INNOVATOR magazine
FRYER SYSTEMS Technology
Creating NUT Snacks
adding more value to food OVEN Talk
Go Back to COATING School
adding
VALUE
Success in the food industry is measured by the satisfaction of consumers and the enjoyment of what they eat. Adding value to food products enhances this enjoyment and contributes to years of brand loyalty. Our commitment to innovative machinery and technology that adds value to food and production efficiency has helped brands to continually reinvent their product offering and keep customers happy.
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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 3
About Us
5
Interpack 2014 Wrap-Up
6
Complete Solution
8
CEO Spiral Oven
10
Oven Talk
13
Fryer Systems Technology
18
Oil Matters
19
Frying Tips
20
Where’s My Caddy? Fryer Support Module
21
All About Crunch
22
Fryers: Thermal Fluid
23
Dynamic Duo: Brand + Sear
24
Coating Systems
26
Adding Value Via Coating
29
Market News: Global Snack Value
30
Meet The Team in India
33
Flavorite Now In Africa
34
Value Added Nut Snacks
37
A-Z Of Nut Snack Processing
38
Nut Weighing Solutions: POEX
40
FastBack Latest: WeighBack
41
The FastBack Advantage
42
Q+A: Dave Homeyer, Spray Dynamics
45
Corn Snack Processing + Packaging
47
Latest Products From Urschel
48
How To Cut Meat
50
TOMRA Sorting Solutions + H&C
52
Food Safety @ Five Star Gourmet Foods
54
Metal Detector Buyers Guide
56
Latest Inspection Technology From Ishida
57
Inspection Results With CEIA
58
Our Global Network
we know what to 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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PROCESSING + PACKAGING SOLUTIONS “Heat and Control offered delivery times needed to meet our schedule. From the project design phase through vendor selection and installation, Heat and Control stood out with the level of service and dedication to understanding and meeting our needs.” Brian Foster, Senior VP of Operations Inventure Foods
Over 65 Years of innovation and world-class service. • Snack Systems • Process Prepared Systems • French Fry Systems • Seasoning + Coating Systems • Conveying Systems • Weighing + Packaging Systems • Inspection Systems • Control + 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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WE ARE PASSIONATE ABOUT PROBLEM SOLVING. DESIGN + ATTENTION TO DETAIL
FASTBACK AT WORK
The FastBack product team has developed a strong leadership position within the food conveying industry. Over 20 US and international patents signify an innovative approach to solving industry problems for hard-to-handle products like salads, snacks, fresh chicken, cookies and candies.
Simple design, robust architecture and extreme attention to detail. Provides a precise and reliable conveying design to build an entire plant around. From conveying, distribution and accumulation to on-machine seasoning, proportional feeding and blending systems.
Leader in horizontal motion design and performance. FastBack drives are the simplest, most robust, and highest performing horizontal motion conveyors available. Backed by a 5 year drive train warranty and the confidence of Heat and Control quality manufacturing.
We are on
By Heat and Control
www.heatandcontrol.com/fastback
info@heatandcontrol.com
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2014 saw the world’s biggest packaging and processing show, Interpack, showcase innovations in the world of industrial process automation technologies. Visitor numbers were strong: Heat and Control saw a 37% increase in snack industry visitors. India was the most active single country in terms of individual visitor numbers. Featured at the show was the FastBack Revolution™ Mid-Gate. Designed with the flexibility to be mounted anywhere along the pan length of a FastBack conveyor, the Revolution Mid-Gate eliminates transfer pinchpoints to prevent product breakage. Plus, it delivers all the advantages of proportional distribution: Consistent product delivery to multiple locations; improved weigher efficiency; no leaks or cross contamination; easy cleaning; and safe operation. Also launched was the AccuFlavor™ dual geometry seasoning drum. This patent pending two-stage design doubles product dwell time for improved seasoning adhesion and coverage. AccuFlavor is available only with the Revolution On-Machine Seasoning system.
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COMPLETE SOLUTION 6
R&D + TESTING Heat and Control Technical Centres are the ideal place to develop new products and evaluate equipment performance without interrupting production schedules at your plant. Depending on equipment availability and location, demonstrations of coating, cooking, conveying, seasoning, weighing, packaging, and inspection machinery are available.
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 most reliable and longest working food manufacturing equipment.
INSTALLATION, COMMISSIONING + OPERATOR TRAINING Complete installation services utilising a team of multi-disciplinary 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.
WWW.HEATANDCONTROL.COM
THE PREPARED FOODS MENU CONTINUES TO GROW
We are on
PREPARED FOODS PROCESSING SYSTEMS Since the inception of industrial food production, Heat and Control has partnered with prepared food manufacturers to meet every challenge to achieve higher capacities, lower production costs and superior product quality. For meat, poultry, seafood, vegetables, bakery goods and a growing menu of other prepared foods, Heat and Control builds a complete range of equipment for coating application, frying, cooking, grill marking and searing.
www heatandcontrol.com Email info@heatandcontrol.com
High-capacity spiral oven cooking with precise control product colour
CEO
™
Spiral Oven
perfects product browning
8
> Develop colour and flavour on entire product > Enhanced browning air flow is adjustable > Uniform cooking across all conveyor tiers > Cook with steam, dry heat or both > Natural gas or thermal fluid heating > Single and twin-drum spiral models
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Heat and Control has perfected product browning in a spiral oven with its new CEO Colour Enhancing Oven™. Available in single and twin-drum models, CEO combines controlled browning of both sides of products with uniform high-volume cooking. “CEO develops appetising product colour and flavour during the final stages of cooking where these enhancements are most effective,” explains James Padilla, of Heat and Control. “After listening to our customers and spending months on R&D testing, Heat and Control has developed a colour enhancement system that applies browning at the optimal point in the cooking process,” he adds. “Now our customers have the control to develop colour on both sides of products, while enjoying all the benefits of high-capacity, high-yield cooking in a limited floor space.” In addition to superior browning, the CEO spiral oven cooks product uniformly, wherever it is located on the conveyor belt. Hot, moisture-controlled air is evenly distributed in a 360˚ pattern to ensure equal and uniform heating across all tiers. Steam, dry heat, or combinations of both, are controlled independently to provide optimal cooking conditions for different products. The fully modulating moisture control system, combined with gas, electric, or thermal fluid heating, produces an optimal cooking environment. The PLC control with easily accessible process parameters for multiple products provides repeatable browning and cooking with fast changeovers.
CEO develops appetising product colour + flavour 9
Heat and Control offers one of the widest ranges of ovens to suit a variety of prepared food processing applications. Models include impingement, convection, spiral (single/twin drum) and steam (linear/spiral). For rapid, high volume cooking with precise control of product browning and surface texture, the AirForceÂŽ impingement oven provides independent adjustment of cooking conditions on both sides of the product. AirForce cooks uniformly across the belt width to eliminate the need for overcooking, assuring all product is safely finished without sacrificing valuable yield. For the highest finished product yields, the MPOÂŽ oven utilises a patented moisture-controlled convection cooking process. By precisely controlling the interaction between temperature and moisture, the MPO provides rapid heat transfer and development of unique surface textures.
Spiral In Control Processors are often searching for a solution to overcooking product and sacrificing yield when using spiral ovens. Ovens that do not distribute heat evenly create an imbalance in cooking which requires longer cook times to ensure all product reaches a safe core temperature. Unfortunately, this practice reduces yield and overall production output.
“OVEN
TALK 10
Drawing on vast experience with multi-zone cooking, an oven was designed to ensure balanced air flow around the entire spiral conveyor. Instead of housing both spiral drums in a single rectangular box, separate cylindrical enclosures were used for each drum. An air circulation fan is centered atop each enclosure and surrounded by heat transfer coils. Heated moist air flows in a 360 degree pattern uniformly across the conveyor providing consistent temperature across the belt width and from top to bottom. Temperature profile data proves cooking is completely uniform across the full width of the belt. Separate drum enclosures also provide truly independent two-zone cooking control. Steam, dry heat, or any combination of both, and air speed are independently controlled in each enclosure, and offers unprecedented versatility for cooking and the development of unique product characteristics. In other ovens which use one enclosure with a divider between the spiral conveyor drums, heat and moisture seek equilibrium across the divider and this severely limits the independent settings for the two zones. The spiral oven design ensures separate cooking control in each zone.
Uniform cooking assures each piece of product reaches the same safe core temperature in the same amount of time, and has consistent surface qualities, such as texture and colour. It saves fuel and delivers high product yields because it reduces cook times and eliminates the need to overcook. AirForce • Plenums with internal fans in hood and base • Fans create high air pressure inside plenums • Uniform pressure forces air evenly out of all nozzles above and below the product conveyor Even air flow in AirForce eliminates areas of uneven temperature common in ovens using fans located outside the plenums.
Spiral • Fan centered over a dispersion cone above the spiral conveyor • Air flows in an even 360-degree pattern all around the conveyor • Fan suction draws air equally across all conveyor tiers as it returns up the centre of the spiral conveyor One centerline fan evenly envelops the entire spiral conveyor in the cooking atmosphere. This eliminates areas of uneven temperature found in ovens utilising different airflow patterns.
Impingement cooking increases safety + profits As demand grows for higher production rates and a greater variety of fully cooked prepared foods, so does the concern over safety. Each and every piece of product must be fully cooked to ensure it is free of harmful micro-organisms. The speed and versatility of impingement ovens have helped processors meet these demands. Unfortunately, most ovens do not apply heat evenly, forcing processors to sacrifice yield for safety by “overcooking” to ensure all product reaches a safe core temperature. The AirForce is the only impingement oven that cooks uniformly across the entire product conveyor width. Air circulation fans located in plenums above and below the product belt develop completely uniform airflow to the product so each piece is cooked equally.
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FRYER SYSTEMS TECHNOLOGY Why fry food? Considering consumer interest in healthy foods and the introduction of so many non-fried products, one would anticipate a declining market for fried foods. Sales figures, however, indicate the opposite. The multibillion dollar fried food industry continues to enjoy steady growth because, whether it’s fried chicken, french fries or potato chips, fried foods taste good to the consumer. 13
FRYER SYSTEMS TECHNOLOGY Criteria for fryer selection Frying is one of the fastest heat transfer methods available for cooking. It is a simple and commonly used technique for developing flavour, colour and unique product characteristics that cannot be duplicated by any other method. Frying can be accomplished in a batch or continuous system. Regardless of the product type, fryer system selection is critical to producing the desired product. Product characteristics Both coated and non-coated products can be fully cooked or partially fried (also known as par-fried or blanched) for colour. Non-coated products include meatballs and turkey breasts (fried for browning); dough enrobed products such as fruit turnovers and chimichangas; snack foods such as potato chips, tortilla chips and nuts as well as grain or meat-based pellets. Coated products include all kinds of battered and breaded meat, poultry, seafood and vegetables. These can have a variety of coatings such as tempura batter, seasoned flours, glazes and coarse crumbs. The type of product and the product’s sensory qualities and physical dimensions all have to be considered when selecting a frying system. Desired production rate The production rate needs to be established in order to determine the appropriate fryer size. The physical dimensions required to accommodate the expected production rate are determined by the process time and the product loading per square area, better known as a belt loading. Belt loading can be expressed in kilograms per square metre, kilograms per linear metre, pieces per linear metre, etc. If the belt loading were calculated in weight per square area, the formula would be as follows: Belt loading required =
Desired production rate, kg/hr kg per m2 x (60 min/process time min)
Oil pick-up Oil pick-up of a product is the result of the product’s physical characteristics and process parameters. Most products will absorb the majority of oil during the initial stages of frying. Oil pick-up can be affected by the coating, frying temperature, product flow rates, ∆T of the frying process and drain time. It should be noted that there are products in which this does not apply. With some types of noncoated products such as meatballs, fat is rendered into the cooking oil. Oil turnover Oil turnover is critical to the success of any product because it determines how frequently used oil is replaced with fresh oil. The oil turnover rate in a fryer system is a function of the amount of oil contained in the system and the rate at which the oil is removed as it is absorbed by the product. The more frequent the turnover rate the more consistent the product and better shelf life. Oil turnover rate is calculated as follows: Oil turnover rate (hour) =
Litres of oil in the system Oil pickup per hour in litres
For example, if a fryer system contains 1515 litres of oil and 1800kg/hour of product with a 9% pick-up rate were produced on an hourly basis, then the turnover rate would be 7.6 hr. Fines removal or filtration Debris from products left in the fryer will burn and carbonise. Burnt fines are one of the greatest contributors to degrading oil quality. The particle size of the coating, the floating or sinking characteristics of the product and the flow rate through the system all have to be considered when selecting a fines removal/filtration system.
For example, if the desired production rate were 1500 kg per hour, the product loading is 7.9 kg/m2, and the processing time is 5 minutes, then the belt loading required would be 15.8m2.
For example, sinking debris settles on the bottom of the fryer pan, where they are difficult to remove. To prevent fines accumulation, a sludge conveyor or pan wipers are necessary to drag sediment from the pan bottom to a discharge port, where the sludge is removed by an auger, conveyor or oil flow to a filtration system.
Heat load
Product conveyor
Heat load of the fryer system has to be designed to deliver the heat necessary to cook the product. This requires a mass heat load balance calculation to be run on the system. The heat balance takes into consideration loss of heat due to the oil, the fryer vessel, the piping, the processing room, the fryer exhaust, ancillary equipment (filters), the thermal efficiency of the heat transfer mechanism and the product.
For a buoyant product, a hold down or submerger conveyor is necessary to keep the product fully submerged in the oil. This type of conveyor may also be used to hold a product in place when orientation must be maintained to prevent bonding or product pieces.
One other item must be considered in the equation: the temperature differential (∆T) of the cooking oil. This is the temperature differential that the oil achieves when heat is given up to the system, including the product. The heat load or requirement is expressed as BTUs required for the fryer system.
To avoid coating damage, some products require a short section of free fry area where there is very little mechanical movement from a conveyor belt. The product is dropped directly into an oil bath and allowed to fry for several seconds. This sets the coating prior to the product settling onto a conveyor belt for system transfers.
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Some products with a delicate coating like tempura require a special conveyor known as a “tempura conveyor” or “Teflon in-feed conveyor”. This type of conveyor allows a batter coating to begin frying on a belt without developing a belt mark or disturbing the integrity of the coating. Once the coating is set, the product is transferred onto a conventional style stainless steel product conveyor. Environment By-products of combustion can be minimised by utilising the best available combustion components and by keeping them properly maintained. Special incinerating systems can also be made a part of the fryer oil heating system to bring emissions into compliance with government air quality standards. To address these concerns, two types of emissions must be considered: oil-laden exhaust created by the frying process and the by-products of combustion from the fryer’s heat source. Oil-laden exhaust can be dealt with by using an Oil Mist Eliminator. Air, steam and oil are emitted as exhaust from the fryer hood are drawn through a specially designed stainless steel mesh pad. The mesh pad captures entrained oil droplets, while allowing air and water to pass through. Oil droplets drip back into a catch pan and are discharged outside the fryer.
breaded products fryer | with fines removal system
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FRYER SYSTEMS TECHNOLOGY Types of fryers Once all the criteria for a fryer have been evaluated the fryer type has to be considered. There are two basic types of fryers: direct-heated and indirect-heated. Direct-heated fryers heat the cooking oil inside the fryer pan using heat transfer mechanisms such as burner tubes, thermal fluid fins or electric elements (Fig.1). Indirect-heated fryers heat the cooking oil outside the fryer pan by circulating oil through an external flue-fired, thermal fluid or steam heat exchanger (Fig. 4).
fig.2 | gas fired heating tubes
fig.1 | direct-heated fryer system Oil bath
Belt Conveyor Heating Tubes
fig.3 | thermal fluid heat transfer tubes
Direct-Heated Fryers Direct-heated fryers use the natural convection current of the heating mechanism to heat the cooking oil. The heating, tubes or rods are fully submerged in the oil bath. Adequate oil is necessary to fully cover the heat source and a buffer area of oil between the heat transfer mechanism and the product is required because it allows the natural convection currents to rise and have adequate time to uniformly heat the oil. This buffer area prevents hot spots in the fryer that can create non-uniform cooking. These types of fryers will have some form of sediment or drag conveyor to remove the debris that settles on the bottom of the fryer. Fines are moved to a sump where they are conveyed to a filtration system. Only a portion of the fryer oil volume is filtered at any given time. Direct-heated fryers are limited to the available heat generated by the surface area of the heat transfer mechanism in the oil. This limits product throughput, even though the fryer’s square area can hold more products. Those direct-heated fryers in which the oil is heated by means of gas-fired tubes (Fig.2) or electric heating elements require less floor space than other systems and often cost less for the same square foot area. However, fryers that heat the cooking oil by circulating steam or thermal fluid through tubes (Fig.3) placed in the pan (also known as direct heatedindirect fired fryers) have floor space and cost requirements similar to those in indirect-heated fryer systems. Direct-heated fryers are usually used in systems in which oil turnover rate is not a factor, where floor space is a concern and where lower cost is an issue.
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fig.4 | indirect-heated fryer system
fryer
heat exchanger
filtration
Indirect-Heated Fryers Indirect-heated fryers heat oil by circulating it through an external heat exchanger. The cooking oil is also circulated through the frying pan and a filtration system. This type of frying system has the ability to match the product heat load requirements to the square feet of frying area required by the product. The indirect system minimises the oil volume required for cooking. In the frying vessel, only enough oil is needed to cover the product. This usually results in up to 40% less oil volume in the entire system than that in direct-heated fryers of a similar size. Because of the lower oil volume, indirect-heated fryers deliver excellent oil turnover rates. With indirect-heated fryers, oil is filtered in a very short period because it is continuously circulated through the fryer and its components. Product particles are constantly removed from the oil, preventing fines and carbon buildup anywhere in the fryer system. The indirect-heated fryer system does use some form of external heat exchanger. The most common ones include the Coil-Type Heat Exchanger (CTHX) or some type of shell and tube heat exchanger, i.e. thermal fluid or steam.
Air pollution control KleenHeat® heat exchanger
These systems deliver gentle oil heating compared to other designs because the oil flow rate is engineered to maximise heat transfer without thermally degrading or scorching the oil. This fryer can be configured with either inside or outside return conveyors along with a tempura in-feed or free fry area. Oil is introduced to the fryer through single or multiple inlets located at the bottom of the pan. Oil flow can be adjusted at inlet points to match product flow patterns and to minimise temperature drop (∆T) along the fryer’s length. In addition, zone control can be provided for multiple cooking profiles, which can affect the product’s characteristics. Cleaning indirect-heated fryers is very simple. These fryers have a built-in, clean-in-place system and the cleaning solution takes the same path as the cooking oil, ensuring that all areas of the fryer are cleaned using a minimal amount of chemicals in a minimal amount of time. Indirect-heated fryers are used when reduced oil volumes, minimal thermal degradation and full oil filtration are required. These systems cost more than a direct-heated system but will guarantee the highest product quality.
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FRYERS
Oil Matters Oil may be the invisible ingredient in fried foods, but it clearly stands out as a critical factor in product quality. Heat and Control fryers treat oil as carefully as the product. Precise temperature control, fast fines removal, and rapid oil turnover deliver the freshest, most consistent fried foods possible. Each frying system is designed to customer specifications to ensure that the oil temperature remains at the desired set point and aligned to production requirements. This temperature will remain the same all through production thereby giving a consistent product as well as maximising the life of the frying oil.
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With our new fryers throughput has increased, oil life has been extended and oil usage reduced, cleaning is easier ... and product quality is better and more consistent.
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Frying Tips Frying tips that help maintain good oil quality:
Start as late as possible Fill and start heating the fryer system only when production is about to begin. Pumping and heating oil without cooking any food not only damages the oil but results in additional operating costs.
Keep the fryer closed Keep the fryer closed as much as possible to keep the protecting modified atmosphere (e.g. steam) within the fryer. At the same time this inhibits the ingress of fresh air into the fryer. The machine operator should not lift the fryer hood or its openings as the machine will quickly lose this protective atmosphere.
Fresh oil may need older oil Fresh oil does not have the flavour characteristics that are developed during the frying process and some processors purposely age their oil when starting with a clean fryer. They may “bruise or condition” the oil by heating it without product or simply put some older oil in with the fresh oil to get this fried flavour in to the product when they start production. After commencement they revert to using fresh oil thereby allowing these flavour characteristics to develop in the oil but at a controlled rate.
Cool and store as soon as possible After production or during extended production stoppages, the oil should be cooled to below 100ºC as quickly as possible and then stored in the appropriate storage areas.
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Where’s my caddy? Just like a pro golfer needs a good caddy, a fryer needs an oil support team to keep up performance. A fryer support module is designed for specific fryer applications and plant layout and can include the heat exchanger, oil filters, pumps, storage tank, oil cooler and flow control valves, all fully piped and wired to single-point utility connections. This module significantly improves system access to all components in order to facilitate easy inspection, maintenance and sanitation tasks. The module significantly reduces the time and cost of fryer system installation and simplifies maintenance, reduces piping runs and floor space requirements.
OIL COOLER MODULE
How much profit would one more hour of daily production provide? An Oil Cooler Module will cut up to an hour off the waiting time between production and sanitation for most fryers. Before a fryer can be cleaned, the oil should be cooled to 120°C or less before draining so that ‘thermal shock’ doesn’t damage the fryer. This delay typically lasts 1½ to 2 hours. The Oil Cooler Module reduces cooling time to under 30 minutes, thereby allowing production to continue for an extra hour or longer. Quickly cooling cooking oil also reduces the damaging effects of oxidation to prolong oil quality. The Oil Cooler Module saves floor space and can be installed on most existing fryer systems. Built to USDA sanitary guidelines, the module includes a cooler, pumps, valves, piping and controls pre-plumbed, wired and mounted on a stainless steel drip pan skid ready for operation.
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ALL ABOUT CRUNCH Now it is possible to produce over 226 finished kg/ hr of batch fried potato chips of almost any style with excellent consistency. The MasterTherm Batch Fryer uses an efficient thermal fluid heat exchanger to deliver high heat transfer rates with a low oil film temperature. Oil heating is gentle and uniform throughout the fryer, yet rapidly adjusts to changes in product load. Potato slices are automatically agitated and removed from the fryer by the patented Chip-Stirr速 paddle system. PLC control maintains a consistent temperature profile from batch to batch, and stores multiple product profiles for quick changeovers and repeatable product quality. For safety, energy efficiency, and improved oil quality, the cooking area is covered by a hood, like that used on a continuous fryer. This reduces heat loss and allows steam to blanket the oil, purging oxygen to prolong cooking oil quality. It also reduces exhaust volume about 70% less than fryers using area hoods. Generous spacing between the heating tubes facilitates cleaning and eliminates areas where fines can accumulate. Each tube expands independently, greatly reducing damage caused by thermal stress. Tubes are electro-polished to simplify cleaning. Features include continuous fines removal, automatic oil level control, an exhaust stack Oil Mist Eliminator, a clean-in-place spray system, and screw jack hoists to safely raise the hood and heat exchanger for complete access inside the fryer.
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Thermal fluid heat exchanger technology Designed for uniform oil heating and rapid response to changes in product loads, the MasterTherm™ U-tubes are also durable and simplify sanitation
Utilising a thermal fluid heat exchanger, the MasterTherm continuous fryer provides every advantage for cost-efficient cooking of coated and uncoated poultry, fish, meat, vegetables, and other food products. Uniform, responsive oil heating • The U-tube heat exchanger uniformly heats oil throughout the fryer so product is cooked equally and with even colour • Cooking oil moves freely between the tubes, promoting uniform heat transfer across the width and length of the fryer • Uniform heating eliminates oil currents that force product to one side of the fryer and cause coating damage and uneven transfer • Rapid circulation of a low volume of thermal fluid in the heat exchanger maintains cooking oil temperature even if product loads change Simple sanitation • Generous spacing between heating tubes facilitates cleaning and eliminates restricted areas where fines accumulate and cause overheating and failure of the heat transfer tubes • Elevated design provides access to clean beneath the fryer Reliable operation • Heat transfer tubes expand independently to prevent thermal stress • Robust construction to USDA standards.
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Configure MasterTherm with product-specific conveyors, multiple temperature zones, continuous fines removal and other options.
Dynamic Duo Add an appetising just-grilled appearance and flavour to meats, seafood, poultry, vegetables, breads, and other products using the combination Rotary Brander and Direct Flame Searer. Gas-fired burners create a wide range of finishes, from char-grilled accents to overall browning. Obtain different effects by the number of burners used, by adjusting the firing rate and individual angle of the burners. Brand marks can be applied to one or both sides of the product. In addition to standard parallel grill stripes, diamond patterns and other markings are available for a customised finish. There is also a Floating Ring roll available for natural products of irregular thickness. Use the brander and flame searer together or separately, or simply operate the unit as a transfer conveyor when surface treatment is not needed.
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COATING SYSTEMS meat | poultry | seafood | vegetables
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Dip-Type Batter Applicator Product is deposited at the infeed end and conveyed through the batter well. The hold-down conveyor maintains product speed and orientation through the submerged section. The length and depth of the batter pool are controlled by the batter level in the well, which is adjustable. As the product moves out of the batter well, it is conveyed under an adjustable air blow-off manifold to remove excess batter.
Top Curtain-Underflow Batter Applicator A stainless steel belt conveys product under a two or four-curtain batter fall and over a bottom manifold that delivers an adjustable flow of batter. Single or double-dip batter pools, fixed or angleadjustable bottom flow manifolds, and custom-designs are available to maintain product orientation and achieve uniform coverage for fresh and formed products.
Standard Pre-Dust & Breading Applicator Product is deposited at the infeed onto a bed of breading, and conveyed forward through an adjustable curtain fall of breading. A lifter conveyor adjust density of the breading bed for uniform coverage on all types of products. An adjustable compression roller gently presses the top layer of breading onto the product. An air blow-off section with two air knives removes excess coating.
Micro Breader Provides all the features of a full-size breading applicator in a smaller package. Only 2.3 metres long, this breader allows for the addition of another coating pass. Applies all styles of pre-dust, crumb and flake coatings.
Triple-Flip Breading Applicator To assure uniform coverage of hard-to-coat products, the TripleFlip breading applicator turns product in breading three times. The triple-flip conveyor can be converted to a straight-through conveyor for products that do not require extra coverage.
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Adding VALUE via coating The coating process, which was commercially introduced with seasoned breading mix for seafood in the late 1930’s, has evolved greatly. Today, every food imaginable has been coated and the commercial coating formulations have become more sophisticated and elaborate. Coatings deliver a desirable product appearance and texture, while locking in flavour and moisture. Food coating equipment has advanced to better handle the variety of coatings and to coat all types of products, from the fragile to the frozen.
COATING TYPES PRE DUSTS
Are a blend of finely ground grain-based breaders, or dry batter. They are applied as the first layer in the coating system. A pre-dust provides a binding surface to which batter can attach, and contributes to increasing the total coating pickup. Agents are often added to pre-dusts to help other coatings bind better to the substrate. Pre-dust is frequently used as a flavour carrier. Flavourings in the pre-dust are somewhat protected during the frying process, making their taste more noticeable. Typically, a pre-dusted product will have a more uniform coating, improved appearance and texture, and will have reduced coating blow-off during the frying process.
STANDARD BATTER
Are generally a blend of several ingredients, such as flour, starches and water. Provides an adhesive surface to which flour or breadcrumb coatings can stick. Adhesive agents are often added to batters to coat specialty products that are slick or have a dense surface. Batters with flavours and colours help to create final taste and appearance characteristics. Batter viscosity is key to obtaining the desired coating pickup, adhesiveness and texture.
TEMPURA BATTER
Is prepared and blended like any other batter, except that leavening agents are added to form gas in the mixture. The gas expands when fried, resulting in puffing of the coating and the hard-bite texture that is typical of tempura-battered products.
WASH BATTER
Combinations of water, eggs, starches, adhesion agents, colour agents and flavour agents provide a unique surface texture to fried products like french fries and seafood products. There are times when a gumbased clear gel batter will be used to protect product from dehydration during the freezing process.
MARINADES & GLAZES
Are combinations of flavourings, seasonings, water and juices that enhance product taste, mouth-feel and appearance, or are liquids that are injected into the product or poured onto its surface to increase flavour, moisture and tenderness. Depending on the desired result, the food is left to become saturated from a few minutes to several hours. Glazes can be either dry or liquid, and are applied only to the product surface.
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BREADING
Each breading type has a characteristic flavour, size, texture and colour. Adding spices, nuts and other natural and artificial flavourings, as well as different flours, starches and crumbs, can augment breading taste and appearance in nearly limitless combinations.
FLOUR
Is a simple mixture of various types of flour, mostly wheat. Flour is a natural for carrying flavours and colours and it is often mixed with various spices, starches and other ingredients. Flour is one of the most widely used coatings. It produces a home-style appearance that is popular, while its flexibility and tolerance to frying make it successful for producers.
CRACKER MEAL
The same basic process that produces saltine crackers produces cracker meal. The dough mixture, consisting of flour and water, is sheeted thin and baked. After baking, the cracker is further dried then ground to specific granulation sizes. Most cracker meal is ground fine. It is a very durable coater, and is often used in long fry applications because of its low oil absorption characteristic. Cracker meal is a versatile, low cost and very popular breading.
EXTRUDED CRUMB
Is produced from high starch ingredients cooked continuously under pressure. At the end of the process, the sudden release of pressure causes the quick expansion of moisture, which in turn expands the extrusion. The inexpensive process allows high production volumes of crumbs that have light to medium density.
AMERICAN CRUMB
Is usually baked as a continuous bread loaf, but contains less water in the dough and has a dark and hardened crust after baking. Because of its hard texture, it is largely used to coat products such as croquettes and fish. It is available in grist sizes from fine to coarse and provides the coverage and appearance needed on the product being coated. To enhance appearance, colouring agents such as paprika and turmeric are used to develop a rich brown colour during frying.
JAPANESE CRUMB
Is manufactured with yeast using an electrical induction process. Yeast contributes to the open and porous structure of this elongated and uniquely shaped crumb. The texture, lightness and crunchy bite of this crumb is unlike any other breading. Compared with other breadings, the coating surface is remarkably free of oil when reconstituted. Special care must be taken in handling this fragile breading to maintain the integrity of the particle shape and size for as long as possible.
FRESH CRUMB
Is not dried like other breading, and must be refrigerated for extended storage periods. When fried, fresh crumb is desirable for the crispy texture and delicate appearance it gives the coated product.
heatandcontrol.com
APPLICATION TIPS PRE-DUST
Most products are pre-dusted to improve batter adhesion and total coating pickup. Slick or hard surface substrates almost always require pre-dusting. Batter needs some amount of roughness and dryness to adhere, and pre-dusting a substrate creates an excellent surface. Frozen substrates are especially difficult to coat, and also require faster line speeds to coat before thawing. Machinery used ranges from drum dusters and standard breading applicators. The triple-flip applicator is especially effective in coating hard-to-reach product cavities. Some product is best coated in a drum breader and is used to fill a products nooks and crannies, or to achieve a home-style hand-breaded surface texture.
STANDARD BATTER
Standard batters are applied through dip-type, top curtain, or underflow applicators. The dip-type applicator is the most commonly used batter applicator because of its versatility and simple operation. The top curtain applicator is used for products that tend to have orientation issues or for deep packs such as chicken wings. Successful batter coating depends on two machines that feed the batter applicator: the pre-duster must uniformly coat product to achieve good surface adhesion and the batter mixing system must deliver a homogeneous mixture of hydrated batter at a consistent viscosity and temperature.
Drum, single belt no flip, single-flip and triple-flip applicators each handle special applications or can be multi-use machines. Belt applicators for non-free-flowing breaders contain two key elements: a top coat hopper with a conveyorised bottom to carry the breader out of the hopper, and high horsepower low energy drives to handle the heavy breading. Belt applicators for free-flowing breaders move the coating as gently as possible, and have a low volume hopper with a discharge opening that prevents bridging. Drum breaders provide high capacity pre-dust or breading application. Flour dust or breading is thoroughly applied to all surfaces as product is gently tumbled inside a slowly revolving drum.
JAPANESE CRUMB
This delicate coating demands that the processing machines incorporate special features to keep the crumb intact. Special batters are often formulated to ensure sufficient pickup of the lightweight crumb. Too much pressure will damage the crumb too little pressure and the crumb will not adhere properly through the entire process. Because the product generally sits on top of the bottom bed, side coverage is more difficult than with other breaders. Japanese crumb is expensive and is used specifically on high-end products for the distinctive highlights and crunchy bite it provides. The applicator must handle the breader gently to maintain particle size, and must uniformly coat top, bottom and sides.
TEMPURA BATTER
Tempura batter application needs special gentle handling. Otherwise, the gas contained in the batter is easily released by some of the normal mechanical application processes, resulting in a flat batter and a hard-bite surface. Exact control over viscosity and temperature promote the expansion lift of batter gases. The mixing system must generate as little heat as possible to prevent gas release. Tempura batters generally need to be fried at temperatures above 195 ËšC to ensure a quick sealing of the product surface. Lower temperatures can make the coating rubbery and raise the oil absorption rate. The fry temperature also affects the speed at which the trapped gas expands, which will affect coating texture.
BREADERS
Breaders fall into two general categories: free-flowing and nonfree-flowing. Japanese crumb is the most well-known free-flowing crumb. Most other breaders are non-free-flowing since they contain very small particles or flour that will cake once slightly hydrated. The many types of available breaders dictate the need for several types of breading applicators.
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WWW.HEATANDCONTROL.COM
AT THE HEART OF EVERY BITE
We are on
POTATO CHIP PROCESSING SYSTEMS Every machine features innovative technology developed through 65 years of experience in delivering snack food systems around the world. From raw potato preparation to frying and seasoning, Heat and Control provides all the equipment and services required to make the highest quality natural potato chips, hard-bite chips, sticks, formed chips and other potato snacks.
www heatandcontrol.com Email info@heatandcontrol.com
MARKET NEWS
GLOBAL SNACK FOOD SALES INCREASE TO
$374bn www.nielsen.com
A Nielsen report has revealed that consumers across the globe spent a total of $374bn on snack foods annually between 2013 and 2014. More than 30,000 consumers from 60 countries were polled online. The industry has seen an overall year-on-year increase of 2%. Europe and North America are the biggest snackers, $167bn and $124bn respectively. Growth in demand for snacks is also apparent in regions such as Asia-Pacific ($46bn) and Latin America ($30bn). Sales in Middle East / Africa ($7bn) grew by 5%. Confections (which include sugary sweets, such as chocolate, hard candy and gum) comprise the biggest sales contribution to the overall snack category in Europe ($46.5 billion) and the Middle East/Africa ($1.9B). Salty snacks contribute more than one-fifth of snack sales in North America ($27.7B), refrigerated snacks comprise almost one-third of snacks in Asia-Pacific ($13.7 billion), and cookies and snack cakes make up more than onefourth of total snacks in Latin America ($8.6B).
Favourites + Variety
Fast growth categories
Over a span of 30 days, however, global respondents say they ate a wide variety of snacks, including chocolate (64%), fresh fruit (62%), vegetables (52%), cookies/biscuits (51%), bread/sandwich (50%) and yoghurt (50%). More than four in 10 respondents consumed cheese (46%), potato chips/tortilla chips/crisps (44%) and nuts/seeds (41%). Onethird chewed gum (33%) and devoured ice cream/ gelato (33%), while about one-fourth munched on popcorn (29%), crackers/crisp breads (28%) and cereal (27%). Softer offerings like dumplings (26%) and instant noodles (26%) were also popular with a quarter of global respondents.
According to Nielsen retail sales information, sales of savoury snacks, which include crackers, rice cakes and pita chips, increased 21% in the last year in Latin America. Meat snacks, which include jerky and dried meat, grew 25% in the Middle East/Africa and 15% in North America. Refrigerated snacks, which include yoghurt, cheese snacks and pudding, rose 6.4% in Asia-Pacific, while dips and spreads, which include salsa and hummus, increased 6.8% in Europe.
Taste preferences for snack options are noticeably different around the world. Exceeding the global averages, large percentages of respondents snack on vegetables in Asia-Pacific (57%), cheese in Europe (58%),ice cream/gelato in Latin America (63%) and potato chips/tortilla chips in North America (63%).
“Non-sugary snacks closely aligned with mealreplacement foods are showing strong growth, which signals a shift in a consumer mindset to one focused on health,” said Susan Dunn, executive vice president, Global Professional Services, Nielsen. “While conventional cookies, cakes and confections categories still hold the majority of snack sales, more innovation in the healthy snacking and portable food space is necessary to adjust to this changing dynamic.”
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heatandcontrol.com
MEET THE GLOBAL TEAM
> INDIA
Heat and Control (South Asia) Pvt. Limited operates from Chennai and services India, Pakistan, Sri Lanka, Bangladesh and Nepal. Offering sales, design and engineering as well as installation, commissioning and after-sales service, the Chennai office is dedicated to the food industry in the region. In 2011 Heat and Control acquired Flavorite Technologies to expand the snack processing systems catalogue. Also focusing on the Indian snack market, Heat and Control is an agent for Ishida weighing packaging and inspection systems. For a wide range of consumer products, Sanko sachet packaging systems are available from the Heat and Control team in India.
SNACK PROCESSING + PACKAGING FLAVORITE TECHNOLOGIES PVT LTD Manufacturing in Indore since 1997, Flavorite Technologies has provided the south east Asian food industry with affordable, quality engineering and technology that optimises initial capital investments. Applications experience with challenging snack products has resulted in systems that maintain the traditional flavour of handmade snacks utilising modern methods.
• Raw product preparation • Thermal processing + cooking • Flavour application + seasoning • Product handling + packaging • Design, engineering + manufacture
www.flavoritetechnologies.com
WEIGHING, PACKAGING + INSPECTION ISHIDA INDIA PVT LTD Ishida India, was established in April 2007 in response to the surging customer demands in India. Located in Gurgaon, Harayana, the company provides weighing and packaging solutions to food, pharmaceutical and other industries.
www.ishidaindia.com
• Multihead weighers • Snack bagmakers • Checkweighers + seal checkers • X-ray + metal detection • Tray sealers • Scales + balances
AUTOMATIC SACHET PACKAGING SANKO MACHINERY CO LTD Sanko is a specialist in manufacturing automatic • Coffee, tea and flavoured beverages packaging machines to package various materials • Snacks + confectionery including powder, granules, liquid and paste into small • Sugar + flavour additives bags. • Sauces + dressings • Cosmetics + detergents www.sanko-kikai.co.jp
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The team @ International Foodtech India (Mumbai) 2014, joined by Mr. Chandu Bhai, Managing Director of Balaji Wafers
• Euromonitor predicts Indian snack market to reach US$4 billion by 2018 • Neilsen reports packaged salty snacks topped the FMCG category sales in 2013 Rs 12, 679 cr
02
Traditional Snacks
Potato Chip + Wafers
Rs 5,200 cr
03
Rs 3,900 cr e.g. Kurkure
“
• Total Indian salty snacks market value Rs 13,000cr (Business Today)
01
04
Bridge Puffed Category Snacks Rs 1,950 cr Rs 1,950 cr
TURNING HANDMADE INTO MADE IN INDIA 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® snack frying system can process a wide variety of Namkeen snacks with outstanding results. The modern continiuous processing technology introduced to the market has opened up new opportunities for Indian snack food companies nationally and internationally. Most importantly, the systems maintain the flavour and integrity of traditional recipies. NAMKEEN> BESAN BHUJIA, BOONDI, MUNG (MOONG) DAL, GREEN PEAS, FRIED CHICKPEAS, BATTER COATED PEANUTS
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SNACK PROCESSING & PACKAGING SYSTEMS Raw product preparation Thermal processing & cooking Flavour application & seasoning Product handling & packaging Design, engineering & manufacture
Now Available In Africa Manufacturing in India since 1997, Flavorite Technologies has provided the south east Asian food industry with affordable, quality engineering and technology that optimises initial capital investments. Applications experience with challenging snack products has resulted in systems that maintain the traditional flavour of handmade snacks utilising modern methods. www.flavoritetechnologies.com
By Heat and Control
Cape Town +27 21 948 5934 | Indore (India) +91 731 2875 012/013 info@heatandcontrol.com
[L-R] Manoj Paul – Country Manager of Heat and Control South Asia (India), Raman Dhoot – Director of Operations Flavorite Technologies Pvt Ltd India, Jeff Rossouw – General Manager Heat and Control Africa
FLAVORITE SNACK PROCESSING AND PACKAGING SYSTEMS NOW AVAILABLE IN AFRICA
Heat and Control (Cape Town, RSA) has announced expansion of its product range in the Africa and Sub-Saharan market to include one of India’s long serving manufacturers of snack processing and packing systems, Flavorite Technologies Pvt., Ltd. The exclusive representation includes comarketing of products and services including sales, import, installation and commissioning. Jeff Rossouw, General Manager of Heat and Control Africa explains, “We are extremely excited about partnering with Flavorite and our ability to now offer an entry level and cost efficient technology to the African market. Through this strategic alliance we can help our customers’ business grow and provide equipment at every stage.” Manoj Paul, Country Manager of Heat and Control India says, “We at Heat and Control and Flavorite Technologies Private Limited, feel there is immense potential for the Flavorite range of snack food processing machines in the African market. The Flavorite range offers excellent quality equipment, with very competitive prices. The equipment is manufactured at the company owned facility with state-of-the-art equipment. Processors in Africa will be able to produce consistent quality snack products like potato chips, extruded snacks and pellets on Flavorite equipment and grow their market.”
Flavorite Technologies Pvt Ltd was established in 1997, and acquired by Heat and Control in 2011. Since this time Flavorite has served the Indian market. To accommodate growth within India and to serve international markets, a new larger, manufacturing facility is under construction. This state-of-the-art facility coupled with experience and expertise in quality food processing plant, machinery and process engineering, means Flavorite is poised to serve and meet the challenges and needs of the process food industry. FLAVORITE EYES MENA IN 2015 As well as the African market, Flavorite is looking to enter the Middle East and Northern African food industry in 2015. Working with the Heat and Control MENA team, the complete line of Flavorite snack systems will be available.
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HOW TO
VALUE ADDED NUT SNACKS
As consumer demand for healthy snacks continues to grow, the variety of value added nut snack options will grow due to creation of unique flavours/recipes, coatings and blends. Just as the Namkeen (traditional savoury snack) industry in South Asia has a multitude of methods and recipes to achieve unique flavours for each brand, nuts also provide an opportunity to offer a unique product that evolves with the changing needs and tastes of snack consumers. Methods to create a value added nut snack product include: • Roasting • Seasoning + Coating • Blending
Oil Roasting (Frying) Oil roasting is a process by which nuts are submerged or covered in hot oil and fried. Roasting accomplishes many tasks including flavour enhancement, shelf stability (1 to 1.5% finished moisture) and also destroys microbes such as Salmonella. In almonds for example, 2 minutes at 260°F (127° C) is required to destroy microbes. Basic frying principles can apply to most nut varieties: peanuts, almonds, cashews, pecans, walnuts, brazil nuts and sunflower seeds. Certain nut types, such as Macadamias, need to be handled with care. They are high cost and are more fragile. They also have a delicate flavour and it is necessary to fry them in very high quality oil. Frying time and temperature is critical as the period between adequately cooked and burnt, is quite short. This varies depending on the nut variety, hence can only be established by testing and experience. Product feed to roaster is critical in order to achieve a consistent production rate and uniform product depth. It is also important to remove any debris before nuts enter the roaster. Oil type or blend is also important for flavour development and is often a brand’s secret recipe. Typical oils include canola, safflower, sunflower, peanut and various hydrogenated blends. If oil solidifies at room temperature, all piping and tanks (especially “low lying”) must be heat traced (steam or electrical). Various processes can take place prior to oil roasting that impart a specific mouth-feel, taste and flavour experience. Examples include brine soaking, coating and drying. If nuts are dry roasted prior to coating, the frying will be required to cook the coating only.
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Dry Roasting A dry roast involves processing by means of hot air and there seems to be a tendency to use this method to reduce oil content. Entry level processors use forced air or semi industrial type convection ovens with nuts in a single layer and stirred regularly to avoid surface burning. Temperatures vary between 110 - 180 degrees C for 15 – 20 minutes, whereas larger volumes are done in custom designed drying ovens.
Seasoning + Coating This is where the uniqueness of a nut snack comes into play and has the potential to position a product as a premium snack. Seasoning nuts with salt, water or a mix of spices can be done on its own or additional to a batter coating. Exotic flavour recipes are used as a means of achieving premium price point or appealing to specific taste profiles in markets around the globe. The application of glazing oil, water, salt, spice based seasonings, sugar, dough, chocolate, yoghurt and batters gives personality to the product. Flavour and especially colour can be added to the base formulation with frying or drying temperatures enhancing the flavour profile. Colour is also added to the base flavour mix to help with sight appeal. Coating and seasoning application can be done either in the kitchen, in the packaging room or on a belt along the line. In-kitchen seasoning can occur directly after the dry roaster OR after the cooling process and before transferring into the packaging room. On-machine seasoning (OMS) occurs in the packaging room, directly before the product goes into the weigher and bag maker.
Dry Seasoning Dry season application of nuts can be complex as oil tack (stick) is required for adhesion of the dry seasoning. In many cases this requires a water or oil application before the dry application. A lot depends on the roaster type (oil or dry). For example if the nut is dry roasted then a two stage, oil plus dry or salt application, is required to achieve adhesion. For a coating such as Tamari or brine, a water application plus dry is applied after a dry roaster, with the cooler system turned off. If an oil roaster is used then dry seasoning or salting will occur after the fryer. Consultation with Heat and Control seasoning systems experts is recommended to achieve the best adhesion and coverage of dry seasoning application.
Batter Coating An example of batter coating is seen in the Indian snack category, Namkeen. Often peanuts are coated with a batter made from Besan Flour (chick pea flour) and spices before going into the fryer. For this market the key is to maintain the traditional taste and texture of a handmade product in a continuous system. A specially designed vibratory feeder singulates the product and feeds it into a curtain of batter. This ensures that the product is presented to the batter curtain in a single file hence reducing the risk of getting doubles or married product. The batter curtain has a counter flow which ensures that the product is fully encapsulated before being placed into the fryer for cooking. These features ensure a premium coated product is produced with minimal wastage.
Honey Coating Honey coatings popular in Europe and the Middle East apply a viscous honey solution that is sprayed into the infeed end of the tumble drum. This is followed by sugar/salt to dry the slurry at the discharge end of the drum.
Brine and Starch Coating A popular coating in the Middle East, this is normally a water based coating and is done directly after the dry roaster and before the cooler. The heat of the nut evaporates the water in the coating leaving a nicely coated nut. Dry seasoning can be added when using a starch and water combination.
Dough Coating Coatings used in Asia are typically quite thick and utilise cracker and dough based ingredients to achieve a thick enrobing type coating on the nut. In some cases, raw skin on peanuts is used. The flavour the skin imparts provides a unique taste and also helps the coating better adhere to the nut as opposed to a “naked” nut.
Blending Blending nuts, fruits, candy, and other products provides another opportunity to create innovative products such as trail mix. Accurate blending systems are able to mix multiple products into proportionally even blends, that don’t stratify or separate before they reach the packaging station. The key is to maintain the blend so that the consumer will get the variety and proportions they expect.
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WWW.HEATANDCONTROL.COM
DEMAND FOR HEALTHY SNACKS GROWS
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NUT SNACK PROCESSING SYSTEMS For seasoned, coated, honey-roasted and blended nut products, Heat and Control builds a complete range of equipment for nut preparation and handling, frying, cooling, glazing, application of seasonings and coatings and blending systems to make value-added nut snack products.
www heatandcontrol.com Email info@heatandcontrol.com
A-Z of Nut Snack Processing As consumer demand for healthy snacks continues to grow, Heat and Control has partnered with nut processors to meet their equipment needs for superior product quality and safety, lower production costs, and high operating efficiency regardless of capacity. Every Heat and Control nut processing system features innovative technology developed through years of experience and expertise in delivering food equipment lines around the world. Heavy duty construction provides decades of reliable operation and low lifecycle costs to produce nut products of the highest quality.
Heating
For seasoned, coated, honey-roasted, and blended nut products, Heat and Control builds a complete range of equipment for nut preparation and handling, frying, cooling, glazing, application of seasonings and coatings, conveying, weighing, packaging and inspection.
Filtration
NUT DELIVERY Raw nut handling and delivery systems to suit any capacity and installation. OIL ROASTING Batch and continuous fryers are individually engineered to meet desired product and process specifications. Direct and indirect-heated continuous fryers are available using natural gas, steam, or thermal fluid oil heating. Specialised conveyor systems, multiple temperature zones, and a variety of continuous oil filters can be included according to requirements. Optimal product handling, uniform oil heating and flow control, efficient fines removal, and simple sanitation are all part of the fryer package that produces the highest quality nut products with a long shelf life. • • • • • •
Batch frying system Externally continuous heated fryer system Mastermatic direct gas-fired fryer MasterTherm® thermal fluid fryer HeatWave® oil curtain fryer Honey-roast fryer system
PRODUCT + PROCESS CONTROL
Fryers are available with a variety of heat exchanger systems using natural gas, thermal fluid or steam. All deliver gentle, yet rapid oil heating and extremely responsive temperature adjustment to changes in product load to maintain consistent product quality. Total system oil volume is filtered each minute in all externally heated continuous fryer systems. Rapid removal of product particles is essential to preserving oil quality. It also eliminates unsightly carbon specks on product and reduces fryer cleaning time. Filters for large particles, nut flour, and micon-size fines are integrated into each system depending on fryer requirements. Cooling Quickly reduce product temperature to control cooking and prepare nuts for seasoning and packaging. Systems using ambient or conditioned air are available with product transfer conveyors for all production capacities. THE FINISHING TOUCH As required, surface oil can be removed or added as nuts leave the oil roaster. GLAZING, SEASONING + COATING Choose from a variety of coating systems to continuously apply glazing oil, salt, seasonings, sugar, dough, chocolate, yoghurt and many other coatings. Apply the ideal finishing touch with seasoning, enrobing, and coating applicators from Spray Dynamics, in-kitchen salt and flavouring applicators, or a FastBack Revolution® On-Machine Seasoning System in the packaging room.
Every component is designed to maximise process control and product quality. Careful attention to control of oil heating, filtration, roasting and cooling produces the freshest and safest nut products possible.
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POEX > Jaroslav Caha & Dana Harvey
ISHIDA SOLUTION COMBINES ACCURACY AND END OF LINE QUALITY An Ishida packing solution – comprising a multihead weigher, checkweigher and X-ray inspection system - at leading Czech confectionery manufacturer POEX has enabled the company to increase its packing capacity while at the same time delivering excellent accuracy and effective end-of-line inspection for enhanced product quality. POEX Velké Meziříčí, a.s. is based near Brno. The company packs coated and uncoated fruit and nut products, extruded and co-extruded cereals and snacks, extruded crisp breads and promotional items for its own range (branded EXCLUSIVE) and for many leading European retailers. The company had decided to increase its capacity for chocolate-coated and other nuts, as well as dried fruit, with a complete new line. Having already had experience with Ishida weighers, it knew that the latest Ishida R-Series models would deliver best-in-class speed and accuracy. However, the inclusion of an Ishida X-ray inspection system and checkweigher has ensured the highest standards of quality assurance, without multiplying the number of machinery manufacturers involved.
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POEX had in the past used both linear weighers and volumetric fillers and, most recently, locally manufactured multihead weighers. “We pack at target weights ranging from 30g to 500g, with the average being in the region of 100g,” says Jaroslav Caha, head of Poex’s packaging division. “This is mostly into pillow bags, but also into standup bags. The previous line produced 40 packs per minute compared with the 75 packs per minute we are now achieving with the new Ishida. That’s a near-90% improvement.” “In the past, the problem was that the faster we ran the machines, the less accurate they became. Also it was quite difficult to get the level of feeder vibration right in order to keep the product flowing.” With the new Ishida R-Series multihead weigher, the accuracy, even at the higher speeds, has been such that giveaway is down to near zero. For a 100g target weight, the mean weight is about 100.1g and standard deviation is only about 0.2g.
heatandcontrol.com
NUT SOLUTIONS
As well as improvements in production efficiency, POEX also wanted the new line to pay equal attention to product quality and safety. The Ishida IX-EA-2161 X-Ray Inspection System is able to detect even tiny particles of materials that could conceivably contaminate confectionery, including metal, glass, stone, rubber and plastic. Equally important, the high belt speeds (up to 60 metres/minute) help maintain the excellent throughput achieved by the upstream equipment. Stationed immediately after the X-Ray system, and sharing a double reject bin, is an Ishida DACS-W checkweigher, the fastest and most accurate in its class. It brings an important level of Ishida reliability to ensuring compliance with weight regulations, while again providing the speed needed to keep up with POEX’s increased capacity. POEX has achieved its aim of increasing capacity, with a typical output performance of five tons of confectionery per shift. But, as Jaroslav Caha puts it “What has been most beneficial for our business has been the accuracy across a range of products, with practically zero giveaway, and the improvement in final inspection.”
“
With the new Ishida R-Series multihead weigher, the accuracy, even at the higher speeds, has been such that giveaway is down to near zero. JAROSLAV CAHA HEAD OF POEX’S PACKAGING DIVISION
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FASTBACK LATEST
WeighBack™
Advantages
Continuous Weigh Conveyor • Cleaner operation than weigh belts
WeighBack integrates gentle FastBack horizontal motion conveying with direct load cell weight measurement to deliver precise mass flow data to processing, seasoning application, or packaging equipment. The patented non-slip pan improves travel rates and weighing accuracy. ®
• Sanitation-friendly construction for dry and washdown applications • Stainless steel pan with removable weight measurement tray • Eliminates errors due to variations in product density and flow rate • Load cells deliver high accuracy • Precise weighing at up to 12m per minute • Touch screen control with Ethernet and 4/20 mA output • No tools required to access load cells • Use standard scale weights for calibration • No preventive maintenance, belts or pneumatics
Easy-to-read touch screen control features: Automatic countdown timer for periodic tare notification
• 5 year drive train warranty • Replaces most standard weigh belts
EtherNet/IP or 4/20mA weight and mass flow outputs Ready status signals for upstream equipment Large easy-to-read touch control screen Manual and auto-tare functions display instantaneous and cumulative operating data
WeighBack surpasses weigh belts for accurate, sanitation friendly, low maintenance, weigh conveying 40
heatandcontrol.com
FastBack horizontal motion conveyors were developed to eliminate the problems caused by harsh product handling during vibratory conveying: product fractures and breakage, seasoning loss and build-up in the conveyor pan, unscheduled downtime for cleaning, and high noise levels. Over the past 20 years, FastBack has become the leading global brand of sanitary conveyors. Thousands of installations have proven FastBack to be the most efficient conveyor for frozen fruit and vegetables, meats, snacks, cereal, and many other food products.
“
With the new system, product breakage has been reduced 40% to 50%. Seasoning loss has been reduced 70%. When our 117 conveyors are running full with product, the decibel rating is so low.
NICK COBURN PLANT MANAGER | WYANDOT
The FastBack Advantage Gentle motion does not damage products Maintains seasonings and coatings Keeps pans clean
Quiet, low 70 dB sound levels
Does not segregate product blends
Used in a wide variety of applications: • • • • •
Product blending Weighing Distribution Statistical weigher feeding Accumulation
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Q+A Dave Homeyer
General Manager of Spray Dynamics, shares some of his extensive knowledge about flavour application of snack products. Q: What is the right system for different snack products? Dry only systems are used on products that have natural adhesion (tack) and include potato chips and pellet snacks. Oil and dry systems are used on snacks that do not have natural tack and includes corn and tortilla chips, mini rice cakes or other dry puffed products, popcorn, baked chips and extruded snacks. Slurries and slurries with dry ingredients added to create a flavour “pop�, is suitable for extruded snacks, popcorn and puffed snacks. Q: What is the right layout for my needs? In-kitchen seasoning systems are ideal for large capacity volumes that have minimal flavour changes and can include two-stage or slurry systems. On-machine seasoning (OMS) systems are ideal for one stage coating and offers opportunity for many flavour changes in a production run/shift. Two-stage coating is also possible with OMS and features an oil spray before the dry application. Belt coating systems are used primarily for salt only application. Q: What does two-stage seasoning involve? This is an in-kitchen application that includes both oil and dry coating on products that have no tack; oil acts as an adhesive for the dry flavouring. The oil is sprayed on the product directly followed by the dry seasoning. The temperature of the product is very important to how much oil stays on the surface and the dry product coverage is totally dependent on the oil coverage. This is suitable for large volume lines and is the best choice for high absorption products such as croutons. This method does require long flavour changeovers and must be stopped for cleaning.
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Q: What is the difference between in-kitchen & OMS With in-kitchen seasoning there is opportunity for large volume output, however there are fewer flavour changeovers. For example each run (production plus flavour changeover) takes one day and therefore will produce 5 seasoning changes per week. OMS offers variety of flavour as opposed to large volume and can be applied in one production run. For example five seasonings can run simultaneously every day. This means at the end of the first day the truck is loaded with the five varieties of flavour and shipped to fulfill orders. This provides a saving of approximately 4 days of shelf life, reduced on-site warehouse space and supports just-in-time delivery scheduling. Q: Tips on ensuring good coverage? The coating drum is the heart of the system and it creates the rolling bed to coat the snack. If using oil, adjust oil application for more complete coverage by spraying onto the rolling bed, never on the coating drum. It takes about 4 to 7 turns in the coating zone to achieve good oil coverage. If applying dry flavour, make sure seasoning is falling onto the rolling product bed and make sure you are getting 4 to 7 turns in the coating zone.
Counting the cost of changing tastes?
Flavour application you can count on Manufacturing since 1952 and snack specialisation since 1970. Leaders in controlled application of liquid and dry ingredients on a wide range of food products. Powdered seasonings, oil and water-based coatings, slurries, chocolate, yoghurt, release agents and many other coatings. By Heat and Control
www.heatandcontrol.com/spraydynamics
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WE KNOW WHAT TO DO WITH CORN
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CORN PRODUCTS PROCESSING SYSTEMS From masa production to forming, toasting, conditioning, frying and seasoning. Heat and Control provides all the equipment and services required to make the highest quality corn and tortilla chips, taco shells, tostadas and tortillas.
www heatandcontrol.com Email info@heatandcontrol.com
heatandcontrol.com
CORN SNACK PROCESSING + PACKAGING
Corn A - Z. From masa production to forming, toasting, conditioning, frying, seasoning and packaging, Heat and Control provides all the equipment and services required to make the highest quality corn and tortilla chips, taco shells, tostadas and tortillas.
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速DiversaCut Sprint is a registered trademark of Urschel Laboratories, Inc.
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The compact DiversaCut Sprint速 Dicer accepts a wide variety of fruits and vegetables and produces small to large sizes of dices. You can count on Urschel design and engineering to deliver the benefits you demand: Usability. Durability. Precision output with minimal waste. Continuous operation. Efficiency. Exacting controls. Ease of maintenance. Expert worldwide service and support. Explore the family of Urschel dicers at www.URSCHEL.com.
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Sprint 2™ Dicer
Flat-VÂŽ Cut
Urschel has released the Sprint 2™ Dicer. The Sprint 2 builds on the technology of the DiversaCut SprintŽ Dicer combined with the footprint of the longstanding dicer Models G-A, GK-A, and H-A. This new dicer features a three horsepower stainless steel motor with optional VFD (variable frequency drive) and accepts products up to 165 mm in any dimension. Using the existing footprint of these industry-proven dicers, allows processors to easily replace older tried and true machinery with the latest technology.
Urschel introduces the new Flat-V Cut available for use on the Models CC, CC-D, CC-DL, and CCX-D. The cut was developed originally for potato chip processors, but also has potential in both the cheese and vegetable industries.
FULL & REDUCED Flat-V SHREDS Full Flat-V Shred: Hexagonal shaped cross section measuring approximately. 3.8 mm on all sides. Reduced Flat-V Shred: Flattened top and bottom that form corrugated shred.
Flat-V SLICE Slice thickness 1 up to 4.6 mm (measured across flats) with 2.1 corrugations per inch. The depth of each corrugation is 3.2 mm. Centers: 12 mm.
1 SHRED
SLICE
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HOW TO
HOW TO CUT MEAT
WWW.URSCHEL.COM
AFFINITY® Dicer Is the largest dicer Urschel manufactures and specialises in the cutting of difficult-to-cut meat products such as soft meats, cold temperature applications or meats with high fat content. The machine accepts a large infeed product size of up to 254 mm in largest single product dimension. All transitional components work with the cutting elements to maintain positive advancement of the product throughout the cutting process - this is critical in difficult-to-cut applications. The rotating feed drum and feed roll are especially key in maintaining consistent, positive feeding into the dicing elements. Delivers precise dices on meat products such as beef/chicken logs, pepperoni, ham and salami.
Diversacut 2110A™ Dicer The largest machine in the DiversaCut line, the DiversaCut 2110A™ Dicer produces dices, strips, slices and shreds at high production capacities. With a maximum infeed of 254 mm in any dimension, the machine offers cost-savings by eliminating the need to pre-cut product. This dicer promotes more precise cut tolerances with slice adjustment and lockdown features. The machine also features fine-tuning through adjustable collars on both cutting spindles for ultimate precision.
Model M6 This patented cutter is a versatile, two-dimensional cutting machine designed for dicing, strip cutting or shredding a variety of products through a wide range of sizes. Ideally suited for cutting frozentempered, fresh-chilled or hot cooked beef, poultry or pork.
Model J9-A Uniformly dices or strip cuts cooked or frozen tempered meats at high production capacities with a minimum of fines. Dices of 4.8 to 38.1 mm are cut from firm products up to 9.5 mm in thickness including beef, veal, poultry, pork, or fish. Diversacut 2110A™
Model RA-A Dices or strip cuts chunks of processed meats. Maximum infeed size is 88.9 mm in any dimension. Ideal machine for meat processors that also cuts various vegetables to produce small to intermediate dices and strip cuts. Urschel also offers the Model RA-HD, a heavy duty dicer.
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E Translicer® Cutter This patented cutter uniformly slices a wide variety of products including cooked and processed meats and various food products. The cutter is ideally suited for elongated products. Maximum product infeed of firm products is 101.6 mm in diameter. Also, an optional hold-down top belt is available for additional positive feeding assistance. Different styles of cutting wheels are available, including the slicing wheel and the patented MicroSlice® Wheel. Of the two wheels, the slicing wheel is currently the most widely used in the meat industry. For processors seeking thinner slices, the patented MicroSlice Wheel is also an option. Meat processors who also process other types of products may find the other cutting wheels a valuable option.
E Translicer® Operating Principle
Comitrol® Processors • • • • • The word “Comitrol” means controlled comminution. The Comitrol Processor line uses the principle of incremental shear to ensure highly efficient comminution by rotating the product inside a stationary reduction head at high rotational speeds. In addition, continuous single pass operation achieves consistently uniform output product size reduction at high capacities.
CUT TYPES
SLICE
AFFINITY Dicer
3.2 to 19.1mm
DIVERSACUT 2110A Dicer
• • •
MODEL M6
Shred beef for barbecued meat products Flake cut poultry in cooked ham products Produce a meat slurry for use in nutritional supplements Comminute beef, fat and pork rind for sausage production Reduction of gristle and connective tissue into minute sizes for fabricated meat products Reduce meat into a smooth, uniform consistency for use in gravies and sauces Emulsify pork for sausage and sandwich meats Comminute beef, fish and poultry for use in pet foods
E TRANSLICER Cutter
MODEL J9-A
Slicing Wheel: Straight or crinkle 0.8 to 50.8mm
3 to 25mm
MODEL RA-A
1.6 to 9.5mm
MicroSlice Wheel: Flat 0.8 to 6mm DICE
A slicing knife, circular knife spindle & crosscut knife spindle are use for dicing
Circular Knife Spindle: 3.2 to 50.8 mm Crosscut Knife Spindle: 3.2 to 50.8 mm
Flat strips can be made by removing either the crosscut knife spindle or circular knife spindle STRIP
SHRED
Circular knife: 3.2 to 76.2 mm Crosscut knife: 2.4 to 63.5 mm Crosscut knife crinkle: 7.1 to 15.9 mm Min. flat strips such as 3.2 x 3.2 mm x length of product Crinkle strips such as 7.1 x 7.1 mm x length of product
Combinations of circular knives or crosscut knives can shorten length
Max. flat strips such as 25.4 x 25.4 mm x length of product
3.2 to 50.8 mm in length
Crinkle strips such as 15.9 x 15.9 mm x length of product
Fine, medium, and coarse shreds can be produced on hot or chilled cooked meat products
Circular knives: 4.8 to 38.1 mm
Circular knives: 4.8 to 76.2 mm
Circular knives: 3.2 to 25.4 mm
Crosscut knives: 3.2 to 144 mm
Crosscut knives: 4.8 to 76.2 mm
Crosscut knives: 1.3 to 76.2 mm
Strip cuts can be made by removing the crosscut knife spindle from the machine The length & thickness will depend upon the size of the original product
Feed discs work together with special shredding discs or blunt knives to produce a wide variety of shred consistencies from coarse to fine. Various shred lengths are possible depending upon set-up
Length can be controlled by using various crosscut knife selections Cuts can also be made by removing the crosscut knife spindle from the machine. Length & thickness will depend upon size of the original product
Strip cuts can be made by removing the crosscut knife spindle. Length & thickness will depend upon the size of the original product
Urschel Laboratories® size reductin systems are available from Heat and Control in Australia, New Zealand, Sub-Saharan Africa. Contact your local H&C team for more information.
Comminution is the process of reducing a product to a smaller size. Conventional methods of comminution employ some type of grinding, smashing, or tearing action which can produce excessive heat and degrade the quality of the finished product. This can also generate a higher percentage of final product which falls outside the desired targeted size and negatively impacts on yield.
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TOMRA SORTING SOLUTIONS JOINS THE HEAT AND CONTROL PRODUCT LINE-UP FOR AFRICA + OCEANIA TOMRA sensor based sorting systems developed specifically for the processed food industry are now available exclusively from Heat and Control in Australia and New Zealand. This agreement builds on the partnership created for the Africa market in 2012 and further strengthens the relationship between two innovators in the food processing industry.
Nimbus 1200 BSI
With a wide range of technologies designed specifically for food, TOMRA systems can resolve many sorting challenges by optimising the end product and removing defects and foreign material from good products. TOMRA’s sorting solutions boost throughput and availability while increasing yield, quality and food safety. WWW.TOMRA.COM/FOOD
Halo 3-Way Sorter
TOMRA Sorting Food, designs and supplies innovative worldclass sorting, peeling and process analytics solutions for a wide range of applications. Through continued investment in research, development and people, TOMRA Sorting has acquired prominent positions in several sectors of the food processing industry such as fruits, vegetables, potatoes, lettuce, dried fruit, nuts, meat and seafood. With over 30 years of experience, ODENBERG and BEST provides customers an integrated approach to maximise yield and efficiency. The unrivalled strength of these well known brands provides TOMRA Sorting with the ability to meet customer needs by developing stateof-the-art technologies that optimise the customers’ production flow and supports consistent high-quality output. TOMRA Sorting Food has more than 7000 machines installed worldwide and has a comprehensive support network ensuring prompt customer service. In addition, customers can trial their own products at one of eight test and demonstration centres worldwide to ensure our solutions meet their requirements. Whether you’re a multinational organisation or a small farm, TOMRA Sorting has a solution that will meet sorting needs.
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GENIUS™ SENSOR TECHNOLOGY The Genius is a modular food sorting machine that can be tailored to the customer’s unique requirements and needs. Removes all unwanted discolourations and foreign material from many food applications such as carrots, corn, peppers, spinach, French fries, potato chips, almonds, cranberries and many more. With high resolution cameras and lasers, the Genius sorter offers a variety of inspection technologies in different inspection zones.
The QVision 500 fat analyser allows meat processors to secure the maximum benefits available from in-line fat analysis and real time process control. It can measure fat and lean, protein, collagen, moisture in fresh or frozen meat, at any grind size, across the full width of its conveyor belt, with analysis penetrating far into the meat. It can also provide a live batch weight measurement and operate at an unrivalled capacity of up to 30 tons per hour. In addition to capacity increase and the reduction of lean giveaway, the QVision helps customers to get better yield from their raw materials, while ensuring consistent product quality. This eliminates the risk of ‘out of spec’ fat claims.
“With its accuracy, price point, ease of integration and ability to simplify production control, the QVision system has the potential to make in-line fat analysis mainstream.” Brought to you by Heat and Control AUST, NZ, AFRICA Exclusive supplier Testing available
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Five Star Gourmet Foods maintains top food safety with CEIA metal detectors One of the USA’s premier frozen food manufacturing companies, Five Star Gourmet Foods, produces and co-packs so many different food products it could fill a restaurant menu. Frozen entrees, pizza products, custom sauces and marinades, handheld snack foods, savoury stuffed pockets and frozen sandwiches are just a few of its products produced and private labelled for many retailers across the USA. This variety seemed to make reliable metal detection impossible. “We tested several top brands of metal detectors and all failed to deliver the consistent level of security we demand,” complained Q.A. Manager Marissa Myat. “We inspected fresh and frozen products. The temperature differences and the multitude of product conditions overwhelmed every metal detector we tested.” Finally, Five Star Gourmet tried the CEIA THS 21 detector. “Our line operators decided to give it the torture test,” recalls Myat. “We mixed different types of fresh and frozen product in the same run to quickly expose any shortcomings. To our surprise, the CEIA detector passed every test. Its performance really exceeded our expectations.”
Five Star Gourmet runs all its products through CEIA detectors. “Speeds range from 150 to 450 items per minute per line and each metal detector runs a minimum of 14-hours-a-day, 5-days-a-week,” explains Tal Shoshan, C.E.O. “With a very high volume of products, downtime is not an option and food safety is non-negotiable.” The state of the art USDA-inspected facility in California manufactures and co-packs food products that are distributed to restaurant chains, clubs, retail chains, airlines, schools and foodservice distributors. Starting in 1999, Five Star Gourmet Foods employs 146 full and part-time employees and also offers product development and custom formulation. “We care about our clients and we care about the products we produce,” explains Shoshan. “Our business has been built on quality and food safety and that’s why the CEIA detectors are an integral part of our company. Heat and Control’s installation, startup, operator training and post-sale support have also been very good.”
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“With the CEIA metal detectors, our security and comfort levels are extremely high. Their data reporting features are very important to us and the detectors are simple to operate and have been completely trouble-free, CEIA has been a fantastic system for our company and our customers.”
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Metal detector
BUYERS GUIDE INSPECTION SYSTEMS
PRODUCT EFFECT
AUTO CALIBRATION & AUTO LEARN ADVANTAGES
Product effect is an important factor in the selection of a metal detector. If the product is conductive (usually because it contains water or salt) it will generate a signal which affects the electromagnetic field of the metal detector. This will produce a false reject. Dry or neutral products generally do not emit such a signal. If product effect is a factor, then the correct frequency must be selected in order to help move the signal of the product effect away from the signal of the contaminants.
The metal detector that will become a successful part of a plant quality control program is one that not only provides good sensitivity performance, but is easy to set up, easy to use, and provides a low level of false rejects. Most metal detectors on the market today perform self-checks to verify that the unit is in balance and performing properly.
A metal detector that has a single frequency may not accommodate much product variation and so may not be suitable where inspection of a variety of products is required. This could include, for example, the difference between the product effect of a frozen product and that of the same product when at a higher temperature. On the other hand, a three frequency metal detector will allow the inspection of a greater range of products on the same metal detector. The most sophisticated metal detectors on the market today use multi-spectrum technology. Instead of relying on just one frequency, a range of multiple frequencies simultaneously filters out product effect in a way that is much more powerful than a single frequency. In addition, the number of false alarms is greatly reduced.
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The auto learn routine allows the user to acquire the characteristics of the product in the unit so that the product can be inspected. An efficient auto learn gives the best sensitivity and the least number of false rejects with a minimum of manual adjustment. This gets the unit into production with a new product in a minimum amount of time.
EVENT TRACKING As food manufacturing regulations become more demanding, equipment must keep up. What are the internal requirements for event tracking for a metal detector?
SUPPORT-PARTS, SERVICE & TECH ADVICE
Is it good enough to operate with the factory default passwords that everyone knows? Or should users have individual passwords, allowing access to only those levels that management considers appropriate for their position?
As with any equipment purchase, the buyer is not just purchasing a piece of equipment but also entering into a long-term relationship that includes up-front application assistance, training, parts supply, and technical support. Choose a reliable supplier that offers ongoing assistance.
In this case, each machine entry (product change, sensitivity change, reset etc.) can be traced to a specific operator. A metal detector should offer the required access and event tracking in a way that responds to these internal requirements.
heatandcontrol.com
HELP DESK Developing and maintaining an effective, verifiable inspection program is no longer an option. The investment made establishing a reputation of quality could be lost in one safety recall. Metal detection is an effective and relatively inexpensive method of protecting a food brand and technical performance must be the primary factor when evaluating a metal detector.
COMMUNICATIONS CONSIDERATIONS
CONSIDER THE ENVIRONMENT
Will the metal detector be a stand-alone piece of equipment or does it need to be integrated into the plant’s network, providing periodic data reporting for statistical package?
Evaluate the inspection area. Is it wet or dry? What are the variations in temperature?
Does the unit have ready-made software that can provide these functions? Is it Ethernet ready? Some manufacturers provide software packages that allow for remote programming and diagnostics via laptop, including oscilloscope emulation via Bluetooth without the need to even open the power supply cabinet.
SENSITIVITY & COMMUNICATION
Selecting a metal detector suited for specific operating environments is critical. Water intrusion into the electrical components is one of the most common causes of metal detector failure. If there is a wash down regimen in the plant, is it high or low pressure? An IP65 wash down rating means that the metal detector can withstand low pressure wash down with ambient temperature water. An IP69K rating means sustained high temperature and pressure. Does the wash down include caustic agents?
Metal detection sensitivity needs vary according to the operation. For example, a metal detector’s primary function might be to protect a key piece of equipment, such as a sheeter or slicer. The goal would be to eliminate metal that is large enough to damage the equipment.
If so, careful attention should be given to the specific alloy of the stainless steel used for the metal detector’s case. Type 316L is more resistant to caustic agents.
In another part of the line, a different level of sensitivity would be required to inspect a bulk flow of product. And because final package inspection is the most demanding, a higher sensitivity would be needed at the last step out of the factory and before the product goes to market.
Placing a painted surface in the product stream could eventually contaminate your products with chips of paint. Also consider impact resistance.
Quality control teams should have specific sensitivity targets for ferrous, non-ferrous, and stainless steel (type 316) contaminants for each inspection operation. These targets should be communicated to the metal detector manufacturer so that they can select the right equipment for each application. Be sure to set realistic and achievable goals.
For dry environments, is the finish of the metal detector painted?
Plastic covers and membranes are subject to wear or impact penetration. A robust display screen and keyboard avoid downtime and parts replacement costs.
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LATEST PRODUCTS
INSPECTION TECHNOLOGY
Ishida IX-G2 X-Ray The Ishida IX-G2-4027-H uses advanced dual energy technology to easily distinguish contaminants from the product, even in the most difficult applications. It is particularly appropriate for foods where the density of the product and the potential contamination is similar, for example the bone and meat of a chicken which have almost the same density. Machine setup is fully automatic to ensure that the highest levels of detection are reached. This allows the IX-G2 to identify difficult to detect contaminants with a high degree of accuracy at fast throughput rates, using image data analysis over a number of inspections. As it is common in food production that similar contamination incidents recur, data logging can help to build up a more precise calibration protocol with each inspection. This enables permanent or recurring defects to be more easily identified and their location in the pack pinpointed. The IX-G2 can also be used for products that are overlapped in a pack or bag, where a possible contaminant may be obscured by product pieces, such as in bags of frozen chicken nuggets or sausages, fresh or frozen vegetables and cereals. In addition, the dual energy model offers many of the other capabilities of Ishida X-Ray inspection systems such as identifying missing pieces and product or pack deformation, and weight estimation. Food inspected is not affected by radiation and therefore not subject to compulsory labelling. The IX-G2’s user-friendly stainless steel design facilitates easy cleaning. The machine’s belt conveyors can be removed and replaced without tools. Ishida IX models offer easy operation via a simple-to-use 17” colour touch screen. Features such as the sensitivity of the inspection process can be adjusted at the touch of a button while up to 100 product settings allow fast changeovers.
Brought to you by Heat and Control AUST, NZ, INDIA, USA, CANADA, AMERICAS
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CEIA’s unique THS/MS21 metal detector achieves the highest sensitivity to smaller metal particles by applying a broad spectrum of frequencies simultaneously and continuously. CEIA’s continuous inspection process simply and accurately distinguishes between metal contaminants and product effects with no reduction in metal detection sensitivity. The THS/MS21 is ideal for fresh, frozen, hot, cold, wet or dry products that have single or multiple ingredients, even different products that run on the same line.
» Eliminate product effect reject errors
» End costly product waste and re-inspection » Detect smaller particles of all metals including AISI-316 stainless steel Why CEIA? CEIA is the world’s largest manufacturer of metal detectors, with over 90,000 units installed and more than 40 years’ experience.
Metal detectors are CEIA’s only business Detection technology for food, pharmaceutical, security and industrial inspection are covered by over 50 patents. Twenty percent of CEIA’s workforce is dedicated to metal detection R&D.
Rigorous quality control Manufactures its own circuit boards, enclosures and other components. Circuit boards must pass a 200 hour burn-in test. CEIA detectors have a Mean Time Between Failure rate of 70,000 hours.
Built for reliability ISO-9001 certified, CEIA detectors feature conformal coated circuit boards, proprietary sealing technology, and AISI 316L stainless steel construction to IP66 and IP69K standards.
Food inspection to pharmaceutical standards CEIA 21-Series detectors meet FDA Title 21CFR Part 11 standards for inspection data security, integrity and traceability.
1000’s of users have improved inspection results with CEIA
CEIA THS/MS21 Production results (with elimination of false rejects) Product
Contaminant Diameter (mm) Fe
Non-Fe
316SS
Shredded Cheese | 2.2kg bags
1.5
2.0
2.5
Ice Cream | Bulk pumped
0.5
0.7
1.0
Chocolate | Bulk single layer
0.6
0.7
0.8
Fresh Poulty | 18kg box
3.0
3.5
5.0
Tortillas | 80 Count
1.8
2.0
3.0
Fresh Spinach | 1.1kg bags
1.5
1.8
3.0
Brought to you by Heat and Control AUST, NZ, INDIA, USA, CANADA, AMERICAS, BENELUX, AFRICA
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