Heat and Control's Innovator Magazine 2017

INNOVATOR magazine 2017-2

When it comes to the

CRUNCH

Equipment for all SEASONS

AFRICA: 25 years’ young INDIA: Mega factory opened SPRAY DYNAMICS: New team, new look

in pursuit of

INGENUITY

We’ve been working to make food look and taste good since 1950 and even though the fashion and flavours have changed our committment to provide the industry with the most efficient solutions without compromising on taste is the same. Our mission is to keep looking for and investing in ways to improve equipment quality, durability and performance.

®�

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

Heat and Control India - Mega Factory

9

Heat and Control Africa - 25 Years Young

12

Access to Technology

13

Spray Dynamics - New Team, New Look

15

ScandiNova - Strategic Partnership

17

Potato Chip Processing Systems

29

A Manufacturers Guide To Cleaning Your Fryer

31

French Fry + Potato Product Systems

33

Coating + Conveying - FastBack®

37

Corn Products Processing Systems

41

Masa In Minutes

42

Fiesta Charras Group - Innovation In Action

43

Snack Flavouring Systems - FastBack + Spray Dynamics

49

FEATURE STORY - Delving Into Batter & Breading

53

ISHIDA - Quality & Accuracy for Petfood Convenience

55

ISHIDA - The Rotary Salad Filler

57

CEIA - All Things Inspection

59

Our Global Network

ALWAYS INNOVATING

Preparation

Inspection

Cooking

Weighing

Processing

Packaging

Conveying

Service

PROCESSING + PACKAGING SOLUTIONS

SINCE 1950

OVER SIXTY FIVE YEARS OF INNOVATION & 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.

HEAT AND CONTROL WE STAND BY OUR PRODUCT

oven picture in bn facility double page

OVEN, MANUFACTURED BRISBANE, AUSTRALIA

Heat and Control is made up of a global team that has, since 1950, built an extensive knowledge bank and developed a wealth of experience and expertise.

Access to production and technical support from a network of engineers, food technicians, skilled tradespeople and support teams provide food manufacturers with confidence to achieve production goals.

Testing | Design | Engineering | Manufacturing | Installation | Commissioning & Operator Training | After Sales Service | Spare Parts

3

ne manufacturing

12

MANUFACTURING FACILITIES

OVER

30

OFFICES WORLDWIDE

9

TEST FACILITIES

OUR BRANDS.

OUR PARTNERS. 4

INDIA “This facility is outfitted with the same cuttingedge technology as all Heat and Control manufacturing sites”.

HEAT AND CONTROL OPENS ITS LATEST MANUFACTURING FACILITY IN INDIA HEAT AND CONTROL has opened a new manufacturing facility in Chennai, India, which has a manufacturing area of over 11,800m2 (the equivalent of over one and a half soccer fields), making it one of the company’s largest facilities around the world.

Built in the Mahindra World City – a new purpose-built business hub just 65km from the centre of Chennai – the facility encompasses a modern technical centre and office space of 2500m2.

“We are extremely excited about the opening of our new manufacturing and office facility in Chennai,” says Manoj Paul – Country Manager India and South Asia. “This facility is outfitted with the same cuttingedge technology as all Heat and Control manufacturing sites, and it is well positioned to service our existing and new customers with advanced manufacturing equipment and techniques.”

The facility, which has the latest manufacturing equipment such as laser cutting technology, sheet metal machinery and bead blasting technology, incorporates energy efficiency standards replicated from Heat and Control’s global manufacturing facilities.

The technical centre, which will be fully operational by the end of 2017, and will cover an area of over 750m2, allowing customers to test new products and production techniques with guidance from onsite food technologists and engineers. To showcase the workmanship and quality, the technical centre will have equipment manufactured in the new facility. A showroom will also display a range of Heat and Control equipment. Both the technical centre and showroom will be operational from 2017.

5

First off the manufacturing line at the new Chennai facility will be a range of snack processing equipment.

“We already have orders for Namkeen lines and potato chip production lines, which incorporate our HeatWave® Fryer and Mastermatic® range of fryers,” says Manoj. “And the pipeline of projects looks very promising. We will be servicing a very wide region, which not only covers the Indian subcontinent but also extends across Asia. This will position Heat and Control with an even greater foothold in the global food production market.”

Around 100 people from a range of departments, including sales, service, manufacturing and engineering will be located at the new site, with capacity to increase to around 200 personnel in the future.

Jim Strang, Chief Executive Officer of Heat and Control’s International operations, sees the new facility as a way to serve the ever-increasing developing markets in the region, whilst also supporting the company’s other manufacturing operations in the USA, Australia and China. “We are continuously growing and moving into new markets. Our customers are constantly developing new products to cater for evolving consumer tastes and trends. This facility will allow us to align ourselves with our increasing customer base in Asia and will also allow collaboration on projects with our International teams.”

Heat and Control’s Chennai facility is easily accessible by air and road, with Chennai International Airport only 35km away and a highway which connects the business district with the centre of Chennai. The Chennai port is a distance of 55km away.

6

“This will position Heat and Control with an even greater foothold in the global food production market.”

BENEFIT FROM OUR GLOBAL EXPERIENCE FOR NAMKEEN SNACKS Stay connected

Over fifteen 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. Heat and Control namkeen systems can process and package a wide variety of snacks with outstanding results.

www.heatandcontrol.com | info@heatandcontrol.com

MARKET NEWS

INDIA LIKES Source ref: potatobusiness.com

TO SNACK

The potato snacks market in India is expected to grow at a projected CAGR of over 12% during 2016-21, according to figures provided by TechSci Research, a research based global management consulting firm. According to TechSci Research, India is the second largest producer of potato, after China, and production was at more than 47.5m tons in 2016.

The factors for growth A rapidly growing retail market is expected to accelerate the potato snacks segment in India during the forecast period of 2016-2021. Furthermore, growing urbanisation has curtailed available cooking time and consumers are buying these snacks to satisfy their hunger on the way to the office or on the way to school/college. India is home to over 1.20bn people and a large number of this population are young people, the primary target consumer of these snacks. Per capita consumption of potatoes in India is around 21kg, while per capita consumption of processed potato stood at around 6-7kgs in 2016.

Potato chips or extruded snacks The potato snacks market in India is broadly categorised into two major segments – potato chips and potato extruded snacks. Potato chips held a majority revenue market share of more than 75% in 2016, which can be attributed to factors such as the presence of few of the largest market players in this segment, acceptability of potato chips in urban and semi-urban areas of the country, easy availability, competitive pricing strategies of the players, and the availability of a wide variety of flavours.

Market players Four major players in the India potato snacks market accounts for the majority of the revenue share. One multinational company is leading the market with a revenue share of more than 50% in 2016. However, it is expected to decline over the next five years on account of more domestic players which are offering potato snacking products as per regional taste and at competitive pricing, with strong promotional activities and good penetration in tier II and tier III cities of the country. “India is one of the fastest growing economies in the world with growing employment opportunities; following the high GDP growth and inflow of foreign direct investment.

Kids and younger generations are the primary buyers of potato snacks and they are also the target customer of these products. Busy work life patterns, easy availability of raw materials and cheap labour cost makes India a lucrative market for companies operating in the potato snacks industry�, said Karan Chechi, research director with TechSci Research.

8

2 5 EST. 1992

DIVERSITY. GROWTH. OPPORTUNITY. HEAT AND CONTROL CELEBRATES 25 YEARS IN SOUTH AFRICA

Heat and Control’s global and historical footprint continues to grow. Year after year, the company celebrates another successful milestone in its 65 plus years of value-added service to the food processing and packaging industry…and 2017 is no exception.

25 years ago, at a time when South Africa was experiencing a rapid transition in its political and economic landscape, Heat and Control opened an office in one of the country’s most historical and picturesque cities, Cape Town. The company had already been supporting the African market since the late 1970’s via their European operations aided by a local agent. However, by 1992 the time was right to establish a dedicated team and office to support the local region.

9

2 5

SOUTH AFRICA

EST. 1992

Heat and Control in Africa works with customers across many market segments, including snack; fruit and vegetable; meat, poultry and seafood; cereals and grain. In this region, Heat and Control has supplied multi-tier drying systems to a major breakfast cereal processing company; distribution systems for a multinational frozen vegetable processor; and complete turnkey processing lines for a multinational savoury snack processor. Heat and Control’s footprint today stretches across Africa and into various industries, even providing services to the growing Indian-based snack food industry, through its experience with Indian namkeen production capabilities.

“When we first opened our office in 1992, we had a small team who worked hard to grow our customer base,” says Jeff Rossouw, General Manager, Africa. “By bringing in our global experience and in-depth knowledge, it helped us to service the expanding South African food processing industry. Our customers saw the value we could bring to the table and before long we were working with some of the country’s most progressive food manufacturers.”

And with the industry continuing to grow, Heat and Control is ready to tackle the challenges of this ever-expanding industry.

“We are seeing an upward trend in the demand for high quality food processing equipment across Africa,” says Jeff. “Producers want highly efficient, robust equipment that can handle the wide array of food products to satisfy consumer needs. They want machines that are energy efficient, provide greater automation and produce more in a shorter amount of time. Heat and Control is able to meet this demand with our invaluable industry knowledge and complete turnkey solutions.

We are definitely ready for the next 25 years and beyond.”

Founded in 1950 by five engineers who had the goal of modernising cooking equipment for the food industry, Heat and Control has played an integral role during the early days of industrial cooking systems transforming the food processing industry and pioneering continuous cooking equipment.

Heat and Control innovations include pioneering the external heat exchanger for industrial frying systems, high-speed processing equipment for potato chips and other snacks, and the invention of the multi-purpose oven, the MPO Cooking System®. More recent innovations include the HeatWave® fryer, FastBack® conveyor, Revolution® Seasoning System and Revolution® Proportional Gate and the KleenHeat® heat exchanger.

“Through our customer relationships, we truly embrace the African proverb, ‘If you want to go fast, go alone. If you want to go far, go together,’” concludes Jeff.

10

MONTAGU IS NUTS ABOUT ITS NEW HIGH TECH FRYER SOUTH AFRICA: Leading producer of dried fruits, nuts and seeds, Montagu Dried Fruit and Nuts, has installed a state-of-the-art indirect frying system that has dramatically reduced costs and improved product quality.

Supplied by Heat and Control, the HeatWave® fryer system installed at the Montagu factory in the Cape uses 50% less oil than traditional systems as the product is never immersed in oil, but only moves through an oil curtain. This ensures rapid oil turnover and the freshest, most consistently fried nuts possible.

Montagu Sales Director De Wet van Rooyen says the key factor that gives nuts their flavour is the oil that they are fried in: “Traditional nut fryers don’t handle oil with as much care as our new HeatWave fryer does. This gentler process gives the nuts a better taste, a longer shelf-life, and has given Montagu products a competitive edge in the marketplace.”

2 5 EST. 1992

Van Rooyen says that because the fryer is energy efficient and maintains the integrity of the oil for longer, the cost of roasting has been reduced by approximately 50%.

With the lowest oil volume per kilogram in the industry, the HeatWave system has a very high oil turnover rate which prolongs the life of the oil.

The entire oil volume is passed through the filtration system in less than a minute, resulting in high oil quality, highly effective fines removal and fewer burnt particles.

Due to the rapid oil turnover rate, the oil stays cleaner for longer, so less oil needs to be dumped.

There is a zero delta T over the fryer width and length as well as a minimal temperature difference (1-2 Deg C) through the bed depth. This leads to uniform cooking and no hot spots.

Hannes van Rooyen, Operations Director at Montagu Dried Fruit and Nuts, is impressed with results. “Taste and quality have vastly improved as a result of superior control over all aspects of the roasting process, thanks to the new system.”

Reproduced with the approval of Food & Beverage Reporter, South Africa.

11

access to technology Experience the HeatWaveÂŽ Fryer with the Heat and Control Augmented Reality App. Available to download from the App Store onto your smart phone or tablet.

12

SPRAY DYNAMICS NEW TEAM, NEW LOOK LUCAS BELL got his foot in the door at Spray Dynamics by sweeping shop floors back when he was in college and immediately took an interest in the engineering and manufacturing areas of the business.

Once Lucas joined Spray Dynamics as a Mechanical Engineer, he worked in project engineering for about 18 months before moving into the manufacturing manager role. After being in that role for 2 years, it opened up the opportunity for Lucas to eventually lead both the manufacturing and engineering groups, giving him a broader view of the business.

In 2011, Lucas became responsible for all operations of the Spray Dynamics product line and filled that role for six years, assuming the position of General Manager after the retirement of Spray Dynamics founder, Dave Homeyer at the end of 2016.

Being involved with multiple facets of the business during his tenure with the company, as well as proactive preparation by the group for the retirement of Dave, has allowed for a smooth transition of leadership at Spray Dynamics.

Lucas Bell, General Manager, SPRAY DYNAMICS

Lucas Bell has spent his career designing and manufacturing top of the line equipment systems for the food and beverage industry.

After graduating with a BS in Mechanical Engineering (ME) and working in the beverage brewing / packaging industry, Lucas joined Spray Dynamics in 2007. With his engineer’s attention to detail and persistent focus on efficiency, streamlining processes and thinking outside the box, Lucas helped drive Spray Dynamics’ efforts towards assisting snack processors improve product appearance and quality, with a variety of cost-effective applicators for dry and wet seasonings and coatings.

The company expanded to serve bakery, cereal, and other food / non-food markets, all while developing ever-higher capacity snack coating systems. As an industry leader, Spray Dynamics joined Heat and Control in 2011 and continues to develop equipment for in-kitchen and on-machine seasoning applications under Lucas’s direction at its St. Clair, Missouri headquarters.

Construction continues at the new Spray Dynamics site, after the ground breaking ceremony at the end of 2016.

13

Q

What market trends are driving development at Spray Dynamics?

A

We are continuing to see a consistent growth in the snack industry, as well as renewed growth in the pet food/litter and agricultural industries. We are also starting to see increased interest in drying applications for a variety of products that span across multiple markets.

Q

Can you give a ‘sneak peak’ developments on the horizon?

A

We are working on a few developments this year. The first involves improving dry powder applications and the second involves taking rotary drying technology to the next level.

of

new

Q

During your time with Spray Dynamics what changes have you seen?

A

I’ve been with the company a combined tenure of 10 years now and have been involved in the growth of our business’s product line. We have doubled our staff numbers and increased annual sales three-fold. We have really streamlined some of our best business practices and manufacturing techniques and workflows over the years to aid in our ever increasing workloads.

Q

Why should food processors’ choose Spray Dynamics equipment?

A

Our extensive process knowledge in the industry, as well as our high standard of quality, customer service and ability to be extremely flexible with custom solutions really gives us an edge over the competition. We help our customers develop new processes and/or assist with optimising existing processes to improve efficiencies and save time and money.

Q

Can one seasoning system do it all or is equipment product specific?

A

While we make our machines as flexible as possible for our customers to get the biggest bang for their buck, each equipment system is custom designed for the product and process at hand. There are several systems for similar products that have an overlap of design to increase the flexibility, but base product type, bulk density, shape and rate, as well as the corresponding liquid and dry application types, rates and ratios needed fully define the correct system required for each application.

Q&A WITH LUCAS BELL

Q A

Tell us about the new ‘look’ team.

We have a very tight-knit team at Spray Dynamics which includes a management group that has the mantra to LEAD and work hard alongside our employees. We firmly believe that each employee in our company makes the facility run optimally every day and each member of the Spray Dynamics team brings something to the table.

Our strengths are relentless energy, transparency, communication and the culture to do the right thing every time. While we always push to be happy, we are never satisfied and are constantly looking for ways to improve ourselves, our product line, our processes and our relationships in the industry.

http://www.heatandcontrol.com/spraydynamics

14

HEAT AND CONTROL

&

SCANDINOVA

Heat and Control Inc., a world leading manufacturer and supplier of food processing and packing systems and ScandiNova AB, have announced a strategic partnership. The partnership will combine Heat and Control’s market leading expertise in food production equipment systems and automation with ScandiNova’s break-through technology and industry leading Pulsed Electric Field (PEF) solution.

Together Heat and Control and ScandiNova are co-innovating with an electroporation solution for the food industry that will bring a new approach to product quality, line efficiency and energy savings.

Initially targeting the consumer potato products sector, namely savoury snack food, French fries and potato products, Heat and Control has released the patent pending E-FLO™ electroporation system that, integral to its design, features the ScandiNova PEF solution.

15

PEF technology to help our customers meet their production goals. We view their PEF solution to be by far the most advanced technology available and as we enter a new era of food production innovation we look forward to developing ways to improve overall product quality and line efficiency.”

Fredrik Mella, President of ScandiNova AB, comments, “PEF is a strategic growth area for ScandiNova and Heat and Control will be the perfect partner with its strong global market presence, game changing mind set and leading technology.

We look forward to supporting the sales of the E-FLO system and together lead the transition from traditional thermal processing to PEF processing in the food industry.”

This system has been designed to address the challenges food manufacturers face such as energy consumption, product quality or minimising the formation of unfavourable product attributes such as acrylamide.

The E-FLO electroporation system, featuring ScandiNova’s PEF technology, joins Heat and Control’s comprehensive catalogue of potato and snack processing equipment and offers many benefits including elimination or reduction of the blanching process, reduction of sugar and asparagine levels, minimisation of acrylamide formation, reduction of fat content and textural improvements.

Tony Caridis, President of Heat and Control Inc, comments, “We are pleased to form this partnership with ScandiNova and leverage their knowledge of

For more information on PEF technology: http://www.heatandcontrol.com/eqmain.asp?eqid=19

PEF technology

About ScandiNova:

EXCELLENCE IN PULSED POWER

ScandiNova is by its break-through technology a world leader in development and production of Pulsed Power Systems with high power levels. The product range covers pulse modulators, generators, turnkey radio frequency (RF) systems and electron guns, all with Solid State technology. The solutions have a key function in several scientific applications, radiotherapy, cargo inspection, non-destructive testing, industrial X-ray, sterilisation and in other industrial applications. More than 95% of the production is exported to clients in 33 countries, mainly in Europe, Asia and North America. ScandiNova Systems AB, a spin-off from Scanditronix, was founded in 2001, by people with extensive commercial and technical experience in pulsed power applications.

The company has its head-office in Uppsala, Sweden with 60 employees and sales representatives in each sales region across the world.

THE POWER AND PRECISION OF THE PERFECT PULSE www.scandinovasystems.com

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potato chip technology

POTATO CHIP PROCESSING SYSTEMS

A GUIDE TO THE STEPS INVOLVED IN POTATO CHIP PROCESSING: • SELECTING, PROCURING AND RECEIVING POTATOES • STORAGE AND RECONDITIONING • WASHING, PEELING AND TRIMMING • SLICING • CONDITIONING AND WASHING • FRYING IN OIL • SALTING OR APPLYING FLAVOURS • PACKAGING

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SELECTING, PROCURING AND RECEIVING POTATOES The raw product determines the quality of the finished processed product. Poor quality potatoes will never give good quality chips.

Some of the most important factors involved in potato chip processing are potato variety, time of harvest and handling practices, which include storage and reconditioning.

Some varieties are not suitable for chip manufacture, even directly from the field, due to low specific gravity, high reducing sugars, being too large or small in size, having poor shape, excess defects and/or peel.

The specific gravity of potatoes should be as high as possible, (preferably above 1.080) to process potato chips. It is possible to process with lower specific gravity potatoes, (1.060) but this will decrease the yield and increase oil uptake in the chips.

Today’s snack food markets are competitive and the consumer has many choices. The goal of the potato chip manufacturer is a product that has good appearance, bright colour, is free from excess oil and with no defects, crumbs or blisters.

STORAGE AND RECONDITIONING Good storage should prevent excessive loss of moisture, development of rots and excessive sprout growth. Ideal storage temperature for potatoes is approximately 1013°C. The sugar content of potatoes increases when stored at temperatures lower than 10°C, leading to darker potato chips. As sugars increase at low temperatures, starch decreases.

At high temperatures, sugars decrease as a result of respiration and starch synthesis. The change from starch to sugar at low temperatures and the subsequent partial re-synthesis of starch from sugars at high temperatures may change the growth structure of starch granules sufficiently to alter its properties.

This is likely to affect the quality of the starch and subsequently the texture of the cooked potato. Avoiding fluctuations in temperature should maintain the quality of the potato for the prescribed storage life.

Potatoes shrink and lose weight during storage. This weight is comprised of water loss from the tuber, carbon dioxide loss and decay losses as a result of rot organisms. The amount of loss is determined by the storage conditions such as temperature, humidity, and evaporating power of the air, composition and movement of the air, maturity and condition of the potatoes at beginning of storage.

After harvest, the potatoes go through a two week period where the skin thickens. During this time, starch is broken down (hydrolysed) to sucrose and the sucrose is broken down to reducing sugars (glucose and fructose), with carbon dioxide and water accumulating in the atmosphere. The levels of oxygen, carbon dioxide, relative humidity and temperature must be controlled and adjusted during storage of the tubers.

If proper ventilation is not provided when the potatoes are in storage, stress conditions can cause an accumulation of sugars. If poor ventilation, low humidity, disease or temperature fluctuations occur when the potatoes are in storage, starch degradation can accelerate, resulting in higher sucrose values and an increase in reducing sugars.

Before processing, it will be necessary to recondition potatoes which have been stored for several months at temperatures below 10°C. With some varieties, reconditioning is needed even though storage temperatures have never been below 10°C. Reconditioning is accomplished by storing potatoes in temperatures of between 15-20°C for a period of time until frying tests, or the level of reducing sugars indicate that acceptable, light coloured chips will be produced.

Relative humidity should be maintained between 8590% and air circulation should be controlled to produce acceptable tubers.

If tubers are stored properly after harvest, potatoes need little or no reconditioning prior to frying in order to produce chips of acceptable colour. If the sucrose is high (above 2%) before going into storage, it may be impossible to make acceptable chips coming out of storage.

If the sucrose is high out of storage but was acceptable going into storage, generally it is possible to recondition the tubers at room temperature (18-20°C) for 1-20 days to produce acceptable chips.

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WASHING, PEELING AND TRIMMING Potatoes are removed from storage in crates and placed in the Crate Dumper. This inverts the crate and deposits the potatoes into the Hopper Feeder. This unit helps control the product flow into the processing line and removes stones and loose debris out of the bottom of the hopper.

In instances where the potatoes contain excessive dirt or grit, a rod washer or barrel washer is included in the process line to reduce wearing of the abrasive peelers.

The potatoes are conveyed along the barrel and cleaned by being tumbled and rubbed against each other and against the sides of the barrel while they are immersed (Barrel Washer) or sprayed (Rod Washer) with water. To aid in the elevation to a batch peeling at high level, a vertical screw elevator can be supplied. This also provides effective removal of large stones as the stones sink to the bottom of the water flooded tank and potatoes float to the screw infeed. Rocks are removed either with an automated rock remover or manual lift out basket.

The longer the tubers are kept in storage, the thicker the skin will become, especially if the relative humidity is not kept high. Freshly dug tubers have very little peel and this can be removed by mild brushing.

The equipment used to remove the peel relies on abrasive removal of the surface layers by rolling the potatoes on roughened rollers or drums. The effectiveness of these peelers strongly depends on maintaining intimate contact between the potatoes and the abrasive surface.

The abrasive surface must be kept clean, sharp and unclogged by debris. Peeling loss depends on the size and shape of the potatoes, depth of the eyes, length of storage time and the equipment being utilised. The peel fragments are flushed out of the barrel with water sprays.

Peeled potatoes need to be rinsed thoroughly to ensure any enzyme released from the cells has been removed. If not rinsed this enzyme will cause browning.

Peeled potatoes should be hand trimmed on an inspection table to remove residual skin, eyes, discoloured areas, black spots, disease, and insect injury, sunburned and green material.

The amount of trimming will depend on the efficiency of the peeling operation, process requirements and the raw material quality. Defective areas or unpeeled product not removed by trimming will result in defects in the finished chip.

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SLICING The potatoes are sliced by rotating them against stationary knives. Centrifugal force presses the tubers against the knives. Thickness of the slice will be varied, not only to meet consumer preferences, but also to fit the condition of the tubers, frying temperature and time.

Slices produced must be uniform in thickness to obtain uniformly coloured chips.

It is important knives are kept sharp and slices are checked periodically for uniformity of thickness. Slices with rough or torn surfaces loose excess solubles from the ruptured cells and absorb larger amounts of oil.

Specific gravity is a measure of the amount of solids in the potatoes, or conversely the water content. Potatoes with a high specific gravity make better potato chips than those with a high water content. Specific gravity is directly related to the efficiency of processing, the time and temperature of frying and the yield or recovery of finished chips. Potatoes with high specific gravity absorb less cooking oil during frying and yield more chips than those with low specific gravity. It stands to reason that potatoes with high water content and thus less total solids will yield fewer chips.

Potatoes low in specific gravity require more energy to remove moisture, which results in greater oil absorption.

They also require longer fry times at given temperatures to reach the desired moisture content of approximately 1.5%. Conversely, high specific gravity tubers require less time to fry to 1.5% moisture. Tubers low in specific gravity may break more easily during packaging and handling than those high in specific gravity.

CONDITIONING AND WASHING After the potatoes are sliced, it is necessary to remove starch and other material from the surface of the potatoes, so that the slices will separate readily and completely during frying. The starch will leach out some of the reducing sugars, to prevent excess darkening of the slices during frying. The slices are washed and rinsed using both top and bottom sprays.

Cold water is normally employed in the Conditioner for properly stored (low sugar) potatoes, whereas hot water is used for removing excess reducing sugars. There is no significant difference between washing tuber slices in water ranging in temperature from 21°C to 60°C. When processing borderline tubers, the use of wash water at temperatures over 60°C could make the difference between acceptable and unacceptable chips.

The major reduction in reducing sugars will occur when the wash water is at temperatures of at least 70°C. The dwell time in the wash water can be altered from 30 seconds to four minutes to improve the colour of the potato chip. The conditioning step can be increased to six minutes on specially designed machines. Slivers and small pieces are continuously removed from the wash water by a motorised fines catch box.

Methods used to reduce the level of reducing sugars are: • Leaching with hot water • Treatment with hot water and chemicals Washed slices are treated for about one minute in a solution of phosphoric acid and sodium citrate or citric acid; hydrochloric or phosphoric acid; citric acid or sodium citrate; calcium chloride and others.

This method causes a reaction between the chemicals and the sugars, so that the sugars cannot participate in a browning reaction.

By adjusting the pH of the water to that of the tuber using organic acids, this should equilibrate the osmotic conditions between the two mediums and allow easier discharge of the sugar from the cells.

To remove excess water from the slices an Air Knife is used; further water can be removed by using an Air Sweep®. These combine a system to blow water off with the aid of a vacuum action. This reduces energy consumption in the Fryer and helps prevent residual Main Oil Pump cavitation.

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FRYING IN OIL Frying time and temperature will vary depending on variety, specific gravity, slice thickness and reducing sugar content. These two parameters of frying are not constant and must be varied to produce uniform quality chips. In general, the higher the temperature the shorter the frying time, and the less oil absorption. Too high a temperature will result in burnt or caramelised chips and quicker oil breakdown.

The steam released from the potatoes forms a blanket of non-oxidising gas over the oil. This not only furnishes the steam blanket, but also provides a continuous deodorisation of the oil. Undesirable products do not accumulate, because there is a rapid turnover of the oil, a result of constant replenishment with fresh oil to compensate for that absorbed by the chips. A negative effect of water vaporisation is that anti-oxidants such as BHT are steam distilled out of the oil. BHT (Butylated Hydroxytoluene) will delay rancidity and flavour deterioration in the potato chips.

Specially designed equipment can be provided to increase the temperature of the chips after they emerge from the Fryer and provide a significant reduction in oil content. As steam is being rapidly released from the slices, oil absorption will be low. As the protective layer of water vapour begins to disperse in the final stages of frying, fat enters the voids left in the dehydrated cells.

FACTORS LEADING TO OIL DETERIORATION Hydrolysis This occurs when chemical bonds holding triglycerides together are broken by water, creating free acids. Frying Systems with high oil turnover rates usually maintain acceptable oil quality and the steam realised tends to strip Free Fatty Acids from the oil.

Oxidation The primary reaction is the formation of hydro peroxides.

Higher numbers of double bonds in the unsaturated oil will increase the rate of oxidation. This reaction is enhanced by heavy ions. Copper is a potent oxidation catalyst and its use must be avoided. No copper fittings or brazings should be permitted in frying equipment.

21

Polymerisation The two major types that occur are: 1. Oxidative Polymerisation - Free radicals are formed when hydro peroxides decompose at high temperatures, and combine, doubling the weight of the triglyceride.

Eventually, as the molecular weight increases, they are no longer soluble in oil and will be deposited on the Fryer wall.

2. Thermal Polymerisation - Primarily occurs at hot spots on the frying equipment, caused by localised overheating.

The oil used for frying has two functions: 1. It serves as a medium for transferring heat from a thermal source to the tuber slices.

2. It becomes an ingredient of the finished product.

Some of the factors affecting the amount of oil absorbed by the potato slice are: • • • • • • • • •

Solids content of the tuber Oil temperature Duration of frying time Thickness of slices Variety of potato Condition of potato Slicer operation Conditioning Type of slice (wavy or flat)

RELATIONSHIP OF FREE FATTY ACID WITH SMOKE POINT OF FRYING OILS Free Fatty Acids (F.F.A.) increase during frying, due to a reaction between the oil and the water released by frying. F.F.A. will rise and should be maintained below 0.5%. This reaction causes the oxygen to react with the double bonds in the unsaturated fatty acids. Free fatty acid values above 0.5% will result in detrimental effects on the quality and shelf life of the processed food.

Initially peroxides are formed, which in turn breakdown to ketones and aldehydes. The peroxide value may be helpful in measuring the degree of oxidative rancidity in the oil.

Smoke point of the oil is an excellent indicator of fresh oil quality. Good oils (as received) will have a smoke point of well over 250째C. As the oil is used the smoke point will be proportionally reduced. The smoke point is the temperature indicated when the oil gives off a thin, continuous stream of bluish smoke.

SHEETED / EXTRUDED CHIPS PRODUCT FLOW THROUGH THE FRYER Blisters develop on the potato chips during the frying operation. They are in part related to potato variety. The blister is formed when the outside of the slice is cooked too fast and forms a dry crust, thus preventing the inner moisture in the centre of the slice coming to the surface.

Hot water conditioners have a tendency to prevent this.

Careful and proper control of the flow of chips going through the Fryer assures uniformity of cooking and moisture removal, as well as uniformity of oil absorption.

Chips fried at 190째C have lower oil content than chips fried at 160째C, the lower oil viscosity of the hotter oil favouring a more complete drainage of the oil from the cooked chip.

This process forms dough from potato dehydrates typically 15 parts by weight ground potato flakes, 15 parts by weight whole potato flakes and 15 parts by weight potato starch. Potato dough has a moisture content of 40-55%.

A potato dough can also be manufactured from cooked potato solids, water and ungelatinised starch to form a dough having a moisture content of 50-60% by weight.

This dough contains a mixture of ungelatinised starch and potato solids that includes a quantity of intact potato cells and a quantity of free gelatinised starch solids.

The fried product develops a structure as a result of starch gelatinisation. The resultant expansion is rapidly controlled by the addition of non-gelatinised starch.

After chips emerge from the Fryer they are inspected for defects, soft centres, moisture and oil content, colour and general poor quality.

This produces a similar texture to that of a potato chip.

The dough pieces expand to at least 1.6 to 3 times their original dimensions.

BATCH FRIED POTATO CHIPS

The dough is fed continuously through rotating rollers, compressing it into a cohesive sheet approximately 12mm thick. The sheet is conveyed through a series of reduction rollers reducing the sheet thickness to approximately 1.5mm. It is critical that the reduction occurs gradually.

The manufacture of this variety of crisps differs from the production of standard chips because they are peeled, sliced, but not washed before frying. The frying temperature of the Batch Fryer may be as much as 38째C below the conventional Fryers and the time may be in excess of eight minutes in contrast to two minutes for conventional chips.

The crunchy texture and greater curl to the chip distinguishes batch fried chips from conventional chips.

Oil content may be quite similar depending on the specific gravity of the tubers and the final moisture of the chip.

Excessive work at this stage causes cell damage, resulting in the formation of a sticky sheet that is difficult to cut and results in an overly expanded product. The reduction rollers can be vertically or horizontally mounted.

The sheeted dough is then passed through an engraved rotary cutter. In the case of non-interlocking shapes, the cutting scrap is continuously returned to the dough feeder for rework. The cut shapes are continuously fed to a fryer, where they are to obtain a moisture content below 2%.

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High Shear Dry Extrusion Potato flakes (coarse ground) and/or potato granules can be dry blended with corn grit at levels up to 25% by weight. It is important to select raw materials that are sufficiently granular, to ensure a consistent feed rate and residence time in the extruder. Fine particles usually cause burn-on to the screw and eventually seizure of the machine.

Fabricated snacks have been manufactured using this method for more than 40 years. This process consists of continuously feeding the selected raw materials to a single screw isothermal extruder. The extruder requires high temperatures and short time at the correct moisture levels to produce the optimum level of puffing.

Extruders for these products generate heat rapidly in the extruder by the high shearing action produced between the grooved barrel and screw, combined with a relatively high screw speed (300-400rpm). The extruder is normally run in the starved condition to ensure low residence time in the extruder.

Typical internal temperatures during operation are 140°C. The hot plasticised mass passes from the screw section into a pre-expansion intermediate die and immediately through the final shaping die where the high temperature causes moisture loss, resulting in a puffed product having approximately 8% moisture.

The expanded product is cut to the required piece thickness at the die interface and is subsequently dried to a final moisture content of about 2% before surface flavouring and packaging.

SALTING OR APPLYING FLAVOURS Chips should be salted or flavoured immediately after they leave the Fryer. It is important that the oil liquid at this point causes maximum adherence to granules. The salt content will vary due to differences in the oil content of the potato chip, affecting the adherence and absorption of the salt or flavouring.

Addition of salt/flavouring must be within specified limits and only by constant monitoring of your finished product can the quality level be maintained.

When applying salt: • •

It should be warmed or equalised to the temperature of the processing room Constant checking and maintenance is needed to ensure uniformed distribution of the salt

Anti-oxidants or other additives may be added to the salt/ flavour to reduct the level of rancidity that will develop.

Anti-oxidants or oxygen scavengers, added at this point, will help to protect during its shelf life. Studies show that shelf life can nearly be doubled by using salt with an antioxidant, compared to chips with no anti-oxidant in the salt.

If the chips are allowed to cool before packaging, better adherence of salt/flavour particles is obtained.

The application of salt is achieved by metering the salt/ flavouring through an Auger into a Tumble Drum through which a continuous stream of potato chips is passing.

Some cheese based seasoning can be suspended in oil and then sprayed onto the product as it moves through the Tumble Drum.

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For more information on Potato Chip Processing Systems, visit, http://www.heatandcontrol.com/ potatochips.asp

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POTATO CHIP PROCESSING LINE: We’re with you all the way, from raw product to final package.

PACKAGING The size of the potatoes used for chips will vary depending on the size of the package the chips will be packed into.

Small tubers are desirable for the small bag, while large potatoes may be desirable in larger size packages.

Packaging must be tested for water vapour and oxygen transfer rate, greased resistance, odour permeability, taste permeability and ink and coating adherence. Each load of file should be checked by the supplier and/or the customer through visual examination for physical damage (pin holes, rips etc) and misprinted graphics. Stock should be limited to a three month supply as film deterioriates as it ages.

The packaging lines should be continually checked to ensure the correct fill, net weight, elimination of breakage, proper seal, designated code and proper expiry date.

If the frying oil is stabilised, packaging film is opaque and has a low moisture vapour transmittance rate, a shelf life of 4-6 weeks should be achieved when chips are stored at temperatures of approximately 21°C. Opaque packaging will prevent light from being transmitted through the film and prevent accelerated oxidation of the potato chips.

Once potato chips are in the bag, three forms of quality degeneration will have the greatest effect on consumer acceptance: 1. Breakage - This can be partially prevented by stiff packaging material, making the package “plump” with contained air.

2. Absorption of Moisture Causing Loss of Crispness - This is largely prevented by the choice of packaging material. The film needs to have a high degree of resistance to moisture vapour transfer. The film needs to have a high degree of resistance to moisture vapour transfer. Foil containing film is preferred, since it not only resists moisturevapour transfer but reflects light. Potato chips are commercially unacceptable when they have moisture content above 3%.

3. Fat Oxidation leading to Development of Rancid Odours - Light and normal fluctuations in environmental temperatures affect the rate of oxidation. Sunlight has a strong accelerating effect on rancidity developments.

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PACKAGING LINE

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fryer technology

VERSATILE VACUUM FRYING MADE SIMPLE TECHNOLOGY TAKING PROCESSING CAPABILITY TO A NEW LEVEL WITH THE UNITIZED VACUUM FRYER. Heat and Control has helped their customers increase processing capabilities substantially with delivery of the company’s innovative vacuum fryer technology. The Unitized Vacuum Fryer (UVF) is a self-contained vacuum fryer that saves space and controls acrylamide.

The complete system was designed and manufactured

by Heat and Control to process 500 kg (1100lbs) per hour of finished potato chips and features support/ auxiliary equipment including Vacuum Generation System, KleenSweep®, Centrifugal Oil Filtration System, Heat Exchanger, Fryer Support Module, PLC System Controls, Automatic Heated Centrifuge and Fryer Support Platform.

The patented Unitized Vacuum Fryer is one of a kind in that there is no external vacuum chamber. The unitized design eliminates an external vacuum chamber: the fryer is its own vacuum chamber, essentially creating a ‘ship-in-a-bottle’ effect. This makes it significantly easier to maintain and clean, requires less floor space, and allows the vacuum fryer to act like a regular nonvacuum fryer. This design innovation validates Heat and Control’s snack processing expertise and commitment to the industry.

The Unitized Vacuum Fryer technology offers product line extension for snack manufacturers, so that high sugar food products that could not be turned into snacks with a traditional frying system, can now be processed into unique snack products. The vacuum fryer will fry products with high sugar content such as apples, carrots, sweet potatoes, high sugar potatoes, beets and more without over browning. A further benefit of vacuum frying is the ability to minimise formation of acrylamide by frying at lower temperature.

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As part of Heat and Control’s complete line of snack processing and packaging solutions, this innovative technology demonstrates the commitment to smart design and focus on finding efficiency and quality gains for the food processing industry.

BENEFIT FROM OUR GLOBAL EXPERIENCE NUT SNACK PROCESSING SYSTEMS

For seasoned, coated, honeyroasted

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 valueadded nut snack products.

Local sales + support teams but with a GLOBAL network of manufacturing facilities + support offices.

Food Processing & Packaging Systems

www.heatandcontrol.com | info@heatandcontrol.com

A MANUFACTURERS GUIDE

to CLEANING YOUR FRYER

The cleaning of fryers is greatly dependent upon each processor and their own circumstances and as such, the exact cleaning regime and frequency can vary to each site. Accordingly, this article presents a generic fryer cleaning guide which although basic in form, can be applied to most industrial fryers.

The main chemical for cleaning fryers is Caustic Soda or (Sodium Hydroxide – NaOH) in either a liquid or flake form. It is most often used in conjunction with other constituents such as, wetting agents, suspension agents, detergents, emulsifiers, sequestrants, oxidisers, and corrosion inhibitors. If these additional constituents are used in a CIP system, then a low foaming type should be selected.

Suitable time should be allowed for thorough cleaning of industrial fryers and care taken for safety of personnel with use of adequate Personal Protection Equipment (PPE). The detergent is highly caustic and will cause serious injuries if due care is not taken.

ESSENTIALLY THE CLEANING OPERATION IS DIVIDED INTO THE FOLLOWING STEPS: >> The fryer is emptied of oil and any debris accumulated within the fryer should be manually removed >> Remove appropriate filter materials from the machine for manual cleaning or disposal >> Excessive polymer build-up within and outside of the fryer should be manually scrubbed or abraded with high water pressure application. It is not essential that all the polymer material is removed but rather is loosened so the chemicals do the final cleaning >> Fill the fryer with potable water to just below overflowing, adjust fryer controls to clean mode (ensure the water temperature cannot exceed 85ºC) >> In many cases lesser strength application of a suitable detergent is added to the fryer (the purpose of the detergent is to emulsify any remaining oil in the fryer) >> The detergent used should satisfy the criteria as stated above but for fryer systems with a CIP sub-system, the detergent must be of a low foaming type. If using a granular chemical cleaning agent, the detergent should be dissolved in a water solution before carefully adding the mixture to the fryer >> Ensure the CIP hose is fitted and appropriate valves are adjusted. Turn the fryer on and heat to temperature and maintain at temperature until the soil or contaminate load is removed from the fryer. This time may vary for each fryer cleaning. >> Drain the system to the appropriate drainage point and then refill the system with potable water again (fill to maximum). This time fill to as per the chemical supplier’s dosing recommendation. It is expected that the detergent should have a range of 2% - 10% Sodium Hydroxide (w/w) within the detergent chemical matrix. However this range is dependent upon the individual circumstances.

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CLEANING YOUR FRYER

>> Ensure the area is clear of personnel, start the fryer and keep at temperature until the expected time to remove expected soil loads has elapsed. After this time, stop the fryer and carefully inspect the system for cleanliness within the fryer and if the fryer is clean then stop this step, however if it is still dirty continue cleaning.

Keep stopping and inspecting after each subsequent hour until the fryer is clean. Care should be taken to monitor the fryer cleaning liquid level and add water when required. >> While the CIP system is automatically cleaning the inside of the fryer, the operator should use a suitable detergent and cleaning aides to safely clean the outside of the fryer >> When the fryer is clean, empty the fryer liquid to an appropriate drain >> Refill the fryer with potable water, start the fryer and heat at the set temperature. At the same time carefully rinse down the outside of the fryer systems with potable water >> Empty the Fryer into a suitable drain and refill again with potable water. Heat the water at the set temperature >> Stop fryer and empty fluid into suitable drainage system >> Check the fryer pH with the fryer empty. If the pH reading is above 7 repeat the above step of draining, refilling and bringing to temperature until the pH reading is 7 >> If the incoming potable water pH is higher than 7, rinse the system until the fryer water is similar to the incoming water >> Open all drains, valves and appropriate lids and allow the system to drain and dry before restarting production

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potato product systems

FRENCH FRY + POTATO PRODUCT SYSTEMS

Whether its straight cut fries, crinkle cut fries, curly fries, or potato wedges, Heat and Control's french fry and formed potato products frying systems are the workhorses of the industry. Our fryers, heat exchangers, oil filtration, pumping and control systems can produce up to 50,000 pounds per hour of finished product.

FRYER SYSTEMS EXPERTISE A Heat and Control continuous fryer design provides total control of product quality. Oil may be the invisible ingredient in fried foods, but it is a critical factor in product quality. Renowned for clean and reliable operation, 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. Continuous oil circulation between the fryer, filter and heat exchanger provides precise control of temperature and rapid adjustment to product load changes.

Heat and Control is the leading manufacturer of fryers and support systems for the global food industry and offers process customisation to meet production specifications.

• Oil Heating + Filtration • Oil Transfer + Storage • Cooling + Oil Stripping

FRENCH FRY FRYER

Choose from multi-zone and two-stage continuous fryer systems for the most uniform french fries, formed potato products and batter-coated fries. In a two-stage (regular and batter coated fries), the unique design reduces oil volume and delivers the highest production capacity using minimal floor space.

Stage 1 Set Coating Oil velocity matches the speed of the incoming monolayer of product to prevent coating damage. Oil flow through multiple AccuFlow™ inlets control product-tooil velocity. Fines are quickly removed through multiple outlets to minimise oil degradation.

Stage 2 Completes Cooking With batter firmly set, fries are heavily loaded into Stage 2 for final cooking. Multiple zones of oil inlets and outlets maintain a consistent frying temperature. Oil flow penetrates the pack for uniform cooking, eliminating clusters and quickly removing fines.

CO-PRODUCTS FRYER

A continuous frying system for formed potato products such as hash browns and novelty shaped potato snacks.

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UNITIZED VACUUM FRYER

Frying without external vacuum chamber, excess floor space and labour. Creates its own internal vacuum and boils off product moisture at a lower temperature to produce snacks from high-sugar products without browning, and at less than 120°C minimises formation of acrylamide.

BATTER APPLICATION Uniformly apply batters and marinades to all surfaces of formed and natural potato products. Available in submerger, curtain-fall, and under-pumping models.

The E-FLO™ in action The E-FLO™ in action What is the E-FLO? The E-FLO is an innovative machine designed to benefit the food processing industry, in particular potato product producers. It increases yields and reduces long-term costs.

The patented E-FLO uses Pulse Electric Field (PEF) processing, or electroporation, to perforate the cell walls of potatoes, creating micro holes that allow amino acids and sugars to be washed out in a cold water wash. The process provides numerous benefits, especially for French fry producers.

PRODUCE UNLOADING + HANDLING A wide range of potato unloading, transfer, storage and delivery solutions are available for pre-processing of the raw product. Includes produce transport and bin storage systems.

ELECTROPORATION E-FLO™ Electroporation uses Pulse Electric Field (PEF) processing, or electroporation, to perforate the cell walls of potatoes, softening the tissue. Less starch is lost as a result, improving overall yield. Another main benefit of the E-FLO for the French Fry market is that the cut potato slices (before frying) are more malleable - so they can be bent and twisted without breaking.

Electroporation perforates my cell walls to allow amino acids and sugars to be washed out in a cold water wash. This gives me a lot of benefits!

What are the benefits of the E-FLO? Yield improvements

Producers can produce a higher yield from slicing as less starch is lost due to the electroporation process. This in turn leads to greater profits.

PEELING, INSPECTION + SLICING A complete range of systems to peel, slice and inspect potatoes before processing. Maintain peeling control and high yield of potatoes as well as a polished peeled potato with reduced peel loss.

Greater flexibility

These systems collectively provide a continuous and uniform flow of potatoes to the slicer for maximum slicing efficiency, improved potato slicing quality and reduced waste.

Slicing between the cells of the potato also produces a smoother surface. A smoother surface means less oil is absorbed, which reduces oil expenditure.

ENERGY SAVING + POLLUTION CONTROL KleenHeat® Pollution Control Heat Exchanger combines the incineration of fryer exhaust pollutants with highefficiency oil heating to help processors meet emission control regulations. Thermal efficiency meets or exceeds that of other heat exchangers not equipped with pollution controls.

Oil Mist Eliminator Removes oil mist from fryer exhaust without water or high-horsepower fans. Includes reusable stainless steel filter pads and clean-in-place spray system.

Heat Recovery System Recover normally lost heat from the fryer exhaust stack.

Includes Mist Eliminator, Heat Recovery Coils and suction fan. Suitable for outdoor installation.

The E-FLO improves the ability of cut potato slices to bend and twist without breaking. This in turn reduces product loss and increases profits.

Reduction in oil

Less time for blanching

The tissue of the potato becomes more permeable, which reduces the need, or length of time needed, to blanch potatoes before cooking.

Reduction in acrylamide

The E-FLO can significantly reduce the levels of acrylamide in potato products. Acrylamide has been labelled as “probably carcinogenic to humans”.

The final verdict

I am now more uniform, have higher yields and am less likely to break!

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S

Conveying

P

Seasoning

coating & conveying

Hygienic design drives next generation of FastBackÂŽ solutions

FastBack 260E G3 Revolution Gate+ Cartridge System

Heat and Control announces the next generation of FastBack solutions to meet industry sanitation requirements; FastBack 260E G3, Revolution Gate 3.0 and Cartridge open channel support system.

With headlines such as “plant shuts down due to Listeria”, and “E- Coli affects multiple states” Heat and Control brings hygienic design into play where it counts for the food industry. Continuous product development based on industry need has resulted in the development of the next generation of FastBack solutions.

“As the leading supplier of sanitary food conveying equipment across the globe, we wanted to make sure our clients were several steps ahead of the food safety issues that are making headlines” says Blake Svejkovsky, General Manager - Product Handling Systems, Heat and Control Inc. “Food processing sanitation requirements have increasingly become a number one priority so the design team incorporated sanitary design as a standard feature of the G3. Now processors can easily meet hygiene standards while taking advantage of FastBack benefits.”

Heat and Control has released new models for FastBack; 260E G3 and Revolution Gate 3.0; and for the first time, the Cartridge open channel support system.

Key design features like IP65 cabinets with flush doors assist cleaning in both wet and dry applications.

Threadless feet, open channel support structures (no closed tubes), sloped tops and easy access drawer control panels all contribute to sanitation and ease of use.

“These technologies combine the latest thinking in true sanitary design providing a level of comfort for processors that simultaneously saves time and money at each and every sanitation window.” says Svejkovsky.

These distinct improvements come with the legendary reliability (five times the design life of the competition) and rugged capability (the highest travel rates and throughputs), gentle motion with near zero product breakage and seasoning loss/build-up that has made the FastBack famous while also having the highest resale value in the market.

“Heat and Control is once again proud to lead the industry in providing the most advanced and reliable equipment on the market – and is a reinforcement of why our clients say ‘No one ever went wrong choosing Heat and Control’’, says Svejkovsky.

For more information on the FastBack 260E G3 system, visit www.heatandcontrol.com/fastback

www.heatandcontrol.com 34

Processing

CUSTOMISED SOLUTION

Engineered to integrate with a customer’s existing potato handling equipment, Heat and Control manufactured a continuous potato chip slicer feeding, washing, and frying system which will boost finished chip production capacity and improve product quality.

To continuously produce 5,000 finished pounds/hour (2,268 kg/hr) of potato chips, the system accepts a high volume of peeled potatoes from the customer’s existing preparation equipment and singulates them into multiple slicers. Accurately feeding potatoes into each slicer increases the yield of whole slices, which consumers prefer.

Efficient slicing reduces the amount of scrap transferred to the washer and fryer, so slice washing efficiency is maximised and cooking oil degradation is reduced.

New potato processing equipment seamlessly integrates into existing line

For operator safety and increased productivity, the slicer platform includes a pre-plumbed sink and service station where operators can safely replace blades on the slicer heads.

Before frying, surface starch and potato particles are washed from the slices by Heat and Control’s latest two-stage speed washer. Low water volume and a rapid wash cycle minimise slice breakage and increase finished product yield. Slices are spread in an even mono-layer across the washer’s discharge conveyor to optimise dewatering efficiency, promote uniform cooking, and reduce production of unsalable slice clusters.

After a final fresh water rinse, surface moisture is removed from the slices by a patented AirSweep® vacuum blow-off system. Reducing the amount of water carried into the fryer by the slices lowers fryer fuel usage by as much as 8% compared to systems using an air knife alone. Heat and Control offers the AirSweep on all of its potato slice washers and blanchers, and as a de-watering kit to reduce energy usage of freezers.

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From the washer, dewatered slices enter a new Heat and Control PC-50 multi-zone fryer. Oil flow and temperature in the fryer automatically adjust for changes in product load and temperature.

Cooking oil enters the fryer through patented inlets that produce even cooking across the width of the fryer pan. Multiple oil inlets and outlets maintain precise temperature control for consistently uniform finished chips. The oil circulates rapidly through the fryer, filter, and heat exchanger for gentle heating.

This also keeps fines in suspension for efficient removal. One hundred percent of the fryer system’s oil volume is continuously filtered once every minute.

Low system oil volume produces a fast oil turnover rate to produce the freshest chips with a long shelf life. The oil filter, main circulation pump, piping, and control valves are all re-assembled on a compact Fryer Support Module to reduce piping runs, installation downtime, and maintenance costs.

An oil cooler is available to quickly reduce the temperature of cooking oil before it is stored after production. This eliminates delays and allows profitable operation to continue longer.

Heat and Control continues to develop efficient and sustainable technology for large and small processors to produce the highest quality potato chips and snacks‌which helps explain why most of the world’s potato chips are produced with Heat and Control equipment. Preparation, washing, and frying systems are custom-designed for continuous production from 400 to over 6,500 finished pounds per hour (181 to over 2,948 kg/hr), or for batch frying 150 to over 500 finished pounds per hour (68 to over 227 kg/hr).

http://www.heatandcontrol.com/potatochips.asp

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corn products technology

WE KNOW WHAT TO DO WITH CORN

CORN PRODUCTS PROCESSING SYSTEMS Corn is the primary grain farmed and produced in the world, and has been used for centuries in Central and South America to produce products such as tortillas, tacos and corn chips. The growing diversity of the global population in the early 1900’s saw many people exposed to different foods and flavours, with Mexican based foods such as fried tortilla chips gaining popularity in the United States.

Since the 1930’s, corn based products have increasingly become part of the mainstream snack food industry, with fried tortillas evolving into mass produced corn chips, and are now one of the world’s most popular snack foods. As one of the most established equipment manufacturers for food production equipment, Heat and Control has been involved with producing corn based snack foods since the 1950’s and are a one stop shop for specialised processing, seasoning, inspection, conveying, weighing and packaging for corn products.

HOW DID COMMERCIAL PRODUCTION OF CORN BASED PRODUCTS START? Tortilla chips and Tostados, a type of tortilla chip, were sold in the US in the early 1900’s in restaurants in Texas near the Mexican border. I.J Filler, a salesman travelling along the Mexican border, was eating tostados in a small Mexican restaurant in San Antonio, Texas, when he conceived the idea of manufacturing a rectangular shaped corn chip. With the help of his father who designed a rudimentary grinder and rolling machine for the grinding and forming of the corn meal, Filler was granted a Trademark for corn chips in 1932.

A man named Elmer Doolin was also in Texas at this time and bought the rights to a ribbon shaped corn chips recipe from a Mexican man, as well as his retail outlets and production equipment. He started producing and selling this product as ‘Fritos’, with sales averaging $8.00 to $10.00 a day, yielding a $2.00 profit.

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WHAT IS THE DIFFERENCE BETWEEN A TORTILLA CHIP AND A CORN CHIP? The process for manufacturing corn and tortilla chips is similar, but simmering and soaking times will vary considerably.

Another difference is that tortilla chips are baked in the oven and then fried, while corn chips only go through the frying process.

By the mid 1930’s, all the key elements for the development of the snack food market were in place, and the catalyst that created a boom industry was the introduction of the corn chip.

Today, corn based snacks foods are a multi-billion dollar global industry. Tortillas and taco kits are seeing record purchases, with over 1 billion units sold in 2016 in the United States alone according to a report by Chicago Based research firm Information Resources, Inc. U.S. sales for Hispanic foods and beverages are expected to hit $11 billion in 2017, up from more than $8 billion in 2012, according to a report from Packaged Facts. Heat and Control has long provided the equipment and means for snack food producers to keep up with demand of this burgeoning market by providing complete systems for tortilla and corn chips, taco shells, tostadas, corn tortillas, extruded corn snacks and fried corn kernels.

HOW ARE CORN-BASED SNACK PRODUCTS MADE? The production of corn based snack foods has come a long way since Elmer Doolin started selling corn chips from his garage. Today, there are simple manually operated lines, semi-automatic or fully-automated systems available for corn based snack products.

Heat and Control will assess the needs of the individual customer and design a tailored production line to suit the production requirements and growth goals.

For processors, cooking corn allows the development and maintainence of a unique, consistent flavour and texture for their corn and tortilla chips, taco shells, tostadas and tortillas. Over the years, Heat and Control has perfected the operations of corn preparation to assure consistent quality of corn products for our customers, giving each product a unique, tasty flavour.

Given the large variety of corn-based products, there are different processes and equipment for each line of snack foods. Corn preparation can be quite complex if you do not have the correct equipment. There are many variations in finished corn products - with the shape developed to suit the purpose - corn chips for dipping are produced with a curve to make it easier to pick up dip; chips that are used for Nachos are larger to accommodate salsa, guacamole and melted cheese.

CORN COOKING PREPARATION The corn used should be whole grain, free of foreign material and contain a minimum of cracked kernels.

Most manufacturers use yellow corn rather than blended. However some processors use corn variety such as white or blue to differentiate their finished product. It is essential that clean, uniformly sized and impurity free corn is used in the mixture. The cleaner the corn is before cooking, the better the masa is later.

Broken pieces of corn will absorb larger quantities of water and will cause wet, sticky masa, making it difficult to cook and resulting in a poor product.

The first step is to produce a dough, or masa. When cooking the corn, it is important to hydrate the corn kernels and loosen the pericarp (external skin) and to increase the moisture content of the corn by adding water. Calcium Hydroxide or “food grade lime� as it can sometimes be referred to, must also be added to the corn to improve the flavour, as well as weakening and removing the outer layer of the corn pericarp so the chip is crispier. The addition of lime also controls the microbial activity, improving shelf life.

Heat and Control has a wide range of equipment to produce the Masa and ensure consistent quality. Our processing systems including Masa Production Systems and Corn Washers that enable food manufacturers to duplicate the masa recipe every time. Extruders and Sheeters accurately form and transfer masa without altering the texture and flavour of the product.

CORN OVENS AND FRYING When toasting tortilla chips, a belt moves chips through the oven and exposes both sides of the chip to the oven burners. The oven burners crust both sides of the chip and toast the bottom side of the chip using burners located under the top belt. This seals the chip and prevents the chips sticking to the belt after the first transfer point. The quantity of toast marks varies depending on what the market desires.

In the frying process, moisture is removed from the chip and replaced with oil to develop the texture, flavour and appearance of the chip. Heat and Control cooking systems, such as fryers and ovens, can evenly distribute heat and give precise control of cook time and temperature. We have a range of Tortilla Toaster ovens for uniform toasting of tortilla and taco shell production.

Our world class frying systems can provide precise control of oil flow, temperature and cook time for corn chips, tortilla chips and tostadas. We also have a specialised range of frying systems for taco shells and tostados.

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SEASONING AND CONVEYING Conveying corn based snack foods is a delicate process, as the product can break and the all important seasoning can fall off if lower quality conveyors or vibratory systems are used. Heat and Control conveyor systems can reduce product breakage by up to 60% using FastBackÂŽ Horizontal motion. The gentle slow-forward, fast-back motion prevents product damage and seasoning coating loss. The Heat and Control seasoning applicators, such as our FastBack RevolutionÂŽ Seasoning Systems, uniformly apply seasonings with less breakage and waste.

Corn snack foods are an ever-changing industry, as consumers are exposed to new products and flavours.

Since 1950, Heat and Control have committed to assisting food manufacturers respond to market changes by continuously improving equipment, and providing our customers with the best equipment and technology to increase production levels.

Our complete Corn Product Systems are designed by engineers with years of experience in snack food products, making Heat and Control the leading single source supplier of all the equipment you need to process, season, weigh, inspect and package the highest quality corn chips, tortilla chips, and other corn snacks.

h t t p : / / w w w. h e a t a n d c o n t r o l . c o m / tortillachips.asp

THE COMPLETE SYSTEM From masa production to forming, toasting, conditioning, frying, seasoning, and inspection, 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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Dry corn cooking Corn washing/draining Milling and pumping Sheeter Toaster oven Equilibrator/conditioner Extruder Fryer Fryer support module Ambient air cooler Seasoning application Conveying and distribution Ishida weigher Ishida bagmaker Ishida seal checker CEIA metal detector Ishida checkweigher Ishida X-ray inspection

Food Processing & Packaging Systems

BENEFIT FROM OUR GLOBAL EXPERIENCE for Corn Product Processing systems

From MASA production to forming, toasting, conditioning, frying and seasoning, HEAT AND CONTROL provides all the equipment and sevices required to make the highest quality corn and tortilla chips, taco shells, tostadas and tortillas.

Local sales + support teams but with a GLOBAL network of manufacturing facilities + support offices.

Preparation | Cooking | Conveying | Seasoning | Weighing + Packaging | Inspection | Controls + Information

heatandcontrol.com | info@heatandcontrol.com

MASA MAKERTM WILL CHANGE THE WAY THE INDUSTRY THINKS ABOUT MANUFACTURING CORN PRODUCTS Production of corn masa traditionally requires lots of time, water, and floor space and has always been a challenging area to achieve efficiency gains. Heat and Control developed a method to overcome these barriers and created a unique process of making fresh masa that eliminates corn simmering, soaking, and washing.

Masa Maker™ will change the way the industry thinks about the masa making process.

Since the inception of industrial food production, Heat and Control has helped corn snack and tortilla product manufacturers meet every challenge to achieve higher capacities, lower production costs, and superior product quality. Heat and Control’s Guadalajara, Mexico manufacturing facility, one of nine global manufacturing operations, is in the heart of the tortilla and corn products industry. Close relationships with manufacturers over the last 30 years has resulted in continued advancements in corn processing technology.

The patent-pending Masa Maker system produces fresh masa from dry corn in minutes compared to hours required by the traditional simmer/soak process. Masa Maker needs no steam generator, simmer kettles, soak tanks, or washers and eliminates water discharge and sewage fees. It allows tortilla and snack manufacturers to produce customised masa almost on demand, eliminating the long lead times for dry corn preparation.

Compared to using pre-milled corn flour, Masa Maker produces masa at a significantly lower cost.

“This is revolutionary technology which has eluded the industry for decades,” says Andy Caridis, Chairman of Heat and Control. “The flexibility of the Masa Maker process allows you to develop unique flavours and textures for your end product,” he explains. “To truly understand the versatility of this new process, we invite processors to visit our technical centre in Guadalajara, to see how Masa Maker can produce customised masa formulations for many different types of corn products.”

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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Making Masa in Minutes Corn product formulations in less time, with less water and with less waste ...to this...

How do you go from this...

...in less time? ...at a lower cost? ...with less water? ...with less waste?

The answer: use Heat and Control’s Maser Maker™ Making corn products, such as tacos, tortillas and chips, can be a complex process. The first thing that needs to be made is corn masa (meaning ‘dough’ in Spanish). Producing large quantities of masa requires a number of steps, such as dry corn cooking, corn washing & draining, and milling and pumping.

While this process is very effective and necessary for certain types of corn and corn products, it uses a lot of water, produces a lot of effluent, needs large floor space and takes a lot of time. For specific types of corn product formulations, Heat and Control’s Masa Maker is ideal in eliminating these steps.

1

Eliminate these steps:

2

1. Dry corn cooking 2. Corn washing & draining

3

3. Milling and pumping

And replace with Heat and Control’s Masa Maker

masa maker™

Making corn products is a complex Knowing which process system works best for your product and type of corn is essential. Contact Heat and Control to find out more

Benefits of the Masa Maker The Masa Maker can save money and time while ensuring your final product maintains the highest quality.

Masa production takes minutes, not hours

Use water only as an ingredient

The result: high quality corn products

No need to simmer, soak or wash the corn Less equipment needed to do the same job

Reduce production costs, floor space and sanitation costs.

Eliminate water discharge and sewage fees.

Innovation in Action

TECHNOLOGY THAT HAS ELUDED THE INDUSTRY FOR DECADES....IS NOW HERE! FIESTA CHARRAS GROUP IS ENJOYING THE BENEFITS.

Founded in 1982, Fiesta Charras Group is a leading producer of tostadas and other foods. Distributed throughout the United States, Canada, Mexico, and Central America, Charras brand foods include 16 varieties of fried and baked tostadas, plus tortilla chips, salsas, and extruded snacks system for masa production at its Tostadas Charras plant.

Fiesta Charras recognised the benefits of Masa Maker, and adopted the system for masa production at its Tostadas Charras plant.

“We are always looking for products that surprise our customers in both innovation and quality, and this system has helped us to lower production costs and become more productive in our processes without neglecting quality,” explains general director, Raul Leal.

“We are always looking for ways to improve and exceed the expectations of our customers,” he adds. “Masa Maker has helped us succeed in both areas.”

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snack flavouring technology

SNACK FLAVOUR APPLICATION SYSTEMS Seasoning is an integral part of any snack product, it is a way to differentiate and create interest in your product.

The Seasoning systems most commonly used in savoury snacks include: • • • •

Conveyor based dusting system Drum based single-stage dry flavour application Drum based two-stage oil and dry flavour application Drum based slurry

The key to great seasoning coverage is consistent flow with process control. So what is the right flavouring system for your snack product?

Dry only systems are used on products that have natural tack • Fried potato chips and crisps • Fried pellet snacks Oil and dry systems are used on snacks that do not have natural tack • Tortilla chips • Corn chips • Mini rice cakes or other dry puffed products • Popcorn • Baked chips and crisps • Extruded snacks Slurries • Extruded snacks • Popcorn • Puffed snacks

Seasoning systems fall into the following 3 categories: In-kitchen seasoning systems typically have a large capacity and are used where minimal flavour changes are required, they include two stage or slurry systems.

On-machine seasoning systems are used for one stage coating and are ideal for applications where many flavour changes are required.

Belt coating systems are used primarily for salt only application.

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SINGLE STAGE COATING APPLICATIONS 45

IN-KITCHEN SEASONING SYSTEMS In-kitchen or process seasoning systems consist of a large coating drum, seasoning metering device and a seasoning spreader device. They are ideal for core products on process lines that change flavours once a shift or less. These systems are great for high volume products and designed for continuous product flow.

The advantages of an In-kitchen system: • • • •

Ideal for large production lines that have a few flavour changes Most consistent seasoning System can be rolled in and out of the line Typically less expensive

ON-MACHINE SEASING SYSTEMS (OMS)

On-machine seasoning is seasoning application at the weigher (sometimes referred to as on head). An OMS system comes pre-assembled and mounted to a platform prior to shipping, allowing it to be quickly set in place and connected to utilities at the plant so production can begin without delays.

Benefits include, ease of operation, sanitation, cleaning and simple to use, as well as newer designs to provide excellent coverage.

OMS systems apply seasonings to snacks just before they enter the weigher to increase production versatility. They allow processors to run a different flavour on each bagger, running multiple flavours at one time leads to smaller warehousing requirements. Fryers continue to run during flavour change-overs and with higher packaging equipment efficiency experienced.

DUST-ON/OVER THE BELT SEASONING These systems are typically used for salt only. They require less capital outlay than the more sophisticated In-kitchen and OMS systems and are simple to use.

Spray Dynamics® metermaster salt applicator: Dispenses powdered and granulated salt over-product on a moving belt with consistent and repeatable accuracy.

TWO STAGE COATING APPLICATIONS

OIL + DRY FLAVOUR Two-stage systems are employed when the natural or process induced tack is not present on the product to be flavoured. Oil is sprayed onto the product prior to adding the dry flavour. The temperature of the product is very important to how much oil stays on the surface, similarly the dry flavour coverage is totally dependent on oil coverage.

An all-in-one package, the two-stage seasoning - in-kitchen system can handle large product volumes. If temperature is critical the placement is flexible. This system is the best choice for high absorption products.

TWO STAGE SEASONING SYSTEMS Two stage seasoning – oil in-kitchen dry flavour on head Advantages • Short dry flavour changes • Oil spraying confined to the kitchen area • Allows for time adjustments between oil and dry • More flavours can be produced at one time Two stage seasoning – oil and dry flavour on head (OMS) Advantages • Short flavour changes • Works well with low fat and high absorption products • More flavours can be produced at one time Two-Stage Coating System: The Spray Dynamics two-stage coating system provides consistent, uniform application of liquid and dry coatings on extruded, baked, frozen, and fried products.

APPLICATIONS SYSTEM - DRY DUST APPLICATORS There are various types of dry flavour applicators that can be used for applying seasoning to snack products, these include Scarf plate dispensers and electrostatic systems.

SCARF PLATE FEEDERS Scarf plate feeders are easy to operate, easy to clean and can work with most products, creating a consistent curtain of seasoning.

On the scarf plate feeder the bias is cut on a vibratory or horizontal motion conveyor, and a screw feeder is used to feed the spice at the desired rate.

Electrostatic applicators work by applying a static charge to the powder, oil or slurry as it is being sprayed onto the base product. As the flavourings and coatings become ‘negatively’ charged, they repel each other making a nice curtain or spread of seasoning.

Electrostatic applicators offer a reduction in dry powder usage, even coverage and a cleaner working environment.

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SNACK FLAVOUR APPLICATION SYSTEMS

SNACK FLAVOUR APPLICATION SYSTEMS SPRAY APPLICATORS Pulsing sprays are a proven economical, simple but highly accurate system with a small footprint.

They include a piston pump with adjustable cavity size.

Spray Applicators - continuous air assist atomise low pressure liquid using air. The air is added around the annulus or internal mixing chamber and is typically low pressure creating a continuous stream of oil. The system works well with a PD pump and flow meter and is good for high oil rates.

With Spray Applicators - continuous oil spray systems getting an even coating of oil on each piece is key to flavour adhesion and appearance.

Processors should use as many nozzles as practical to apply to more pieces at once. If using a pulsing system keep rate above 150 pulses per minute and make sure continuous systems have balanced pressure to each nozzle. Always spray on tumbling product.

Spray DynamicsÂŽ Slurry spray system - For snack and other applications to maximise coverage and minimise waste.

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For more information on any of the snack flavouring application systems, visit www.heatandcontrol.com

SLURRY APPLICATORS

When product specifications call for more oil than seasoning, a slurry is typically used. Typically oil is more than 60% of the slurry weight. Mixing tanks are required as many ingredients including salt will not dissolve in oil and constant mixing is required.

Most slurry applications require a soak, time for the oil seasoning mix to be absorbed in the base product.

The advantages of using a slurry applicator is the correct mixing of several liquid and dry powder ingredients in proportion. They also work well on extruded and pellet type products as well as popcorn.

Spray DynamicsÂŽ master series tank system - Engineered mix/use liquid blending and supply station.

BENEFIT FROM OUR GLOBAL EXPERIENCE FOR CONVEYING HARD-TO-HANDLE PRODUCTS.

CONVEYING + SEASONING SYSTEMS FastBack ® technology has transformed the product handling market by providing varied solutions for hard-tohandle products like salads, snacks, fresh chicken, cookies, candies and many more.

The energy efficient, versatile and reusable FastBack drive that includes a full 5-year drive train warranty.

LOCAL sales + support teams but with a GLOBAL network of manufacturing facilities + support offices.

Food Processing & Packaging Systems

Preparation | Cooking | Conveying | Seasoning | Weighing + Packaging | Inspection | Controls + Information

feature story

DELVING INTO BATTER & BREADING

By Darren Foster, Food Technologist: Heat and Control Pty Ltd The concept of covering a basic food product with some sort of coating before cooking has been around for a long period of time. Think of English fried fish in a batter coating (with chips, of course!) or Japanese Tonkatsu. A quality coating on a product plays an important role in maximising product yields, while delivering flavour as well as textural and visual differences. The big difference today is that a product produced in Thailand may be destined for a market in Japan, the EU or North America, complete with regional authenticity.

The manufacture of these coatings is now a major industry which has challenged food processing machinery manufacturers to develop application equipment that keeps pace with increasingly complex coating formulations.

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There are two main types of coated product, those with an outer layer of coating applied as a liquid, called battered products and those with an outer layer of coating applied in granular form called breaded products. Many variants of each type exist and most will be covered in this article.

In general, the cost of the coating ingredients is lower per kilogram than the food to which they are applied, usually called the substrate. As a result, it can be cost beneficial to add a high a percentage of coating, called pick-up, as the product can accept without loss of quality. Once the pick-up for a particular product has been determined it is important to maintain this percentage in order to achieve a consistent end product. For some lower grade raw products, adding a coating may actually improve the quality of the finished product.

One of the main requirements of any application system is to ensure the coating adheres to the substrate. A well designed coating system will maximise coating adhesion to the substrate ensuring a high quality finished product.

Breaded Products The most prevalent of the coated foods is the breaded product where a coating is usually applied on top of an adhesive batter on a predusted substrate. The process is usually described as pre-dust/batter/bread; if a higher pick-up percentage is required the batter/bread stage can be repeated.

Applying a pre-dust absorbs moisture on the surface of the substrate allowing the batter improved adhesion to the product. Usually consisting of a flour base, pre-dusts can have a wide variety of additives with some being quite product specific. It is common for manufacturers to add gums or other starches to promote adhesion of the batter.

Flavours can also be included in the pre-dust as this is the coating layer that directly contacts the food substrate. In a flat Breading applicator, the substrate is conveyed on a bed of pre-dust, through a curtain of pre-dust falling from an upper hopper, to ensure that both upper and lower surfaces are evenly coated.

Following this a compression roller may be used to push the substrate into the bottom bed and help to coat the top and sides as well as improving adhesion to the substrate.

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.

The pre-dust needs to be kept free of lumps which occur as moisture is absorbed from the product and coagulates. This is usually done on a continuous basis at some convenient location on the applicator, by sifting to keep a light consistency. As well the inclusion of an air blow off to prevent excess coating material from being left on the substrate will prevent excess coating material getting into the batter. This stops the batter from thickening and more difficult to maintain at correct viscosity.

A WELL-DESIGNED COATING SYSTEM WILL MAXIMISE COATING ADHESION, ENSURING A HIGH-QUALITY FINISHED PRODUCT. After pre-dusting, the substrate is given a coat of adhesive batter on which the outer breading will be applied. Such batters start from a basic flour and water mix to which functional ingredients are added to suit the product. Typically, these ingredients will include additional starches and gums such as alginates or carageenan for adhesion and guar or xanthan gum to increase viscosity. Control of viscosity and temperature of the batter throughout production is essential for consistency of product texture, appearance and for coating system performance in the fryer. Viscosity is generally checked frequently during production using a variety of both manual and automated methods that are available.

Batter can be applied in one of two systems. Low viscosity batters, which includes most adhesive batters, may be applied in a curtain (or weir type) applicator or in a submerger type applicator.

Tempura batters are most commonly applied in a submerger type applicator. In the curtain type applicator, the substrate passes through a shallow pool of batter whilst more batter is poured over the upper surface from a series of curtains. As the excess batter flows off the substrate the sides of the product are also coated. Air knives and wipers may be used to remove excess batter which might otherwise carry over into the breader and cause wastage or unsightly coatings.

Flour is a non-free flowing material which bridges quite easily in hoppers and causes high belt tensions in applicator conveyors. Secondly flour “floats” very freely in air and dust control can be a significant issue to be addressed by these machines, particularly those running highly seasoned pre-dusts! There are a lot of specialty pre-dust units marketed by different equipment manufacturers which address the specific needs of the materials being applied. Some machines have interchangeable parts which allow them to be converted for use as free flowing breaders. This can assist smaller processors, greatly increasing their flexibility to configure lines for products having different coating systems with a minimum level of equipment investment. Once production increases and dedicated process lines are required, flexibility becomes less important, but does allow for a “universal” breading applicator to be used as a backup when required.

The curtain type batter applicator is equipped with a pump to circulate the batter to the weirs and to prevent the solids from settling out when using lower viscosity batters. The pumps are specifically selected to reduce shear on the batter which can lower the viscosity and degrade the coating system. Pumping generates heat which may need to be compensated for by inclusion of a chiller in the circulation loop to ensure the batter temperature is maintained within a certain range.

The final step in this process is to add the outer breading coating which comes in many forms and styles. The “crumb” style breaders that are most frequently encountered are: CRACKER MEAL – a versatile, low cost breader, this is quite finely ground from baked and dried cracker type dough. It is often blended with other, more expensive breaders to control cost and assist with application and oil absorption. Colour may be added to change the appearance of the finished product.

AMERICAN CRUMB – is a dryer, yeast raised bread dough baked and dried to the required moisture. The crust forms darker highlights in the ground up crumbs, whilst product appearance can be further enhanced by colouring agents.

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... / COATING TYPES AND EQUIPMENT SELECTION JAPANESE CRUMB – is generally cooked in an electric induction process using a traditional, yeast raised bread dough. It has an elongated shape and porous texture which makes it quite fragile, requiring special application equipment. Applicators will require the capability to apply smaller particles close to the substrate with the larger particles at the finished product surface.

The other main class of breader is the flour or powder breading. Based on wheat flour into which a variety of other flours, starches, gums, seasonings and colouring agents may be added. This coating will produce a very different bite to a crumb coating, but is capable of carrying much heavier flavours than crumb.

Flour coatings behave in much the same way as predust, and the same applicator can be used for both products. Dust control is very important here as the seasonings added to the flour can be quite irritating if inhaled or rubbed into the eyes. Some substrates can be quite difficult to cover fully with a flour breader due to their shape, flexibility or skin flaps. Special machines have been developed to flip the substrate two or three times during application so that the difficult to get at places can be properly coated.

Control of temperature and viscosity of a tempura batter is even more critical than for adhesive batters, therefore they are usually mixed in small batches to enable them to be used within 5-10 minutes of mixing.

Alternatively, they may be mixed in automated system which recirculates the batter between the applicator and a temperature controlled reservoir. Water and batter mix are added in accordance with the sensed viscosity of the circulating batter, to maintain the required values in the applicator. Circulation pumps are usually of the positive displacement type to minimise batter shear damage. They are designed for easy removal of the impeller to facilitate cleaning and all piping is connected to the equipment with quick release couplings for the same reason.

There is also a number of special purpose batters used for specific products. Some of these are designed to act as binders, holding the breading onto the substrate during frying without changing the appearance of the product.

Other batters are designed to reduce the amount of oil take-up in the fryer, which is attractive to the health conscious consumer. Another, clear, coating can be applied to French fries which enables them to be presented crisp and palatable for up to 30 minutes after frying.

Frying and Oil Quality

Battered Products When the outer coating on the product is a batter, it will usually be a tempura style which is applied. These batters have similar ingredients to the adhesive batter with the addition of a leavening agent. The leavening ingredients combine with the heat of the frying process to produce carbon dioxide, causing the batter to expand as it sets forming the crisp open structure which characterises tempura coatings.

The basic process is predust/batter with predusting used to ensure good adhesion of the batter to the substrate. Some products will get a pre-treatment with a wash batter to ensure that the substrate surface has uniform moisture for even predust coating and to increase the pick-up of coating in the final product.

Wash batters are usually applied in a curtain type applicator however tempura or other puff style batters are most commonly applied in a submerger applicator because of the high viscosity of these coatings. Air knives are used to remove excess batter before the fryer to avoid unnecessary fines building up in the cooking oil.

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Frying could be considered the most common method of cooking coated foods. It sets the coating, imparts flavour and colour producing an appetising finish.

Choosing the right frying system is vital for processors to ensure they get optimum results. In order to maximise their return on the fryer systems, the processor should take into consideration the questions below when selecting frying equipment: • Is the product fully fried or par fried?

• What is the type, physical size and shape of the product?

• What are the expected production throughput rates?

• How much oil will absorb into the product during frying?

• What will the heat load be on the fryer?

• What is the most economical type of heating for my process?

• What is the optimum conveyor design to suit the products being fried?

• How easy is it to clean the fryer?

• What are the oil filtration requirements?

• Does the product have a batter or breading final coating?

• Is the machine suitable for all current and future oil types?

During the frying process the heat energy from the hot oil starts a chemical reaction leading to the formation of a crust on the coated product. One of these reactions is where water from the coating is heated to form steam and produces the bubbling normally associated with the initial frying of food. This skin then deepens to form a crust while all the time releasing steam from within the product, as well as in the area where this evaporation is occurring; the temperature is seen not rise above 100°C. As the pressure from the escaping steam reduces, hot oil enters and fills the voids within the crust left after the water has been boiled away.

As the use of suitable frying oils is a major ongoing cost and concern, food processors must endeavor to maximize the oil life used in their frying process. There are a considerable number of areas that can impact ongoing oil quality including the use of the correct oil for the product, effective oil filtration, production rates, oil turnover time, fryer design, oil handling and storage and correct fryer operation practices.

Coating Application and Frying Equipment A basic batter/bread system will do a good job in a coat and freeze situation, however, when the product is to be further processed by frying or oven cooking before freezing the coating system needs to be more sophisticated.

In the latter case, the processor is taking responsibility for the finished appearance of the product whilst in the former, this responsibility is taken by the consumer, who is likely to shoulder the blame if the coating falls off in the fryer.

For the best coating on the finished product a processor needs to work closely with both the ingredients supplier and the equipment supplier. In the case of the latter, both the coating equipment and any subsequent cooking (fryers and/or ovens) should be considered as a whole, with processing systems needing to work together to obtain an optimum result.

The selection of coating and cooking equipment involves decisions which must cover many facets including functionality, operational needs, marketing and consumer needs as well as hygiene integrity and legislative requirements. Furthermore, market opportunities require the equipment to contend with current products and situations in addition to having to comply with possible future needs and requirements.

http://www.heatandcontrol.com/meats.asp

BENEFIT FROM OUR GLOBAL EXPERIENCE

Prepared Foods Processing Systems

LEARN MORE

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QUALITY AND ACCURACY FOR PETFOOD CONVENIENCE, THANKS TO ISHIDA An Ishida multihead weigher and X-ray inspection system are ensuring weight accuracy and quality control for a new range of single-serve cat and dog food in doypacks, produced by Italy’s leading pet food manufacturer Morando S.p.A. The Ishida weigher is a CCW-RV-212 from its latest and most advanced multihead weigher series. In addition, to the weigher is an Ishida IX-EA-2161 X-ray inspection system, specially designed for smaller sized packs, for the quality monitoring of the finished pouches.

At Morando’s factory in Molfetta southern Italy, 7,000 kgs of meat is produced each day for the doypacks. The meat is first extruded into long strips which then pass through an oven, are cooled and diced, and then cooled again before being fed via an elevator and vibratory cross feeder to the top of the weigher. Jelly or gravy are added to the meat after weighing.

The Ishida CCW-RV-212 is weighing the diced cooked meat at target weights of 85g, 100g, 150g and 300g, the largest two sizes specifically for dog food and the smaller sizes for cat food as well. The 12 head machine is divided into two halves, each one feeding a separate pouch machine below. Special embossed surfaces help to ensure a smooth flow of product throughout the weigher. To maximise speed and accuracy the six pool hoppers on either side each feed two weigh hoppers.

This is generating a throughput of up to 90 packs per minute but the weigher has the capability to go even faster.

Weighing accuracy is precise and consistent, according to quality manager Sabino Tattoli.

“We have been very pleased with the performance of the Ishida weigher, and we have found that giveaway is minimal,” he explains.

Another benefit of the weigher, says Sabino, is its ease of use. “Product changeovers can be carried out literally at the touch of a button, and the weigher is also very easy to dismantle for cleaning. This is definitely very helpful for a lot of our operators.”

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give our friends the treat they deserve

With over 65 years of industrial process automation experience, Heat and Control improves line efficiency with equipment that boosts productivity, cuts waste and enhances quality for pet food products.

• Ovens that deliver uniform cooking and maximum yield • Optimised coating and seasoning application Indeed, so simple is the machine to use that just one operator is needed at any one time to oversee the entire packing operation.

• Conveyors that meet high sanitation needs • Weighers that cut giveaway to the lowest level • High speed checkweighers for accurate weight verification • High sensitivity x-rays for foreign object detection

With Morando typically operating two eight hour shifts, five days a week, the reliability of the weigher has also been exemplary since its installation. “It has continued to perform consistently well,” confirms Sabino.

Quality is a watchword throughout the Morando operation and the company therefore uses the Ishida X-ray for a final check to ensure that there are no unwanted contaminants, particularly metal pieces, in any of the pouches.

• Metal detectors that find contaminants and eliminate false rejects

Cook | Season | Convey | Weigh | Package | Inspect

complete line solutions to make superior quality pet food products

The Ishida IX-EA-2161’s X-ray tube enables the machine to offer higher detection levels than a standard metal detector, checking products for a much wider range of foreign bodies. For Morando it is able to spot contaminants as small as 0.6mm “With the help of Ishida, the introduction of this new pack format has gone very smoothly and we now have another range of high quality products to add to our portfolio,” concludes Sabino. “The simplicity of operation of the weigher and the precise and consistent weights it delivers are major benefits.”

If the new doypack range proves as successful as anticipated, Morando will be looking to double production with the installation of a second line. And, says Sabino, Ishida will certainly be a part of this once again.

info@heatandcontrol.com

|

www.heatandcontrol.com

http://www.heatandcontrol.com/ packagingandweighing.asp

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SALAD FILLING TURNS OVER A NEW LEAF

SALAD PROCESSING IS EVOLVING THANKS TO THE LATEST AUTOMATED WEIGHING AND PACKING SOLUTIONS TO HELP PROCESSORS BOOST END-TO-END EFFICIENCY. FRESH produce processors are benefiting from significant technological improvements in recent years, with increasingly advanced weighing and packing solutions offering them higher than ever levels of automation.

Conveyors, for instance, are now designed to provide greater efficiency, according to Robert Marguccio, Heat and Control’s Business Manager of Packaging and Inspection Systems Australia.

“Features such as an infeeding conveyor belt with buffers and the mechanical indexing tables mean 100 per cent positional accuracy”, he says.

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“These high levels of accuracy result in virtually no spillage at the fill point, reducing product waste and giveaway.”

DIMINISHED DAMAGE Marguccio says salad product handling is also now more gentle, which means less bruising and product damage. “The weighers have been built with special high-embossed surfaces to prevent product from sticking, which means the product is weighed at a faster rate,” he says.

Dispersion feeders are also now more powerful, he says, offering optimal speeds for maximum efficiency and productivity. “Automatic feeders can maximise performance and reduce maintenance on the machines.

“The large volume hoppers on the weighers allow producers to develop a large range of bag sizes, so consumers have a greater choice when it comes to which product they purchase.”

Ishida Rotary Salad Filler

Marguccio says weighers are also better integrated with packaging machinery. When all machines are connected to a single network, benefits include more efficient transfer of information and data analysis.

LESS LEAF WASTAGE Marguccio believes Ishida’s Rotary Salad Filler, available from Heat and Control, solves the issue of leaf wastage better than others in the field.

Usually, salad leaves can have a free-flowing volume of up to three times the volume of the tray, which means the leaf does not naturally fit into the confines of the tray and easily spills over.

Ishida’s new system automatically fills salad into preformed trays at high speeds with minimum spillage.

With up to 50 trays per minute per lane on all pack

“THE AUSTRALIAN FRESH FOOD MARKET HAS SEEN THE INTRODUCTION OF READY-MADE MEALS WITH PRE-PACKAGED SALADS AND PRE-CUT FRESH VEGETABLES AND FRUIT.”

formats, the system combines combination weighing with the filler to pack salad into trays cleanly and quickly.

The Rotary Salad Filler accepts preformed trays which can be fed by hand or via an automatic denesting system.

The filler then fills the tray via an Ishida combination weigher and settles the product twice to ensure its fully in the tray. Trays are then lowered at the exit of the machine to ensure all product remains in the tray.

* This article first appeared in FOOD AND DRINK BUSINESS and has been reprinted with permission.

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ALL THINGS INSPECTION CEIA - THE WORLD LEADER IN METAL DETECTION UNITS CEIA is the world’s largest manufacturer of metal detectors, with over 90,000 units installed. CEIA has more than 40 years of experience and holds over 50 patents for innovations in metal detector design and construction.

ISO 9001 certified, CEIA metal detectors are built to rigorous quality control standards. Each circuit board receives a 200 hour burn-in test. Mean Time Between Failure rate is 70,000 hours, typifying CEIA’s reputation for reliability in all operating environments.

CEIA metal detectors are the only metal detectors in the world that use multi spectrum technology, meaning they can use several frequencies simultaneously. All other metal detectors can only use one frequency at the same time, meaning you have to reduce their sensitivity to prevent false reject signals caused by salt, moisture content, and other product effect conditions that may produce a signal on the metal detector.

THS SERIES The CEIA THS series provides the highest level of sensitivity to magnetic and non-magnetic metals, including Type-316 stainless steel. Immunity to interference and response speeds exceed the highest standards, and additional advantages include: • Sensitivity independent of product speed • Automatic product effect compensation • Highly accurate, repeatable multi-band auto learn • Superior water resistance and reliability • Models for conveyed, falling and pumped products THS/21 detectors for every application.

The CEIA THS/21 Series metal detectors are available separately and in pre-assembled configurations for conveyed, pumped, and free-falling products of all types.

Multi-Spectrum THS/MS21 Using CEIA’s proprietary multi-spectrum technology, the MS21 detectors accurately differentiate between product effect and metal contaminants with no need to reduce sensitivity. The simultaneous use of multiple detection frequencies delivers the greatest sensitivity to all magnetic and non-magnetic metals - plus accurate compensation for product effect to reduce waste and false reject signals. They are suitable for horizontally conveyed foods, free-falling products, and pipeline applications with or without a reject valve.

• Extreme compensation of product effect • Highest sensitivity to all metals • Continuous auto-testing and embedded self-calibration • 316 stainless steel construction to IP66 and IP69K

Single high-frequency THS/21 The CEIA THS/21 Standard metal detectors detect metal contaminants accidentally present in food products, with levels of sensitivity, immunity to interference, and response speeds designed to satisfy the strictest quality control requirements. THS/21 metal detectors allow interception of all magnetic and non-magnetic metals, including high-resistivity stainless steel. They are suitable for ultra-high sensitivity inspection of dry, non-conductive products in horizontally conveyed and free-falling configurations with or without a reject valve.

Economical THS/21E The THS/21E-3F metal detector provides excellent results on multi-product lines, where the individual products have very different conductivity characteristics. Under these circumstances, THS/21E-3F allows maximum sensitivity for detection of contaminating metals, including ferrous, non-ferrous and stainless steel. They are suitable for horizontally conveyed, free-falling, and pipeline applications of dry/neutral products.

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INNOVATION AND COMMITMENT TO INTELLIGENT PACKAGING SOLUTIONS

As a world leading single source supplier, HEAT AND CONTROL

can

provide

complete solutions for efficient and reliable packaging lines, including conveyors, weighers, checkweighers,

bagmakers,

metal

and

detectors

X-ray

systems.

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