Value added food processing the Sandvik way
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1 Value added food processing the Sandvik way
2 Steel belts for a wide range of food processing systems Continuous steel belt cooling systems Rotoform systems for pastille production Contact freezers for meat, seafood and coffee concentrate Dehydration plants for fruit and vegetables Steam cookers for petfood Film/sheet casting lines Steel belts and steel belt conveyors 2
3 Sandvik: delivering improved performance in food processing Drying Sandvik s specially developed drying systems are used for the efficient and hygienic processing of a wide range of foodstuffs. Benefits include faster throughputs, lower bacteriological counts, optimum drying cycle profiles and reduced operating costs. Cooling For demanding cooling applications as diverse as chocolate, candies, mashed potato and agar agar, we offer a choice of three cooling systems: water cooling, chilled air cooling and air flow-through cooling. Sandvik engineers will work with you to establish the optimum cooling method for your products, and deliver a system complete with integral feeding and discharge devices. Freezing The combination of air blast freezing and the superb conductivity of the steel belt make Sandvik freezing systems first choice for reduced freezing times, consistently high product quality, low energy consumption and total hygiene. Our standard applications include the freezing of coffee and tea extracts and the IQF freezing of whole fish, fish fillets, crabs, scallops and shrimps. Storage/conveying Use of the Sandvik steel belt extends into all areas of the food processing industry. Its absolute hygiene, easy cleaning and simple discharge make it the automatic choice for applications as diverse as high capacity storage silos, chocolate conveyors and sugar conveyors. 3
4 The Sandvik steel belt: the vital ingredient in our recipe for success At the heart of every Sandvik food processing system is the Sandvik steel belt, a product we invented, and in which we lead the world in production and precision. The Sandvik steel belt is smooth, flat, continuous and hardwearing, and its outstanding hygiene and heat conductivity properties make it the ideal medium on which to base a highperformance food processing package. Each belt is manufactured to close tolerances, and carefully checked for quality at every stage of production. Steel grades can be selected to match the precise demands of all kinds of food processing applications, and supplied in widths up to 6 metres. The versatility of the Sandvik steel belt is extended even further through a whole range of dividing, diverting and discharge mechanisms and retaining strips, ensuring that process and performance parameters can be met as efficiently and cost-effectively as possible. Sandvik steel belts can be supplied in solid or perforated form. 4
5 The Sandvik solution to conveying and live storage problems Chocolate conveyor Belt silo for potato powder The advantages of the Sandvik steel belt are well known in the food processing industry; indeed, many of today s most widely used techniques would not be possible without them. In bake ovens, they contribute the benefits of high temperature resistance, easy product removal from the smooth surface and ease of cleaning. As meat cutting tables they provide a hard, durable surface, total hygiene and corrosion resistance. Peeled tomato inspection conveyor Meat cutting conveyor But the benefits of the Sandvik steel belt and the applications-driven engineering support behind it also make it ideal for in-process storage and accumulation. Products can be stored (for instance, between processing and packaging), and fed into the line as needed, without the damage that can occur with conventional batch storage and product transfer. If you believe that your process lines could benefit from the imaginative application of this efficient system, our engineers will be happy to give you detailed information, and demonstrate how a Sandvik solution could be the answer to your conveying and storage requirements. Perforated steel belts for baking better biscuits The perforated belt provides an ideal alternative for bakery industry applications such as high-moisture laden biscuits which can tend to blister if baked on a solid belt. 5
6 A total capability in cooling systems Cooler for cooked carrots Air flow-through cooling system Chilled air cooling system To cater for the widest variety of products, Sandvik offers three basic types of steel belt cooling systems, plus a range of feed and discharge devices that enables individual process parameters to be matched precisely. A perforated Sandvik steel belt enables cool air to be drawn down through the product as it travels towards the discharge end of the system, thus cooling it at a controlled and consistent rate. The system is particularly suitable for cooked or blanched products. Similar in principle to the water cooling system, chilled air is used to cool products such as chocolate, couverture, caramel mass, stock cube mass and sugar candy, at controlled rates, and to consistently high standards of product quality. 6
7 ...to put your product in perfect shape The final shape of a solidified or crystallized product depends on the feed and discharge device.we offer a range of units that enable product characteristics to be matched with handling, appearance and other process requirements most effectively. These include stripformers, overflow weir feeders for flakes and the unique Rotoform system, a precision pastillating unit that delivers uniform, easily-handled, dust-free pastilles from 1 to 40 mm diameter. Among the many different products that have proved suitable for the Rotoform pastillation process are chocolate, sugar candy drops, chewing gum base, fats, emulsifiers, soup concentrate, cheese and many others. Rotoform system for chocolate pastilles Rotoform system for sugar candy drops Water spray cooling system Ideal for cooling and/or solidification of products in liquid or paste form, like gum base, mashed potatoes, gelatines and gums, emulsifiers and food additives. The water cooling system utilises jets of water sprayed against the underside of the steel belt to cool the product at an even and precisely-controlled rate. The solidified product is then simply discharged from the end of the belt. 7
8 A total capability in food dehydration systems The ever-increasing use of dried or dehydrated products demands highefficiency processing systems for all kinds of fruits and vegetables.which is precisely what this specially developed Sandvik system provides. Based around our perforated steel belt, this system enables controlled dehydration to be achieved by the flow of air through the product. Combined with the ability to control the speed of the belt travel, this unique feature contributes to a reduction in processing time of up to 50%, while still delivering a product of the highest quality with minimal bacteria counts. Significant performance benefits Sandvik s unique dehydration system offers significant competitive advantages: reduced process times as much as 50% lower modular design enables units to be linked into multi-stage dryers that deliver the optimum time/temperature profile for each product airflow system eliminates undesirable product dust formation minimum operating costs, thanks to low energy usage and reduced labour requirement highest possible hygiene levels and bacteria/yeast/mould counts far lower than other continuous drying methods superb product quality and appearance. The Sandvik dehydration system has been developed around a modular concept. Drying processes and relevant dryer capacities have been studied and tested in conjunction with research institutes and affiliated universities. Multi-stage drying line Dryer for highly sensitive products This expertise has also enabled the development of drying systems suitable for highly sensitive products such as bananas, pineapples and strawberries. Multi-stage drying for maximum control Up to three drying stages can be built into our dehydration systems. Each stage is formed by several modular sections to ensure that each product can be processed with the optimum mix of air temperature and moisture content throughout the cycle. Precise control of the time/temperature curve for each product provides maximum operational efficiency, quality and appearance for each item. 8
9 Drying stages Unloading station Suction section Some applications: Potatoes, tomatoes, cabbages, onions, sugar-infused cranberries, celery, garlic, carrots, orange peel, cranberries, agar-agar and gums, pet food, minced meat, seaweed, nuts and seeds, even problem products like grapes Flow section Sectional view: " Perforated steel belt # Upper air chamber $ Lower air chamber % Maintenance + cleaning doors & Fan ' Heat exchanger ( Exhaust air ) Belt return strand 9
10 High performance freezers for high quality freeze-dried coffee Coffee freezer (cooling section with NIRO equipment) Coffee freezer viewed from feed end Sandvik air blast contact freezing systems draw on the special qualities of the Sandvik steel belt to provide exceptional standards of quality with low running costs and substantially reduced process times.the superb conductivity of the steel belt, its smooth, joint-free surface (for maximum hygiene), and the ability to slide products smoothly and cleanly from the end of the belt (thus minimising wastage and breakages) all contribute to maximum operational efficiency and economy. Product versatility The use of blast-forced refrigerated air together with automatic belt defrosting and cleaning on each cycle provide the versatility and hygiene to handle products such as hamburger patties, fish fillets, poultry, shrimps, and also freezedried coffee, tea extract and baby food. The Sandvik freezer handles them all, reliably, economically, productively and cost effectively. Coffee freezer feeding station incl. belt tracking and tension device 10
11 Sandvik high performance IQF steel belt freezer for a wide variety of seafood Sandvik air blast freezers are designed to ensure fast, efficient production while at the same time maintaining the highest standards of hygiene. The smooth surface of the belt enables it to be continuously cleaned after discharge, ensuring a clean, hygienic surface ready for new product feeding. Steel belt advantages: highest standard of hygiene easy to clean smooth surface fast freezing due to good heat transfer Ideal for shrimps, king prawns... fish and fish fillets... and shellfish (mussels, cockles, scallops, oysters, etc.) 11
12 Full demo center and service support The right level of technical service will ensure that your system continues to deliver maximum competitive advantage, and our service organization which, operating from main centers in Europe, the Americas and Asia Pacific, covers the entire world is always there. Your regional Sandvik service center will provide all the support you need, including: Spare parts Commissioning and start-up Operator/technician training Maintenance & repair Process upgrades User manuals Training programs 24 hour technical tele-assistance Proof of the process... at a Sandvik demo center Our worldwide network of demo centers is at your disposal for assessing the benefits in terms of product quality and productivity of our systems. We can even arrange to set up a working production line for you to try out your own products, and our processing specialists will assist you in planning the most efficient and economical cooling system. Whether you require a simple feasibility test or full scale production data, our demo centers are there for you. Among the facilities available are: Static cooling test tank For establishing residence time and surface area required for your product and processing needs.when the belt width and layer thickness are known, the belt speed can be calculated from the capacity of the belt. PS-450 ENG Printed in Germany Sandvik Process Systems, Div. of Sandvik GmbH Demo center in Fellbach, Germany Demo center in Totowa, N.J., USA Pilot scale belt cooler For establishing the same data on a life-size basis.this and the test tank described above are both available on loan. Also available are cooling graphs and reports of several materials previously processed. Full scale test units For assessing the benefits to your operation of a Sandvik steel belt cooler, in terms of production rates, energy consumption and, of course, quality of end product.
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