Industry-changing equipment and technology designed for results. We engineer and manufacture modern industrial processing, coating, seasoning, conveying, weighing, packaging, inspection and controls systems. Each piece of machinery or end-to-end system is designed with expertise, experience, and excellence.
Advancing process technology with creativity, passion, and unmatched expertise on a global scale.
WHO WE ARE
ABOUT US
We are process and product technologists committed to advancing food, pharmaceutical, and other industries with science and imagination. Whether you measure success by flavour, efficiencies, improvement, or innovation, count on us to deliver results.
MISSION AND VALUES
Rising to the challenge, advancing processes, and helping to bring the best products to the world using science, technology, and creative thinking.
LEADERSHIP
Overcoming challenges and advancing operations is at the heart of what we do. We bring decades of knowledge, understanding, and experience across industries and borders to our client’s solutions that can’t be matched.
INTEGRITY
We listen carefully and do our best to exceed expectations in everything we do. We stand by our clients and are the first company they call when they need help.
PERFORMANCE
Our passion for excellence and exceeding expectations drives our creativity, engineering, and perseverance. We deliver quality, scale, and results to our clients and add success to each project to help them offer the best products possible.
COMPLETE SOLUTIONS
R&D + TESTING
Heat and Control Technical Centres are the ideal place to develop new products and evaluate equipment performance without interrupting production schedules at your plant. Depending on equipment availability and location, demonstrations of coating, cooking, conveying, seasoning, weighing, packaging, and inspection machinery are available.
DESIGN, ENGINEERING + MANUFACTURE
Innovative design and engineering solutions produce equipment designed for maximum versatility and production efficiency. Skilled craftsmen, using state-of-the-art manufacturing tools, build rugged machinery to withstand the toughest production schedules and harshest working environments. Attention to detail results in the industry’s most reliable and longest working food manufacturing equipment.
INSTALLATION, COMMISSIONING + OPERATOR TRAINING
Complete installation services utilising a team of multi-disciplinary experts to install new or upgraded systems followed by line commissioning that ensures smooth integration and operation to required specification.
Classroom and on-site instruction that teaches plant personnel how to safely operate equipment and to maintain optimum production capacity.
POST SALES SERVICE + SPARE PARTS
Gain access to service across the world utilising a network of locally-based field service teams and spare parts.
BLEND YOUR WAY
Blending food products with diverse characteristics presents a significant challenge for food processors. One of the key hurdles lies in understanding how these products behave throughout the transportation and blending stages of production.
During transportation, food products may undergo changes in their physical state due to factors such as movement, vibration, or surface contact. Fragile items risk breakage, while sticky or moist products may adhere to surfaces, complicating the handling process.
Similarly, achieving uniform blending poses challenges. Each component must blend seamlessly to create a consistent final product. However, products with different characteristics may mix unevenly, resulting in variations in quality or composition.
Understanding how food products behave during transportation and blending, allows you to fine-tune your processes, to minimise issues such as product damage, uneven mixing, or segregation. This understanding is essential for ensuring the production of high-quality blended food products.
Blending Fresh Produce
Handling fresh produce during conveying and blending can be challenging due to its variable behaviour. Factors such as texture, moisture content, and fragility can affect how produce behaves during the blending process. Achieving a consistent, high-quality blend requires careful synchronisation of your equipment — and processes — to handle the variations effectively.
FastBack® blending systems meet these challenges by providing consistent component streams, accurately metering components, and conveying blended products without segregation.
To create well-balanced blends of fresh produce, you need to coordinate different technologies in your production line. Our blending systems give your operators full control, ensuring everything works together seamlessly. Our systems guarantee synchronisation, ensuring consistent streams of ingredients, accurate measuring, and smooth blending of your final product.
FastBack systems simplify the blending process by weighing only the final product stream of each component, avoiding the need for bulky hoppers. This allows for precise measurement using high-resolution load cells. Plus, our durable stainless steel load cells are sealed to withstand tough environments. With quick-disconnect weight trays and easy sanitation design, cleaning is a breeze, minimising downtime and maximising production efficiency.
In addition to fresh produce, FastBack blending systems are ideal for snack foods, nuts and trail mixes, fruit snacks, frozen fruits and vegetables, wrapped candies, cereal, pet food and more.
Meet the innovative new heat exchange technology set to revolutionise the food industry — iHX Intelligent Heat Exchanger (iHX).
iHX is a low oil volume model of heat exchanger designed to offer a highly efficient, low cost, oil heating solution for food manufacturers.
This next generation heat exchanger is suitable for all manner of snack food applications including bakery, potato chips, corn products, nut products, French fries, potato co-products and all continuous frying operations.
Discussing its development, our Chief Engineer, Mick Walsh, highlights utilisation of modern computing technology to innovate, and enhance, the existing heat exchange technology in the creation of the new intelligent heat exchanger.
“Using the latest advancements in design and automation in computer code allowed us to perform the millions of calculations needed — to optimise radiative heat transfer and create an optimised tube bundle design and heating technology — for reduced oil volume,” he said.
“This innovation in design offers a twenty five percent increase in efficiency gains over our previous, base model heat exchanger.
“iHX performs at an optimal level because all tubes within the radiative zone use their whole surface area for heat transfer, reflecting heat from the insulation onto the back of tube surfaces which aren’t in direct line of sight to the heat source.”
The use of heat exchangers in food processing has revolutionised the industry, and their efficient heating performance and reliability make them a superior alternative to steam or thermal heating.
Our iHX Intelligent Heat Exchanger can be used as part of a new equipment line, or easily retrofitted to your existing line.
Mick Walsh, Chief Engineer Heat and Control
Customisation
When expanding product lines, adapting to market trends, and staying competitive, customisation and flexibility are essential. Our fryers provide unmatched versatility to meet your needs. Essential features include adjustable conveyor speeds, variable flow and temperature zones, and customisable frying profiles. These capabilities are key to meeting a diversity of processing needs and optimising your operational efficiency. Adjustable conveyor speeds optimise production throughput, while variable temperature and flow zones ensure precise control over frying parameters, increased flexibility, reducing energy consumption and producing a more consistent product.
THE ULTIMATE GUIDE TO CHOOSING AN INDUSTRIAL
FRENCH FRY FRYER
Choosing the right fryer is crucial for processors who want to make high-quality French fries — efficiently. With numerous options available, understanding the main features, benefits, and challenges of frying potatoes is key to making a well informed decision. Ready to perfect your French fries? Let’s take a look at six crucial factors and learn how they can help you boost efficiency, maintain quality, and tackle common production challenges.
Core Product Types
A key factor in selecting the right fryer involves understanding the core product types you intend to cook. For French frying applications key considerations include whether your product is unbattered — thin/thickly battered — or both.
Cooking fibrous products, such as sweet potatoes or other tuber types, can also impact the requirements for auxiliary equipment, such as filtration systems. Ranges of cut sizes, cook times and delta T requirements, pack depths and heat load requirements are also important factors to consider when selecting the appropriate frying system.
The frying of potato co-products, for example hash browns, often requires a more specialised frying and filtering system design. The shapes of the products, whether they are 2D or 3D, and the formulation and cooking temperature
profiles, such as whether they are simply battered, or battered and breaded, will influence your choice of frying and filtering technologies.
Ultimately, grasping the limitations of various frying technologies and determining the necessary flexibility for your product portfolio is key to selecting the optimal frying system.
Capacity
Another crucial consideration when selecting an industrial French fry fryer is its capacity. Start by assessing your production requirements, ensuring to choose a fryer capable of meeting — or even exceeding — demand while maintaining the quality of your product. High-capacity industrial fryers enable continuous production with minimal downtime and reduced oil turnover time, while maximising efficiency, quality and output.
When investing in frying equipment, it’s essential to choose options which align with your unique processing requirements. The best fryers meet these criteria, and go beyond, providing the versatility you need to thrive in an ever-changing industry landscape.
Maintenance and Cleaning
Regular maintenance and cleaning are paramount for preserving the longevity and ensuring consistent performance of industrial frying equipment. It’s important to prioritise models with design features and technologies that promote cleanliness right from the outset.
Features that mitigate residue accumulation, along with accessible design features such as removable components and easy-to-clean surfaces, to streamline maintenance tasks and reduce downtime are ideal. Automated cleaning systems and self-diagnostic tools are invaluable for detecting and resolving potential issues proactively, ensuring maximum uptime and productivity.
Oil Management
Efficient and effective oil management, combined with low system volume, is essential for preserving product quality, extending oil life, and decreasing operating costs in fryer systems. Our industry leading fryers feature integrated oil filtration systems capable of effectively handling a variety of product types, including unbattered products, thin or thick battered products, breaded products, and fibrous products.
Additionally, precise flow and temperature control in the fryer bed and system ensure consistent and even frying results across the full product bed width, and across all product ranges. This results in higher quality finished product and increased consumer satisfaction.
Energy Efficiency
Energy consumption represents a significant operational expense for potato processors, underscoring the importance of prioritising energy efficiency when choosing a fryer. Traditional heating technologies such as steam, thermal oil
and direct-fired systems are widely used in the industry. Insulation and auxiliary heat recovery systems, that capture and reuse waste heat in other process areas like dryers and blanchers, further contribute to reducing overall energy costs and minimising environmental impact.
Advanced heating technologies, such as pollution-controlling heat recovery systems like KleenHeat® and our innovative GreenHeat technology, offer you a competitive edge through substantial energy savings. For example, our GreenHeat technology can reduce up to 40% of the total heat requirement in the French fry process.
Moreover, these advancements can generate up to a 50% reduction in greenhouse gas emissions. Beyond the environmental benefits — you can also expect improved operational efficiency and potentially lower maintenance costs, thereby enhancing their overall competitiveness in the market.
Complete French Fry Solutions
Since our inception, Heat and Control has pioneered solutions to complex challenges in industrial food production, consistently delivering higher capacities, lower production costs, and enhanced product quality.
Our French fry and formed potato product systems are industry workhorses, which are setting the standard for sustainable potato processing. We work with a broad range of styles, including straight cut, crinkle cut, and coated and noncoated products, among others. Our solutions extend beyond traditional fries to encompass innovative products like hash browns, potato gems, and various co-products and fibrous items.
Selecting the right fryer is essential for optimising efficiency, quality, and profitability. With Heat and Control and our strategic allies, you get comprehensive turnkey solutions, and we can guide you through every stage, from potato receiving to palletising.
Ready to take your operation to new heights? Partner with us for swift access to industry expertise and customised solutions tailored to your needs. Let’s elevate your business together.
Exploring the Enduring Popularity of Hard Bite Chips
When it comes to savoury snacks, few can rival the iconic status of potato chips. Within this lucrative category, one crunchy contender continues to steal the spotlight. With their signature crunch and seemingly endless flavour varieties — hard bite chips are an enduring consumer favourite. But what’s the secret to their popularity — and what is it exactly — that makes them so very special?
The answer begins with their cooking method. This type of potato chip undergoes a traditional cooking process known as ‘batch cooking’ or batch frying, and whether you know them by ‘hard bite’, ‘kettle-fried’ or ‘kettle-style’ — the signature crunch is the same.
Origins of batch cooked potato chips
Long ago, in the time before commercial production, potato chip lovers used the batch cooking method at home. They’d slice up their own small batch of potatoes — before lowering them into a kettle of hot oil — taking them out to drain them off — then repeating the process. In those days, the vessel people used to cook their small batches of potato chips was a kettle shape, and this is where the term ‘kettle chips’ or ‘kettle cooked’ originated. This rustic cooking method achieved a distinct taste and texture — which is much the same now — as it was then.
In modern-day potato processing, the commercial batch fryer is an industry workhorse. They’re known as an economical frying solution for high volume production of batch-fried potato chips, French fries, prepared foods, meat, poultry and seafood and meat alternative products.
Our batch fryers produce superior quality products with a long shelf life. This equipment offers years of efficient, reliable service, with a
small footprint. They’re ideal for entry level or start-up brands, or established snacks processors looking to expand their product lines.
Batch Frying vs Continuous Frying
Several factors differentiate a batch fried potato chip from a regular potato chip. While regular potato chips are known for being mass produced, most consumers associate batch fried varieties with a smaller more ‘artisan’ cooking process. The regular style of potato chip is made using a ‘continuous frying’ method that focusses on speed and efficiency. In this method, potato slices are continuously fed into the equipment and carried through the fryer with circulated oil externally heated to a set temperature before being discharged. Many of the larger players in the potato chip industry are utilising continuous frying to produce regular style potato chips.
By contrast, the process of making batch fried potato chips is significantly different. To start with, the potato slices used are typically thicker, and as the name suggests these potato chips are cooked in individual batches. An inherently longer process than continuous frying, batch fried potato chips are cooked in small batches, at much lower temperatures than regular potato chips. It’s a slower, more traditional cooking method which sees the chips spend more time in the oil with a specified controlled temperature profile through the batch cook cycle.
While the process of batch frying potato chips is certainly longer, it is the slower cooking process that achieves the unique texture and signature crunch consumers love. Not washing the potato slices prior to frying (allowing starch to remain on the surface of the slices) is what
CRUNCHY CONTENDER
“
By embracing new technologies, processes, and strategies, you can enhance efficiency, improve product quality, while responding quickly to consumer preferences and market dynamics
“
Bobby Kane, General Manager Western Europe, UK and Middle East
allows the traditional ‘home-made’ appearance of batch fried chips to develop.
Innovations in Sustainable Snack Processing
Strong consumer preference for potato chips with characteristics such as firm texture (hard bite), natural ingredients and the association of a more artisan cooking process make batch fryers a favoured choice for production.
However, the efficiency of traditional pan-fired batch fryers, which tend to consume more fuel per kilogram of product, compared to modern continuous frying systems, is a key sustainability challenge for potato processors.
Bobby Kane, General Manager Western Europe, UK and Middle East, says that adoption of innovative technologies and processes can help processors achieve their sustainability goals throughout the production line.
“We’ve developed and manufactured three advanced systems
— which allow batch frying to approach the same level of energy efficiency found in the best continuous frying systems
— while still preserving the premium product qualities inherent to the batch frying process,” he says.
“Our systems are proven to reduce fuel costs, energy waste, air pollution, and water consumption — to help you process more responsibly, while benefiting the environment and your bottom line.
A great example of our commitment to sustainable food processing are our Booster Heaters. These innovative devices reuse waste gases to boost production efficiency and cut energy costs, all while reducing carbon emissions.
Whether as a new addition, or retrofitted to existing batchfried style fryers, they can reduce energy use by up to 30%.
Embracing such technology translates into real benefits for businesses, including significant cost savings and a smaller environmental footprint.
“By embracing new technologies, processes, and strategies, you can enhance efficiency, improve product quality, while responding quickly to consumer preferences and market dynamics.”
As a global leader in snack processing equipment, we have fast, high-performance, and sustainable solutions for every facet of your snack production line, paired with innovative problem-solving approaches.
Booster Heater - Preheat cooking oil to boost fryer production up to 13% with no extra fuel consumption. When extra production is unneeded, it can reduce fuel usage by up to 11.7%.
Delivering the ultimate in Potato Chip processing flexibility and quality
Precisely control temperature, product, and oil flow for superior potato chips with uniform colour and consistent finished moisture content. You can create custom temperature profiles with the same fryer to produce different styles for greater return on your equipment investment.
Heat and Control recognises the vital importance of sustainability in today’s world. In addition to providing industry-leading solutions, we are committed to aiding global processors in reducing their carbon footprint while increasing productivity by transitioning to renewable energy sources.
Within our portfolio, you’ll find some of industry’s most advanced vacuum frying systems, batch fryers, and continuous fryers designed specifically for hard-bite chips, and beyond.
We lead the industry with cutting-edge French Fry equipment, offering a comprehensive range of throughputs from 3 tonnes per hour to 40 tonnes per hour. In a recent project, we installed a fryer with a 3-metre cook width, achieving a nominal throughput rate of 35,000 kg/hr for a specific cut type. In addition to fryers, we’re at the forefront of innovation when it comes to filtration, heating, and oil management solutions.
What are some of the key sustainability challenges facing potato processors today? Let’s take a look at these critical issues and explore the cuttingedge solutions we’ve designed to tackle them.
SUSTAINABILITY CHALLENGE: ENERGY RECOVERY APPLICATION: FRENCH FRY
Within the broader landscape of potato processing, each product type presents unique challenges that affect sustainability goals. In the context of French Fry production — significant energy is consumed throughout the blanching, drying, and frying processes.
Ideally, much of this energy could be recovered and recycled. As drying and blanching typically take place at lower temperatures (compared to frying), it’s fairly common to utilise waste heat from the fryer stack to provide some of the energy needed by the dryers and blanchers. That said, a significant amount of steam heating is still necessary, which can be costly and also contributes to your carbon footprint.
To meet this challenge, our engineers have developed an innovative strategy which allows potato processers to power all of their blanching and drying processes with waste heat. Our system works by adding a small amount of extra (renewable) energy to the fryer exhaust, which enables the capture and recovery of a much larger portion of the waste heat. This cutting-edge innovation provides a saving of up to 40% of the total heating requirement of the French Fry line — while also providing an impressive 50% reduction
Our development of this innovative new sustainability solution utilises thermodynamic engineering and process expertise to achieve this impressive outcome.
SUSTAINABILITY CHALLENGE: ENERGY EFFICIENCY APPLICATION: BATCH FRYING
Driven by robust consumer demand for ‘hardbite’, ‘natural’, and ‘Kettle-style’ potato chips, batch fryers remain as a favoured choice among potato processors. However, a key sustainability challenge is found in the efficiency of traditional pan-fired batch fryers, which tend to consume more fuel per kilogram of product, compared to modern continuous frying systems.
We’ve developed and manufactured three advanced systems — which allow batch frying to approach the same level of energy efficiency found in the best continuous frying systems — while still preserving the premium product qualities inherent to the batch frying process.
1. Booster Heater for Batch Fryers (BF-BH)
Our Booster Heater for batch fryers is an exciting innovation for processors of batch fried potato chips. This equipment recovers waste heat from your fryer’s burner exhaust (chimney) and uses it to boost the heat input to the fryer. It can be applied to new builds, or retrofitted to your existing fryer in the field. Adapting or upgrading your production line with a Booster Heater will include an oil circulation system that offers additional benefits for product consistency, with an option for filtration.
BF-BH can reduce gas consumption by up to 30% which is an excellent saving in energy and greenhouse gas emissions.
2. Thermal Oil Heater Batch Fryer (MTKF)
Our MTKF is a batch fryer heated by thermal oil, making it compatible with a highly efficient thermal oil heating system. Its suitability is particularly notable for sites employing multiple fryers, as a single thermal oil heater can efficiently heat several fryers simultaneously.
3. Universal Potato Chip Fryer (UPC)
Our revolutionary Universal Potato Chip fryer (UPC) is a continuous frying system that has the ability to replicate batch fried product — with a higher production capacity, reliable consistency, and high energy efficiency.
SUSTAINABILITY CHALLENGE: WATER
CONSERVATION APPLICATION: POTATO CHIP FRYERS
Another production process with a unique set of sustainability challenges is seen in the production of potato chips. This process requires a substantial volume of water for washing and preparing the potatoes prior to frying. While water is precious globally, its scarcity and significance are particularly evident in certain regions.
At Heat and Control, we’re committed to consistently maximising the efficiency and productivity of your processes. Recent advancements in water conservation signify a significant leap forward in sustainability for potato chip producers.
SWSM is a water clean-up module that removes up to 90% of the starch from a potato slice washer and allows the processor to dramatically reduce water consumption. The cleaned-up water can be re-used directly in other processes (e.g. peeling and whole potato washing) without expensive external water treatment plants. Our PRSM is another water module that can remove larger particles from peeler and washer systems and minimise the amount of external water turnover required.
For many leading potato chip brands, earlier versions of SWSM have become standard equipment. With the introduction of our latest generation of SWSM, processors such as these can further enhance their performance and sustainability outcomes.
To address sustainability challenges in potato processing, innovative manufacturing designs like this are crucial.
CHOOSING
To secure future growth and sustainability, potato processors must persist in seeking innovative ways to stay competitive and overcome the industry's primary sustainability hurdles. By minimising environmental impacts such as energy use and pollution, processing costs can be reduced.
Positive results from our sustainability solutions are gaining the attention of potato processors globally. We have fast, high-performance, and sustainable equipment solutions for every aspect of your production line, along with innovative problem-solving approaches.
Join us in harnessing the evolution of energyefficient potato processing equipment, made possible by years of research and development.
Our best advice? Collaborating with a turnkey supplier provides the fastest and simplest access to the industry expertise and process knowledge necessary to grasp available solutions and their unique benefits for your organisation.
No matter your objectives — whether they involve boosting productivity, enhancing energy efficiency, shrinking your carbon footprint, or shifting to renewable energy sources — sustainable potato processing is possible, and we're here to support you at every stage.
LEARN MORE
Each year the quest for new and different flavour experiences yields a long and often fantastical list of predictions. All manner of food industry experts, come together to weigh in on which flavours consumers will want next, and the food industry sets about making the fantasy a reality.
Limited only by their imagination, snack processors are expanding their traditional lines with new products that challenge the boundaries of format, texture and flavour. Exciting and unexpected taste experiences add novelty to the snack experience and nostalgic flavours, cross category inspiration and flavour mashups are trending. Some of the most adventurous flavours we’ve seen include meat pie, fruit, cappuccino, sushi, butter chicken and beer flavoured chips.
Consumers seeking healthy and nutritious snacks are driving the trend for unconventional, better-for-you options. Clean label products are in high demand, and pulse, vegetable, and bread chip varieties in additional formats (like puffs and straws) are providing sensory experience through texture and crunch. Dehydrated potato, dried avocado, chickpea, lentils, baked kale, multigrain pita, and seed- and bean-based chips are also emerging in a variety of flavours.
While novelty and nutrition is capturing consumer interest, classic flavours remain a favourite. These flavours symbolise reliability and comfort, and the challenge for snack processors is finding the balance between novelty and familiarity.
Top Flavour Trends
_ Nostalgic flavours
_ Legacy recipes
_ Provenance flavours
_ Flavours that tell a story
_ Cross category flavour mashups
_ Plant based ingredients
_ Functional ingredients
These flavour trends put greater pressure for efficient recipe changeovers to minimise both product waste and production downtime.
As operations continue to expand past core product ranges, the right equipment is critical to optimising production and ensuring quality control. Flavour trends require efficient recipe changeovers to minimise both product waste and production downtime. Working with an experienced food industry expert, with extensive snacks experience, is the quickest and easiest way to get your new recipe right.
NOVELTY, NOSTALGIA
VALUE ADDED NUT SNACKS
As consumer demand for healthy snacks continues to grow, the variety of value added nut snack options will grow due to the creation of unique flavours/recipes, coatings and blends. Just as the Namkeen (traditional savoury snack) industry in South Asia has a multitude of methods and recipes to achieve unique flavours for each brand, nuts also provide an opportunity to offer a unique product that evolves with the changing needs and tastes of snack consumers.
Methods to create a value added nut snack product include:
• Roasting
• Seasoning + Coating
• Blending Oil Roasting (Frying)
Oil roasting is a process by which nuts are submerged or covered in hot oil and fried. Roasting accomplishes many tasks, including flavour enhancement, shelf stability (1.0 to 1.5% finished moisture), and destruction of microbes, such as Salmonella. For example, almonds require 2 minutes at 260°F (127°C) to destroy microbes. Basic frying principles can apply to most nut varieties (e.g., peanuts, almonds, cashews, pecans, walnuts, brazil nuts, sunflower seeds). Certain nut types, such as macadamias, need special care and handling considering their high cost and fragility. Also, because of their delicate flavour, it is necessary to fry them in high quality oil.
Frying time and temperatures are critical due to the very short time between adequately cooked and burnt. Customised conveyors are designed to help meter product for consistent roasting through the fryer. This varies depending on the nut variety, and attributes should be determined by testing and experience. Product feed to the roaster is critical to achieve a consistent production rate and uniform product depth. Moreover, it is essential to remove any debris before nuts enter the roaster.
Oil type or blend is an important factor for flavour development and is often a significant part of a brand’s secret recipe. Typical oils include canola, safflower, sunflower, peanut, and various hydrogenated blends. If oil solidifies at room temperature, all piping and tanks (especially low to the ground) must be heat traced, using steam or electricity.
Various processes can take place prior to oil roasting that impart a specific mouth feel, taste, and flavour experience (e.g., brine soaking, coating, drying). If nuts are dry roasted prior to coating, frying will be required to cook the coating only.
Dry Roasting
A dry roast involves processing by means of hot air, and some snack processors use this method to reduce oil content. Entry-level processors use forced air or semi-industrial type convection ovens with nuts in a single layer, stirring regularly to avoid surface burning. Large volumes are typically roasted in custom design drying ovens and include rotary type dryer/roasters. Certain types of rotary dryer/roasters are designed to lift, to fold, and to expose each product piece to fan-forced heated air thus fluidising the product bed so product is more evenly roasted and dried. This process is beneficial not only for traditional roasted nut products but also for honey-roasted and dough-coated Japanese- or Holland-style nuts. Independent heating zones allow for precise temperature control throughout the process.
Seasoning + Coating
This is where the uniqueness of a snack nuts comes into play and where the product can be positioned as a premium snack. Seasoning nuts allows snack processors to add sweet or savoury dry ingredients or a water-/oil-based seasoning emulsion to traditional nut products, as well as dough-coated products. Exotic flavour recipes are used as a means of achieving premium price points or appealing to specific taste profiles in markets globally.
The application of glazing oil, water, salt, spice-based seasonings, sugar, dough, chocolate, yoghurt, and batters gives personality to the product. Flavour and texture can be added to the base formulation with frying and drying temperatures enhancing flavour profiles. In addition, colour can be added to the base flavour mix to improve visual appeal.
Coating and seasoning application can be done in the process area (i.e., in-kitchen), in the packaging room, or on the belt along the line. Process area seasoning can occur directly after the dry roaster or after the cooling process and before transferring into the packaging room. On-machine seasoning (OMS) occurs in the packaging room, directly before the product goes into the weigher and bag maker.
Dry Seasoning
Dry season application of nuts can be complex as often a tack solution (stick) is required for adhesion of the dry seasoning. In many cases, this requires an oil- or a water-based solution, such as a gum or maltodextrin applications, before the dry application. Furthermore, the roaster type (oil or dry) is a crucial factor. For example, if the nut is dry roasted, a two-stage oil plus dry or salt application is required to achieve adhesion. For a coating such as a Tamari or brine, a water application plus dry is applied after a dry roaster with the cooler system turned off. If an oil roaster is used, then dry seasoning or salting can be used after the fryer. Consultation with seasoning system experts and often testing is necessary to decide the best adhesion and coverage of dry seasoning application.
Batter Coating
An example of batter coating is seen in the Indian snack category, Namkeen. Often peanuts are coated with batter made from Besan flour (gram or chickpea flour) and spices before going into an oil roaster (fryer). For this market, the key objective is to maintain the traditional taste and texture of a handmade product in a continuous system. A specially designed vibratory feeder singulates the product and feeds it into a curtain of batter. This ensures that the product is presented to the batter curtain in a single layer, thus reducing the risk of getting doubles or married product. The batter curtain has a counter flow which ensures that the product is fully encapsulated before being placed into the fryer for cooking. These features ensure a premium coated product is produced with minimal waste.
Honey Coating
Honey coatings, popular in Europe and the Middle East, apply a viscous honey solution that is sprayed into the infeed end of the tumble drum. This is followed by sugar/salt to dry the slurry at the discharge end of the drum. Often, other ingredients are added, such as dried fruit pieces and spices.
Brine and Starch Coating
A popular coating in the Middle East, this is normally a water-based coating and is done directly after the dry roaster and before a cooler. The heat of the nut evaporates the water in the coating leaving a lightly coated nut. Dry seasoning can be added when using a starch and water combination.
Dough Coating
Coatings used in Asia and parts of Latin America are typically quite thick and utilise cracker or dough-based ingredients to achieve a thick enrobing type of coating on the nut. In some cases, raw skin on peanuts is used where the skin imparts a unique taste and helps the coating adhere better to the nut, as opposed to a “naked” nut.
Blending
Blending nuts, fruits, candy, and other products provides another opportunity to create innovative products such as trail mix. Accurate blending systems are able to mix multiple products into proportionally even blends, that don’t stratify or separate before they reach the packaging station. The key is to maintain the blend so that the consumer will get the variety and proportions they expect.
Industrial blending is a complex food processing task.
Processors must produce consistent, high-quality mixes to meet consumer expectations and retain loyalty. Achieving consistent replication of your recipe hinges on maintaining steady component streams, with precise metering, and conveying blended components without segregation.
WANT TO KNOW HOW?
CHECK OUT THESE TOP 10 FEATURES FOR CHOOSING A BLENDING SYSTEM
01
Capacity: The volume of the blender is based on your production goals. Consider the size of batches required to ensure the blender can handle the quantity.
02
Feeders: Consider both ‘into’ and ‘out of’ the machine. The speed and the loading technique for inflow and outflow impacts throughput and which machine performs best.
03
Mixing speed and efficiency: Evaluate the speed and efficiency of the system, including the time required to blend your specific recipe. If the blender has adjustable speed settings, it can accommodate different materials to achieve desired blending results.
04
Construction: Look for equipment made from robust, durable, food-grade materials. Stainless steel, carbon steel, and/or specialised alloy which is resistant to corrosion, wear, and contamination.
05
Cleaning and maintenance: Blending equipment must be easy to clean and maintain to prevent contamination, bacterial growth, and preserve product quality. Look for equipment with features like removable parts, smooth finishes inside and out, clear visibility for cleaning, easy access, and quick cleaning capabilities to reduce downtime. Ensure airtight seals to contain powders and easy replacement of worn parts. Cleaning should be simple, with minimal operator training.
06
Customisation: Decide if a standard model can meet your production needs on time. If adjustments are needed due to floorspace, compatibility with other equipment, or physical constraints of the operating area, ensure the manufacturer you work with can customise a system to fit your goals.
09
07
Safety features: Look for built-in safety features that protect both users and the equipment itself. This includes emergency stop buttons, overload protection, secure locking systems to prevent accidents, and safety interlocks to ensure the blender only works when the jar (or lid) is correctly in place. Guarding mechanisms are important for safety and accident prevention.
08
Automation and control: Consider the level of automation and control offered by the blending system. Look for advanced features like programmable recipes, touch-screen interfaces, data logging, and remote monitoring to enhance safety, consistency, and productivity.
Energy efficiency: Industrial blending systems can consume significant amounts of energy. Energy efficient models provide a better return on investment. Look for blenders with features like variable frequency drives, which optimise energy usage based on your blending requirements.
10
Reputation and support: Read customer reviews and seek recommendations from industry professionals. Choose a manufacturer with a reputation for quality and reliability. Make sure they offer after-sales support with assistance, spare parts, and technical support as required.
A final piece of advice? Experienced vendors hold the key to alternative techniques to optimise your operation. The best manufacturers provide support and consultation during the specification and selection stage and offer services throughout the entire lifecycle of the machine.
our solutions empower processors worldwide to save water, reduce costs, and strengthen their sustainability credentials “ “
A PATH TO SUSTAINABILITY
ADVANCED WATER MANAGEMENT FOR FOOD PROCESSORS
As the food processing industry confronts escalating operational costs and stricter environmental regulations, the need for innovative water management has never been more pressing. Heat and Control leads the way with cuttingedge technologies that not only reduce water consumption but will improve the efficiency and sustainability of your food processing operations.
Highly Efficient Equipment
Central to water conservation efforts is the deployment of highly efficient equipment designed to optimise water usage. Our advanced washing systems, including the Submerged Barrel Washer (SBW) and Potato Slice Washing System (PSWS), are engineered to minimise water use while meeting the highest cleanliness standards. These systems employ precise water control mechanisms to ensure efficient utilisation of every drop, reducing waste and enhancing operational efficiency.
Process Optimisation
Optimising the water usage process is a key area of our expertise. By implementing alternative techniques and finetuning water flow rates, we help food processors significantly reduce water consumption, without compromising hygiene standards. For example, our Batch Peelers — this equipment is engineered to operate with minimal water sprays. They feature smart design elements such as waste collection chutes periodically rinsed with built-in sprays, reducing the need for continuous water flow.
Advanced Water Treatment Technologies
One of our most impactful areas of innovation is our advanced water treatment technologies. Water recovery offers an excellent solution for processors worldwide — and particularly in regions facing water scarcity. However, even in areas with abundant water supply, reducing water use can be advantageous due to the associated costs of purchasing and disposing of water.
With our advanced water management technologies, processing water can be recycled and reused to wash soil from incoming raw potatoes, all while adhering to all legal requirements. This recycling process maintains food safety and product quality, ensuring full compliance with all applicable regulations.
Water Clean-up and Reuse
Our Water Clean-up Systems (WCS) remove starch and dirt from circulating water in potato processing lines, significantly reducing the need for fresh water. By allowing the reuse of cleaned water across different stages of the process, these systems achieve up to a 90% reduction in water use.
Effective water clean-up and reuse are essential for achieving significant water savings, and our WCS play a pivotal role in this effort. They efficiently remove contaminants like starch and dirt from circulating water, enabling processors to reduce their reliance on fresh water and decrease both water and wastewater volumes. The cascading approach, which reuses overflow water from cleaner stages in upstream processes, exemplifies our commitment to maximising water efficiency.
Water Recovery from Products
In addition to water reduction and recycling, recovering water from the products themselves presents a significant water recovery opportunity. Potatoes, for example, contain about 80% water. During processing, much of this water is lost as steam in the fryer. Our Stack Heat Recovery System (SHRS) captures this steam, condenses it, and recovers the water, which can then be treated and reused in the processing line. This system also recovers energy, providing an additional benefit of reduced energy costs.
Regulatory Compliance and Sustainability
At Heat and Control, we champion sustainability in food processing through our innovative and advanced water management solutions. From highly efficient equipment and process optimisation techniques to advanced water treatment technologies and water recovery systems, our solutions empower processors worldwide to save water, reduce costs, and strengthen their sustainability credentials.
Our technologies ensure compliance with international water use and wastewater discharge standards, safeguarding against penalties, maintaining licenses, and enhancing your public image. Partnering with an experienced sustainability leader in the food industry offers the fastest route to adopting new technologies, ensuring efficiency, sustainability, and profitability for your operations.
CREATE DELICIOUS, EXCITING FOOD PRODUCTS THAT REALLY STAND OUT
SURFACE TREATMENT
ROTARY BRANDER
Improve the look and flavour of formed and natural meat, poultry, seafood, and vegetable products by customising colour, texture, and flavour during various stages of the cooking process.
Continuously sear grill marks on meats, poultry, seafood, and vegetables for an appetising justgrilled finish.
Apply BBQ grill marks, standard parallel grill stripes or custom markings, so that your product will stand out amongst other brands.
Also available with an integrated Direct Flame
Searer to brown or char for additional surface treatment.
Brand top, bottom, or both sides
Choose from single and two-sided branders for formed and naturally shaped products to meet your branding requirements.
Control branding colour
Easily adjust branding depth and speed to suit product requirements. If branding is not required, the roll can be raised clear of the conveyor.
IDEAL APPLICATIONS:
_ Meat patties
_ Chicken breasts
_ Seafood
_ Vegetables
_ Baked goods
_ Meat Alternative Products
DIRECT FLAME SEARER
Continuously brown or char-grill formed and natural meat, poultry, seafood, and vegetable products to enhance their flavour, texture, and appearance.
Value-added appearance
Apply different degrees of browning with adjustable flame exposure to give products a unique seared look. Also available with an integrated Rotary Brander to apply grill marks to one or both sides for additional surface treatment.
Precisely control your products appearance
Obtain different finishes by the number of burners used and by adjusting the individual angle and height of each burner. Variable conveyor speed lets you control exposure time to meet your product appearance requirements.
IDEAL APPLICATIONS:
_ Meat patties
_ Chicken breasts
_ Shrimp and seafood
_ Squash and bell peppers
_ Baked goods
_ Meat Alternative Products
Meet your efficiency and environment goals by processing more responsibly
Achieve sustainable improvements that benefit the environment and your bottom line. Our proven food processing and packaging systems reduce fuel costs, energy waste, air pollution, and water consumption.
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Process more responsibly
Greater production efficiency helps you reduce your environmental footprint.
Save energy
We offer multiple technologies that help you improve energy efficiency so you can create positive change.
Support pollution control
We help you follow the rigorous pollution control regulations required by agencies worldwide.
Our French fry and potato co-products processing equipment sets the industry standard for dependability, offering rapid and efficient processing of potato products including fries, wedges, and an array of co-products. Collaborating with our experts and strategic partners, we deliver comprehensive turnkey solutions — from spud to shipping.
Unrivaled Frying Control and Performance
We offer a diverse range of heating options, allowing you to choose between natural gas, oil, steam, thermal fluid, electric heating, KleenHeat® and GreenHeat . Our fryers boast optimal product handling, uniform oil heating and flow control, efficient fines removal, rapid oil turnover, and clean-in-place sanitation. These features ensure the production of high-quality products with extended shelf life.
We process a broad range of styles, including straight cut fries, crinkle cut fries, curly fries, potato wedges, and a variety of potato co-products.
Need precise oil flow control and even cooking in a large fryer? Our systems offer full control of zone flows and minimise oil volume, enhancing operational efficiency and oil quality. Enjoy reliability with minimal operator intervention and benefit from highly effective Clean-in-Place (CIP) systems. Control your operating costs while maximising production with our advanced solutions.
French Fry Fryer
The Heat and Control French Fry Fryer ensures trouble-free, high-capacity production with precise oil management for uniform cooking, and consistent quality. Integrated seamlessly into our full French fry processing lines — already operational worldwide — our systems boast an impressive processing capacity of up to 35 tons per hour of finished product.
Our French fry and formed potato product systems are the workhorses of the industry. With options including multi-zone and two-stage continuous fryer systems, manufacturers are guaranteed uniformity in their products.
Two Stage Fryers
With a specialised two-stage setup, tailored for the production of batter-coated fries, but equally suited to uncoated fries, this style of fryer boasts a unique design that maximises production capacity, with a minimal footprint.
Unrivaled frying control and performance ensures troublefree, high-capacity production with precise oil management for uniform cooking and consistent quality.
Our french fry and formed potato product systems are the workhorses of the industry.
Stage 1: Set Coating
Oil velocity control and flexibility reduce damage to your product and minimise coating losses. Controlled oil flow through multiple AccuFlow™ inlets ensures each French fry receives a consistent cooking time. Oil inlet directs fines out of the fryer to safeguard oil and product quality. An outside belt return reduces oil volume, further minimising oil turnover time. Fines are efficiently removed through multiple outlets, minimising oil degradation. The design of this system includes a drip tray oil flush system and full Clean-in-Place (CIP), ensuring optimal hygiene and reduced fines build-up in both stages.
Stage 2: Completes Cooking
With the batter firmly set, fries undergo final cooking in the second stage fryer. Multiple zones of oil inlets and outlets maintain a consistent average cooking temperature, low Delta T, by rapidly adjusting to changes in product load. Oil flow penetrates the pack for uniform cooking, eliminating clusters and quickly removing fines without product damage.
Multi-zone frying is a great option for processors seeking to customise cooking conditions for different cuts of coated and uncoated French fries with minimal fryer footprint.
Precise Frying Control for Product Quality
Our unique continuous fryer design gives you complete control over product quality. AccuFlow™ oil inlets are proven to offer equal side-to-side oil flow for uniform cooking across all fryer width classes.
Multiple oil inlets and outlets enable adjustments to oil velocity, volume, and temperature drop to suit specific products, while efficiently removing fines.
Continuous oil circulation between the fryer, filter, and heat exchanger provides precise temperature control and rapid adjustment to changes in product load. Low oil volume and rapid oil turnover ensure fresh products with extended shelf life.
Easy Cleaning
CIP spray nozzles in the hood and exhaust stack clean all areas above the oil path. Self-locking motorised screw jacks conveniently raise the hood, and conveyors, clear of the pan for complete cleaning and maintenance access. Our fryer includes cleverly engineered features which minimise fines buildup from the outset - to reduce overall cleaning time and improve cleaning effectiveness.
Industry changing equipment
Our French fry and formed potato product systems are the workhorses of the industry. We process a broad range of styles, including straight cut fries, crinkle cut fries, curly fries, potato wedges, and a variety of potato co-products. Working with our strategic partners, we are capable of full turnkey solutions, from potato receiving through palletising.
SEASONING SPOTLIGHT
In-kitchen seasoning and on-machine seasoning—choosing the right seasoning method helps optimise production and ensures quality. In-kitchen seasoning offers greater seasoning application precision and is ideal for small to large scale productions. On-machine seasoning offers higher volume, reduced holding time and storage space, and fewer staff and trainings - but it has a high initial investment cost.
Potato chip seasoning
Potato chips seasoning application, when part of a continuous in-kitchen seasoning production process, utilises a drum based, single-stage coating system for application of salt or dry seasonings. Typically, the coating system is located near the discharge of the fryer, allowing the coating system to use the residual surface oil as a tack agent to allow the dry seasoning to adhere to the chips. The single-stage coating system consists of a coating drum, a powder feeder, and a scarf plate seasoning distributor.
For optimal seasoning, the temperature of the potato chips should be less than 54° C (130° F). Product temperatures above this temperature may have a negative effect on the dry seasonings, especially those containing dairy solids.
Two-stage coating system
Should the potato chips require additional surface oil, a twostage coating system replaces the single-stage coating drum. The two-stage coating system requires a longer drum to accommodate the addition of an oil spray system prior to the dry seasoning powder feeder and the scarf plate distributor.
Coating drum sizing is primarily based on product throughput, bulk density, and number of coating applications performed in the drum. Once the drum is properly sized, additional design features, including product flight size, angle, and spacing, complete the design. These features establish the proper product bed throughout the drum to ensure a consistent and an evenly coated finished product.
Product dwell time in the drum is critical for successful coating, and proper dwell time within both the liquid and dry coating zones exposes each chip to the surface of the product bed, resulting in uniformly coated finished product.
For optimal product coating, only use the system for the intended throughput rate range. Running a product throughput higher than designed will potentially increase product breakage and will prevent product from exposure to the applied liquid and dry additions. Also, overloading the system will negatively impact the consistency and the uniformity of the finished coated product.
Running products at less than 50% of the system design capacity also increases product breakage and negatively affects the finished coated product. Lack of base product in the drum reduces the system’s ability to target coat the product with both the liquid and the dry additions.
This results in a sizable portion of the oil and seasoning applied to the surface of the drum cylinder instead of the product. This reduces the function of the coating drum to a poorly designed blending system and yields both poorly seasoned finished product and unattached seasoning exiting the drum.
Tortilla chips
Tortilla chips are another product that can be seasoned in a continuous production process. As they exit the fryer and begin to drain and cool, tortilla chips give the appearance of having sufficient residual surface oil for seasoning. Unfortunately, the surface of the tortilla chip varies in its texture and composition.
These variances result in an uneven amount of residual surface oil on the chip. Seasoning of the product further highlights the effects of the uneven residual surface oil.
A drum-based, two-stage coating system including an oil spray system, followed by a seasoning feeder and a distributor, applies a light coating of oil to the tortilla chips, evenly coating each chip prior to dry seasoning. This results in a consistent, evenly coated finished product. Typically, the location of the coating system is within four metres of the fryer discharge.
As coated product exits the drum, the product requires careful handling to prevent damaging the seasoned product. The energy and motion from vibratory conveyors, for example, can remove significant amounts of seasoning from the coated product. Horizontal motion and belt type conveyors are good alternatives to minimise possible damage to the finished product.
Also, seasoned finished product should go directly to packaging, if possible. Discharging coated products into boxes, totes, or hoppers for packaging later in the process can have a negative impact on the finish coated product. In addition, increased product breakage can be a concern with this packaging process.
Conclusion
In-kitchen seasoning offers precise control over the flavour profile during seasoning application. With the option of a single-stage or a two-stage coating system, food producers can use the one that best allows them to achieve the goal of producing the perfect snack chip that stands out from the market. A more consistent application of seasoning can lead to uniform flavour distribution in every batch and give greater control over the seasoning process to help them to reduce flavour inconsistencies and to maintain the highest standards.
Because of market trends of greater flavour variety and package sizing, many food producers opt to have both Inkitchen seasoning and on-machine seasoning solutions and use the appropriate system to run a particular product. In the end, determining the best solution will always depend on their existing needs, future market expectations, and goals.
Spray Dynamics Two-Stage Coating System
Make the Most of Demand for Meat and Meat Alternative Products
As the global market for prepared foods continues to experience unprecedented growth, so does the demand for meat-free alternatives. Health-conscious consumers are increasingly choosing plant-based options, leading to a shift in dietary preferences. As a result, prepared food processors must adapt to meet these evolving consumer needs.
Numerous factors are fuelling the surge in demand for meat alternative products. Health and nutrition concerns, ethical considerations, religious beliefs, animal welfare, and sustainability are all contributing to more mindful purchasing decisions. Consequently, the market for plant-based alternatives is expanding at a faster pace than traditional prepared foods.
Meat alternative products are already reshaping both the dairy and meat industries. To capitalise on this trend, forward-thinking brands are diversifying their product offerings to include meat alternative options. Innovation will be key to success in this growing consumer market and for processors of prepared foods — there’s good news.
The same equipment that is currently utilised to create all the beef, pork, chicken, turkey, and fish items your consumers love, can also prepare and cook a diverse array of meat alternative food products as well.
Our comprehensive range of innovative, high-performance solutions for prepared foods enables you to tap into both meat and plant-based markets. This equipment consistently delivers superior results — regardless of whether the recipe calls for meat or plant-based ingredients.
Meeting Your Standards for Meat and Plant-Based Foods
Choosing the right equipment for meat and plant-based food products involves considering various factors. With our extensive experience in designing food processing lines, we can assist you in creating all the products consumers love, while achieving more yield, efficiency, and safety, than ever before.
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We work with you to understand your specific product objectives, recipe requirements, and processes for ready-to-eat meat or meat alternative products. Our range of innovative solutions that encompass cooking, coating and seasoning, conveying, and inspection, provide superior results across the board.
Achieving great taste, high yield, and consistency — where each item is prepared or cooked precisely to specification, each and every time — is entirely feasible with our equipment.
To learn more about how we can assist you, let's explore some of our ready-meal industry superstars!
AirForce Impingement Oven
The AirForce® Impingement Oven sets the standard for processors of par and fully cooked ready-to-eat food products. Utilising advanced technology, this oven cooks significantly faster than comparable ovens by evenly transferring heat across the full width of the product conveyor. The true impingement process helps preserve the flavour and moisture of meat or meat alternative products, resulting in higher finished yields and superior quality.
Perfect for meat and meat alternative products, this particular style of oven is an industry workhorse with many ideal applications, including meat, meat alternative products, prepared foods, poultry, seafood, breaded/battered foods, baked foods, and even pet food.
AirFry System
The popularity of air frying has surged in recent years, presenting new opportunities for brands in the prepared foods industry. Our AirFry System combines multiple technologies to create a highperformance, industrial linear air frying system for producing lower oil content food products. This innovative frying system enables processors to create air-fried or oven-fried products with taste, texture, and appearance like fried foods, without the need for traditional submersion frying methods.
AirFry is able to continuously produce a “fried-like” product by using a controlled application of topical oil, followed by a uniform flow of pressurised, high velocity cooking atmosphere from an impingement oven.
It uses highly accurate, Spray Dynamics® oil application equipment to ensure complete and uniform coverage of your products, while keeping oil use to a minimum. When paired with our AirForce Impingement Oven it achieves the most uniform — and fastest — air fry time in the industry.
You can invest in a brand-new system, or if you already own an impingement oven, you can retrofit a spray applicator system, with minimal investment. Additionally, the AirFry System seamlessly integrates with standard batter and breading application systems for added convenience.
SureCoat Breading Applicator
The dominant trend in breadings right now is gluten-free and clean label options. With a staggering 121 million gluten-free consumers worldwide, processors are making significant investments in equipment to facilitate the production, or expansion of their product lines to incorporate gluten-free variations of beloved classics.
Our SureCoat® Breading Applicator is designed to deliver highly uniform coverage on all product surfaces, facilitating the production of gluten-free versions of traditional favourites. The right equipment is critical to achieving the same crispiness, and flavour development, as with traditional breadings, and these factors are highly important for both meat, and meat alternative products.
Our industry-leading SureCoat applicators have fast changeover and cleaning times, making them ideal for a wide range of products. Their unique design allows them to uniformly apply predust, granular, and non free-flowing breadings, as well as delicate Japanese-crumb or flake coatings.
Breaded Products Fryer
Clean, efficient, high-capacity frying is the key to processing the highest quality breaded products for convenience meals in the meat and meat alternative category. The fryer used to cook these products has a dramatic impact on the quality of the finished product and this is especially important for meat and meat alternative products.
Heat and Control’s Breaded Products Fryer provides clean, efficient and high-capacity frying for consumer favourites like chicken nuggets, bone-in chicken, meat patties, tempura shrimp, breast fillets, meatballs, egg rolls, coated vegetables and meat alternative products.
Another standout in the prepared foods industry, our Breaded Products Fryer offers significant reductions in system oil volume by removing heating elements from the fryer pan. Every minute, 100% of the system oil volume circulates between the fryer, filter, and external heat exchanger. Oil and product velocities are meticulously synchronised to maintain the integrity of the product's coatings and orientation.
Gentle-flow oil inlets ensure uniform oil flow and temperature across the width of the pan, eliminating high velocity currents. This fryer utilises precisely enough oil to cover your products, resulting in a total system oil volume 25-40% lower than comparable directly heated fryers. This enables faster oil turnover and extends the shelf life of your meat or meat alternative products.
AirFry System
See what you don’t see!
Ishida's photon counting dual energy IX-PD Series X-ray system plays a pivotal role in revolutionising food manufacturing, packaging and inspection systems.
Since the 1970s, our longstanding partnership with Ishida has driven progress across various industries, including food and pharmaceuticals. By seamlessly integrating Ishida's cutting-edge technology with our innovative solutions, we have continuously fostered efficiency and innovation.
This enduring collaboration has not only enhanced our product offerings but also propelled significant advancements in multiple sectors, underscoring the transformative impact of our combined efforts.
While our expertise lies in diverse food processing solutions, Ishida, a leader in food packaging and inspection technology, seamlessly complements our offerings. This collaboration fortifies the IX-PD Series, seamlessly integrating it with our processing equipment. Simply put — our processing equipment makes the products that Ishida’s systems weigh, pack, and inspect.
Understanding the functionality of the IX-PD Series is crucial for grasping its impact on the industry. So, what exactly can it do? Leveraging photon counting dual energy technology, the IX-PD X-ray machine features an advanced sensor and refined image processing.
Its
and precision,
particularly in identifying low-density and minute foreign objects. A key distinguishing feature is its ability to differentiate between product and foreign materials with remarkable accuracy, significantly reducing false detection rates.
When it comes to quality control and product safety — X-ray inspection plays a crucial role in identifying material inconsistencies within product packaging or a continuous flow of items passing a specific point.
It can detect a variety of foreign objects like bone, stone, glass, and all metals, such as ferrous, non-ferrous or Stainless steel included. Leveraging advanced Algorithm (GA) image processing, this technology enhances detection sensitivity swiftly and efficiently for any product.
Beyond foreign bodies, the XP-PD system can also highlight voids, broken, or missing product portions, while ultimately expanding quality control capabilities. Unlike metal detectors, these systems identify inconsistencies in products packed in cans or metallised film. Moreover, X-ray inspection is also able to be used to measure and estimate piece weight.
Now, let’s explore how the IX-PD Series operates and the technology behind its functionality.
Our business team manager for packaging and inspection systems Robert Marguccio explains - that the IX-PD system utilises photon counting technology, a departure from traditional X-rays which rely on wavelength absorption.
In photon counting,” he elaborates, “a detector records each photon that strikes an object, enabling precise determination of the number of photons at different energy levels. This method offers enhanced sensitivity and accuracy in X-ray detection, particularly at lower radiation doses. Additionally, it facilitates better differentiation between different energy levels or types of photons”.
legal actions, impacting all links in the supply chain. Such incidents can severely damage reputations and brand names, culminating in substantial financial losses.
Even if retailers intercept contaminated items before reaching consumers, suppliers bear the brunt of the fallout. They face the financial burden of returned products, potential fines, and the looming risk of contract termination or damaged relationships. Maintaining a strong brand image is imperative for any food manufacturer or processor because customer perception significantly influences their decisions, and loyalty. A positive brand image fosters trust and enhances the perceived value of products or services. Unfortunately, product contamination will quickly erode trust, resulting in loss of customer confidence.
And, while prevention is the best strategy to avoid product contamination — it’s not always feasible.
Marguccio notes many Heat and Control customers see the IX-PD as a form of insurance - “Manufacturers strive to control product processes, but machinery in processing and packaging still poses contamination risks. While efforts minimise foreign bodies, for peace of mind and brand protection, an insurance policy is crucial. X-ray inspection technology offers assurance and protection when needed.”
Running costs
The IX-PD system boasts economical running costs, making it a prudent investment for businesses in the food industry. X-ray tubes, generators and line sensors are the main wear components, as well as the most expensive factor in system maintenance, based on the number of running hours these may need replacing every two years at a substantial cost.
An energy source is passed through the product, at which point the software identifies any contaminants based on the contrast between their darkness, and that of the product, using a grayscale analysis.
The darkness and the algorithms essentially determine the size, clarity, and focus of the contaminants. Conversely, voids and fissures appear as lighter areas due to increased penetration.
Quality Control
Quality control remains the backbone of any successful food processing operation, crucial for maintaining product integrity, along with brand insurance. The presence of foreign objects in food products can evoke various consumer reactions, ranging from mild dissatisfaction to severe health risks, such as broken teeth or illness.
Incidents involving product contamination often result in complaints, with more severe cases potentially leading to
The beauty of Ishida’s X-ray models lies in their remarkable reliability. Typically, an X-ray tube comes with a warranty period of 8,000 running hours. However, we’ve witnessed X-ray tubes in the field operating for up to 40,000 hours while maintaining clear images.
Additionally, the IX-PD system provides a generous 5-year warranty period on its line sensor units. This extended warranty is attributed to the IX-PD’s photon counting technology, which contrasts with traditional methods reliant on wavelength absorption. By counting photons, the IX-PD minimises deterioration of the line sensor over time, ensuring consistent performance.
Solutions over sales
Understanding what an inspection solution can, and can’t do, is crucial. For instance, some customers may want the X-ray machine to detect specific-sized objects. However, variations in inspected products can impact its ability to do so with 100% certainty. Factors like differences in product composition, shape, or packaging can influence the machine’s effectiveness, occasionally leading to instances where detection isn’t guaranteed.
Setting the machine too finely can lead to false rejects due to product variation. At Heat and Control, we truly believe that working with an integrated equipment supplier ensures you’re well-informed about the capabilities and limitations of the X-ray machine before purchase. Our objective is to achieve a 100% probability with realistic sensitivity levels, ensuring you understand your investment fully.
Safeguards that help ensure your products match the prescription
Take advantage of the world’s only multi-spectrum metal detector technology and deliver unparalleled inspection with extremely high detection sensitivity for contaminating metals with CEIA - whether ferrous, non-ferrous, or stainless steel - for pharmaceutical products such as powders, capsules, tablets, gel caps, liquids and more.
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IX-PD Series X-ray
METAL DETECTORS IN FOOD AND NUTRACEUTICAL PRODUCTION
The growing market for nutraceuticals and functional foods leads to additional challenges for metal detection which can be solved through the use of multi-spectrum technology.
Nutraceuticals are increasingly becoming a part of the food industry as consumers seek products that offer health benefits beyond basic nutrition. Nutraceuticals are driving collaborations between the food industry and pharmaceutical companies that can facilitate the development of innovative products that combine the expertise of both sectors.
The progressive integration of nutraceuticals into the food industry can be observed in several ways:
Functional foods: food products that have been fortified or enriched with additional bioactive compounds or ingredients to provide specific health benefits, such as vitamins, minerals, antioxidants, probiotics, prebiotics, omega-3 fatty acids, and plant extracts.
Dietary supplements: concentrated sources of nutrients or other bioactive compounds that are intended to supplement the diet, usually available in various forms, including capsules, tablets, powders, and liquids.
Health and wellness products: products that may include nutraceutical ingredients known for their health-enhancing properties, such as herbal extracts, superfoods, and functional beverages, with examples including energy bars, herbal teas and protein shakes.
Nutraceuticals also often require specific packaging to preserve their potency and stability. The food industry has responded by incorporating specialised packaging technologies, such as barrier packaging, airtight containers, and UV-protective packaging, to maintain the quality and efficacy of nutraceutical products. These packaging options ensure that the bioactive compounds in the products remain intact and protected from external factors that can degrade their effectiveness.
Metal detectors in food and nutraceutical production
Overall, metal detectors play a crucial role in food and nutraceutical manufacturing by safeguarding product integrity and consumer health. They help prevent potential hazards associated with metal contaminants, ensuring that the final products meet the required quality standards and regulatory guidelines.
The use of metal detectors in nutraceutical manufacturing serves as a critical quality control measure to identify and remove any metallic contaminants that may be present in the products. These contaminants can originate from various sources, such as raw materials, processing equipment, or packaging materials. Metal contaminants can pose serious risks to consumer health if ingested, and their presence must be eliminated or minimised.
How metal detectors work
There are several types of metal detectors, and each uses a different detection method to operate.
In the food industry, metal detectors usually apply the balanced coil method. These metal detectors are equipped with a transmitter coil, which generates an electromagnetic field, and two receiver coils. The receiver coils have an equal but opposite output, creating a balanced state.
When a conductive object passes through the detector, it interrupts the balanced state of the electromagnetic field and causes a signal that is detected by the receiver coils. The electronics unit in the metal detector then analyses this signal, evaluates it, signals a metal detection, and either activates the automatic reject units that separates the contaminated product from the production line or alerts the operator.
Factors that lead to false detections
There are two main factors that can lead to false positives in metal detection: environmental factors and product factors.
Environmental factors
Most food and pharmaceutical manufacturing and packaging lines involve the movement of product via conveyors, and the metal detectors are often installed close to the conveyors and often other electromechanical equipment. The preference today for the use of variable frequency drives, mainly to maximise energy efficiency, means that there is an increased potential for electromagnetic interference across a wide spectrum of frequencies.
Such interference can often lead to disruption of the field of the balanced coils in a typical single-frequency or multi-frequency metal detector, leading to a false detection.
Product factors
Some products contain salt, iron, and moisture — each of which can alter the detector’s field and can trigger a false detection. This effect increases with higher inspection frequencies that are typically used to detect smaller particles and can lead to significant levels of wasted product and downtime.
In the case of nutraceuticals, the risk of false positives increases, due to the specialist packaging and the fact that many of the supplements used in nutraceuticals contain various types of metallic and conductive additives.
Types of metal detectors
There are three main types of metal detector technologies: single-frequency, multi-frequency and multi-spectrum metal detectors.
Single frequency detectors
The majority of metal detectors on the market use only one frequency when inspecting product. The selected operating frequency depends primarily on the product being inspected. This is satisfactory when the product is dry and non-conductive.
Single frequency metal detectors have limited abilities to work with different products and are difficult to optimise for varying conditions of temperature, water content, and packaging types.
Multi-frequency detectors
Using a metal detector that offers more detection frequencies can result in more sensitive metal detection and fewer product effect errors, as well as being able to use the machine on products with differing characteristics.
Multi-frequency metal detectors can only use one of the available operating frequencies at a time, however. The operator may need to switch from one frequency to another when changing products, or in more advanced multifrequency systems, the metal detector will switch back and forth between two or more frequencies in rapid succession. However, only one frequency (one electromagnetic field) is capable of ever being on at any given time, and to prevent false rejections on more difficult product, reducing the sensitivity typically is still required.
Multi-spectrum metal detectors
Developed by Italian company CEIA, these metal detectors operate over an entire spectrum of frequencies that are simultaneously analysed and applied to completely eliminate product effects and interference, allowing for an improved inspection of the product.
Equipped with advanced computer technology and patented algorithms, CEIA’s multi-spectrum metal detectors can not only eliminate false positives, but can ‘learn’ the product being scanned, and perform automated testing to ensure correct detection, minimising false negatives.
A long history of leadership in metal detection
CEIA was founded in 1961 in Turin, Italy – initially to produce electronic components and systems for industrial automation. In 1971 the company began developing metal detectors, their products first gaining recognition in the security industry. They developed advanced walkthrough metal detectors for high-security applications, such as airports, government buildings, and public venues.
CEIA later expanded its metal detector range, developing devices now widely used in applications such as food processing, pharmaceuticals, textiles, plastics, mining, and recycling. CEIA focused on developing metal detectors specifically designed for the unique requirements and challenges of these industries.
Delivering the ultimate in Namkeen processing with flexibility and quality
We transform the raw recipe into the extruded, pulse, and legume snacks consumers know and love. We provide solutions to create cheese balls, cheese puffs, namkeen, and green peas.
• Preparation & Processing
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Want to know more about Single Frequency vs Multi Frequency Metal Detection?
CEIA is at the forefront of technological advancements in metal detection. They introduced the world’s only multi-spectrum technology to enhance detection capabilities by simultaneously using multiple frequencies. The CEIA THS/MS21 has unique detection capabilities and extreme sensitivity to magnetic, non-magnetic, and even 316 stainless steel metal contaminants.
The THS/MS21 is suitable for nearly all variations of food and nutraceutical product characteristics — and can detect foreign objects while operating simply, efficiently and at high speed — at the same time, collecting and retaining important production run data. The technology is capable of detecting particles as small as 0.25 mm (depending on the aperture size) including 316 stainless steel, and can be integrated into modern automation systems. Product data can be accessed from anywhere via a cloud service provided by CEIA.
A cost-effective solution designed to consistently grade potatoes according to size then halve any that are larger than the predetermined size. Operators can easily adjust the grading size at any time during the production process and can also adjust the minimal size before rejecting very small potatoes, as well as foreign objects.
A common issue facing potato product manufacturers is the variance of the product in its raw form. After recognising the need to overcome the problem of size irregularity in potato supply, Heat and Control developed the Potato Grader-Halver as a cost effective solution to consistently grade and halve potatoes.
Designed to grade potatoes according to size, then halve the products that are larger than the predetermined size. The grading size can be easily adjusted at any time during the production process - improving the grading process and resulting in final (in bag) product consistency. Most importantly, this process also stops chips getting ‘stuck’ in the former of the bagmaker when packaging ‘snack’ size packs.
THE PRODUCT PATH
The Grader-Halver is designed to slot into the processing line after the peelers and before the Inspection and Trim Table (Rollers). The system consists of a rugged stainless steel frame, adjustable multiple auger system featuring adjustable phasing, a roller conveyor, and slicing discs to halve larger potatoes.
Potatoes are delivered to the infeed of the Grader-Halver from upstream equipment. Adjustable grading augers sort product by size, after which over-sized product passes to a circular knife arrangement for halving.
Larger sized product continues along to the grading augers while undersized product falls through. Adjustment can be done during operation giving instant assessment of grading size. Product that falls into the adjustable
chute is directed into the FastBack® 260E conveyor pan below the Grader-Halver machine and continues along the line. Product sorted as being larger than the maximum set size passes to the roller conveyor which orients the product and transports it to the circular halving knives which then halves the potatoes across the longest dimension. Halved product items fall from the circular knives onto a curved chute that carries them to the FastBack 260E conveyor pan to mix with the previously sorted smaller items to be passed to further downstream equipment for further processing.
The Heat and Control Grader-Halver provides consistency of potato grading and halving in a convenient, low maintenance, cost effective system, and is part of our complete potato handling, processing, and packaging solutions.
FEATURES OF THE POTATO GRADER-HALVER
• Adjustable multiple auger system
• Adjustable phasing, roller conveyor and slicing discs
• Small product captured along the full length of grading area
• Sizing auger adjustment allows the gap between the augers to be easily changed according to desired size
• Lower cost of ownership
• Easy operation
• Low maintenance
• Ease of cleaning
• No water consumption
• Remove food traps - eliminate spaces where product fragments can collect and where bacteria can grow with the hygienic stainless steel construction
_ Potato Chips
Pet Food Processing Principles and Possibilities
WRITTEN BY: Tim Nanney
Technical Sales Manager - North America
Consumers appreciate the quality in the food they eat, and even though unable to say it, so do their pets.
Manufacturing dry pet food involves the same processes as many other processed foods. The most common application for coating of dry pet food kibble or pet treats involves applying sequential coatings of liquid fat/oil, followed by adding a liquid digest or palatant, and lastly, applying a powdered digest.
Because of the wide variety of products, there are multiple pet food coating system options, including continuous coating drum, centrifugal, gravity, blending, and screw feeder systems, depending on the manufacturer’s specific desired product characteristics.
Heat and Control®’s Spray Dynamics® offers our innovative technology in continuous coating drum-based systems for pet food coating. Our system includes a coating drum, a liquid spray system, a powder metering, and a distribution system. Also, heated mix/use tank assemblies are often part of the supply scope.
Key principles for continuous drumbased coating are product residence time, product bed width consistency, and depth throughout the length of the drum. Another vital design principle is utilising independent, expanded liquid and dry application zones. In this example there are four independent zones, one for each liquid product; a transition zone; and a dry ingredient application zone.
These zones allow us to apply the liquid and dry additions at multiple points over a set distance of product travel rather than to introduce them at a single point of contact. When properly positioned above the base product as it travels through the drum, the coating of each product piece can match the correct amount of liquid and dry ingredients.
COATING DRUM
The size of the drum is determined by the amount of product to be coated, the product density, and the number of liquid and dry applications required. Drum diameters vary between 30–72" (76—183cm) in diameter and in lengths from 96–180" (244—457cm). Properly engineered coating drums feature horizontal product flights that are designed to gently lift and fold the product as the drum rotates. The drum operates at a slight decline towards discharge to allow the product to travel through the drum. An inlet cone directs the product into the coating drum cylinder and prevents spillage while a discharge spiral acts as a weir to help control the product bed and the dwell time.
An advantage of the coating drum method is its ability to control both product dwell time and product piece exposure. The lifting and folding of product throughout the length of the drum ensures each product piece is brought to the surface repeatedly for targeted application of the liquid and evenly coated product.
Please note that optimally finish coated product requires a consistently metered flow of base product into the drum.
This method of exposure and expanded coating zone application is far more reliable than other drop-through coating methods that coat product falling vertically through a single point of contact then rely on a post blending process for product-to-product contact. The coating drum method ensures consistent,
Continuous coating drum systems feature mist/dust collection shrouds or fully enclosed drums to prevent exposing plant personnel to the applied liquid and dry ingredients. An external collector is also part of the mitigation process. Clean-in-place foaming and spray bars are recommended for ease of sanitation at the end of the run.
LIQUID COATING SYSTEM
As the kibble or treat enters the coating drum, the first of the two liquids, fat/oil is applied. Application rates typically vary between 2–10% by weight of base product throughput. Chicken fat is commonly used and heated to a range of 120–140°F (49–60°C) and usually done in a water or steam jacketed tank. A shaft mounted mixer is used for agitation. Once at temperature, the product is transferred to a use-tank that supplies product to the fat/oil spray manifold.
A positive displacement product supply pump is used to pull product from the heated supply tank and to transfer to the manifold. A three-way valve located at the manifold is used to supply the metered flow of fat to be applied. In addition, a liquid product flow meter is included for rate verification. When there is a pause or stop condition during production, the three-way valve diverts and continuously circulates fat through the loop until production resumes.
The fat/oil spray manifold features multiple spray nozzles in series with the first nozzle located ~8" (20cm) from the beginning of the drum. The length of the liquid coating zone varies depending on the size of the drum but is usually 24–36" (61–91cm) in length. The manifold is positioned at the proper height and angle to target the product traveling in the drum below, and air assist and positive shut-off nozzles generate the desired spray pattern. Using high-volume, low-pressure air avoids over atomisation of the fat. Each nozzle produces an approximate 6–8" (15–20cm) diameter spray pattern, and the nozzles can be staggered and offset along the manifold for optimal coverage. Each nozzle includes an internal piston assembly that is used as a positive shut-off for standby or end of run conditions. Also, the piston functions as a cleanout mechanism to prevent build-up of liquid on the nozzle tip. A solenoid valve controls air on both sides of the piston head to regulate the piston actuation. The clean out cycle is done during the coating process, lasts only about one-quarter of a second, and does not interfere with the coating process.
After the liquid fat is applied, a second manifold positioned within the drum applies the liquid digest. Liquid digest application rates typically vary from 2–4% by weight of base product throughput. This product is also heated, to a range of 90–120°F (32–49°C). The manifold and the application process are identical to the liquid fat product described above.
The manifold assemblies are frequently mounted to pullout trolley assemblies for ease of sanitation.
DRY COATING SYSTEM
After the liquid coatings have been applied, product travels through a short transition zone of about 18” (46cm). The transition zone separates the liquid coating process from the applied dry digest powder. The transition zone allows the base product to absorb the digest prior to dry coating. The dry powder or palatability enhancer is typically applied at 1.0–1.5% by weight of base product for canine products and 2–3% for feline products.
The dry coating system consists of two pieces of equipment, an auger-based powder feeder and a scarf plate dry ingredient distributor. The powder feeder features a product supply hopper, an internal agitator assembly, a positive displacement auger, and a dispensing tube. The output of powder is determined by the speed and ratio of the motor and gearbox assembly. Depending on the layout, the powder feeder can be mounted to load cells for gravimetric control and verification of powders.
The powder feeder is positioned outside and perpendicular at the discharge end of the coating drum. The dispensing tube deposits product onto the inlet of the scarf plate distributor, a 6” (15cm) wide vibratory conveyor with a mirror finish and a bias-cut tray that extends into the coating drum. The metered digest powder travels down the length of the tray and passes over in an integrated weir that spreads the powder across the width of the tray. After the weir assembly, the powder transitions to the bias cut of the tray. As the tray tapers towards the discharge end, a curtain of digest is produced. This 24–48” (61—122cm) curtain (or dry coating zone) allows for a gradual application of the digest powder onto the liquid coated product below. The scarf plate distributor is frequently mounted to a pullout trolley assembly for ease of cleaning during sanitation. After the dry seasoning is applied, the finish coated product discharges from the coating system, ready for packaging.
Spray Dynamics Coating Drum
Industry changing equipment + technology designed for results
Our value-added systems prepare and cook consistently superior beef, chicken, turkey, fish and other meat products including alternative meat to create a distinctive quality that stands out in the marketplace.
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• Product Handling
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We’ve been in the business of advancing the food production industry since 1950. We pride ourselves on building strong, long-term relationships with customers who know they can rely on us to help them creatively solve problems, lower costs, increase productivity, and improve quality for the life of the machinery.
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Our partnership with Ishida, a leading producer of weighing and packaging systems for food, pharmaceutical, and industrial products enables a full range of integrated weigherbagmaker systems, product infeed equipment, and finished package handling machines.
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Our checkweighers, X-ray machines, metal detectors, and vision inspection systems from our partners and leading manufacturers Ishida and CEIA® improve inspection processes for food, pharmaceuticals, and non-food products.
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We offer a complete control and information system solution, from design to manufacturing to operation and data management, so you can achieve full line optimisation.
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Our machines can take your produce at any stage—raw, cooked, partially processed—and transport it for processing at the next step on the line—wash, peel, slice, and/or dice root vegetables. With years of experience processing food around the world, our experts have developed extensive and proven preparation solutions for potato chip and french fry systems and optimise efficiency and performance in our smartly designed solutions.
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Our food processing philosophy focuses on two things: flavour and consistency. We’ve developed innovative technology from food preparation, frying, and baking to ancillary support systems established through decades of experience around the world.
SEASONING AND FLAVOURING
We love making food taste good, which is why we support all kinds of seasoning and flavouring applications. For unmatched performance, coverage, and efficiency, check out our FastBack® Revolution® Seasoning System and Spray Dynamics® applicators.
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Our solutions feature the world-renowned FastBack horizontal motion conveyor, with smart design and line management to achieve accurate feed, accumulation, proportional feed, and distribution flow. We also offer other conveyors, elevators, and feeding systems.
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