Kar's Nuts
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Demonstration Facility Opens
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Global Teamwork
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Smart Handling At Tastee Choice
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Spray Dynamics Solutions
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Energy + Enviro Efficiency
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Snack Production Success
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Food Hot Spot: Namkeen Snacks
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Take Control: Info Systems
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Festida Foods: The Gold Standard
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Reinventing Vacuum Frying
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New Micro Breader
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French Fry Systems
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In The Kitchen: Bawang Goreng
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Our Global Network
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ABOUT US
we know what to PROCESSING + PRODUCT HANDLING + PACKAGING SOLUTIONS “Heat and Control stood out with the level of service and dedication to understanding and meeting our needs. Other vendors offered equipment solutions but Heat and Control offered a total package solution!” Brian Foster, Senior VP of Operations Inventure Foods
Over 60 Years of innovation and world-class service. • Process Prepared Systems • Snack Systems • French Fry Systems • Seasoning and Coating Systems • Conveying Systems • Weighing and Packaging Systems • Inspection Systems • Controls and Information Systems With manufacturing facilities and sales support offices worldwide, Heat and Control has the experience, expertise and resources to develop the most efficient solutions for any production challenge.
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www.heatandcontrol.com
do with food
SNACK FOOD CANDY + CONFECTIONERY PREPARED / CONVENIENCE FOODS FRENCH FRY FRESH PRODUCE / VEGETABLES MEAT, POULTRY + SEAFOOD CHEESE PRODUCTS CEREAL + GRAIN
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ACHIEVE CONSUMER REALITY helping food companies turn an idea into consumer reality every step of the way; utilising an experienced team across all areas of development to production pathways
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www.heatandcontrol.com
DEVELOPMENT TO PRODUCTION REALITY
R&D + TESTING Test new product ideas in the latest frying, oven, coating, branding, searing, seasoning, coating and packaging technologies in any Heat and Control functional test kitchen or packaging room. Identification of appropriate equipment to produce required results as well as detailed laboratory analyses of the cooking processes and the effects on product moisture, fat content, taste, mouthfeel and finished yield is determined.
DESIGN, ENGINEERING + MANUFACTURE Innovative design and engineering solutions produce equipment designed for maximum versatility and production efficiency. Skilled craftsmen, using state-of-the-art manufacturing tools, build rugged machinery to withstand the toughest production schedules and harshest working environments. Attention to detail results in the industry’s toughest and longest working food manufacturing equipment.
INSTALLATION, COMMISSIONING + OPERATOR TRAINING Complete installation services utilising a team of multidisciplinary experts to install new or upgraded systems followed by line commissioning that ensures smooth integration and operation to required specification. Classroom and on-site instruction that teaches plant personnel how to safely operate equipment and to maintain optimum production capacity.
POST SALES SERVICE + SPARE PARTS Gain access to service across the world utilising a network of locally-based field service teams and spare parts.
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FASTBACK OMS REALITY
New conveying and seasoning system helps private label snack maker keep up with demand for more than just pretzels. As one of the largest private label pretzel makers in North America, Pretzels, Inc. makes more varieties than you can shake a pretzel stick at: twists, minis, rods, balls, rings, and ultra-thins, to name a few. But the Indiana based company also makes lots of extruded and baked corncheese snacks, like puffs, balls, curls and crunchy curls. "Currently, we produce a dozen products in seven different flavours and we're anxious to expand our offerings in the future," says Vice President and General Manager, David Faust.
"Accuracy and consistency has improved by nearly 30% . . . product scheduling flexibility has roughly increased by 50% because of the dynamic functionality of our packaging room" David Faust Vice President & General Manager, Pretzels, Inc.
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All that variety has steadily boosted consumer-demand for Pretzels, Inc. products. However as the product line grew so did the challenge of consistent seasoning application. "We season a variety of products, from extruded to pretzels," says Faust. "The densities of each product vary greatly, which makes coating application a more complicated aspect of our business," he explains. Frequent product changeovers and cleaning have also taken a toll on profits. "We had one coating applicator for everything," laments Faust. "If we had a base product but wanted to put three different seasonings on it, we'd require a clean-up in between each." Faust was determined to improve efficiency and pave the way for new growth. He contacted Heat and Control which had supplied a FastBack distribution conveyor system in 1997. Pretzels, Inc. chose a new FastBack Revolution product distribution and On-Machine Seasoning (OMS) application system, in part, due to the reliability and efficiency of the existing FastBack conveyors. Working together, Pretzels, Inc. and Heat and Control considered 15 different layouts, finally deciding on a system to apply seasoning in the packaging room (instead of in the processing area) that would expand production flexibility and efficiency. "Heat and Control did lots of work on the front end and back end," says Faust. "They worked very closely with our onsite engineers to conceptualise and design the layout and equipment. We did most of the installation ourselves, but Heat and Control got heavily involved when it came time for commissioning the equipment. Much help and long hours was given by them to make sure everything was running well and operators were trained adequately." The new FastBack Revolution distribution and OMS system accepts product from two sources and distributes proportional quantities to six seasoning, weighing and packaging stations. Each bag maker controls its own Revolution gate so it receives a consistent flow of product. The unique gate rotates to divert the exact amount of product requested by the bag maker. Product flow is precise for both small bag sizes and large packages. And when not diverting product, the gate rotates to a fully closed position, preventing any possibility of cross contamination between lines.
www.heatandcontrol.com
FASTBACK OMS REALITY
"Consistent proportional feed product delivery eliminates stop-start operation and improves the efficiency of weighers and bag makers by allowing them to run for long uninterrupted periods," explains Blake Svejkovsky, Product Handling Systems manager at Heat and Control. This produces big improvements in coating consistency and even bigger efficiency improvements in packaging, for Pretzels, Inc. "Accuracy and consistency has improved by nearly 30%," notes president, David Faust. Improvements apply to all Pretzels, Inc. flavourings, including cheeses, jalapeĂąo, honey mustard, buffalo, spicy, salt and pepper. The OMS system matches seasoning output to product flow to produce extremely accurate application rates without excess seasoning usage. Integrated product conveyors and tumble drums save space and produce consistent coverage. "This technology opens so many doors for us," says Faust. The OMS system provides so much more flexibility in terms of running multiple flavours at once. In fact, he adds, "product scheduling flexibility has roughly increased by 50% because of the dynamic functionality of our packaging room now. In the future, we're excited about opportunities to offer our customers more packaging variety, such as multi-pack configurations, because we now have the flexibility to do so." Elimination of product cross contamination is another benefit of the Revolution gate system. "Different products can safely run side-by-side in the conveyor system and the Revolution gate prevents any possibility of cross contamination," says Heat and Control's Svejkovsky.
"This is helpful to companies like Pretzels, Inc. which run many different products. The gate's gentle rotary motion, accurate electronic positioning and lack of pinch points all contribute to maintaining peak product quality," he adds. Another dramatic improvement over the old system is the reduction in cleaning and changeover time. "We're seeing a 50% reduction in cleaning time," notes Faust. The gentle slow-forward fast-back horizontal motion of the FastBack conveyors prevents the loss and build-up of seasonings in the conveyor pan and greatly reduces product breakage compared to vibratory conveyors. Seasoning drums and feeders can be removed without using tools for cleaning away from the production area. All of these features contribute to maintaining Pretzels, Inc.'s standard of excellence. "We have a great reputation in the market for high quality snack foods and the company was built on making the best product possible.� www.pretzels-inc.com
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FIRST CHOICE FOR OMS
REVOLUTION™ SEASONING SYSTEM [RSS] Apply seasonings to snack or baked foods at each weigher/ bagmaker station instead of in the kitchen. Referred to in the industry as On-Machine Seasoning (OMS). • • • • •
A different flavour at each RSS station Increased production uptime Just in time inventory and reduced warehousing Decreased change-over time Improved production flexibility
SYSTEMS APPROACH The Heat and Control advantage delivers unmatched efficiency by operating RSS as part of an integrated system with distribution, seasoning and packaging elements. Performance of this OMS system yields a standard deviation as low as 0.35 compared to 0.80 on competitive systems that utilise traditional in-kitchen seasoning technology. OMS specific technologies developed by Heat and Control include: Revolution proportion feed gates, WeighBack™ in-line measuring, integrated tumble drum and FastBack horizontal motion conveyors, Dispersion Feeder (DF) Revolution gate control, Ishida weighers and bagmakers, accumulation and recovery with ClimbBack.
RSS FAQ PRODUCTS?
Snack or baked food where topical seasoning coverage and appearance is important. This includes potato, corn, tortilla, multi-grain and other types of chips, nuts, popcorn, extruded snacks, crackers, mini rice cakes and more.
OIL SPRAY?
FastBack + Spray Dynamics have pioneered a combination of OMS and oil spray systems to provide excellent results.
CROSS CONTAMINATION?
Used with Modular Dust Collection and Powder On Demand seasoning refill system, the causes of cross contamination are significantly reduced.
LOW TEMPERATURE EFFECTS?
Tests of temperatures between 27˚C and 54˚C show no or little seasoning degradation or adhesion problems with corn, tortilla, potato chips, grain chips and popcorn.
SEASONING ACCURACY?
Seasoning application rate yields as low as 0.35 standard deviation on a 6% application rate.
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www.heatandcontrol.com
FIRST CHOICE FOR OMS
Since 1995, the FastBack product team has developed a strong leadership position within the food industry. Over 30 US and International patents signify innovation and attention to detail applied to solving industry problems. When it comes to On Machine Seasoning Systems, the team takes a wholistic systems approach, providing technology innovations that result in the most consistent seasoning coverage with the lowest seasoning usage rates measured today.
Excaliber™ seasoning applicator delivers a controlled, even curtain of seasoning into a drum.
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ACHIEVE PRODUCTION EFFICIENCY from the innovators in horizontal motion conveying systems for accumulation + distribution clean conveying, gentle product movement, end product segregation, end seasoning loss and buildup, eliminate unscheduled downtime for sanitation
www.heatandcontrol.com
FASTBACK MID-GATE / FDX CONVEYOR
DISTRIBUTION JUST GOT EXCITING REVOLUTION MID-GATE™
Mounted at the beginning, middle or end of the FastBack conveyor pan, the Revolution Mid-Gate provides the advantages of proportional distribution where it is needed.
FORCE DISPLACEMENT HORIZONTAL MOTION CONVEYOR FDX™
Forty percent smaller than comparable inertia drive horizontal motion conveyors, the FDX handles runs up to 30 metres long and up to 8.5 cubic metres of product accumulation. Like other FastBack conveyors, FDX reduces product damage, prevents separation of blends, is easy to clean and needs no preventative maintenance.
• • • •
Full accurate proportional feed and control No pinch points or product breakage Easy cleaning and zero cross-contamination Safe and responsive full-open to full-closed speeds for all throughputs
With the FastBack FDX conveyor, there is larger scope for increased volumetric capacity including 2.5 and 10 cubic metre designs. The smooth stainless steel pan provides a more sanitary alternative to belted accumulation systems.
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THE LATEST FROM FASTBACK
ACCUFLAVOR™ Dual geometry seasoning drum decreases standard deviation of chip-to-chip dwell time by over 30%. This patent pending design improves seasoning coverage, adhesion and application rates Available for Revolution On-Machine Seasoning
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www.heatandcontrol.com
THE LATEST FROM FASTBACK
MODULAR DUST CONTROL [MDC] Eliminate the problems of airborne seasoning dust by capturing it at the point of application. Available only on FastBack Revolution On-Machine Seasoning systems, MDC costs about 40% less than whole-room systems and can reduce energy usage by up to 30%.
WEIGHBACK™ WEIGH CONVEYOR Designed for inline weighing and seasoning applications, WeighBack integrates direct load cell weight measurement with gentle FastBack horizontal motion conveying. WeighBack is a cleaner, more reliable alternative to weigh belts and is 35% more accurate than vibratory methods. This continuous weighing conveyor features a removable weigh tray for easy cleaning and access to load cells. User-friendly controls provide manual and auto-tare functions with clear displays of instantaneous and cumulative operating data.
HIGH CAPACITY SWITCHBACK™ FDX The FastBack accumulation conveyor, SwitchBack, is now available in a choice of sizes. Due to the utilisation of the FastBack FDX conveyor, there is now larger scope for increased load capacity. The SwitchBack conveyor provides in-line accumulation of delicate snacks, frozen meats, poultry and other food. The system automatically stores product in the lower unit while conveying product in the opposite direction in the upper feed conveyor.
HIGH CAPACITY POD Reduce hazardous lifting with POD. Now with an increased holding capacity, the High Capacity Powder On Demand (HC POD) will transfer seasonings, powders and granular products using energy-efficient dense phase conveying to seasoning applicators, mixers and other processing and storage equipment. POD comes with a compact docking station containing all pneumatic supply and control components.
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product handling systems for complete line distribution
Design & Engineering | Manufacturing | Installation & Commissioning Service & Spare Parts | Operator Training
FastBack horizontal motion conveyors Varilift bucket conveyors incline transfer conveyors vibratory conveyors sizing + sorting systems blending conveyor systems accumulation systems in + out feed conveyors
progress through innovation since 1950
Food Processing & Packaging Systems
COMPARING CONVEYORS
www.heatandcontrol.com
COMPARING HORIZONTAL MOTION & VIBRATORY CONVEYING Conveying in the food industry has become more sophisticated than simply moving product from points A to B. System layouts, accumulation, feed modulation, product diverting methods, sanitation, operator safety, cross-contamination, sustainability and product quality control are just a few considerations to keep in mind when upgrading a conveyor or ordering a new line. Luckily many of these issues can be addressed by choosing between two basic methods of moving product: Vibratory or Horizontal Motion conveying.
FEEL THE VIBRATIONS
Horizontal motion conveyor features / function:
Vibratory conveyors move product by bouncing it. Different magnitudes of amplitude (vertical lift) and frequency (forward pitches) produce different product travel rates. Vibratory conveyors use two basic drive types, each suitable for certain products and actions.
• Virtually eliminates product breakage and stress fractures • Does not shake off seasonings and breading • Eliminates accumulation of seasoning, oil and other coatings in the pan, thus reduces cleaning downtime • Reduces conveying noise with product (typically to 70 - 74 dB) • Maintains product blends and does not segregate product pieces • Maintains travel rates consistent with bed depths and product weights • Conveys large quantities without bogging down • Transmits less vibration, allowing lighter, less expensive support platforms and no ceiling supports • Accepts different pan lengths and configurations (with certain horizontal motion drives)
Electromagnetic drives produce variable-speed movements with short amplitude (lift) and high frequency (speed). Bestsuited for light, easy-flowing products like snacks, it is ideal for conveying limited bed depths, spreading and fines removal. Mechanical drives produce the opposite type of movement: fixed-speed long amplitude and low frequency conveying for moving large quantities of heavy, sticky products. Mechanical drives come in direct or indirect designs. Choose direct for sorting, grading and bi-directional conveying. Indirect is best for product transfer, dewatering, spreading, laning and fines removal. Vibratory conveyor features / function: • Vertical separation of product pieces; great for scalping, grading, sizing and separation of fines • Spreading product across pan width • High travel rates (with high-amplitude conveyors) • Leveling product piles • Moving sticky products • Conveying product uphill, sometimes as much as 7 degrees
While bouncing is useful for piece separation and inspection, it is rough on fragile products and separates pre-mixed product blends. The constant impact on the pan shakes off seasonings and coatings, causes breakage and generally reduces the quality of finished products. Vibration can cause micro-cracks in products making them susceptible to eventual breakage. High noise levels (79 dB - 90 dB) are caused by product bouncing in the pan. Also, travel rates decrease as the bed depth or product weight increases, although some conveyors can partially overcome this.
HORIZONTAL MOTION SLIDES HOME Instead of bouncing product, horizontal motion conveyors slide it along the pan. This has become the preferred means of transferring and distributing fragile and coated snacks, fresh produce and frozen prepared foods.
While sliding product prevents breakage, coating loss and noise, it also limits the application of horizontal motion conveyors: • Product spreading only achieved with specially shaped pans • Product travel rates are slower than aggressive vibratory conveyors but may be faster than high-frequency designs • Uphill conveying is limited to about 1.5 degrees, although there is now on the market, a pan that conveys up to 8 degree incline • Does not level piles of product without pan modifications Horizontal motion conveyors are available with direct and inertia drives. Direct drives use long strokes producing travel rates up to 12.5 m/min. In addition to greater throughput/ pan size, direct drives stop and start instantly, offer modular expandability, provide fast travel rates to reduce stale product complaints and improve the efficiency of seasoning and overall packaging room performance. Inertia drives generally deliver slower product travel rates, have delayed stop and start operation and do not work well in modular and packaging feed applications. Selecting the proper type of horizontal motion drive will greatly reduce maintenance, energy usage, improve safety and packaging feed efficiency. When selecting direct or inertia drive horizontal motion conveyors the pan size is usually a key determining factor.
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FASTBACK SUCCESS: KAR'S NUTS
Kar’s Nuts has a simple formula for success: Consistent quality nut and trail mix products with an emphasis on customer service. That philosophy has helped the 80-year-old Michagan (USA) manufacturer achieve ten years of steady growth in all 50 states and now internationally. In 2004, the company moved to a new manufacturing facility and doubled its production capacity to 10,886 kilograms an hour with two Heat and Control nut roasting lines and a FastBack® product distribution system. Since then, expanded sales to convenience, grocery, and club stores, and the introduction of its "Second NatureTM" brand of all-natural snacks necessitated another boost in production. So Kar’s Nuts again called on Heat and Control for a new distribution conveyor system to handle the output of two new blending lines. "Because of our history with Heat and Control, we were confident in their
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equipment’s reliability and performance," explains Bill Elam, vice president of finance and operations. "They were able to quickly grasp the scope of our project and provide good guidance and input." Elevating trail mix from the two new blending systems to the packaging platform in the next room is handled by Varilift® bucket elevators. Their unique infeed design eliminates gaps between the buckets to prevent product spills. Ascending buckets remain upright and do not roll back or spill if the conveyor stops. Kar’s layout uses Varilifts having an S configuration, although the modular conveyor can also be provided in C and horizontal arrangements.
www.heatandcontrol.com
FASTBACK SUCCESS: KAR'S NUTS
"we have the ability to move larger amounts of product to one or more lines simultaneously" Bill Elam | VP Finance & Operations, Kar's Nuts
Compact, powerful FastBack 90E horizontal motion conveyors then distribute the product to twelve separate weighing / packaging stations. Pivot gates eliminate damaging pinch points as they deposit product into the FastBack conveyors feeding the weighers. "The FastBacks have performed consistently well," notes Elam. Since product does not bounce in the pan, FastBacks maintain pre-mixed blends and eliminate stratification of the various ingredients. Gentle horizontal motion reduces product damage and prevents build-ups in the pan and unscheduled cleaning downtime. The two new lines have added about 9525 kilograms an hour of production capacity to Kar’s Nuts Madison Heights plant. "We currently run 20 hours per day, 4 to 6 days per week," says Elam. "We have the ability to move larger amounts of product to one or more lines simultaneously." Elam adds that Heat and Control’s product distribution system has also helped Kar’s Nuts strengthen its ability to provide superior customer service: "The new line has added flexibility to our lines and has improved our ability to respond to customer orders." www. karsnuts.com
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Snack partners in
processing + packaging systems
www.heatandcontrol.com
DEMONSTRATION FACILITY OPENS
IN PARTNERSHIP WITH ISHIDA EUROPE NEW SNACK DEMONSTRATION CENTRE Achieve energy efficiency via integration with Heat and Control and Ishida. In order to give the European snack industry test access to the latest product handling, seasoning, weighing and packaging technologies, Ishida Europe with help from Heat and Control has opened a million pound demonstration/test centre in Birmingham, England. With over 170 years of combined experience in processing and weighing / packing technology, snack lines can achieve greater efficiency when all components are aligned and working together. The successful integration of Heat and Control and Ishida snack manufacturing systems is unparalleled in the industry and covers full line solutions for processing, weighing, packaging and inspection. The gains achieved through cohesive integration are many, and include faster installation and commissioning; reduced downtime, giveaway, waste and labour cost; increased flexibility; enhanced yield and line efficiencies and increased product and pack quality. It is the philosophy of this unique partnership to be more than suppliers to the snack food industry but to establish and maintain long-term business relationships that generate mutual and sustainable success. The Birmingham demonstration centre line-up includes: Heat and Control > FastBack Product Handling and Distribution Systems • Revolution distribution gate • Revolution Seasoning System (RSS) • Horizontal motion conveyors • ClimbBack incline horizontal motion conveyor • SwitchBack accumulation conveyor Ishida Full range of Ishida equipment from entry-level models to state-of-the-art high speed system.
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GLOBAL TEAMWORK
Global
Teamwork
Heat and Control is made up of a global team that has, since 1950, built an extensive knowledge bank and developed a wealth of experience and expertise. Access to production and technical support from a network of engineers, food technicians, skilled tradespeople and support teams provide food manufacturers with confidence to achieve production goals. Testing | Design | Engineering | Manufacturing | Installation | Commissioning Operator Training | After Sales Service | Spare Parts
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AUSTRALIA
USA
INDIA
MEXICO
8 Manufacturing Facilities | 8 Test Centres | Over 30 Offices Worldwide
CHINA
SMART HANDLING AT TASTEE CHOICE The humble shrimp has been the mainstay of the Choice Canning Company for over 50 years. Already a leading supplier of shrimp in North America, the company expanded into the ready-to-cook meal market in 2006. It now produces twelve IQF skillet meals under the Tastee Choice® brand and distributes them to retail grocery stores throughout the eastern, midwestern and southwestern states and Canada. Tastee Choice skillet/microwavable entrees are available in Asian, Mediterranean and Italian blends of shrimp, chicken, vegetables, rice, noodles and pasta with sauces such as Oriental, Marinara and Roasted Garlic Alfredo. Getting hungry? Tastee Choice customers sure have been. Sales have increased 80% in just the last year. "We consistently offer the consumer superior value, top quality fresh ingredients and a satisfying eating experience," explains Junior Vice President of Operations, Nithin Poulose. "Tastee Choice’s growth has been fueled by expanding our meal kits to include chicken in addition to our shrimp meals. Some of our most popular products include Shrimp Scampi, Sesame Chicken and Chicken Alfredo." To meet increasing demand and to prepare for a new range of meal kits and IQF shrimp items, the company opened a new product blending and packaging plant inside a cold storage facility in Quakertown, PA. Poulose wanted the new line to boost production capacity and overcome previous inefficiencies with individual component weights and product uniformity. He contacted Heat and Control for solutions and a new product conveying, weigh blending and inspection line. The heart of the new line is an Ishida CCW-R-224 waterproof blending weigher. Software divides the weigher’s 24 heads into quadrants of six heads, for mixed vegetables, sauces, pastas/rice and protein. The four components are precisely weighed and deposited into a form-fill-seal bagmaker.
"Ishida’s 24-head waterproof weigher was a natural for this project," says Sandy Pease, Heat and Control’s regional sales manager. "It is specifically designed for very accurate four-part blending at speeds up to 60 weighs per minute with near-zero giveaway. All product contact parts are easily removed without using tools, and its sanitary design is easy to clean." Pease notes that Heat and Control’s packaging platform has built-in wash racks for the weigher’s feeders and hoppers to simplify cleaning and prevent damage. Product components are manually loaded at floor level into four FastBack 90E metering conveyors. 60° incline belt conveyors elevate product to the weigher platform and deposit it into separate 90E conveyors that feed each of the weigher’s quadrants. FastBack’s gentle horizontal motion protects product quality and assures consistent delivery to the weigher. The small 90E conveyors are mounted closely together and provide unrestricted access to the weigher. After bagging, the meal kits are given a final quality control check with an Ishida DACS-G checkweigher and CEIA MS-21 metal detector. CEIA’s unique MultiSpectrumTM technology eliminates product effect false rejects common to non-homogeneous products like multi-component meal kits, yet provides the highest detection sensitivity to all potential metal contaminants. Total throughput of the Heat and Control system is rated at 2268 kilograms an hour. "This system has considerably increased our productivity," says Poulose, adding that it has also reduced excessive handling of the product. "Heat and Control had the equipment, quality and reputation that we were looking for," says Poulose. "Their sales, project management, installation and start-up was excellent and very professionally handled. The whole process was made very simple to understand and handled in a very efficient and thorough manner." "We value and invest in technology to help us grow and deliver on our promise to our end user," smiles Poulose, "the customer at home, enjoying our Tastee Choice products."
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www.tasteechoice.com
www.heatandcontrol.com
SMART HANDLING AT TASTEE CHOICE
"This system has considerably increased our productivity" Nithin Poulose Jnr VP of Operations
SPRAY DYNAMICS COATING SYSTEMS
FOOD SEASONING + COATING Spray Dynamics® is a leading innovator of equipment for the controlled application of liquid and dry ingredients on a wide range of food products. Manufacturing applicators for powdered seasonings, oil and water-based coatings, slurries, chocolate, yoghurt, release agents and many other coatings. These systems are designed to optimise the efficiency and quality of the line and the finished product. Spray Dynamics was established in 1952 and has worked closely with the snack food industry since 1970. • Snack food seasoning and coating • Ready-to-Eat cereal coating • Chocolate enrobing and coating • Coffee flavouring • Meat, fish and poultry flavouring and coating • Petfood flavouring and coating • Bakery and cheese systems
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www.heatandcontrol.com
SPRAY DYNAMICS COATING SYSTEMS
TWO-STAGE COATING SYSTEM Application of liquid and dry coatings on extruded, baked, frozen, and fried products. This complete and easy to operate coating system is engineered for proper dwell time and product-appropriate flight configuration. Made up of a Soft Flight® coating drum, a Micro-Meter ITM airless liquid applicator and a Uni-Spense® dry ingredient distributor, the two-stage coating system offers tools-free operation.
SOFT FLIGHT® COATING DRUM A shell-in-shell drum that provides sanitary operation and simple cleaning for snack, meat, dairy and other processspecific applications. Variable tilt frame assembly and product flight design exposes each piece of product to the application of liquid and dry coatings. Custom product flight configuration reduces breakage.
SLURRY SPRAY SYSTEM Engineered for cereal, snack and pet food applications to maximise coverage and minimise waste. The Clog-Free™ spray station design prevents nozzle plugging. Available for use in coating drum and conveyor belt applications. Spray virtually any pumpable slurry including sugar, syrup, chocolate, oil or emulsion.
CENTRIFUGAL BATCH COATING SYSTEM This fully automated or continuous batch centrifugal coating system is ideal for products such as dough-coated peanuts, flavoured coffees, nuts and sunflower seeds. The base product supply hopper with pneumatically controlled slide gate delivers product to the PLC controlled weigh scale. Accurately measured batches of base product are fed to the coating chamber. Rotation carries the base product out to the coating chamber wall.
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ACHIEVE CLEAN ENERGY GOALS helping food processors reduce the environmental impact of their manufacturing with cooking equipment that protects air quality, conserves water, and reduces energy use
www.heatandcontrol.com
ENERGY + ENVIRO EFFICIENCY
KLEENHEAT® HEAT EXCHANGER [KHX] Remove oil, odours and particulates from fryer exhaust with this high-efficiency heat exchanger. The KHX combines efficient external heating of cooking oil with pollution control. Connects to the fryer exhaust stack and incinerates virtually all odours, oil and other particulates that would normally pollute the air and area around the plant. Can also be used as a thermal fluid heating system with the added advantage of controlling fryer pollution at the same time.
COMBUSTION AIR PREHEAT SYSTEM Increase heat exchanger combustion efficiency up to 5% and achieve fuel savings by utilising normally wasted exhaust heat with this sytem and a booster heater.
FRYER STACK HEAT RECOVERY SYSTEM Recover millions of BTU's of heat from the fryer exhaust stack. This system condenses otherwise wasted steam to make hot water for blanching, sanitation or building heat.
ENERGY RECOVERY HEAT EXCHANGER [ERHX] Ovens waste millions of BTUs in exhaust emissions that can be utilised with this heat recovery system (ERHX) to pre-heat the fryer system’s cooking oil, heat water for sanitation or heat buildings.
BOOSTER HEATER Mounted in the stack of almost any heat exchanger, the Booster Heater uses normally wasted exhaust gases to preheat cooking oil. Without using additional fuel, it will increase heat exchanger efficiency by up to 11-15%.
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innovations in processing systems for snacks A - Z
Design & Engineering | Manufacturing | Installation & Commissioning Service & Spare Parts | Operator Training
storage + preparation fryers + roasters ovens seasoning + coating distribution + accumulation pollution control oil management controls + IT
progress through innovation since 1950
Food Processing & Packaging Systems
www.heatandcontrol.com
SNACK PRODUCTION SUCCESS
CAPE COD POTATO CHIP'S SMALL BATCH FRYERS DELIVER BIG OUTPUT IN LIMITED SPACE How do you squeeze higher output from the same floor space used since 1980, without changing the quality of a winning product or ruining the charm of a popular tourist destination? "We were space-constrained, and simply didn't have the ability to make the plant bigger with brick and mortar," says Jeff Newell, plant manager at Cape Cod Potato Chips (USA). "The project was based on the premise that the kettles we work with are the original fryers the brand started with. So our challenge was to replace those fryers without expanding the plant and still make the Cape Cod Potato Chips our customers love." "The goal was to make the same product whether we have low-gravity potatoes or high-gravities, and do it with much higher throughput," reasons Newell. Heat and Control's solution was to develop a new fryer based on its proven 800B platform, which closely matched the footprint of Cape Cod Potato Chip's existing fryers. Heat transfer tubes were positioned lateral to product flow with BTUs provided by a new combustion system. To preserve floor space, combustion components were mounted above the fryer, instead of beneath it. Cape Cod Potato Chips had utilised separate exhaust hoods mounted six feet above each of the old fryers, although these area hoods pulled a large amount of draft air from the cook room. The new fryers would pull up to 30% more air, and add nearly a million dollars to the project for additional air makeup equipment if a similar approach was used. To save energy, Heat and Control equipped each fryer with a hood enclosure, like those commonly used on continuous fryers. In addition to reducing draft air volume to below 1,700 acfm, the hoods blanket the oil with steam, purging oxygen to improve oil quality by reducing oxidation. "There is an improvement in product appearance. And because the BTU conversion is so powerful in the new fryers, I get a searing effect early-on in the batch cycle which holds the chips to the right number of fold-overs and a good cup shape," says Newell. "Texture change is neutral," he adds, "which is a good thing. The fact that I'm making significantly more product in the same size of equipment and not sacrificing any texture is a huge positive." www.capecodchips.com
Heat recovery is a fuel-saving winner for Wyandot With four tortilla chip ovens operating for three shifts, five days a week, Wyandot Inc. saw an opportunity to utilise a vast supply of energy that had been going out the exhaust stacks. Using a partial funding grant from its state energy conservation program, the Ohio (USA) snack processor purchased an Energy Recovery Heat Exchanger for each pair of ovens from Heat and Control. Exhaust energy now pre-heats cooking oil before it enters the heat exchangers serving Wyandot’s chip fryers. This reduces natural gas usage by about 20%, almost 20,000 MMBTUs per year and will provide a return on investment in two years. "The system has made a significant impact on our sustainability program," notes plant manager, Jim Augur. 28
FOOD HOT SPOT NAMKEEN SNACKS
FOOD HOT SPOT NAMKEEN SNACKS The Hindi derived term Namkeen is broadly translated to ‘salty snack’ and covers an entire range of snacks including whole legumes such as green peas and chickpeas and dough based extruded products. Traditional for consumers in South Asia, Namkeen is seasoned with spices and come individually or in mixtures such as the popular Bombay Mix. Whole legumes that are made into snack products include Peanuts, Cashews, Moong Dal, Fried Chickpeas, Peas, Lentils and Broad Beans. These are sold individually or included in a blend such as Bombay Mix or Khatta Meetha. Depending on local tastes they are coated, highly seasoned, lightly seasoned or not seasoned at all. Many legumes are manufactured into flours and are used in formulations for low-pressure forming systems. One prominent snack market is the Bhujia market. The number of shapes, sizes and ingredients used are extremely diverse but the basic principle involved in producing the product is the same. Besan (chickpea) Bhujia for example, is mixed with other ingredients and made into a dough or batter that is suitable for extruding. Extrusion technology enables numerous products to be made and includes various types of Bhujia and Boondi. With clever formulations and recipes of legume types or dough ingredients the characteristics and flavour of the final product is enhanced. Plus, seasoning is an obvious area where manufacturers can be creative and design endless number of products by adjusting the proportions of the legume, the cooking technique and the flavours added.
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FOOD HOT SPOT NAMKEEN SNACKS
BESAN BHUJIA
BOONDI
Besan flour dough mix is extruded into long straws which are then broken into small pieces after frying. Has many variations for final flavours, shapes and presentations. Is common in most variety products such as Bombay mix.
A spherical shaped product made from Besan flour batter, was traditionally hand-formed using a sieve directly into a large batch fryer. Heat and Control has developed extrusion systems to automate this process.
MUNG (MOONG) DAL
GREEN PEAS
Moong Dal is a dehusked mung bean, that is hydrated, dewatered, fried, cooled and then packed. It is eaten on its own or mixed with other ingredients.
Peas have high protein and carbohydrate content and are eaten as a fried snack on its own or consumed as part of a variety such as Bombay mix.
BATTER COATED PEANUTS
FRIED CHICKPEAS
Peanuts that are coated with traditional spice flavours mixed with besan flour.
Chickpeas are fried and seasoned and in some recipes the chickpea is flattened. Chickpeas have high protein and low fat and high fibre content.
Over ten years of development working closely with the South Asian snack market has resulted in a "multi-purpose" frying system suitable for processing the majority of raw materials which make up this complex snack product range. The HeatWave速 snack frying system can process a wide variety of Namkeen snacks with outstanding results in a single system.
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TAKE
CONTROL
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TAKE CONTROL INFO SYSTEMS
PROVEN CONTROLS FOUNDATION All controls systems allow access to critical data points for plant manufacturing execution systems (MES), utilising widely available industry software solutions that enable an easier controls setup process. All Heat and Control’s systems combine real-time control of the plant with efficiency tools for new and existing operations. Utilising industry standard software solutions, the goal is to strike the right balance between delivering control innovation that is both robust and flexible while enabling operations to focus more on the success of creating a better product and not worry about system function or control technology.
Information That MattersÂŽ (ITM) delivers production line information metrics, in real-time, to plant floor dashboards, computers or smart phones. The dashboard continuously displays health levels of system via large displays. ITM systems present information in an easy to understand format so that operations and maintenance personnel have the tools necessary to improve line performance. ITM delivers critical role base reports that help plant personnel understand how well equipment performs over a selected period of time. Overall equipment performance (OEE), downtime reasoning and quality information are key reporting areas that improve the bottom line.
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FESTIDA FOODS THE GOLD STANDARD
Founded in 1989, Festida Foods produces private label corn chips and tortilla chips in a variety of shapes and sizes made from white, yellow and blue corn and specialty flours. Their customer base includes national and regional brands, food service distributors, school systems, specialty retail and big box stores. Soaring sales were squeezing Festida out of its original plant in Cedar Springs, USA. "We needed space desperately," recalls president, Kyle Curtiss. "For over a year, we were working 6 days a week and 24 hours a day. In this economy, that's a blessing, but with it we needed to make some changes." Expansion to a larger building in Grand Rapids enabled Festida to double its capacity, while providing additional room for future growth and better working conditions. Curtiss pushes Festida to strive for excellence in all areas of its business: from team members and processes, to technology. So with the addition of a second processing line, Curtiss turned to Heat and Control to provide a new distribution, seasoning and packaging system that could handle the line's output of 1360 kg per hour. "Because of our wide range of products," explains Curtiss, "the system needed to be able to move, season and pack a large number of chip sizes and weights." Heat and Control designed, built and installed a system featuring the latest technology for consistent product delivery, versatile and uniform seasoning application and non-stop weighing and packaging efficiency. From multiple processing lines in the cook room, chips are briefly accumulated in two SwitchBack in-line storage conveyors. Product is now always available to packaging in the event of a temporary halt in production and the chips never need to be bulked-
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off or wasted during brief packaging delays, such as changing bagmaker film. This river of chips is proportionally distributed to five seasoning-weighing-bagmaking stations by a dual-lane FastBack Revolution gate conveyor system. Built into the pan of each FastBack horizontal motion conveyor, the patented Revolution gate rotates to divert the exact amount of product requested by each bagmaker, while maintaining a steady supply of chips to downstream stations. Unlike traditional slide gates, Revolution has no pinch-points that can break chips or injure workers. Revolution is very precise, seals completely preventing product cross contamination, and does not require the complex mechanisms of waggle conveyors that can create uneven product flow, product spillage and mixing and maintenance headaches. "With the addition of our second production line and multiple distribution channels, production flexibility has been significantly improved with the Revolution gate technology," says Curtiss, adding that it has allowed Festida to improve order fulfillment. Festida chose Heat and Control's Revolution On-Machine Seasoning application system. Product flow is continuously measured in the conveyor pans. This information is used to instantly regulate the amount of seasoning deposited, providing accurate and even application without waste. "The state-of-the-art FastBack Revolution system treats chips gently, resulting in less breakage for our customers," observes Curtiss. "This system allows for a more uniform flow of product and a more efficient distribution of chips to the packaging machines." An integral part of the seasoning system and for additional seasoning versatility, two Spray Dynamics oil spray applicators were also added to the cook room to reintroduce oil to chips for uniform seasoning adherence in certain applications.
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FESTIDA FOODS THE GOLD STANDARD
"In addition to internal product flavourings, Festida applies many different external seasonings, including salt, sea salt, cheese-based, savoury flavours and more," says Curtiss. "FastBack on-machine seasoning provides enhanced coverage of salt, seasonings and flavours. It greatly reduces both cross-contamination and clean-up time. Seasoning application rates are consistently accurate and we can now produce up to four different products simultaneously." From the Revolution seasoners, chips flow through Ishida R-series multihead weighers and into Ishida Atlas vertical form-fill-seal bag makers. Festida produces 28 g to 1.36 kg bag weights at speeds ranging from 90 to 12 per minute for the largest bags. Built-in vacuum splice tables simplify film changes with the Ishida bag makers. The Ishida bagmakers produce consistently perfect seals for all bag sizes at all speeds. Additionally, overall packaging efficiency is up, thanks to longer equipment run-times resulting from uninterrupted flow of chips through the system. "Ishida weighers and bagmakers are cutting-edge technology," observes Curtiss," and they provide accurate bag fill weights, and exceptional seal integrity." "The entire system reduces cleanup times for seasoned products and provides the versatility needed to run multiple products simultaneously," says Curtiss. "It reduces chip breakage due to the manner in which the chips are conveyed and gives greater control over production due to the accumulation capability," he adds. "One of the largest improvements to date has been in the area of order scheduling," notes Curtiss. "We can produce four different products simultaneously. Certain products have better overall throughput, and there has been some reduction in waste thanks to our accumulation ability," he concludes. System operation is managed using Heat and Control's icon-based control system via one easy-to-navigate operator interface touch screen. Curtiss notes that the user-friendly operating controls provide significant system management and training benefits. "For operations, it is primarily the ability to control the system more easily and accurately," explains Curtiss. "In maintenance, the advantage is ease of access to various preventive maintenance areas. For sanitation, the system design allows for easy disassembly, which reduces cleanup time and provides the opportunity for more thorough and effective cleaning."
"One of the largest improvements to date has been in the area of order scheduling, we can produce four different products simultaneously." Kyle Curtiss | President Festida Foods
All these benefits have helped Festida Foods achieve the productivity and quality standards embodied in its promise to strive for excellence. In fact, the company has recently been recognised as a Gold Standard manufacturer of tortilla chips by a large national brand. Festida's chips are now considered the "go by" standard by which product from all other co-packers across the country will be compared by this brand. "Based on this achievement, our expectations of quality for all our products have increased, resulting in better quality for all Festida customers," smiles Curtiss. www.festidafoods.com
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REINVENTING VACUUM FRYING
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Smaller footprint vacuum frying Until now, vacuum fryers had to operate inside an external vacuum chamber. This "ship-in-a-bottle" design required excessive floor space and hazardous, labour-intensive removal of the fryer for cleaning and maintenance. To eliminate these problems, the Unitized Vacuum Fryer (UVF) design features an ability to create its own vacuum and requires no external vacuum enclosure. Operating at 10% or less of normal atmospheric pressure, the UVF boils off product moisture at a lower temperature. This enables frying of snacks made from high-sugar potatoes, apples, yams, and other products without browning. And because water boils at a lower temperature in a vacuum, frying oil temperature can be kept below the 120째C point at which acrylamide begins to form.
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Unitized Vacuum Fryer (UVF) provides a more space efficient vacuum frying environment
processing systems for prepared food products
Design & Engineering | Manufacturing | Installation & Commissioning Service & Spare Parts | Operator Training
meat | poultry | seafood | french fry | vegetables batter + breading applicators fryers + ovens branding + searing flavouring + seasoning blending systems distribution + accumulation controls + IT
progress through innovation since 1950
Food Processing & Packaging Systems
ACHIEVE LINE PERFORMANCE designing a smart footprint solution that punches well above its weight, helping processors achieve volume goals with space and budget restrictions
NEW MICRO BREADER
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Apply all styles of breading in less space
Only 2.3 metres long, the new Micro Breader™ frees up 610mm of line length that allows for the addition of another coating pass for greater production versatility. Micro Breader uniformly applies all styles of predust, crumb and flake coatings. Top coverage and bed density are independently adjustable. Automatic belt tensioning increases conveyor belt life. Interchangeable top hoppers and large clean-outs permit fast changeovers between free-flowing and non freeflowing coatings.
1 2 3 4 5 6
Automatic belt tensioning Lifter adjusts bed density Interchangeable hoppers Low level easy-filling Large clean-outs Central hydraulic control & connection
The Micro Breader provides all the features of a full-size breading applicator in a smaller package. < See the full range of batter & breading applicators
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FRENCH FRY SYSTEMS
MULTI-ZONE FRYER SYSTEM FOR FRENCH FRY Over 16,000 kg/hr of finished crispy batter-coated french fries will be produced using the latest batter applicator and multi-zone fryer system. The batter applicator applies a clear coating that gives fries a crisp texture and long serving life. Submersion in a pool of premixed batter and passage through two batter curtains ensure uniform coverage. The applicator’s batter tank and drip pan are chilled to maintain batter consistency and reduce cleaning requirements. The outside-return conveyor belt can be raised clear of the pan to simplify cleaning, and the entire applicator system slides aside for sanitation, or when uncoated product is run. The fryer features Heat and Control’s latest technology for controlled, uniform cooking and efficient operation. Each of the fryer’s two independent stages has three oil temperature zones for precise temperature control and rapid fines removal. Oil inlets and outlets are specially designed to deliver uniform side-to-side oil-to-product velocity and Delta-T. The outside-return conveyor belt reduces oil volume in the fryer. Unitised construction provides a stable pan structure that resists thermal deformity. Oil filters, pumps, the steam heat exchanger, clean-inplace components, and piping are pre-assembled on a compact Fryer Support Module to reduce installation time and maintenance costs. The complete system and all batter-mixing, coating, cooking, and cleaning functions are controlled from one PLC touch screen. Oil Mist Eliminators and Heat Recovery Systems are available to remove oil mist and utilise otherwise wasted heat from fryer stack emissions.
< See the full range of frying systems available
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Heat and Control builds french fry and formed potato product fryer systems for up to 22.6 metric tons/hr and supplies complete lines including potato unloading, storage, processing, seasoning and coating applicators, conveyors, weighers, inspection, and packaging equipment, all backed by post-sale service and technical support.
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IN THE KITCHEN BAWANG GORENG
Maintaining a competitive edge and keeping up with changing consumer taste is a challenge for food companies and their R&D teams. Testing and product development involves a lot of trial and error and in many instances the ability to test new products are limited by lack of facilities and equipment, especially when it comes to large scale volumes. Heat and Control helps manufacturers to develop new products and improve quality and consistency with the aid of testing facilities. The Heat and Control Technical Centre in Australia was recently the site for testing Bawang Goreng (fried red shallots), a popular ingredient and garnish for soups, salad, rice and noodle dishes in Indonesia, Thailand, Vietnam and Malaysia. The manufacturer currently batch fries shallots in palm oil using a large wok or batch frying equipment and is facing problems with rapid oil degradation resulting in poor product quality as well as high oil usage. The trials tested combinations of dehydration and frying methods to improve oil life, product consistency and find product data important to the production process for the manufacturer. Using analysis for total oil and moisture content a process can be designed to ensure optimum quality for fried shallots.
frying + cooking prepared foods thermal processing that offers the highest end product quality and line efficiency for prepared food products including meat, poultry, seafood, french fry and other value-added foods
With this end product information the goal is to develop a modern process for Bawang Goreng that focuses on product quality and reduced oil usage following the specified parameters determined during the testing stage. With traditional products such as Bawang Goreng, the challenge is ensuring a quality product in a modern processing environment. Once the process moves from traditional to modern and there is an increase in output volume, there are significant changes in the reaction of the food product during the modern process as compared to the traditional method. This is where information gathered from testing is transferred into parameters used to design and engineer the processing line.
Food Processing & Packaging Systems
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