Fruit processing solutions

Transcription

1 Fruit processing solutions

2 Processing lines for fruit applications FRUIT PROCESSING Terlet has been specializing in fruit processing for many decades. Being one of the first manufacturers of stainless steel food equipment, for both continuous and batch processes the focus on fruit processing is a very logical one, as the delicate product requires state of the art processing in terms of gentle handling and hygienic design. Over the years Terlet has involved mechanical as well as process and food technology engineers in the design of fruit processing lines. Our portfolio is divided into the types of processing the industry tends to use: Jams for the consumer market; jams and bake stable fruit preparates for the industrial market and aseptic fruit preparates (yoghurt fruit). JAM Jam is a traditional product, made of fruit, sugar and pectin. Citric acid and calcium citrate are added to improve the binding of the pectin. The mix of ingredients often doesn t match with the final required percentage of the two main components: fruit and sugar, either required by food legislation, customer demands or the traditional taste profile. Fruit with its natural sugar content adds too much water to the recipe. One way to overcome this is to use fruit concentrates. However many jam producers like to use IQF and fresh fruit to achieve the quality they require. The alternative is to remove water. The traditional method, used for homemade jams as well as in some industrial processes, is to cook under atmospheric conditions for longer times. Terlet adds a sophisticated cooking method to traditional jams: vacuum cooking. By evaporating water at lower boiling temperatures, under vacuum the process takes only a fraction of the time and the thermal impact on the products is much lower than while cooking under atmospheric conditions.

3 Three concepts: DONUT COOKER BASED This process line is mostly dedicated to the production of traditional jams. The mixing and pre-heating of ingredients and cooking / evaporation are done in separate process tanks. Mixing of ingredients and pre-heating take place in the MMR tanks. The vacuum cooking and evaporation in the Donut cooker is combined with a condenser and fluid ring vacuum pump. This Donut cooker is a pure evaporator, using the natural convection caused by cooking in steam heated pipes at low pressure. The convection and large heat exchanging surface contribute to efficient and quick evaporation. The process is suitable for free and easily flowing liquids with a relatively low viscosity. CONDENSER Aromas Colorants Pectin Gumms Citric Acid Air PRE -MIX Water Brix DONUT COOKER BUFFERTANK BIN LIFTER MMR HEATING BIN LIFTER MMR HEATING

4 MAXXITHERM COOKER BASED MMR COOKER BASED The Maxxitherm cooker combines the advantages of the Donut cooker (large heat exchanging surface) and the MMR tank (gentle and efficient mixing). Process lines built around the Maxxitherm can therefore handle a wider range of products, with higher viscosities with pectin and starch as binding agents. Also combining heating, mixing and evaporation in one tank, with a condenser is possible. Another option is to use a vacuum tank version of the MMR with a condenser in case of lower capacities. Although process times will be longer than in the two other options, still high quality jams and other fruit products can be produced. CONDENSER Atmosph. Atmosph. Water BINLIFTER Steam MAXXITHERM Brix Steam Cond. Condensate Condensate CONDANSATE WITH AROMA S Steam MAXXITHERM Brix Steam Cond. Condensate Condensate BINLIFTER BUFFERTANK

5 BAKE STABLE JAM ASEPTIC FRUIT PREPARATES These products are characterized by high sugar contents and in many cases the use of starch in combination with temperature resistant pectins. Evaporation is essential for efficient production and so is the mixing of ingredients, including starches, without damaging fruit particulates. Both Maxxitherm and MMR based vacuum cooking lines are used for these types line of products. These products are often referred to as yoghurt fruit, indicating one of the main markets for these products, the dairy industry. Important characteristics are related to the final destination: large particulates, assuring the consumer recognizes the real fruit present in the dessert and produced and filled under aseptic conditions, so that the product with which it is mixed does not get contaminated. These characteristics are reflected in the typical design of Terlet process lines for aseptic fruit preparates: gentle in terms of mechanical and thermal impact and equipment of the highest hygienic design standards assuring aseptic conditions.

6 BATCH SYSTEMS The advantages of batch processing are the flexibility and ease to switch recipes and the fact that the whole process takes place in one or two tanks. Mixing of ingredients and pasteurizing is done in a Maxxitherm or MMR tank. Cooling takes place by a combination of vacuum cooling and jacket cooling. The cooling tank therefore must be a vacuum tank with fluid ring vacuum pump and condenser. Both Maxxitherm and MMR design tanks can be used. Cooker and cooler are two separate tanks preferably, but can also be combined in one tank. In this case measurements must be taken avoiding cross contamination from raw to pasteurized product, such as steam flushing the top of the tank between cooking and cooling. CONDENSER WATER Brix PRE -MIX BIN LIFTER MMR COOKER Sample valve MMR VACUUM COOLER CULINARY METAL DETECTOR Ster. nitrogen VAN MEURS BAG-IN-BOX STAINLESS STEEL CONTAINER FILLING

7 CONDENSER HOLDING TUBES PRE -MIX Pect. / Starch Water Water HEATER COOLER BIN LIFTER MMR VACUUM COOKER Brix BUFFERTANK CULINARY METAL DETECTOR Ster. nitrogen VAN MEURS BAG -IN-BOX STAINLESS STEEL CONTAINER FILLING CONTINUOUS SYSTEMS In continuous systems the preparation, mixing and pre-heating is separated from the pasteurization of the product. MMR tanks are typically used for preparation, followed by the Terlotherm scraped surface heat exchanger for heating and cooling. The fact that the thermal part of the line, Terlotherms and holding tube, are separate and always operating under a slight over pressure which makes maintaining aseptic conditions relatively easy. The separate pasteurization section adds equipment and a process step, but the Terlotherm design assures that even delicate products pass through the whole line with minimum damage. Often the process line is followed by Terlet-made filling stations for aseptic containers and a van Meurs Bag-in- Box filling machine. The container can act as a buffer when operating a flip flop filling station and when using the Van Meurs filling machine. Alternatively an aseptic, horizontal buffer tank can be used. Cleaning In Place and Sterilization In Place procedures are standard on both batch and continuous aseptic systems.

8 Processing equipment for fruit applications Terlet B.V. has a large product portfolio to supply state-of-the-art fruit production lines. Many of these components which forms the heart of the process are manufactured in house. OVERVIEW LINE EQUIPMENT MMR cooker in various configurations Donut cooker Maxxitherm cooker Horizontal buffer tank Terlotherm scraped surface heat exchanger Van Meurs Bag-in-Box filling machine To supply a turn-key production line, Terlet can incorporate and integrate components from different sources to design the optimum line required.

9 MMR Cooker The MMR cooker is a heating/mixing tank that is used for fruit products requiring a combination of processing operations. FEATURES AND BENEFITS MMR COOKER Donut Cooker The Donut cooker is specially designed to accelerate the cooking and evaporation process for (pectin) low viscosity fruit products. It is used in combination with an atmospheric MMR cooker to optimize process times. FEATURES AND BENEFITS DONUT COOKER Hygienic design Multiple executions possible such as: Atmospheric Vacuum cooking including head space for foaming products Vacuum cooling application Aseptic and non-aseptic execution Many options possible for raw material infeed and connections Multiple heating levels possible for different batch sizes Homogenous suspension of (fruit) particles though special screw agitator CIP cleaning Hygienic design No moving agitators inside the tank Gentle transportation through natural convection flow Variety on options possible such as Brix measurement CIP cleaning Up to 3 times faster than conventional jacketed tank

10 Maxxitherm Cooker The Maxxitherm cooker is developed to have the best of both worlds; Gently mixing and rapid cooking and evaporation via the large steam heated surface of the rotating coil. Horizontal Buffer tank The horizontal buffer tank is designed to keep product with (whole) particulates in a homogeneous suspension. Sinking products are moved upwards, floating particulates are pushed down. FEATURES AND BENEFITS MAXXITHERM COOKER FEATURES AND BENEFITS HORIZONTAL BUFFER TANK Hygienic design Products can also be mixed and pre-heated Suitable for high viscosity products Gentle mixing and heating Variety on options possible such as Brix measurement CIP cleaning 2 3 times faster than a conventional jacketed tank Hygienic design Special design agitator for keeping product homogeneous Multiple executions possible such as: Atmospheric Vacuum - pressure Indirectly headed or just insulated Aseptic and non-aseptic execution CIP cleaning

11 Terlotherm The Terlotherm scraped surface heat exchanger can be used as heater or cooler in a continuous production line. A wide range of capacities is available to optimize for a desired line capacity. FEATURES AND BENEFITS TERLOTHERM Hygienic design Low pressure drop and reduced shear to minimize product damage Can handle fruit particles up to 25 mm Tangential inlet ensures smooth flow and no product damage CIP cleaning Van Meurs Bag-in-Box filling machine The Van Meurs Bag-in-Box filling machine is suitable for applications to fill bags with a 1" filling connections. Suitable for fruit products like purees jams and concentrates. The Van Meurs is available in various models from semi to fully automatic. For bags from 2 to 25 liters. Drums can be filled from 200 to 1,000 liters. FEATURES AND BENEFITS VAN MEURS BAG-IN-BOX FILLING MACHINE High hygienic filling capabilities Very low operational costs and simple orientation Can handle fruit particulates up to 12 mm (depending product properties) Stand-alone unit with integrated controls CIP program in controls

12 From design to maintenance Terlet has a team of experienced and professional engineers and process specialists who not only understand machines but also our customers products and the manner in which they are manufactured. Our machines are designed in-house and are fully geared to your specific needs and are perfectly in line with your process. This know-how and the flexibility of a personalised production facility are evident in our high quality standards. An added value you experience during the complete life cycle of our products. Terlet B.V. Oostzeestraat 6 NL-7202 CM Zutphen THE NETHERLANDS phone fax info@terlet.com