INNOVATOR magazine 2017
MAKE YOUR MARK! Whatâ€™s in focus? Potatoes Inspection Acrylamide Weighing Solutions
Grow your business with HEAT AND CONTROL
in pursuit of
We’ve been working to make food look and taste good since 1950 and even though the fashion and flavours have changed, our committment to provide the industry with the most efficient solutions without compromising on taste is the same. Our mission is to keep looking for and investing in ways to improve equipment quality, durability and performance.
PIONEERING FOOD PRODUCTION SINCE 1950 R&D + TESTING DESIGN, ENGINEERING + MANUFACTURE INSTALLATION, COMMISSIONING + OPERATOR TRAINING POST SALES SERVICE + SPARE PARTS
Heat and Control News
Potato Processing Systems
Potato Products Fryers
Potato Developments: Grader-Halver
Industry Report: Acrylamide
Flavorite: Potato Mash Up!
Coating + Conveying: FastBack Developments
Prepared Foods Processing Systems
Make Your Mark with the Rotary Brander
Test Drive Your Product
Coating + Conveying: Spray Dynamics Whatâ€™s the Right System for you?
Packaging Wrap Up
Exploring Inspection: The Journey to Quality Assurance
Why Invest in X-RAY Inspection?
Inspection Integration with CEIA
TOMRA Sorting Solutions
How to Cut Fruit & Vegetables with Urschel
Our Global Network
Innovation is our business
AT HEAT AND CONTROL, WE TAKE OUR ROLE AS INNOVATORS SERIOUSLY. FOR OVER 65 YEARS WE’VE BELIEVED THAT:
EXCELLENCE IS A CEASELESS PROCESS: We are committed to constant
THE MEASURE OF OUR SUCCESS IS YOUR SUCCESS:
improvement. Through our global teams of experts
By committing ourselves to develop individual dynamic
including designers, engineers, technicians, sales,
and innovative solutions for each of our customers,
and service, we continue to discover ways to improve
we ensure their goals are met and they are armed for
equipment quality, durability, performance, and service.
OUR CUSTOMERS ARE ALSO OUR PARTNERS: We understand that
NO TWO CUSTOMERS ARE ALIKE: We understand that each customer will have individual goals and challenges, therefore no
working hand-in-hand with our customers to develop the
two equipment systems we provide are the same. It’s
real-world processes and technologies that make their
absolutely core to provide each of our customers with an
products successful is instrumental in our own evolution.
equipment solution that’s tailored to achieve their specific product goals.
CREATIVITY AND INGENUITY ARE NOT ABSTRACT CONCEPTS, THEY’RE TANGIBLE COMPANY ASSETS: With 211 patents and counting, our
WE THINK GLOBALLY, BUT ACT LOCALLY: Our ever growing global presence reflects our thirst for knowledge expansion. Each new market we enter provides us with an opportunity
commitment to take risks and ask “what if” continues to
to apply our relevant experience, while exposing us
be one of our treasured principles. We understand that
to unique challenges, perspective and insight into
to be truly innovative and successful, there will always
the practices of that region, allowing us to grow and
be boundaries to push, and new ideas to explore. Our
improve. Understanding and engineering equipment
ability to not only produce current processes, but to also
for the distinctive diets and tastes of each culture, while
forge ahead with inventive new ideas allows us to stay at
providing quality systems, service, and accessibility in
the forefront of our industry.
each geographic region we enter allows us to stay at the forefront of the industry.
PROCESSING + PACKAGING TURNKEY SOLUTIONS
OFFERING A SINGLE SOURCE OF SUPPLY Being a single source supplier allows us to provide holistic solutions designed and manufactured specifically to meet the requirements of each individual customer now and in the future. With a team of expert engineers and service technicians, we partner with our customers every step of the way, from design, to onsite training, as well as future servicing and maintenance. Our thought leadership within the industry and ability to provide solutions for all steps of the manufacturing process ensures our customers have the highest level of flexibility, investment security, consistency, and success.
â€œBENEFIT FROM OUR EXPERIENCEâ€?
NETHERLANDS: NEW TEAM MEMBERS, LARGER FACILITIES IN RESPONSE TO GROWTH
Expansion of Heat and Control’s Netherlands’ team has required an office move to accommodate the growing number of employees and service capabilities. Located in Lelystad, the new facility will service the wider region of Eastern Europe, Commonwealth of Independent States, Benelux and Germany, demonstrating the company’s commitment to support customers with dedicated local, technical, sales and service teams around the world. Strong activity in this region combined with our desire to better support our customers with increased project management, engineering and after sales customer care and service has increased staffing levels, necessitating the larger facility. Now comfortably settled within the new office we’d like to introduce you to the team and invite you to get to know us better. Jurrien Overheul has assumed the duties of General Manager for North and East Europe. For over 20 years working in the potato and vegetable processing industries Jurrien has gained extensive experience in sales and management and is backed by a team of industry specialists across the disciplines of Project Management, Engineering, Sales and Spare Parts and Service Support.
Customers can be assured of local sales, engineering, project management and technical service capabilities from concept to the production line with a partner for developing and implementing all food processing and packaging challenges. Our established sales team has been further enhanced with the addition of several new team members, with regional or product specialisations. Joining Maciej Gandecki (based in Poland) and Tim Keizer are Wilco Bakker, Wouter Van der Veek, and Esther Mekjan. Mekjan, Area Sales Manager Russia, is excited to join the team, “It is great to join a dynamic organisation that has this global depth of expertise. I am committed to working with customers in Russia to offer the industry’s best turnkey equipment solutions”. The Engineering team has also grown. Dedicated project managers Jarno Blokland, Martin van Beusichem, join Bram van Velzen and will monitor the progress of each project. Keeping close contact with all stakeholders they will ensure specifications are met and deliveries are on-time, with careful attention to the integration of all system components and management of on-site installation.
To keep your newly installed equipment in tiptop shape the local, dedicated service and spare parts team can provide the best advice, technical breakdown or scheduled maintenance to keep your plant running smoothly. The Netherlands’ team, together with the office in the United Kingdom, and representation in Spain, France and Poland means Heat and Control is easily accessible and can provide on-the-ground support to customers all over Europe.
Speaking on his new appointment, Blokland said, “It is great to join the Engineering team. Heat and Control equipment is at the forefront of the industry and I look forward to providing customers with high quality installations professionally managed from start to finish”.
THE TEAM Left to Right: Jordy Van Leusen, Tim Keizer, Michiel Ribbens, Martin van Beusichem, Jurrien Overheul, Marien van Laar, Jarno Blokland, Wouter van der Veek, Frank Pieper, Saskia Autar, David Tambyah. Not pictured: Esther Mekjan, Nicolette Bouwmeester, Alfons Aussems, Mike Villiger, Wilco Bakker, Maciej Gandecki and Bram van Velzen.
................................................................................................................................................................ CEIA – METAL DETECTORS: EXCLUSIVE REPRESENTATION. To further enhance the product range of Heat and Control, we are the exclusive distributor of CEIA metal detectors for the food industries in the Netherlands. This Italian manufactured CEIA equipment is the world’s only true multi-spectrum metal detection technology. For specific CEIA equipment sales, service and project management talk to the CEIA team based in the Netherlands’ office.
BENEFIT FROM OUR GLOBAL EXPERIENCE
YOUR SNACKS MADE EASY! Over fifteen years of development working closely with the South Asian snack market has resulted in a “multi-purpose” frying system suitable for processing the majority of raw materials which make up this complex snack product range. Heat and Control namkeen systems can process and package a wide variety of snacks with outstanding results.
Local sales + support teams but with a GLOBAL network of manufacturing facilities + support offices.
THINK GLOBAL | ACT LOCAL
Namkeen Processing Systems Preparation | Cooking | Conveying | Seasoning | Weighing + Packaging | Inspection | Controls + Information
LEARN MORE www.heatandcontrol.com | firstname.lastname@example.org
We are on
GROW WITH US...
Building on a foundation of 35 years in India, Heat and Control has invested in a new, purpose built facility at Mahindra World City. Situated a short distance from the existing Heat and Control Chennai office, the new world-class manufacturing and office facility is testament to Heat and Control’s ongoing commitment to be the region’s leading single-source supplier of food processing and packaging equipment. Mahindra World City, Chennai is India’s first operational Special Economic Zone (SEZ) and India’s first Integrated Business City. Built on the model of sustainable urbanisation Mahindra World City has grown from a bed of business, infrastructure and sustainable practices before evolving into a completely integrated city and is now a mature business district with leading companies such as Infosys, BMW, Braun, Renault-Nissan, Lincoln Electric, among others having set up within its premises. Heat and Control’s new facility is due to start production in 2017 and is located on 8.33 Acres (33,710m2) of land. The building will incorporate a Manufacturing Area of 11,898m2, a Technical Centre Area 0f 745m2, with 2500m2 of office space and a 260m2 Showroom. As with all Heat and Control manufacturing facilities world-wide, the new India site will efficiently manufacture equipment using the latest Computer Numeric Controls (CNC) machines, progressive work flow and managed production with SAP. The workforce will also increase to employ 150-200 personnel.
Coating + Conveying Systems | HEAT AND CONTROL
GROUND BREAK ING A ground breaking ceremony was held on 4 November 2016 to celebrate the development of a new manufacturing site for Spray Dynamics. The new facility will be located in Union, Missouri, USA, and will initially employ 50-60 personnel with the ability to expand to over 100 employees in years to come. The building will be located on a 13.32 acre green field site and the total manufacturing and office areas will be approximately 103,000 square feet (9570 square metres). The project has been engineered by Washington Engineering & Architecture Inc. and is expected to be completed by the fourth quarter 2017. Heat and Control acquired Spray Dynamics in 2011 and the last five years have seen significant global growth in demand for coating, seasoning and flavouring application solutions. Spray Dynamics has brought to the Heat and Control catalogue the industry’s best in class engineering and manufacturing solutions for controlled application of liquid and dry ingredients. This new facility will offer the latest in manufacturing capability, modern office and engineering space, product testing rooms and also allows for future site development.
A key feature of the new facililty is a demonstration / trial centre that will provide comprehensive testing capability across a wide range of Heat and Control products. This site offers the ability to test an integrated line of processing, conveying, coating and packaging equipment. R&D teams can perform a complete test, start to finish, or individual as required with the direct assistance of Spray Dynamics’ expertise. The room will be approximately 50’W x 75’L (15m x 23m) and features an inspection and instrumentation room for product attribute testing during trials, walk-in refrigerator and freezer and a temperature control system that can replicate plant conditions. Tony Caridis, President, Heat and Control Inc. “This ground breaking ceremony celebrates the visible beginning of a new chapter for Heat and Control and Spray Dynamics and I would like to thank the Spray Dynamics team for their dedication and hard work to reach this milestone.” Lucas Bell, Spray Dynamics, Group Manager, Heat and Control Inc. “We are very proud of our work ethic and the high quality products produced in Missouri and this groundbreaking will give our group the power to grow Spray Dynamics capability and product line for many years. The investment in this new facility by Heat and Control clearly displays the commitment of a very strong company that is in business for customers, employees and the future”.
SLURRY ON DEMAND WWW.HEATANDCONTROL.COM/SPRAYDYNAMICS
When Spray Dynamics® joined the Heat and Control family five years ago, the two companies knew that there would be synergies between the product offerings, but little did they realise that the merging of technologies and knowledge would result in such a powerhouse of coating seasoning and flavouring application choices for the industry.
Spray Dynamics builds applicators for oils, seasonings, vitamins, tack and release agents, chocolate, syrups and candy coatings, antioxidants, polishing wax, and anti-clumping agents. Between Spray Dynamics liquid and dry application, FastBack® on machine seasoning and Heat and Control In-kitchen seasoning, the widest range of coating, seasoning and flavour application is available to the industry.
Spray Dynamics has brought to the Heat and Control catalogue the industry’s best in class engineering and manufacturing solutions for controlled application of liquid and dry ingredients. Since 1952, Spray Dynamics has developed applications for a wide range of products, both food and non-food, and has served the snack industry since 1970. Late in 2016 Spray Dynamics released the most innovative solution to date for slurry coating application on snack foods. The Slurry On Demand continuous mixer allows for coating application with minimal downtime for ingredient mixing or flavour changeover. For the first time snack companies can apply a recipe driven workflow that includes faster changeover of recipes; just flush with oil, change the dry ingredient and start-up. The system offers integrated pre-mixing of the slurry recipe before the snack product is introduced and the slurry recipe can be adjusted by changing oil and dry ingredient ratios during the pre-mixing phase. The system is able to achieve changes in output or concentration in less than 30 seconds and because the slurry is prepared at optimum time before the snack food is on its way, there is less waste of ingredient in the case of emergency downtime situation. There is now no requirement to mix slurry in advance, or worry about storing the slurry if it was made earlier than the line was ready for. This means huge advantages for lines that accommodate multiple recipes as it provides quicker flavour changeovers.
Innovation & Technology
WE KNOW WHAT TO DO WITH CORN
THE COMPLETE SYSTEM From masa production to forming, toasting, conditioning, frying, seasoning, and inspection, Heat and Control provides all the equipment and services required to make the highest quality corn and tortilla chips, taco shells, tostadas and tortillas.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
7 8 10
11 11 13
Dry corn cooking Corn washing/draining Milling and pumping Sheeter Toaster oven Equilibrator/conditioner Extruder Fryer Fryer support module Ambient air cooler Seasoning application Conveying and distribution Ishida weigher Ishida bagmaker Ishida seal checker CEIA metal detector Ishida checkweigher Ishida X-ray inspection
16 15 WANT TO KNOW MORE? Visit www.heatandcontrol.com/corn OR ask your local sales office for more information.
PROCESSING FOOD FOR CONSUMERS What customers and end consumers want is most important in food processing, says Jim Strang, CEO, Asia/Pacific and Europe, Heat and Control, and he elaborates on how food processors can do this. Reproduced with permission of Asia Pacific Food Industry Publication, 2017.
WITH REGARDS TO FOOD PROCESSING, WHAT ARE SOME TRENDS THAT YOU SEE AT THE MOMENT? There are many current challenges and trends facing the food processing industry. With an expanding global market consumer’s palates are changing, as they are exposed to a wider array of diverse, cultural specific foods. Increased multiculturalism is causing a rising demand in new flavours and taste. This innovative new generation of food products requires more creative processing techniques and equipment to allow us to duplicate and supply these foods on a commercial scale. Consumers are also now becoming more health and energy conscious. Acrylamide reduction and low-oil options are becoming increasingly desired as customers are becoming better educated on such topics. Legislative changes on emissions as well as consumer push is resulting in more energy and water reduction technologies and re-use systems within the processing industry. With this in mind, we are currently designing our batch fryers to provide greater efficiency, giving 18-20 percent more efficiency in the batch fryer; plus, also increasing capacity by up to 60 percent. Batch frying still remains the benchmark for potato chip frying and with new development testing happening, this will be even more attractive. In the case of acrylamide, the degree of concern varies among countries not only in this region but around the world. This can be addressed by solutions such as vacuum frying involving low temperature cooking, electroporation involving pulse electric field, conditioning process, and more.
WHAT DO YOU THINK IS LIKELY TO CONTINUE OR CHANGE NEXT YEAR? • • • •
Cost-effective options Healthier snacks/products Time-saving equipment processing systems for the manufacturer Better sanitary and hygienic food conveying options, as the requirements have increasingly become a number one priority for processors
WHAT IS MOST IMPORTANT ABOUT FOOD PROCESSING IN YOUR OPINION? I think what’s most important is listening to what the customers and consumers want and delivering consistently good quality products at high efficiency and sanitation. And in doing so, we are constantly trying to better our equipment based on the industry needs such as providing more automation, larger production rates, enhanced cleanability, enhanced energy efficiency, longer production runs (with less downtime) and a range of efficient and value-for-money processing systems.
WHAT IS GREEN MANUFACTURING AND WHAT CHANGES DO YOU FORESEE WILL HAPPEN? Green manufacturing for us is focusing on creating clean emissions, reducing water and energy consumption, waste treatment/reductions and reclaiming or reusing material to be environmentally friendly. The company has been able to address these challenges within higher production efficiencies both in the equipment manufacturing process and improving the design of the equipment. For example, where water is used for product or equipment cleaning purposes, we have increased the use of recycled water. Where cooking oil is used during production of the finished food product, we have sought solutions to increase the oil life. In line with green manufacturing, many of our snack systems are now complemented with energy saving and pollution control systems, such as a heat exchanger that combines the incineration of fryer exhaust pollutants with high-efficiency oil heating to help processors meet emission control regulations; an oil mist eliminator that removes oil mist from fryer exhaust without water or high-horsepower fans; and a heat recovery system which recovers normally lost heat from the fryer exhaust stack. This investment into green manufacturing technologies is something we pride ourselves on and are continually looking to develop new processes and enhance the existing method of use.
POTATO CHIP PROCESSING SYSTEMS
We are on
GOOD TASTE Every machine features innovative technology developed through years of experience in delivering snack food systems around the world. From raw potato preparation to frying and seasoning, Heat and Control provides all the equipment and services required to make the highest quality natural potato chips, hard-bite chips, sticks, formed chips and other potato snacks.
FOCUS ON THE “LINE OF SIGHT” Reproduced with permission by Potato Processing International publication, 2016.
Founded in 1950 by five engineers who had the goal of modernising cooking equipment for the food industry, Heat and Control has played an integral role during the early days of industrial cooking systems, transforming the food processing industry and pioneering continuous cooking equipment. In a Q & A with Potato Processing International magazine, Bobby Kane, Sales Manager Europe and Middle East, discusses the company’s innovations and strategy for the future.
Q: How has the company evolved, from the 1950s
Today we have eight Manufacturing facilities, eight
until the present day?
Test Centres and over 30 offices worldwide, with new
A: Heat and Control innovations include pioneering the
manufacturing facilities currently under construction
external heat exchanger for industrial frying systems,
in India and the USA. Along with these, we have
high-speed processing equipment for potato chips
subsidiary companies of Spray Dynamics and Flavorite
and other snacks, and the invention of the multi-
Technologies, providing the ‘total systems approach’.
purpose oven, the MPO Cooking System®. More recent innovations include the HeatWave® fryer,
Q: What is the company strategy, regarding
solutions and equipment for potato processors
and Revolution® Proportional Gate and the KleenHeat®
and how do you see the company evolving in the
next five to 10 years?
A: Heat and Control is a unique global machinery Manufacturing
manufacturer. We provide innovative and collaborative
expanded into Australia, Mexico, China and India and
thinking, extensive project delivery experience, high-
is now supported by a network of regional sales offices
value services, unparalleled industry knowledge and
including South Africa, Malaysia, Singapore, New
we understand the specific commercial, technical
Zealand, Brazil, Argentina, Canada, Scotland, France,
and collaborative challenges involved. What makes
the Netherlands, Poland and Spain. Australia is the
us different is our ‘line of sight’ from project inception
headquarters for all operations outside the Americas
through to completion.
and is home to a large manufacturing facility that
asset lifecycle, combining our business and strategic
exports to the world.
thinking, industry knowledge and technical experience.
Our offering spans the full
We draw from and leverage our global footprint and One of the original founders, Andy Caridis, maintains
bring expertise, lessons learnt and innovative solutions
his enthusiasm and energy for the industry and due
as the foundation to tailor responses appropriate to
to his wealth of knowledge and expertise, plays a key
specific challenges faced by potato processors.
role in R&D programs and travels regularly to impart his knowledge to the global team. Still a family managed
Through continuous innovation and development,
business, Andy’s son Tony Caridis, is the current
combined with real world experience, we help potato
president and has been influential in expanding into
processors create greater value, new possibilities and
Packaging systems whereby Heat and Control, in close
superior outcomes from their assets and businesses.
partnership with Ishida (a world leader in weighing
Our ongoing strategy will always be that we measure
technology), has become a full service provider of food
the success of our business based on our customer’s
Potato Processing Systems | HEAT AND CONTROL Q: What are some of the flagship models of
All of these systems are complemented with the
equipment for potato processing in your portfolio
energy saving and pollution control systems, such
which have placed you ahead of the competition
as the KleenHeat® Pollution Control Heat Exchanger
and how do you explain their success?
(combines the incineration of fryer exhaust pollutants
A: With a number of innovations over the years,
with high-efficiency oil heating to help processors meet
naming just a few of the flagship models for equipment
emission control regulations); the Oil Mist Eliminator
manufacturing would be hard to do. From batch frying,
(removes oil mist from fryer exhaust without water or
continuous frying or, as with
more niche products
high-horsepower fans); and the Heat Recovery system,
like vacuum frying, potato or snack processors are
which recovers normally lost heat from the fryer exhaust
consistently needing greater control, higher capacities,
optimised oil turnover with reduced oil wastage and less oil in the final product. We are currently designing our batch fryers to provide greater efficiency, giving up to 18 – 20% more efficiency in the batch fryer; plus, also increasing capacity by up to 60%. Batch frying still remains the benchmark for potato chip frying and with new developments and testing happening, this will be even more attractive. Alternatively, vacuum frying, whilst can be seen as ‘premium’ technology, Heat and Control has created a less complicated system, and dependent on size and product, will greatly reduce the cost with the return on investment reached far quicker. For french fry product, the Multi-zone fryer is the ‘go-to’ equipment for this market. The fryer features Heat and Control’s latest technology for controlled, uniformed cooking and efficient operation. Each of the fryer’s two independent stages has three oil temperature zones for precise temperature control and rapid fines removal. Oil inlets and outlets are specially designed to deliver uniform side-to-side oil-to-product velocity and Delta-T. The outside-return conveyor belt reduces oil volume in the fryer. Unitised construction provides a stable pan structure that resists thermal deformity.
Q: What about recent innovation and newly introduced equipment? A: In response to snack processors recognising a demand by consumers for a healthy snack product with an enhanced taste and ‘mouth feel’, we introduced a technology that will change the way you think about potato chip processing. Using the process of Pulse Electric Field (PEF) technology, the E-FLO™ electroporation processing system by Heat and Control has been developed with not only the processor in mind, to help with improving yield, but also the consumer, where the potato chip is crunchier and also healthier.
The Pulse Electric Field (PEF) process perforates the cell walls of the potato, creating ‘micro’ holes that allow the asparagine and sugars to be washed out of the potato in a cold wash, which lowers acrylamide in in the final product. This process reduces or eliminates the need for blanching in most cases. Applications are for potato chip and french fry product, with formed
WANT TO MAKE YOUR POTATO CHIPS TASTE EVEN BETTER
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potato products and other root vegetables to follow. Q: What do you consider to be the main challenges on the markets that you are active on and how do you best address them? A: Food trends are ever-changing and with globalisation consumers’ palates are exposed to a wider array of diverse, cultural specific foods and with this evolution, there is increasing demand on new flavours and taste. (RSS Seasoning systems – quick changeovers). Added to these, there are the legislative changes on emissions to which we provide environmental solutions such as Kleenheat, consumers wanting green technology – energy re-use (Kleenheat), reuse of wash water, (Gentlewash) or health driven changes, better education of consumers – Acrylamide reduction, Lowoil options (E-FLO, Vacuum Fryer). Q: What do you believe to be the company’s advantages on the market and how do you capitalise on these?
E-FLO™ ELECTROPORATOR PROCESSING TECHNOLOGY
A: Heat and Control has a think global, act local approach, with a focus on innovation and a worldwide sharing of technology. The company is made up of a global team that has, since 1950, built an extensive knowledge bank and developed a wealth of experience and expertise. Access to production and technical support from a network of engineers, food techni-
Just when you thought the Potato Chip couldn’t get any better, along comes a technology that will change the way you think about potato chip processing. Significant product improvement in chip crunch, taste and texture is achieved as well as reduction in acrylamide formation and oil content. Higher yield and reduced processing costs are also key benefits of this technology with other vegetable applications possible for the future.
cians, skilled tradespeople and support teams provide food manufacturers with confidence to achieve production goals. This global approach with attention to
Talk to Heat and Control today and benefit from over 65 years of experience perfecting the Potato Chip.
the unique differences in each region has been the key success of Heat and Control in the marketplace.
TO LEARN MORE ABOUT THE E-FLO, Visit www.heatandcontrol.com/potatopreparationsystems
www.heatandcontrol.com | e: email@example.com
POTATO PRODUCTS FRYERS There are many factors to consider when determining the best fryer design for you. Ultimately your product quality will have the highest influence on your decision, however it is also important to consider floor space, production capacity, acquisition price, and the method of heating cooking oil. By working with a manufacturer that has experience in custom-designing fryers for each customerâ€™s unique requirements, you can be assured that productivity and product quality will meet your expectations and lay the groundwork for future growth. >>
POTATO PRODUCT FRYERS WHY SPECIALISED FRYER DESIGNS IMPROVE PRODUCTIVITY AND QUALITY
Potato Processing Systems | HEAT AND CONTROL
BATCH FRYERS Batch fryers are used exclusively for hard bite, slow cooked potato chips due to their unique temperature profile. The high-moisture content of potatoes requires a specially designed batch fryer. Potato-specific batch fryers use a kettle of static, hot oil – direct-heated by a gas burner firing under the fryer pan or by heat-transfer tubes immersed in the oil. These tubes can be heated by a gas burner, steam, or thermal fluid. As each batch of potato slices enters the oil, the cooking oil temperature drops and then gradually increases as the burner fires to regain the proper frying temperature. This “inverted bell curve” temperature profile produces the distinctive hard-bite texture that has made these chips the fastest-growing segment of the potato chip market. The art of adjusting this oil temperature profile gives processors the ability to create subtle differences in chip texture. Once these cooking parameters are set, sophisticated batch fryers use a Programmable Logic Controller (PLC) to assure repeatable frying of each batch of chips. Batch fryer capacities range from 35 to over 500 pounds, (15 to 225 kilograms) of finished potato chips per hour.
ADVANTAGES OF BATCH FRYERS
LIMITATIONS OF BATCH FRYERS
1. Low cost (compared to continuous fryer systems) 2. Adjustable temperature curve produces chips with unique textures 3. Slice stirring systems unload the finished chips and enable one operator to handle multiple batch fryers 4. Minimal floor space 5. Versatility: cooks other types of root crops in addition to potatoes
1. Production capacity is limited by the fryer’s surface area and heat input capability 2. Automatic stirring systems eliminate the hazardous, labour-intensive task of manual stirring 3. Product must be stirred for uniform cooking and to prevent slices from sticking together in clusters 4. Large oil volume with relatively slow oil turnover rate 5. Some older models provide only partial removal of fines, leading to degrading oil quality and leaving black specks on the chips
CONTINUOUS FRYERS There are numerous designs of continuous fryers, varying in heat load, product handling, oil filtration, and production-capacity, however all commonly cook a continuous flow of product. Potato products such as potato chips, sticks, potato co-products such as tots and patties, french fries, or battercoated fries require an externally-heated continuous fryer design due to the large amount of moisture that must be boiled off during the frying process, as well as factors such as: • • • • • • • • •
Responsive, accurate, and consistent temperature control Higher thermal efficiency than direct-heating Heat load is not limited by size of fryer due to the fryer and heat exchanger being sized separately Higher capacity production Lower system oil volume (including fryer, heat exchanger, filter, and piping) than direct-heated fryers Continuous removal of product particles Rapid oil turnover rate Oil flow is adjustable to match product flow rates Minimal cleaning required as fine particles remain suspended in the circulating oil for more efficient removal
... / POTATO PRODUCT FRYERS Continuous fryers are available for 200 to 6,500lbs/90 to 2,900kgs of finished potato chips per hour and over 50,000lbs/22,000kgs of finished french fries per hour. External-heat exchangers heat cooking oil using gas or light oil burners, steam, or thermal fluid. These fryers continuously circulate oil through a filter, an external-heat exchanger, and single or multiple inlets and outlets in the fryer. Continuous oil circulation provides multiple advantages: • • •
Maintaining a consistent oil temperature and temperature drop through the fryer Separating and advancing products through the fryer for uniform cooking without clusters Keeping product particles in suspension for more-efficient filtration and clean fryer operation
Unique characteristics and production capacities of different potato products have prompted the development of specially-designed continuous fryer systems, including Multi-Zone Fryers, Multi-Stage Fryers, Thermal-FluidHeated Fryers, and Vacuum Fryers.
MULTI-ZONE FRYERS In these fryers, oil is introduced and removed at different points along the length of the fryer pan to provide accurate control of the temperature drop that occurs during cooking, known as Delta-T. This enables processors to develop custom colour and texture characteristics for different products. It also permits frying at lower temperatures, which produces lighter colour product and reduces oil degradation.
THERMAL-FLUID-HEATED BATCH FRYERS This direct-heated fryer uses a patent-pending thermal-fluid heat exchanger that heats oil uniformly throughout the fryer. A fines removal conveyor and spacing between the heattransfer tubes prevent product particles from accumulating inside the fryer.
MULTI-STAGE FRYERS These are a variation of the multi-zone design and provide a greater range of frying temperatures. Each fryer stage uses a separate continuous oil filter, oil-circulation pump, and heat exchanger. Multi-stage fryer systems are especially useful for batter-coated fries, french fries, or fine particle-intensive co-products.
VACUUM FRYERS Operating at 10 percent or less of normal atmospheric pressure, a vacuum fryer boils off product moisture at a lower temperature than traditional fryers. This means high-sugar content potatoes can be fried without browning of finished chips. Formation of acrylamide can be controlled because oil temperature can be kept below the 248°F /120°C point at which acrylamide forms. Our advanced vacuum fryer design requires no external-vacuum enclosure and takes about the same floor space as a traditional, externally-heated, continuous fryer.
DON GILES DIRECTOR OF SALES, PROCESSING SYSTEMS, HEAT AND CONTROL, INC. Don Giles commenced his career with Heat and Control in 1977 with snack processing equipment technical sales. Under his direction, sales and project management of complete processing equipment systems for potato, corn, nut, pellet, and extruded snacks has grown continuously, making Heat and Control the leading supplier worldwide.
Technology & Innovations
A Heat and Control continuous fryer design provides total control of product quality. Oil may be the invisible ingredient in fried foods, but it is a critical factor in product quality. Renowned for clean and reliable operation, Heat and Control fryers treat oil as carefully as the product. Heat and Control is the leading manufacturer of fryers and support systems for the global food industry and offers process customisation to meet production specifications.
Food Processing & Packaging Systems
Potato Products Processing Systems Preparation | Cooking | Conveying | Seasoning | Weighing + Packaging | Inspection | Controls + Information
LEARN MORE www.heatandcontrol.com | firstname.lastname@example.org
Want uniform chip size?
IT’S IN THE BAG!
WITH THE HEAT AND CONTROL POTATO GRADER-HALVER
The Heat and Control Grader-Halver can offer a lower cost of ownership through: • Easy Operation • Consistent grading & halving • Low maintenance • No water consumption required during operation • Ease of cleaning and clean operation • Hygienic construction - no food trap
Potato Processing Systems | HEAT AND CONTROL
A common issue facing Potato Chip manufacturers is the variance of the product in its raw form. Potatoes come in all shapes and sizes and while improvements in growing conditions has somewhat resulted in sizing consistency - the gap still exists between the smallest and largest potato in any delivery. Despite this variance it is desirable for the chips in the final packaged product to be consistently sized, not only from one chip to the next but also the ratio between chip and bag size. Take for example the small snack size bag ideal for school lunch boxes. If the raw potatoes were large, by weight the resulting large potato slices will mean the actual number of chips in the pack will be low. While the packet weight is the same as one with ‘smaller’ chips consumers feel they are getting less. A ‘large’ chip is deemed more acceptable in a larger family style pack. Sizing potatoes is not just in the production of chips, new products in the convenience sector now include portion-controlled potato that have been sized to suit a specific calorie measurement.
potato foods pieces unit of
After recognising many of our customers needed to overcome the problem of size irregularity in potato supply, our engineering department developed the Potato Grader-Halver as the cost effective solution to consistently grade and halve potatoes all in the one machine. The Grader-Halver is designed to grade potatoes according to size and halve the product sorted as larger than the predetermined size. The machine also has the ability to adjust the grading size with ease and at any time during the production process. This feature improves the grading success resulting in final (in bag) product consistency. And most importantly, this process stops chips getting “stuck” in the former of the bagmaker when packaging ‘snack’ size packs. Featuring a full length grading area to prevent small product from ‘skipping’, and then passing through a short grading, as well as an adjustable reject for very small potatoes and foreign objects. The Grader-Halver model has 2 different size options, a 5 lane (throughput of 5000kg per hour) and a 7 lane (throughput of 8000kg per hour).
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.
From family packs to ‘snack’ packs
Product that falls into the adjustable chute is directed into the FastBack 260E conveyor pan below the GraderHalver 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. Want more information on Potato-Grader by Heat and Control? Visit www.heatandcontrol.com
Can we have our chip and eat it too?
Potato Processing Systems | HEAT AND CONTROL
INDUSTRY REPORT: Acrylamide Ever since Swedish scientists discovered acrylamide in food in the early 2000s, there has been growing concerns over the potential negative impact it could have on people’s health, and some regulatory bodies have been looking at ways to restrict acrylamide levels in consumer products. Acrylamide is a chemical which forms during the cooking process when sugars and amino acids are released from food. Starchy vegetables, such as potatoes, have the highest levels, and certain cooking methods, such as frying and barbecuing, produce higher levels than boiling or steaming. The World Health Organization and the International Agency for Research on Cancer has labelled acrylamide as “probably carcinogenic to humans”; the US Environmental Protection Agency has categorised it as an “extremely hazardous substance”; and the European Food Safety Authority noted that acrylamide was a “public health concern as it potentially increases the risk of developing cancer in consumers of all ages”. While these groups have given clear warnings to regulatory bodies and pushed for stricter, maximum levels to be enforced, some say that not enough is being done to curb the occurrence of acrylamide in consumer products. Is this trend about to shift? In 2016, Denmark lowered indicative levels for acrylamide, and it seems that the European Commission (EC) is only steps away to setting stricter regulations. In 2007 the EC adopted a Recommendation on the Monitoring of Acrylamide Levels in Food, in 2011 they adopted a Recommendation on Investigations into the Levels of Acrylamide in Food, and in 2017 the EC is set to vote on draft regulation on acrylamide. So what does this mean for food producers? The acrylamide topic is continuing to gain traction, and it may only be a matter of time before stricter legislation is realised. Potato chip producers are one group at the greatest risk of being hit by this legislation, with these products producing some of the highest acrylamide levels. European manufacturers especially cannot be complacent and let changing legislation creep up on them without being duly prepared.
This now begs the question: Is there a way to reduce acrylamide in potato chips without compromising on taste and quality? The answer is yes. The upside is that these products can be marketed as a ‘premium’ product to appeal to an ever-increasing healthconscious market segment. There are a number of ways to reduce acrylamide levels in food, such as varying cooking temperatures; storing raw product in different ways; harvesting at different times of the year; ingredient additions; or changing growing conditions altogether. But these methods can affect long-term costs and have negative effects on the taste on your products. For potato product manufacturers, there is an alternative method which can reduce acrylamide levels by over 50%. This method is known as electroporation. Electroporation is a technique in which electrical fields are sent through a cell in order to perforate the outer membrane with microscopic holes. In the case of a potato, this process allows sugars and amino acids to be released from the potato prior to cooking, which in turn lessens the occurrence of acrylamide. Heat and Control, in partnership with ScandiNova - a world leader in the development and production of Pulsed Power Systems, have developed a potato processing machine which does just that. The machine, known as E-FLO™, can fit into any potato processing line and requires low voltage, minimal maintenance and has a patented transformer design. Peeled and washed potatoes are supplied in measured quantities by upstream equipment and delivered to the E-FLO infeed chute. The rotating E-FLO wheel transports the potatoes through the processing area as a compact packed bed through a water bath. Processing has to take place in a water bath for the electrical pulses to influence the product as desired. After a short exposure to the electric field pulses, to perforate the cell walls, the potatoes are lifted and discharged from the water bath by the continuing rotation of the wheel into the discharge chute. The potato then continues down the production line where greater amounts of sugars and amino acids can be removed during the slicing and washing stages. The result: potato chips with a reduction in acrylamide of over 50%, in some test cases. But apart from reducing acrylamide and creating a healthier product, there are a number of other advantages to running your potatoes through a gauntlet of electrical fields:
A CRUNCHIER CHIP – A CRISPIER BITE
Less wear and tear Slicing thousands of potatoes daily can quickly result in dull slicer blades. The E-FLO, however softens the tissue of the potato, allowing the blades to slice between the cells of the potato rather than through them. This lessens the pressure and friction on your tools, which means less down time and longer equipment life. Slicing between the cells of the potato also produces a smoother chip surface. A smoother surface means the chip absorbs less oil, which, in the long run, can significantly reduce your oil expenditure.
Acrylamide in food What is acrylamide? When we cook, sugars and amino acids are released from food to start a process called the Maillard reaction.
Adding heat to food starts a process known as the Maillard reaction
This process gives cooked food its flavour. It also produces a chemical called acrylamide. Starchy vegetables, such as potatoes, are especially high in acrylamide when fried, baked or roasted at temperatures over 120°C. Acrylamide has been labelled by the World Health Organisation as “probably carcinogenic to humans”.
A notable benefit to pulsing your potatoes with electricity is that your chip is crispier. The E-FLO increases the amount of starch in the outer layers of the potato, which helps to give the chip that all-important bite. It also reduces the need or length of time needed to blanch your potatoes before cooking.
For potato-product manufacturers, offering a product which has lower levels of acrylamide opens up a greater market segment of health-conscious consumers.
This is a process whereby sugars and amino acids are released
The sugars and amino acids react to create a chemical known as acrylamide
Reducing the levels of sugars and amino acids in the raw product, such as potatoes, before it is processed, reduces the occurrence of acrylamide during the cooking stage. Reduce levels of sugars and amino acids here...
...and acrylamide levels will be reduced here
Pulsed Electric Field Technology Product potential
Heat and Control, in partnership with ScandiNova, have developed a new potato processing machine which reduces the levels of acrylamide in potato chips by over half.
The E-FLO has the potential to work on a range of products, such as differing root vegetables, making them easier to process. Because the E-FLO softens the tissue of the raw product, different cutting technology can be used to create new shapes more easily.
The E-FLO uses Pulsed Electric Field (PEF) technology which sends electrical fields through the potato and perforates the cell wall with microscopic holes. This allows greater amounts of sugars and amino acids to be washed out by the E-FLO, without compromising the solid state of the potato. The result is a high-quality product with less acrylamide
While there hasn’t been a direct link between acrylamide and cancer in humans, the evidence provides researchers with a ‘more than likely’ scenario. It may just be a matter of time before tougher restrictions are put in place for food manufacturers. Either way, introducing a machine which reduces acrylamide levels while producing a crispier and crunchier chip into your production line makes sense. And giving consumers the choice of a healthier, ‘premium’ product may just increase your customer base. With the E-FLO, we can all have our chip and eat it too.
Added benefits of the E-FLO A crispier chip
The E-FLO increases the amount of starch in the outer layers of the potato, which helps to give the chip that allimportant bite.
Less time for blanching
The tissue of the potato becomes more permeable, which reduces the need, or length of time needed, to blanch potatoes before cooking.
Blades stay sharper, longer
By softening the tissue of the potato, blades slice between the cells of the potato rather than through them, which lessens the pressure and friction on tools.
Reduction in oil
Slicing between the cells of the potato also produces a smoother chip surface. A smoother surface means the chip absorbs less oil, which produces a healthier chip.
GOOD TASTE GET IT FROM HEAT AND CONTROL
FRENCH FRY + POTATO PRODUCTS PROCESSING SYSTEMS Every machine features innovative technology developed through years of experience in delivering potato product systems around the world. From raw potato preparation to frying and seasoning, Heat and Control provides all the equipment and services required to make the highest quality straight cut and crinkle cut fries, curly fries, potato wedges and other potato products. The Heat and Control french fry and formed potato products frying systems are the workhorses of the industry.
Fryer Systems | Fryer Support Batter Application | Produce Unloading + Handling | Peeling, Inspection + Slicing | Energy Saving + Pollution Control
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SNACK PROCESSING & PACKAGING SYSTEMS Potato Processing Ethnic Indian Snack Processing 2&3D Pellet Snack Processing Extruded Snack Processing Flavour Application & Seasoning
TRADITION ON A GRAND SCALE Manufacturing in India since 1997, Flavorite Technologies has provided the south east Asian food industry with affordable, quality engineering and technology that optimises initial capital investments. Applications experience with challenging snack products has resulted in systems that maintain the traditional flavour of handmade snacks utilising modern methods. www.flavoritetechnologies.com
POTATO FLAKES ITâ€™S A MASH UP! Potato Flakes are commonly used in households worldwide for convenient preparation of Instant Mash Potato. Industrial food processors also use potato flakes as an ingredient in the production of potato snack foods.
The texture of the reconstituted product is acceptably mealy, because of a precooking and cooling treatment to which the potatoes are subjected during the processing and the additives of a mono-glyceride emulsifier.
For developing countries where limited potato processing facilities are available, potato flake (dehydrated mashed potato) projects can be a major way to preserve potato to improve availability.
Because potato flakes are quickly dried in a single step, the cells are easily rehydrated and the potato starch retains its high absorptive power. Of all forms of dried potatoes, potato flakes alone can be easily reconstituted with cold water, a fact that has led to their widespread use as an ingredient in products such as fabricated potato chips, formed potato products such as patties or pancakes, or as a thickening agent in soups, gravies and sauces.
Flavorite Technologies, a subsidiary of Heat and Control, recently worked with a processor in the Northern region of India wanting to produce potato flakes. Flavorite installed and commissioned its first complete potato flake processing line that included potato washing, blanching, and cooking, producing a mash. Potato flakes are the leading form of dried mashed potatoes used for retail consumption and as a popular food ingredient worldwide, this process was developed in the USA in the 1950s.
Potato Flakes can also be packaged in retail-size servings and reconstituted as instant mash potato as part of meal preparation in households. Flavorite Technologies Private Limited, India, is currently offering 600 kg/hr & 1200 kg/hr Potato Flakes lines.
How are Potato Flakes produced? The process starts with the separation of stones, sand and other undesirable inclusions from the potatoes. The potatoes then enter a steam peeler to loosen and separate the skins. The peeled potatoes are washed and pass over an inspection table to assure finished product quality with any remaining contaminants removed by hand. Potatoes pass through a cutter to reduce size and are dosed into a blancher. After blanching they are cooled and fed into the cooker to produce a mash. The potato mash is pumped onto the drum of the Drum Dryer (sourced from Europe) where the mash is equally spread by rollers on the drying drum into a thin film. These rollers dry the deposited layer of potato solids rapidly to the desired final moisture content. Once dried, the film of potato mash is scraped off the drying drum. The sheet of dehydrated potato solids is broken into a suitable size for packaging. This process is achieved through the use of Mill Sifters. The uniform flakes are then ready to be packaged.
BRIMHALL FOODS IMPROVES CUSTOMER SERVICE THROUGH FLEXIBILTY, GROWTH AND INNOVATION. Starting out as a one truck direct store delivery service in 1979, Brimhall Foods has grown into a manufacturer and distributor of a wide selection of Brim’s brand and private label snacks. From its 77,000 square foot manufacturing facility in Bartlett, TN, the company produces pork rinds, cracklins, cheese puffs and curls, extruded onion rings, and numerous flavours of popcorn and corn pops. “We also distribute potato chips, tortilla chips, and lots of other snack foods throughout the southeast”, notes General Manager, Michael Patrick. “We’ve grown by having the flexibility to meet the needs of our customers…and because we make great products at affordable prices”, smiles Patrick. With growth came the added challenges to keep up with customer demand and to isolate the many different seasonings applied each day. “We have three lines running extruded and popcorn snacks 24 hours a day, 4 to 6 days a week in addition to our pork rind and cracklin lines,” notes Patrick. Depending on the line, Brimhall Foods applies numerous flavours, such as butter, orange cheddar, white cheddar, hot spice, and some specialty seasonings. Being an SQF Level 2 Safe Quality Food Institute certified facility, the plant takes great care to prevent cross contamination.
“With the variety of products and flavours we run, it became apparent we needed more efficient and reliable equipment that was easier to clean”, Assistant Plant Manager Nick Brimhall recalls. After researching different suppliers and equipment, Brimhall Foods expanded its plant with the installation of new seasoning application, conveying, weighing, and bag-making machinery from Heat and Control.
The new line includes three Spray Dynamics slurry coating systems, each with ten feet long, 48 inch diameter tumble drums and seasoning mist collectors to prevent cross contamination. FastBack® horizontal motion conveyors transfer snacks from each coating drum to Heat and Control incline conveyors that utilise urethane scoop-flight belts to elevate the product to the packaging platform in the adjoining room. There, FastBack 260E and 90E horizontal motion conveyors distribute product to multihead weighers, including new 14-head Ishida R-Series weighers that are direct-mounted to Ishida Atlas 233 VFFS snack bagmakers with integrated CEIA metal detectors.
From seasoning application to packaging, Brimhall Foods was impressed with the new equipment. “We now get 10% more production in 20% less time”, notes Brimhall. “We have had fewer maintenance issues compared to our old equipment. The improved efficiency and the additional baggers have allowed us to realise our production goals”, he adds.
Brimhall remarks the Spray Dynamics seasoning systems provide uniform slurry coverage with better control and consistency of seasoning application. Furthermore, he says the gentle horizontal motion of the FastBack conveyors prevent the loss and build-up of seasonings and the smooth one-piece pans are easy to clean.
The Ishida Total Packaging System integrates the new weighers and bag-makers so they can be controlled and monitored from a single touch screen. Using a Windows-based computer, real-time production data can be obtained to reduce waste and maintain high production efficiency. “The iTPS system makes changeovers and operation easy”, notes Manufacturing Director Joe Crowell, adding that the CEIA metal detectors integrated into the weigher-bagmaker stackups save space and help assure the safety of Brimhall Foods’ products.
“We chose Heat and Control because of their competitive price and good reputation for service after the sale”, says Patrick. “Their sales and project management people were very helpful and have a lot of experience in our industry. There were some issues with the start-up and operator training but Heat and Control sent in additional people to quickly correct these problems”.
Considered a steward of growth in its community, Brimhall Foods felt it was important to stay within Bartlett when it chose to expand its manufacturing facility. “We have been blessed with good people and some great opportunities”, concludes Patrick. “We are also glad to have a partner like Heat and Control to help drive our success”.
coating & conveying
Smart conveying involves more than moving your products from points A to B. When it comes time to upgrade your conveyor system, look for the latest technology in safe conveyors that are sanitation friendly, reduce cross contamination, maintain product quality, facilitate proportional product feeding, and reduce costs for operation and maintenance.
FSMA RELATED IMPROVEMENTS FOR FOOD SAFETY To help processors comply with Food Safety and Modernisation Act directives, new conveyor technology has emerged to ensure more thorough sanitation of product contact surfaces and to reduce the possibility of product crosscontamination. Look for single piece stainless steel conveyor pans with no sharp angles or recesses that can trap bacteria. Also check that product diverting gates on distribution conveyors can be removed quickly and without using tools. This allows such parts to be thoroughly cleaned away from the production area. There is also a new generation of continuous weighing conveyors that eliminate the product loss and unsanitary operation of traditional weigh belts. For product distribution systems, investigate the latest rotary distribution gate designs that reduce leakage and the possibility of product crosscontamination. These rotating cylindrical gates have no pinch points that can damage product and injure operators. There are also soft-edge designs for the traditional slide gate that greatly reduce the risk of pinch point injuries.
NEW TRENDS In response to customersâ€™ needs for gentler, more responsive conveyor systems, equipment manufacturers are developing new designs that move product quickly, cause less damage, and provide an operator-friendly workplace.
DEVELOPMENTS IN CONVEYING Blake Svejkovsky Product Handling Systems Manager | Heat and Control, Inc.
HORIZONTAL MOTION For many foods, particularly fragile snacks and coated products, horizontal motion has become the conveyor of choice over vibratory models. Although better suited for grading, sizing, spreading, and moving sticky foods, the bouncing motion of vibratory conveyors causes breakage and stress fractures, and shakes seasonings and coatings off foods. Horizontal motion eliminates these problems by sliding product in the conveyor pan. This prevents build-ups of oil and seasonings in the conveyor pan and the frequent downtime needed for cleaning. Horizontal motion maintains pre-mixed blends. Some models can even convey up slight inclines. Horizontal motion also transmits less vibration, allowing the use of less structurally complex support platforms. Even running with product, horizontal motion conveyors operate far quieter than vibratory models, usually in the low 70 dB range.
LONG RUNS FOR LESS BREAKAGE The latest horizontal motion conveyors can handle heavier pans for runs up to 100 feet long using a single drive. The lack of transfer points helps reduce product breakage. Users also benefit from lower equipment purchase and maintenance costs since one drive can cover distances that previously required three or more.
REAL TIME FULL PROPORTIONAL DELIVERY Rotary product distribution gates and direct communication between weighers/packaging machines and conveyor systems now enable incoming supply of product to be diverted to multiple locations with no starvation of downstream equipment. When used to feed multiple seasoning applicators, these conveyor systems allow different flavours to be applied simultaneously. Less warehousing, faster order fulfilment, and longer, more efficient machine run times are a few of the benefits.
THE PREPARED FOODS MENU CONTINUES TO GROW
PREPARED FOODS PROCESSING SYSTEMS Since the inception of industrial food production, Heat and Control has partnered with prepared food manufacturers to meet every challenge to achieve higher capacities, lower production costs and superior product quality. For meat, poultry, seafood, vegetables and a growing menu of other prepared foods, Heat and Control builds a complete range of equipment for coating application, cooking - fryers and oven systems, grill marking and searing.
FREQUENLY ASKED PREPARED FOOD QUESTIONS Q
Natural products, like chicken breasts and bell peppers, vary in thickness. How do you apply a consistent barbeque grill pattern across both high and low surfaces, or on both sides of a product?
Heat and Controlâ€™s Rotary Brander applies uniform grill marks to one or both sides of natural and formed products. Our unique Floating Ring branding wheel follows the contours of natural products to produce a consistent justgrilled finish. Two-sided Rotary Branders are compact units complete with pre-piped and wired combustion and control systems. You can easily move them from one line to another. Single-sided Branders can be mounted to your existing oven or transfer conveyor and include a separate combustion/control cabinet. All Rotary Branders can be easily adjusted for different product heights. Customised grill marks and combination searing/branding units are also available.
PREPARED FOODS FREQUENTLY ASKED QUESTIONS Q A
How can we get an impingement oven to yield both high output and improved product quality? Other impingement ovens promise high production output or improved product yields. But they can’t deliver both because of uneven cooking and irregular heat transfer. To ensure all product is safely cooked to the same core temperature, some ovens even require overcooking so part of every production run suffers drastically lower yields. Heat and Control’s AirForce® impingement oven cooks dramatically faster than comparable ovens because it quickly and evenly transfers heat across the full width of the product conveyor. Yields are also higher thanks to AirForce’s patented moisture-controlled heating system, and the uniform cooking across the width and not ‘over-cooking’ product on one side of the oven. A major poultry processor uses the AirForce oven to cook breaded breast fillets in just 1.8 minutes, compared to 4.5 minutes in a competitive impingement oven. Another processor’s AirForce oven cooks breast chunks in almost half the time required by another impingement oven. AirForce also sets speed records for cleaning. With no inaccessible ductwork that harbours bacteria, thoroughly cleaning AirForce takes less time than other impingement ovens. Automated cleaning of individual oven zones is also available to further reduce clean up time and the amount of cleaning chemicals used.
How can we keep from overcooking some of the product furthest from the sides of our impingement oven without sacrificing pathogenic safety?
Most impingement ovens cannot cook evenly across the conveyor width because their air distribution and heating systems are fed from one side of the oven. To ensure a complete kill of e-Coli and other harmful bacteria, these ovens require overcooking to assure all product reaches a safe core temperature…sacrificing valuable yield in the process. Heat and Control’s AirForce® impingement oven solves this problem by using centralised air circulation systems in the hood and base. All product on the left, centre and right sides of the conveyor is cooked to virtually the same core temperature. Temperature probe comparisons with other ovens prove AirForce cooks more uniformly than any other impingement oven... and cooks faster. In addition to safety and high yields, you also get higher production output.
From product coating and cooking, through freezing and packaging, Heat and Control supplies the complete system.
ANYONE FOR A LITTLE SIZZLE?
Bratwurst sausages from a successful cooking test at Heat and Control’s technical centre became a surprise lunch for employees at the company’s California headquarters. Hundreds of juicy bratwurst sausages were cooked in the CEOTM Spiral Oven. Its enhanced airflow browned the sausages to perfection. Mouth-watering was an understatement and most enjoyed more than one. “It’s just like they’re hot off the grill”, exclaimed one employee. “I wish I had one of these for my Labor Day barbecue!”
Heat and Control Technical Centres Test new product ideas in the latest frying, oven, coating, branding, searing, seasoning, coating and packaging technologies in any Heat and Control functional test kitchen or packaging room in one of 8 centres around the world.
Is it time to investigate how your product can make its mark?
Make your mark! We eat with our eyes, and perfect sear / grill marks on a steak make it look even more appetising. But is this surface treatment superficial or does it serve a purpose? Any home chef knows that getting a good sear on a steak, helps food release from the grill naturally. Sear marks seal in the juices and guarantee food wonâ€™t stick to the grill. As well dark brown crusts on grilled meat impart flavour as the result of changes in the chemistry of the meat. Known as the Maillard reaction, this caramelisation or browning occurs when heat changes the structure of amino acids, proteins, and sugars. The result is flavoursome food that looks good. It is only natural that consumers want the same seared / grilled finish in the products they purchase from the supermarket. Convenience meals are in demand as peopleâ€™s busy lives mean they have less time for meal preparation. However, while consumers want convenience, they do not want to compromise on quality or taste. The application of grill marks or a combination sear / grill finish is one way that processors can differentiate their product as one that has a genuine char-grilled finish and flavour. Heat and Controlâ€™s Rotary Brander or combined Searer / Rotary Brander is ideal for applying an appetising, justgrilled finish to products such as meat, poultry, seafood, vegetables and bread. The gas-fired open flame Brander continuously imparts grill marks on the top, bottom, or both sides of formed and natural products. Previously, sugar or caramel stripes were applied to products before cooking, which then darkened into the appearance of grill marks. With the Rotary Brander, products are actually grilled for authenticity. Featuring a short footprint, Rotary Branders are available to mount on existing cookers and conveyors, or as portable self-contained conveyorised units. The variable speed branding wheel adjusts to accommodate different product thicknesses, and can be raised clear when branding is not required.
Choose from standard horizontal bar or custom-designed branding wheels. Floating-ring branding wheels, which follow the contours of products that vary in thickness, are also available. Brand top, bottom or both sides - Choose from single and two-sided branders for formed and naturally shaped products. Custom markings - Diamond patterns and other custom markings can be ordered instead of standard parallel grill stripes. Easily adjustable - Quickly set branding height for different products. If branding is not required, the roll can be raised clear of the conveyor. Floating ring roll - This option uniformly brands shrimp, vegetables and other products of irregular thickness. Control branding colour - Adjust branding depth and speed to suit product requirements. The Rotary Brander can be used in combination with a Direct Flame Searer also available through Heat and Control. The searing section uses multiple heightadjustable burners to provide a variety of surface finishes, from char-grilled accents to overall browning. The location of the Rotary Brander in the processing line is one way processors can further differentiate their product. The placement of the Rotary Brander before or after the oven results in a different tasting end-product. Placing the Rotary Brander before the oven, the belt speed has to be run slower to develop a mark (production considerations), and during the cooking/oven process, the flavour from the grill mark will migrate into the product resulting in more of a mild roasted flavour. If the Rotary Brander is placed after the oven, the belt speed will run faster to develop a grill mark (production considerations) and the product will have a very grilled almost charred taste that is highly favourable with consumers.
PROCESSING MEAT, SEAFOOD OR POULTRY? THIS IS WHAT WE HAVE FOR YOU. Heat and Control supports you with over 65 years of equipment design and process experience, and one of the widest selections of machinery for coating, cooking - frying and oven systems, conveying, inspection and packaging for poultry, meat, seafood and prepared foods... plus excellent technical support. Coating Batter applicators (dip and batter fall) Breading applicators Drum breaders Marinade and seasoning applicators Spray Dynamics® coating applicators Inspection conveyors Fryers Breaded Products Fryer HeatWave® oil curtain fryer MasterTherm™ thermal fluid heated fryer Mastermatic® direct-heated fryer Mastermatic compact fryer Oil Filters Drum Pre-Filter Continuous Belt Filter (metal mesh belt) Continuous Filter (paper) Mastermatic Canister Filter KleenSweep® Centrifugal Filter Fryer Support Modules (integrated filter, piping, storage) Heat Exchangers KleenHeat® pollution control heat exchanger Coil-type heat exchanger Steam-to-oil heat exchanger Thermal fluid heater Electric heat exchanger
Conveyors Progressive packing conveyors FastBack® horizontal motion conveyors FastBack product blending conveyors FastBack sorting/separation conveyors Revolution Gate distribution conveyors Varilift® bucket conveyors Incline belt conveyors Inspection conveyors Automatic Belt accumulation conveyor Cascading accumulation conveyors MinuteMan™ accumulation conveyor SwitchBack™ accumulation conveyor UpGrade™ accumulation conveyor ClimbBack™ uphill horizontal motion conveyor Sanitary packaging platforms Container Fillers Vertical Raceway tray filler Oscillating Funnel Follower Dual Axis Funnel Follower USDA sanitary shuttles
8 TEST CENTRE Ovens AirForce impingement oven IMP Jr. impingement oven Spiral ovens (single and twin conveyor) MPO cooking system convection oven Infrared ovens Steam ovens Rotary dryers
Surface Enhancement Rotary Brander Direct Flame Searer Combination searing/branding systems
Ishida Multihead Weighers Ishida multihead weighers Ishida screw-feeder weighers (for fresh meat) Ishida hygienic weighers Ishida USDA Dairy ultra sanitary weighers Inspection Systems Ishida X-ray inspection systems Ishida DACS checkweighers CEIA® metal detectors Ishida QX Tray Sealers
Control + Information systems
HEAT AND CONTROLâ€™S PREPARED FOODS SYSTEMS Try a selection of the latest processing, seasoning, coating, product handling, packaging and inspection technologies in one of our eight demonstration centres.
Apply the latest frying, oven, coating, branding and searing technologies to products in a relaxed environment that promotes product development + innovation. Bring in a concept or product and use actual production machinery to refine your formulation and identify the equipment that produces the results you want.
Evaluate equipment performance and develop new products without interrupting production schedules at your plant. Perform detailed laboratory analyses of the cooking processes and their effects on product moisture, fat content, taste, mouthfeel and finished yield. Our experienced staff to assist you with all aspects of food processing.
WHAT IS THE RIGHT SYSTEM FOR YOU?
SPRAY DYNAMICS COATING SYSTEMS
Coating + Conveying Systems | HEAT AND CONTROL
SNACK FLAVOURING APPLICATION TYPES
Think of seasoning and coating as the icing on the cake. The right application method will greatly affect the taste and look of the end product. It’s come down to a balance of elements: the right amount of flavour applied to the base product, good adhesion of flavouring to the base product and the right application method to get the end product desired. The most common seasoning systems used in savoury snacks include: >> Conveyor based dry application >> Drum based single-stage >> Drum based two-stage >> Drum based slurry
Question: How do you know what is the right system for you? This quick overview matches a typical coating application to product.
SINGLE STAGE: DRY
Typically for salt application where the powdered and granulated salt is dispensed over the product running on a moving belt. Product has some adhesion ability.
Are used on products that have natural tack; flavouring adheres easily to the product. Product is passed through drum system.
WHAT PRODUCT? >> Crackers and biscuits prior to baking
WHAT PRODUCT? >> Fried potato chips and crisps >> Fried pellet snacks >> Oil popped popcorn >> Corn Chips
TWO STAGE: OIL AND DRY
Are used on snacks that do not have natural tack; flavour does not adhere easily to the product. The oil application provides a base for the dry flavouring to adhere to. Product is passed through drum system when both applications occur.
A thick emulsion of oil and flavouring. For coating types that require more oil than seasoning. Generally the oil content is more than 60% of the slurry weight. Product is passed through drum system. Note: You can also include “dry” application for additional flavour profile after the slurry process.
WHAT PRODUCT? >> Tortilla chips >> Mini rice cakes or other dry puffed products >> Air popped popcorn >> Baked chips and crisps >> Extruded snacks
WHAT PRODUCT? >> Extruded snacks >> Air popped Popcorn >> Puffed snacks
Beat the “right” drum What are the KEY PARAMETERS you should consider when choosing a drum based seasoning system?
Coating + Conveying Systems | HEAT AND CONTROL
The drum is at the heart of the seasoning and coating operation and if chosen correctly for application will ensure a balanced and consistent coverage. When the drum is inappropriate, there are many negative side effects for the end product. Ingredient “clumping”,over-seasoning/under-seasoning, inconsistent seasoning such as only one side coated, and failure to maintain adhesion to the base product will occur.
Drum Flight design Flights are featured in the interior wall of the coating drum that lifts the product bed, turning it over and exposing both sides for coating. Flights are available in different sizes. The flight chosen is based on product shape and density/volume. Flight design can be aggressive for robust products or a gentle folding action for fragile products. An example is the tortilla chip, the lifting flight has to be large enough to create a turning bed yet not lift the product too high to cause a large drop to break the chip.
Drum diameter and length Length is based on the number of coating zones (single or two stage) and the length of the coated zone: • Slurries may need soak time Diameter is based on volume. It’s important to get it right as the the diameter can be too small or too large: • If the diameter is too large, the rotating product bed will be very narrow and the flavour applicator will apply the coating to the drum, not the product • If the diameter is too small not all of the product will migrate to the top to get coated
Even turning product bed The goal is an even turning product bed - no pulsing is preferred. Pulsing is when chips are lifted up as a group and then slide or fall back to the bottom. The only exception to this would be if pulsing is used to break up clumps of product. Drum size that ensures appropriate retention in coating zone. The drum size will have impact on the amount of time spent in the coating drum. At least four turns of the product is needed under the oil or dry applications.
Want to know more? Visit www.heatandcontrol.com/spraydynamics
Weighing + Packaging Systems | HEAT AND CONTROL
WEIGHING, WRAPPING AND LABELLING ARE INTEGRATED INTO ONE UNIT WITH THE ISHIDA WM - AI The Ishida WM-AI Automatic Wrapper with integrated scale and label applicator has been designed to utilise SMART & AI (Artificial Intelligence) to improve field productivity to a maximum.
The WM-AI design is the result of ISHIDAâ€™s extensive expertise, gained by a thorough analysis of global working environments, operational processes, operator ergonomics and production lines. With a small footprint of 100cm width x 112cm depth, the WM-AI incorporates a stainless steel exterior body, a unique two-film roll mechanism, sliding-out printer, robotic label applicator with user selectable positioning, large 22cm label roll and 8cm thermal head, and a 31cm colour LCD touch panel with adjustable viewing angle. The WM-AI offers high-speed wrapping and labelling with the ability to wrap up to 35 packs per minute, print 120mm per second. It also features an increased wrapping weight capacity of up to 4.5kgs. Clear, tight and wrinkle free wrap is accomplished by using the combination of either pre-stretching or ultra-stretching technologies together with the two-roll system whilst at the same time reducing film usage and cost. The CMOS camera system automatically identifies the tray as it is placed on the weighing area of the in-feed. Any tray misalignment is corrected by the pusher and the centering conveyor, ensuring the pack is always perfectly wrapped, eliminating unnecessary rewraps, inaccurate totals, and film wastage. The WM-AI achieves accurate and consistent label placement by the tray detection system, which knows the size and location of the tray together with the label placement co-ordinates. The WM-AIâ€™s user-friendly ergonomic design focuses on maximising operational efficiency. Film or label roll exchange, daily machine cleaning, and error handling have been designed to minimise downtime. The operators need very little training and within a very short time become comfortable with the operation of the system.
Heat and Control is the exclusive distributor of Ishida ICP products in Australia.
WM NANO AUTO WRAPPER BENCH-TOP SIZED FOOTPRINT WITH LARGE TYPE PERFORMANCE • • • • • • • •
Ishida’s auto-wrapper > weigh / wrap / label Most economical / compact auto-wrapper available Reduce operator RSI Increase wrap quality and consistency Long life easy to clean stainless steel construction 7” easy to use colour touch screen with one-shot preset keys Quick change label cassette with label design options Remote PLU price updates (Ethernet or Wireless)
MEET THE TEAM behind Ishida Commercial Products (ICP) in Australia, Ross Phillips, Roy Jury and Neil Astwood, specialising in commercial scales and weigh wrapping equipment. Our team are experts in providing high quality retail scales, weigh wrapping and price labelling equipment in Australia for the retail food industry including supermarkets, greengrocers, fruit & vegetable growers, butchers, fishmongers, fresh product wholesalers, delicatessens & bakeries. If you would like to speak to a member of our team about ICP equipment, please email icpsales@ heatandcontrol.com.au ICP ON FACEBOOK
ICP has embraced social media and now can be found on Facebook. Here you will find updates on our latest projects and information on Ishida’s products. You will also be able to provide ICP and users of the site with feedback and ideas. This is a closed Facebook group dedicated to Ishida dealers. Please send a ‘Friend Request’ so we can add you to the group. Search for ‘ICP (Ishida Commercial Products)’.
Ishida Commercial Products [ICP]: Retail, Food Processing & Factory Automation Weighing Systems Heat and Control; exclusive supplier of Ishida ICP systems in Australia
EXPLORING IN SPEC TI ON THE JOURNEY TO QUALITY ASSURANCE Meeting consumer expectations of food safety and consistency can be a defining factor in your brand’s success in the marketplace. The increase in innovative technology now provides systems that can not only detect, but can also operate simply, efficiently, and at high speed while collecting data to provide a transparency previously unachievable.
Factors as simple as colour and shape, to internal biological factors such as chemical content, elemental composition, and molecular structure, for example, measuring the chlorophyll, fat, or water content can be analysed to determine good or bad product.
With the market shift from a previous focus on quantity and price, to a more conscious market focused on healthbenefits, quality, and safety, inspection is now a crucial part of the food manufacturing process. The technology in this area of food manufacturing continues to advance as companies strive to produce the highest quality products while reducing cost of ownership, as well as risk.
VISION INSPECTION One of the first steps in the inspection journey occurs much earlier in the production line than most other inspection technologies. Irrelevant of your product type, food sorting technology is critical to ensure the initial removal of foreign, potentially dangerous materials, as well as sort bad from good produce. Whether it be potatoes, peas, leafy products, nuts, seeds, dried fruit, meat, or other produce, sensor-based sorting equipment has been developed to be flexible, offering a variety of solutions that are able to be tailored to the product’s specific needs. Research and development in this area has seen improvements across a range of sorting technologies, maximising the use of natural product resources with a reduction in environmental impact, and in turn optimising sustainable growth and profit. Recent technology’s increase in efficiency and accuracy has boosted the ability to detect and remove the smallest of defects and foreign materials from production lines. Food sorting equipment uses a variety of sensor technology such as high resolution cameras, laser, fluorescent lighting, pulsed LED sensor arrays and multi-wavelength bars, X-ray, CCD sensors, Shortwave Infrared (SWIR), and Near InfraRed (NIR) spectroscopy. Each technology works to detect specific characteristics in the product flow to differentiate product from contaminants.
Partnering “smart” technology available to complement sorting equipment allows even further control over the quality of your product at this stage of production. This additional module provides a program set up that the operator may adjust according to the analysis of the incoming product. The ability to change the sorting criteria gives ultimate sorting quality control.
METAL DETECTION Metal detection is an inspection process that can occur at several points throughout your production line. The primary purpose of installing metal detection is to identify ferrous (magnetic), non-ferrous metal contaminants in your product, for example aluminium, stainless steel, and even paint chips. This, as most forms of inspection, is primarily for the quality control of your product and ultimately consumer protection, however metal detection units can also be used to protect machinery throughout your production line. The smallest metal particles can lead to machinery malfunction, resulting in revenue decreases due to the need for production downtime to perform repairs, as well as the cost of the repairs themselves.
Metal detectors perform differently depending on their application. When used in food processing, metal detectors are typically constructed as a metal box housing a three transmitter-receiver coil detector system. The transmitter coil generates an electromagnetic field, similar to how a radio transmitter would function. If a metallic object is present it interferes with the electromagnetic field, causing a signal to be detected by the receiver coils.
There are a variety of controls that are available to work in conjunction with the signal processor in either design of detector. All work similarly in that the signal produced by the contaminant is analysed to provide amplitude and phase information. Most metal detectors are fitted with an automatic rejection unit that, if the product is deemed corrupted, will reject the product from the line. Although metal particles are able to be detected by other forms of inspection systems, metal detection systems are separated by their level of sensitivity. Cutting edge technology in metal detection has seen the invention of a multi-spectrum system. This new generation of metal detector is capable of eliminating false rejects without reducing sensitivity. Using proprietary multi-spectrum technology, it is able to consistently detect smaller metal particles in difficult products like wet spinach, cheese, tortillas, and ground beef.
SEAL CHECKING Seal checking or testing is used to detect leakage as well as identify trends that may give early warning of deterioration in the sealing process, while being gentle and non-destructive to the product. This is an integral step of the inspection process for the reduction of waste as well as product integrity prior to it reaching retailers. Technology in this area has produced systems that can check the integrity of sealed products such as chip packages, and well as flow-wrapped, or lidded tray products. As a product moves through the seal checker/tester, an inspection head applies optimum controlled pressure to the pack to detect and evaluate any subsequent â€˜giveâ€™.
Metal detector systems designed for foil-packed products also contain a system of coils, however differ in their working in that they are designed with a tunnel or passage that is subjected to a strong magnetic field. Any ferrous particle passing under the series of coils is magnetised, generating a current that is amplified and alerts the detection system of the contaminant.
This process can be used to establish the maximum safe pressure that can be applied to a specific product. If a product is deemed to be to be non-compliant, the seal checkâ€™s rejection system will remove the item from the production line, assuring the integrity of all packages reaching the distribution end of the line.
CHECKWEIGHING Checkweighing is a required step of inspection as it ensures the weight of a pack is within specific parameters, ready for distribution. Checkweighers can be used in wide range of applications including snacks and confectionery, ready meals, meat and poultry, fresh produce, dry and frozen foods, bakery, pasta, pharmaceuticals and non-food products. Advances in technology have seen vast improvements in two of the fundamental requirements of a checkweighing system, speed, ensuring minimum production time is lost, and accuracy. New state-of-the-art weigh cell design technology provides exceptionally reliable speed and accuracy, improving quality control, and reduced maintenance in the harshest of environments.
X-RAY Used in conjunction with metal detection, seal checking, and checkweigher technology, an X-ray inspection system is the final check in a complete inspection line. X-ray inspection is a way of identifying inconsistencies, physical defects, and/or contaminants in product packaged in a pouch, bottle, can, jar, or flow of product passing through the system, without damaging the food product. Contaminants can be foreign bodies in the product such as pieces of glass, stone, shell, pebbles, bone, plastics including hard rubber, Nylon, PVC, and Teflon, as well as metals such as steel, iron, and aluminium. X-rays are a form of electromagnetic wave of high energy and short wavelengths that are able to pass through food products. X-ray inspection systems function by passing an X-ray beam through an item as it moves along the line. As the X-ray beam passes through the item, it is converted into a greyscale image that can be easily scrutinised and recorded for historical traceability records. Contaminants denser than the product will present in this image as darker, whereas voids or missing pieces will present as lighter. This forms the basis of identification. X-ray inspection systems can be programed to check multiple quality parameters easily and at high speed, allowing the possibility for the addition of new, more intricate parameters to what had previously been checked. The result is an increase in food/product quality, ultimately raising standards and increasing competitiveness within your market.
ALL THINGS INSPECTION
CHOOSING A SUPPLIER Purchasing equipment is an extremely important investment that will have a great impact on the overall profitability of your product. A supplier that has a long history in the manufacturing industry, with a proven global record in outstanding service can be a valuable partner to the success of your company. It is important when considering a supplier you take into account not only the initial purchase, but the long-term contract you will have with that supplier, including up-front application assistance, training, parts supply, and technical support. It is also vital they are able to provide advice on a tailored solution that will be of most value to you, possibly including various integrated machinery, for example, the combination of a total metal detector and checkweigher system, or the integration of new machinery into your already existing line. The ability to offer trial demonstrations with your product to properly evaluate the systemâ€™s performance is also extremely valuable. This gives you the opportunity to have first-hand experience with the set-up and changeover of the equipment, its integration with other equipment, general quality, and level of service provided by the supplier.
Heat and Controlâ€™s Australian Business Manager of Packing and Inspection Robert Marguccio explores the inspection process.
More than 120 years experience in weighing
Technologies that deliver superior weighing & packaging performance ITPS Coordinator Preset selection, machine setting, production reporting and operator functions from single control panel
Innovative features offer cutting edge solutions for highspeed snack packaging with the Ishida Total Packaging System [ITPS]. Fully integrated operation of weighing / bagmaking / error rejecting / seal checking and check weighing results in high speeds of up to 180 bags per minute.
Ethernet connection provides detailed analysis of production statistics
Exclusive distributor AUS/NZ/USA. Snack systems available in India.
Weighing + Packaging Systems | HEAT AND CONTROL
SMALL IS BEAUTIFUL FOR NEW ISHIDA MICRO Ishida has introduced an enhanced version of its multihead weigher specifically designed for ultra-low target weights. The new Ishida Micro incorporates the latest features from Ishida’s advanced RV series to deliver speeds of up to 120 weighments per minute at accuracy to within 0.01g on packs between 0.5g and 40g. It is ideal for products such as herbs and spices, tea leaves, soup ingredients, dehydrated vegetables, seeds, tablets and capsules. The compact design, (a small 650mm x 650mm footprint and a maximum height of only 970mm) enables it to fit into the tightest of factory spaces. Easily removable troughs, hoppers and chutes speed up cleaning times. Equally important, the minimal gaps between contact parts further improve product transfer and minimise risk of product spillage or loss, while the hygienically designed hoppers and drive units also reduce dust build up and cleaning times.
An interactive 3D menu with clear icons and colour touch LCD screen makes machine operation easy to understand and control. Data exchange can be carried out through a USB memory stick, and the Micro also offers flexible connectivity for Ethernet communication or via SCADA (Supervisory Control and Data Acquisition). Advanced Ishida RV technologies incorporated into the Ishida Micro include a highly sensitive weighing sensor in the dispersion table, which provides smooth, very precise and stable automatic product feed. Stable and reliable stepper motor drives enable the highest weighing speeds and operating efficiency to be achieved. In addition, the availability of a C-shaped main body option with off-centre discharge chute means two weighers can be configured in pairs to enable either mix weighing or a multiple outlet configuration.
MICRO Multihead Weigher • Herbs, spices, tea leaves, soup ingredients, dehydrated vegetables, seeds, tablets and capsules • Up to 120 weighments per minute • Compact design • 0.5g to 40g packs • Configure in pairs to enable either mix weighing or a multiple outlet configuration
a perfect combination
KDV Group is a leading Russian confectionery, bakery and snacks manufacturer. The companyâ€™s origins date back 20 years to the acquisition of the Yashkino food factory in the Kemerovo region. After major investment at the production site, including the full upgrading and refurbishing of its manufacturing facilities, KDV started production of a variety of weighed confectionery products, including waffles, cookies and gingerbread under the Yashkino brand. Over the years KDV products became widely recognised in various parts of Russia. Consistently high demand for Yashkino confectionery led the company extending the geography of its sales, with the establishment of new production facilities in different parts of the country, which enables KDV products to be more accessible to the mass consumer. Today KDV Group comprises of 11 factories, producing over 350 types of confectionery products (including waffles, cookies, marshmallow soufflĂŠ, gingerbread, caramel and chocolate candy, marmalade, and chocolate) and snacks (such as croutons, potato crisps, pellet chips, dried fish, seafood, sunflower and pumpkin seeds and packed nuts).The company owns 15 trade brands including major Russian names Kirieshki, Babkiny Semechki and Yashkino.
Long-standing partners Heat and Control and Ishida have over 170 years of combined experience in processing and weighing / packing technology of snack lines. The successful integration of Heat and Control and Ishida snack manufacturing systems is unparalleled in the industry and covers full line solutions for processing, weighing and packing.
KDV’s snack ranges offer consumers the combination of excellent quality at affordable prices. A key reason for this is that the company grows its own potatoes next to its main factory in Yashkino. The potatoes are then fried in oil, made from sunflower seeds sourced locally from the Altay region and grown by another KDV company, KDV Agro. Just as important to this quality manufacturing is the company’s commitment to using only the best processing and packaging equipment - from Heat and Control and Ishida respectively. In 2008 KDV expanded its potato crisp production to meet growing demand that its existing factories could not cope with. While the intention was initially to produce an additional one tonne per hour, during the development of the project it soon became apparent that the hourly requirement was for two tonnes per hour. Since none of the existing factories could handle the increase, a new processing department was constructed near the company’s confectionery factory in Yashkino. This enables KDV to control the full cycle of production from growing to processing and shipping. As a part of the new potato chips line, specifically designed in conjunction with Heat and Control processing equipment, the line is fully integrated and process and packaging systems are able to work to full capacity and maximum efficiency. From the very start, the Ishida bagmakers were able to demonstrate their flexibility and adaptability. During installation, KDV decided that it needed to pack a wider variety of target weights than had initially been specified when the machines were ordered. Ishida engineers were able to solve this problem with the introduction of special forming tubes for different types of bags, and this continues to give KDV the ability to introduce new bag sizes or product varieties without major additional investment. The Ishida packing line comprises a 16 head Ishida multihead weigher integrated with the company’s Atlas ECO snack food bagmaker, which is able to achieve high speeds for even such a difficult product as potato crisps. The weigher operates in twin mode, with two sets of eight heads weighing the snack products simultaneously at speeds of up to 95 bags per minute per side. The Ishida Atlas bagmaker incorporates a single rotary jaw motion and superior control technology, which minimises product waste, film loss and downtime for film changes. An innovative sealing unit creates tight horizontal and back seals of the bag without wrinkles even during high-speed packing.
The Atlas also effectively controls product charge, reliably stripping any remaining product from the seal area and also preventing product from being blown upward. The whole efficiency of the Ishida packing line is around 98%. Pressure, temperature and sealing time can be easily set on the Remote Control Unit (RCU) to match the production speed and film characteristics, creating optimum seals for any film. The bagmaker’s user-friendly and easy-to-maintain design is simple to set up and operate and a unique auto film splicing feature reduces product changeover times by up to 10%. Currently the four Ishida bagmakers at KDV are handling a variety of leading brands, including Crispy Potato, Pro Chips and Fun Chips in pack sizes ranging from 40g to 160g. Across the four lines, the machines pack 20 tonnes of product in every shift, with giveaway never any more than 2% of target. On a 65g bag, for example, deviations range from just 0.5g under to 0.7g over. Reliability has been excellent with KDV reporting no breakdowns since the lines first began operating in 2012. Currently the factory operates five days per week in 10 hour shifts but during high season it runs 24 hours. Thanks to the ease of operation of the bagmakers and their easy cleaning features, product changeovers take no more than 15 minutes. Another benefit of the twin design is that one side of the weigher is able to continue to operate while the film is being changed on the other side, meaning production can be maintained and throughput maximised. “Undoubtedly the major benefits of the Ishida bakmakers for us are their excellent reliability and high productivity that allow to us to respond to market demand for our products,” comments Mr. Vladimir Grankin, KDV Group’s technical director. “In terms of technical support during the installation and operator training, the level of service is excellent. The bagmakers are easy to operate and maintain and this is another key advantage for us. “Ishida produces equipment that always satisfies the technical requirements of our packaging. The ability to fully automate the weighing and bagging process has enabled us to further enhance the quality of our products. “Indeed, due to the success of our relationship, we develop new projects only with Ishida,” concludes Mr. Grankin. Therefore, it is no surprise that the company is already in discussion with Ishida for a number of new developments for both snacks and confectionery.
WHY INVEST IN X-RAY INSPECTION? X-ray inspection can be an invaluable tool for a food processing company to ensure their products are contaminant free and consistent in quality. This form of inspection is fast growing in popularity as it affords retailers a guarantee of a supplier’s product safety. Due to its non-invasive process, X-ray is becoming seen as industry best practice for packaged, processed foods. WHAT IS X-RAY INSPECTION? X-ray inspection is a way of identifying inconsistencies, physical defects, and/ or contaminants in product packaged in a pouch, bottle, can, jar, or flow of product passing through the system, without damaging the food product. Contaminants can be foreign bodies in the product such as pieces of glass, stone, shell, pebbles, bone, plastics including hard rubber, Nylon, PVC, and Teflon, as well as metals such as steel, iron, and aluminium. Used in conjunction with metal detection, seal checking, and checkweigher technology, an X-ray inspection system is the final check in a compete inspection line. An X-ray inspection system provides a company with the highest protection against physical defects, inconsistencies with the product’s estimated piece weight, and contaminants: allowing for closer control of your product’s quality.
HOW DOES X-RAY INSPECTION WORK? X-rays are a form of electromagnetic wave of high energy and short wavelengths that is able to pass through many materials, such as food products. X-ray inspection systems function by passing an X-ray beam through an item as it moves along the line. As the X-ray beam passes through the item, it is converted into a greyscale image that can be easily scrutinised and saved. Contaminants denser than the product will present in this image as darker, whereas voids or missing pieces will present as lighter. This forms the basis of identification.
IMPROVING QUALITY Quality control can be achieved through the integration of an X-ray inspection system into your line as it is able to identify a variety of variances in products, including but not limited to: • • • • • • •
Contaminants such as plastics and bone Fill levels Number of individual items/components Cracks or voids Gas bubbles Grains stuck together in powdered products Ties or other securing devices missing or out of place
An advantage of this scrutiny can also be used to identify reoccurring problems that may be caused by an issue in your process line, for example, if a product is cracking, this may be due to moisture loss prior to packing. The ability to identify these issues at an early stage may save larger losses of product, and/or equipment failure. X-ray inspection systems can be programed to check multiple quality parameters easily and at high speed, allowing the possibility for the addition of new, more intricate parameters to what had previously been checked. The result is an increase in food/product quality, ultimately raising standards and increasing competitiveness within your market.
PROVIDING REASSURANCE TO YOUR RETAILERS Contaminants found in food products is one of the leading causes of recalls internationally. This can have a variety of negative outcomes for the food processing companies as well as their retailers, including complaints and loss of public confidence in their product and brand overall, to much more serious consequences for their consumers such as health issues, dental injuries, and in severe cases, death. Due to this food processing companies may invest in X-ray inspection systems as a form of demonstrating the practice of due diligence with respect to risk management and product safety. This can be of great advantage for the sale of your product and brand, as it provides confidence and peace of mind to retailers and in turn consumers. Recent times have seen some retail chains insist that all of their suppliers have this technology in place to assure their brand and reputation is protected. ISHIDA IX-G2 DUAL ENERGY X-RAY INSPECTION SYSTEM
FOR THE PHARMACEUTICAL INDUSTRY CEIA manufactures state-of-the-art Quality Control Metal Detectors that offer full compliance with FDA requirements Part 210 and Part 211. The THS/ PH21N provides superior metal detection in the manufacturing process of this strictly regulated industry. The highly reliable proprietary digital technology delivers a consistent detection for metal contaminants in tablets, capsules and powders. All models feature a mirror finish on 316L Stainless Steel that offers the best level of sanitation achievement. SUPERIOR DETECTION CAPABILITY CElA THS/PH21N Metal Detection Systems feature extremely high detection sensitivity towards contaminating metals, whether ferrous, non-ferrous or stainless steel. Once a contamination is detected, the system rejects the identified material. The system’s fail safe operation monitors the opening and closing of the ejection flap through a redundant confirmation sensor. CONTINUOUS EMBEDDED SELF-CALIBRATION CElA THS/PH21N features a continuous embedded Self-Calibration function for maximum repeatability and performance consistency over time. Proprietary signals are sent to the metal detector transmission and reception chain that provides constant monitoring of the detection characteristics. Constant regulation of algorithms supplies compensation for any variations caused by environmental factors. The result is a system with stability, consistency in performance and a product effect assurance. FDA 21 PART 11 COMPLIANT CElA THS/PH21N Metal Detection Systems satisfy the standards of Security, Integrity and Traceability of production data as required by Part 11 of Title 21 of the CFR - Electronic Records - Electronic Signatures.
Inspection Integration THS/RB-800 Easily integrate a CEIA metal detector with any checkweigher or other in-line equipment with the CEIA THS/RB-800. Only 31.5” (800mm) long, the system includes a CEIA THS/SL21 series SlimLine metal detector, round belt conveyor, an optional conveyor speed-sensing encoder and operating controls, all pre-assembled on a sanitary support frame. The RB-800 system is available with different CEIA metal detectors, including models THS 21, 21E, 21E-3F, and the MS21 which features CEIA’s proprietary multi-spectrum technology that eliminates product effect rejects without reducing detection sensitivity. The MS21 typically detects smaller particles of 316 stainless steel, ferrous, and non-ferrous metals in the most challenging applications, such as cheese, wheat tortillas, fresh spinach leaves, ground meat and partially frozen foods. The polyurethane cord conveyor is available in three widths and can be removed without tools. Belt speed and aperture height are adjustable to accommodate a wide range of products. Conformal coated electronic components, a stainless steel casing and keyboard, and specialised aperture seal prevent damage from external and internal moisture.
Inspection control equals security
Improve inspection results with the world’s only multispectrum metal detector Reliability Eliminate product effect reject errors, and end product waste and reinspection.
Quality Control Detect smaller particles of all metals including AISI-316 stainless steel
CEIA’s unique THS/MS21 metal detector achieves the highest sensitivity to smaller metal particles by applying a broad spectrum of frequencies simultaneously and continuously. CEIA’s continuous inspection process simply and accurately distinguishes between metal contaminants and product effects with no reduction in metal detection sensitivity. For fresh, frozen, hot, cold, wet or dry products that have single or multiple ingredients, even different products that run on the same line.
Exclusive distributor USA, AUS, NZ, AFRICA, NETHERLANDS and ASIA.
TOMRA SORTING FOOD SENSOR-BASED FOOD SORTING MACHINES TOMRA Sorting Food is part of TOMRA Sorting Solutions, a global sensor-based sorting systems pioneer in the food, recycling, mining, specialty products and other industries. The company develops and utilises a powerful combination of technologies across these industries with over 13,500 systems installed in 80 countries. With more than 5,000 of its systems installed at food growers, packers and processors worldwide, TOMRA Sorting Food is a global market leader. The company provides high-performance optical sorters, peeling and process analytics systems for nuts and seeds, dried fruits, potato products, fruits, vegetables, meat and seafood. Its sorting machines ensure optimal quality and yield, resulting in increased productivity, throughput and an effective use of resources. TOMRA Sorting Food’s distinct development of advanced technologies supported by excellent customer care to deliver increased yields, improved food safety and enhanced profitability is entirely unified across the company. This proposition sits at the heart of the business and ensures TOMRA Sorting Food continuously improves for the benefit of its customers. “TOMRA Sorting Food offers sorting equipment for a multitude of food applications, from fresh whole products to processed food, from farm to fork.” COMBINED POWER DRIVES TOMRA SORTING FOOD TOMRA Sorting Food has recently reached an important milestone in its history. From 2016 onwards, the company’s BEST Sorting and ODENBERG legacy brands have been retired and the business will progress as a single, unified brand under TOMRA Sorting Food. This final and complete adoption of the TOMRA brand simultaneously marks the successful end of a journey and the start of an exciting new era. BEST Sorting and ODENBERG have been around for more than 60 years in total and the companies’ combined power, knowledge and expertise will continue to live under the umbrella of the TOMRA brand.
The only change that customers will see with the brand unification is that TOMRA Sorting Food machines produced from 2016 onwards no longer carry either the BEST Sorting or ODENBERG logos. TOMRA Sorting Food has successfully integrated the people, processes and technologies of two world-class optical food sorting and peeling businesses while creating a new company which is greater than the sum of its parts. SENSOR TECHNOLOGY TOMRA Sorting Food’s focus on research and development has enabled it to develop a range of innovative sorting machines which are able to detect and remove the smallest of defects and foreign material from production lines. Its range of sensor-based solutions transforms how the world optimises its precious resources, allowing for sustainable growth and maximum profit while reducing environmental impact. TOMRA Sorting Food’s machines use a variety of sensors which go far beyond the common use of colour cameras. Near Infra-Red (NIR) spectroscopy enables an analysis of the molecular structure of a product whilst x-rays, fluorescent lighting and lasers measure the elemental composition of objects. The internal composition and surface structure of objects can also be analysed to determine good or bad produce. “TOMRA Sorting Food’s machines are not only the most efficient way to sort products; they are also a smart investment.” TOMRA’S FOOD SORTERS: SMART INVESTMENTS Genius optical belt sorting machine The Genius optical belt sorting machine uses a combination of sorting technologies to meet the high food safety requirements of the food industry and individual food processors. The sorter uses air ejectors to separate good and bad produce and can be tailored to individual customer requirements, taking into consideration their unique needs. The machines require little maintenance and can handle a high volume of produce at any one time. The Genius can sort a multitude of foods including potato products, nuts, fruit and vegetables. With high resolution cameras and lasers, it offers a combination of inspection technologies in different inspection zones, achieving unequalled sorting performance. For operators, the sorting machine brings multiple benefits. Its graphical user interface enhances ease of use and its high volume abilities means processing is faster, more effective and efficient without compromising food safety and quality. Halo sensor-based optical food sorter The Halo sensor-based optical food sorter is an ideal solution for potato and vegetable processors and packers who want to make their operations leaner and are looking for a return on investment using advanced sorting technology. A high performance machine, the Halo is able to sort according to size and quality. The Halo offers excellent throughput and capacity, without losing consistency and accuracy, boosting processors’ lines and overall efficiency. The Halo’s ability to consistently detect and remove potatoes for example, with unwanted greening defects, blemishes and damage means higher yields and a safer, higher quality final product going to the packing line or onto further processing. Moreover it has the ability to detect, classify and remove subtle defects into a separate stream for second grade pack or further rework in the processing line.
TOMRA SORTING FOOD SENSOR-BASED FOOD SORTING MACHINES Nimbus BSI free fall sorting machine The Nimbus BSI (Biometric Signature Identification) is a breakthrough for nuts and raisin processors. The breakthrough BSI technology detects the biometric characteristics of nuts, dried fruits, potatoes, and other commodities through the ability to identify the material’s unique fingerprint. This allows for an enhanced sorting quality in comparison with conventional spectral technology, while retaining nearly all good material. The Nimbus scan path also features a dust protection shield to ensure stable, reliable sorting results by reducing the number of passes needed, resulting in less breakage or bruising. The platform therefore offers users lower labour time and higher throughput, yield, and efficiency in the rest of the processing line. The flying beam principle (patent pending) implements only two halogen light sources per sensor module, in combination with a rotating polygon. A concentrated and focused light beam allows maximum light efficiency. This results in a significant energy minimisation and no increased heating effect, allowing the Nimbus BSI to be the only sorter in the world that can combine both spectral imaging and lasers on one sole machine. The Nimbus BSI can also be used effectively for reverse or recycle sorts where the volume of ‘bad’ is higher than the ‘good’, targeting good product rather than faulty material, just by the touch of a button. Exclusive Distributor: Australia, New Zealand, Africa For more information on TOMRA Sorting Food sorting machines available, visit www.tomra.com/food
TOMRA SORTING SOLUTIONS WINS INNOVATION AWARD TOMRA was presented at the 2015 Innovation Award at the World Nut and Dried Fruit Congress, May 2015, Antalya, Turkey, for it’s innovative creation of the Nimbus free fall sorting machine with Biometric Signature Identification. Bjorn Thumas, director market development, says: “We are delighted to have won this prestigious Innovation Award, which recognises the latest innovative technology in the world of nuts and dried fruits. Receiving an award voted by the industry we work for and with, is a confirmation we are on the right path. We believe that TOMRA’s Nimbus BSI is a breakthrough for nuts and raisin processors.” Almond processor, Stewart & Jasper Orchards, based in California, has already introduced the Nimbus BSI to its processing lines. Jim Jasper, owner and president, says: “By implementing TOMRA’s Nimbus BSI, our company has benefited enormously. Our throughput has increased immensely and we have seen our labour expenses drop. On top of that, our product quality has improved. “We have thoroughly researched the sorting industry and it goes without saying that TOMRA’s Nimbus BSI is unmatched.” The INC (International Nut and Dried Fruit) Conference is the most important conference worldwide on nuts and dried fruit.
CUTTING EDGE Producing exact shreds to minimise waste and maximise profits.
Â® Explore the family of size reduction equipment at www.urschel.com
delivering targeted cutting solutions
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The Global Leader in Food Cung Technology
The Ultimate Slicer | Shredder | Granulator MODEL CC SERIES The Model CC Series of machines uniformly slice, strip cut, shred and granulate a wide variety of food products at high production capabilities with excellent results. Among these products are potatoes for chips, shredded cheese for pizza topping, mushrooms, cabbage, lettuce, onions and carrots for salad ingredients, and a wide variety of nut meats for bakery ingredients. Each machine features interchangeable cutting heads that enable the processor to change the type of cut in just minutes. Specially designed disposable knives do not require sharpening and are inexpensive to replace. Each model features continuous operation for uninterrupted production and is designed for easy cleanup and maintenance.
Mozarella Full Shred 1.8mm
Standard Crinkle Slice
Parmesan Wide Oval Shred
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Full & Reduced Flat-VÂŽ Shreds
Sweet Potato Flat-V Slice 1.7mm
Full Shreds & Reduced V Shreds
Carrot Shred 6.4mm
*Limited availability based on application.
HOW TO CUT FRUIT & VEGETABLES Type Of Cut
Slice Elongated Products
E TranSlicer® Cutter
Slice, Strip Cut and Dice
Information A wide variety of products especially suitable for elongated products. Three cutting wheels: slicing / patented MicroSlice® / julienne; produce a full range of slices and julienne cuts.
DiversaCut 2110® A wide variety of products including potatoes, tomatoes, carrots, Dicer turnips, turnip, celery, pineapple, and beets.
Dice, Strip Cut and Slice
DiversaCut Sprint® Dicer
Slice, Shred, Dice
TranSlicer® 2510 Cutter
Leafy Vegetable Dice
Dice, Strip Cut or Slice
A wide variety of vegetables and fruits. Efficiency and flexibility are key traits. The compact design combined with the ease of switching over from one cut size or type to another deliver infinite production possibilities.
Specification Accepts firm products up to 4” (101.6 mm) in diameter and leafytype products up to 6” (152.4 mm) in diameter. Maximum product input size: 10” (254 mm) in any dimension. Maximum product input size: approximately 6.5” (165.1 mm) in any dimension.
Input of compressible food products This model revolutionised the leafy vegetable industry. Features include up to 8” (203 mm) in diameter, or firm, ease of maintenance, increase positive product flow and decrease round products such as cabbage up operational costs. to 6-3/4” (171 mm) in diameter. A two-dimensional cutter, designed for a variety of products through a wide range of sizes from product of a predetermined thickness.
Wide range of sizes from product of a predetermined thickness.
A versatile machine capable of processing a variety of fruits and vegetables. Interchangeable drive parts provide maximum versatility and optimum cutting results in the small to intermediate size range.
Maximum input product size: 3-1/2” (88.9 mm) in any dimension.
Slice, Strip Cut and Dice
Ideal for french fry strips a variety of soft ripe fruits and brittle root vegetables. A wide selection of interchangeable cutting parts enables the user to obtain gentle, clean cutting through a wide range of sizes at high production capacities.
Maximum input product size: 5-1/2” (139.7 mm) in any dimension.
Large Product, Slice, Dice, Strip Cut
A wide variety of food products. A crosscut spindle and circular spindle changing tools allow one person to change spindles without assistance.
Maximum product input size : 10” (254 mm) in any dimension.
Slice, Shred and Granulate
A wide variety of fruits and vegetables. Features interchangeable cutting heads that enable the processor to change the type of cut in just minutes. Specially designed knives do not require sharpening and are inexpensive to replace.
Maximum input product size: 3-3/4” (95.3 mm) in any dimension when using stainless steel impellers.
Crosscut Bias Slice on Elongated Products
Cuts an inclined angle of 30 degrees with the long axis of the product. This causes the slices to be radically different in appearance than the standard crosscut pieces. One slice is made at a time which prevents any crushing of the product. A wide selection of slice thicknesses to choose from. Not suitable for slicing sticky products or high concentration of sugar.
Will accommodate products up to 2-3/4” (69.9 mm) in diameter or width.
Segment Cut, Crinkle, Flat Slab, Square or Rectangular Strip
For many food products including carrots, pickles, zucchini and Will accept product up to 4” (101.6 potatoes. Several different cutting heads are available including the mm) in diameter and is easily adapted standard cutting head, slab cutting head, and the patented Velocicut® to automated belt feeding. cutting head.
Mill, Granulate, Flake Cut or Puree
Comitrol® Processor 1500, 1700, 3600 Slant, 9300
For a multitude of dry, paste and liquid size reduction applications. Comitrol Processors vary in feed/discharge configurations, cutting head and impeller options, and horsepower. Standard operations include: granulating, flaking, slicing, milling, shredding, liquefying, pureeing and dispersing.
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