MAFEX 2012 Casablanca company and product information

Transcription

1 1 our company. Heinen Freezing GmbH & Co. KG with its wide product portfolio of five different spiral systems (type compact., arctic., acticool., proofline., pasturic.) two fluidised bed systems (type freezelite. and blizzard.) and one multi level buffer freezer (type packfrost.) is already 30 years now the professional partner of the entire food industry. Between 30 and 40 systems are leaving the premise in Varel, Northern Germany to be installed at customers site professionally and in short time by their own engineers. Therefore Heinen Freezing is Europe s leading company when it comes to machinery and systems for pasteurising, proofing, cooling and freezing. With more than 50 employees, different sales partners and a big number of agents Heinen Freezing has a wide sales and service network, especially in Europe but also beyond that. The North German machine manufacturer is owned by 75% from the Amandus Kahl Group, Reinbek, Germany and by 25% from the Management. Machinery and systems on a high quality level with highest reliability and a extremely long lifetime have lead to the brand HEINEN and to a continuous growth. This brand is binding and everybody at Heinen Freezing GmbH & Co. KG is well aware of this. The spiral systems. compact. a compact spiral system for cooling and freezing - fully assembled on a base frame - capacities up to 800 kg/h - for cooling and freezing - as single drum or double drum, as upwards or downwards conveying system - belt width 457 mm - options like feeding and discharging conveyors, frequency controlled fans - highest hygienic standard due to full stainless steel execution and optional cleaning system The compact. is a spiral system which is very compact, fully assembled on a frame and designed for cooling and freezing of meat, poultry, fish, pizza, bakery products and more. compact duo - a compact spiral system for even higher capacities - fully assembled on a base frame - capacities up to kg/h - for cooling and freezing - double drum, as upwards or downwards conveying system - belt width 457 mm - options like feeding and discharging conveyors, frequency controlled fans - highest hygienic standard due to full stainless steel execution and optional cleaning system The compact duo. is the upgrade of the successfully compact series, more powerful but still a compact system and is available as double drum system in three different layouts and this with absolutely compact dimension. With a number of already sold systems the compact duo shows that it is an adequate solution for small to medium capacities for an attractive price.

2 2 arctic. new and different. The latest developement of Heinen Freezing is concerning the energy consumption of the systems. For reducing the energy consumption Heinen Freezing offers now the standard option energysav first of all for the series arctic. i.e. high efficiency drives, increased insulation values of the insulating enclosure, heat load oriented control of the requested refrigeration capacity and self-optimising defrost management. The reduction of the energy consumption will be achieved at first with reducing the energy loss with a higher thickness of the insulating enclosure. With a thickness of 170 mm there can be already an improvement of 20% in the heat-transfer coefficient (U-value, W/m2*K) achieved. The next step is then reducing the base (heat) load of the electrical motors. HEINEN-Freezing offers here the high efficient energy saving motors from SEW-Eurodrive, which are more than compliant with European Regulation EFF1. The optimised use of the refrigeration energy in the air cooler finally leads to some more energy saving. A special fin spacing and the change to a controlled air circulation in relation to the temperature difference reduces the energy consumption of the fans. All energy saving measures require a higher investment in technique and technology, but they do pay back depending on the daily operation time in a very short time mostly. Production times are valuable, each minute a system can be used is important and each minute the system has a standstill for cleaning or maintenance is expensive. For this reason Heinen Freezing offers comprehensive options for the arctic. spiral systems. Among other things a modular system for extending the production time without defrost. Apart from the standard shift defrost execution there are intermediate defrost system, snow blow off device and the sequential defrost as possible options and executions. The snow blow off device is a continuous running unit, which enormously extends the time of snow and ice build up on the surface of the lamellas. The snow blow off device and the intermediate defrost system can extend in this way the production time without stop for defrost from 8 hours to 72 hours. If there is a request for an extension in capacity additional production time can be realized with a low investment. With the sequential defrost the total needed refrigeration capacity of the system is diverted on to several smaller and individual air coolers. This spilt on to individual air coolers, separated by insulated walls allows the defrosting of one air cooler during production without interruption. Therefore production times of 144 hours without general defrost can be achieved. Heinen Freezing supplies these systems especially for applications in the meat industry when it comes to direct freezing of fried or cooked products without any pre-cooling. arctic. the powerful spiral cooler / freezer - universal and flexible spiral system - preassembled modules, in short time installed on site - for cooling and freezing - as single drum or double drum, as upwards or downwards conveying system - belt widths from 660 mm to 1422 mm - from 12 to 36 tiers - capacities from 500 kg/h to kg/h - central drive underneath the drum, no chains or any other open greasing points - horizontal or vertical air flow - sequential defrost for production times of 144h without interruption - options like feeding and discharging conveyors, frequency controlled fans, energysav system - highest hygienic standard due to full stainless steel execution and optional modular cleaning system

3 The arctic. is an universal and flexible spiral system for conveying, cooling and freezing of meat, fish, poultry, bakery goods and other food products from Heinen Freezing. The arctic. offers for medium to large capacities, especially due to the wide range of standardised additional equipment for each product the optimal and individual solution. 3 proofline. the continuous spiral proofing system permanently good climate for permanently good yeast growth Continuous processes are the key to efficient production, even if the continuous process is not needed 24 hours seven days a week. Decisive is that the process runs without intervention and trouble. Matched to the particular demands of the proofing process, Heinen has developed its proofline. series. Designed for capacities from 500 kg/h to kg/h, the system has been developed especially for continuous industrial proofing processes for high-quality bakery products. It ensures a particularly gentle product treatment with optimally synchronized resting, proofing and cooling stages, combined with the advantages of a spiral system. Further advantages, like product feeding directly onto the already collapsed conveying belt, long retention times as well as flexible and precise climate conditions for a large number of products, have turned the proofline. into a system most commonly used in the industrial production of bakery products. the 3-phase proofing system by Heinen Freezing phase 1 resting phase After preparation, the stressed dough is first relieved of its stress in the resting phase of the spiral proofer proofline at temperatures of between +18 C and +20 C. This temperature range is ensured by a combined cooling and heating register; cold water can act as a cooling medium; warm water or also electricity can be used for heat generation. The 3-phase system is especially suited for very high-quality bakery products such as, for example, flaky pastry and croissants, as it ensures the stress-free entry of the dough into the proofing phase. phase 2 proofing phase As the spiral proofer proofline is an open system, it is possible to create identical climatic conditions at every point of the proofing zone. The cooling and heating registers are arranged on all sides in order to completely avoid an undesired airflow in the system an absolutely stable proofing climate is the result. The use of combined cooling and heating registers in combination with a downstream ultrasonic moistener for re-moistening as well as high-quality frequencycontrolled fans ensures that a precise proofing environment is attained. Depending on product requirements, the temperatures in the proofing stage range between 25 C and 35 C at a tolerance of +/- 1K. The relative humidity lies between 50 and 85 % at a maximum tolerance of +/- 3 %. The air speed during the proofing phase is less than 0.5 m/s. phase 3 cooling phase To achieve a precisely defined and reproducible proofing result, it is necessary to interrupt the proofing process at a predetermined point in time by introducing the product to the cooling phase. At temperatures of between -5 C and +10 C the dough is subject to rigorous cooling. The extent of the evaporator surfaces and the required air speed are matched to the requirements of the respective product. The cooling phase also brings along two further advantages: 1. the cooling leads to a thin skin to form on the product which protects the product from desiccation as well as from escape of ingredients, 2. the thin skin enables the product to loosen slightly from the belt.

4 4 advantage of the Heinen proofline. Particularly careful product treatment at resting, proofing and cooling phases that are optimally coordinated with each other in addition to the advantages provided by a spiral system. Relatively low space requirement at capacities of 600 kg/h to kg/h and continuous production. Product feed by means of a loading belt directly onto the already collapsed spiral belt for particularly shape-sensitive products, long retention times as well as flexible and precise climate control for a multitude of products. combined lines proofing-freezing or cooling-freezing Heinen project engineers have not only created ideas for the conception and integration of the individual series into one production process. During the past few years in particular, combined lines for proofing-freezing (proofline. and arctic.) or cooling-freezing (both with systems of the series arctic.) have gained in importance within the scope of an optimum process solution for the industrial production of bakery products. Thus, Heinen offers individual turn-key solutions including conveying technique and access platforms, for example for the cooling and freezing of bread rolls from taking them off the oven until transferring them to the packaging systems if required as well by integrating components like slicing or decorating systems provided by the customer. On the other hand, continuous pasteurising and cooling processes are an important element of the production process for semi-cooked or ready-made meals. A combination of pasturic. and arctic. is here the counterpart to the combinations mentioned before. acticool. - conditioned bread cooling. To meet the requirements of the modern bakery industry regarding product safety, quality and hygienic needs Heinen adapted its spiral cooler arctic. for the conditioned bread cooling process. The acticool. bread cooler enables a continuous and precise control of the climate parameters air temperature, air humidity and air speed for climate conditions in very small tolerances inside the system. The control system for the climate conditions is executed to run independently from the outside or production room conditions to ensure throughout the year identical process conditions. This is essential because the product outfeed temperature is allowed to vary only in very small tolerances for high quality during the following slicing process (less product loss). Another main design aspect of the conditioned spiral cooler is to prevent products getting dried out due low temperature or high air speed. basic conditions: air temperature +15 C to +25 C air humidity 55 % to 75 % relative humidity air speed < 2,0 m/s Filtered and optionally with UV-V lights disinfected air guarantees no contamination of product and conveying system during the cooling process. Horizontal and laminar air flow through the whole systems guarantees a gentle, soft and uniform cooling of the product. Overpressure inside the insulating enclosure for avoiding contamination by non filtered air entering the insulated enclosure and a complex software for the air conditioning unit first to achieve an accurate climate but second to save energy with the best air mix are also characterizing the Heinen acticool. bread cooler. The available belt widths of 660 mm, 760 mm, 914 mm, 1067 mm, and a number of tiers from 12 to 32 with a maximum product height of 180 mm, normal or reduced radius execution and four different conveying layouts shows the flexibility of the fully stainless steel Heinen spirals systems. Finally the spirals can be designed as single or double drum system as well as upwards or downwards conveying. Possible retention times ranging from

5 30 to 240 min. (belt speeds available and adjustable from 5m/min. to 25 m/min.) as another design criteria will be chosen according the requested final product temperature. A conditioned bread cooler acticool. a7 / 20, installed as one of three systems at a customer in Poland, has a footprint of approx. 7 x 8 m and a height of 5 m. In this application approx breads/h each 1000g are cooled down from +90 C to +26 C. The acticool. conditioned bread cooler can be supplied by Heinen fully integrated, i.e. including transfer conveyor from the oven accepting and aligning the breads after the oven and carrying them to the spiral cooler as well as connecting conveyor or gravity spiral after the spiral conveyor for leading the products in the correct way to a subsequent slicing machine. Apart from the spiral system including the insulating enclosure the following modules are available out of the conditioned bread cooler kit: - separate air conditioning unit for mixing, filtering, cooling and de-humidifying of air from outside, air from inside the production and circulated air - optional air disinfection by UV-C lights which ensures the killing of 95% of all microorganism, integrated in the air conditioning unit - optional air re-humidifying by ultrasonic humidifiers (max. 36l/h), integrated in the air conditioning unit - optional water treatment system with reverse osmosis unit incl. UV-C disinfection and water softening unit - Heinen offers furthermore conveying systems between oven and spiral cooler in different executions, very much oriented to the building and process requirements as well as conveying systems between spiral cooler and slicing machine consisting of e.g. gravity sliding spirals and connecting conveyor for individualizing the product before going into the slicing machine. 5 The fluidised bed systems freezelite. and blizzard. freezelite.and blizzard. are designed for cooling and freezing of bulk products such as diced meat, seafood, peas and all kinds of vegetables, french fries, berries as well as herbs. The small dimensions of the freezelite. assure the application, where only limited space is available. Completely pre-mounted on a frame a maximum flexibility in a growing or changing production environment is guaranteed. With its capacity range up to 1,500 kg/h (type f15) resp. up to 4,500 kg/h (type f45), a belt width of 880 mm (options: metal or plastic modular belt), an integrated belt cleaning system, its stainless steel design as well as its integrated cleaning system, the freezelite. already offers a very extensive standard configuration. The blizzard. is used for capacities from kg/h to kg/h. Additionally there are numerous options for the systems are available: an externally extended infeed, product dewatering, a belt agitator etc. While developing the freezelite. and blizzard. the engineers of HEINEN Freezing attached great importance to a wide field of applications for the fluidised bed system. In the following only a few special features of the series: - frequency-controlled fans (individual control for the pre-freezing and main freezing zones) - standard industrial components as well as DIN- and standard parts increase production reliability and decrease costs for spare parts - inspection bridge between air cooler and conveyor system for supervision of the freezing process and for cleaning purposes - easy disassembly of system parts for maintenance and cleaning purposes without tools

6 - multi-language and symbol-controlled operation via touch-screen display - program selection for freezing/cooling, defrosting and cleaning via comfortable recipe administration and quick selection by means of customer-specific product pictures - modem for remote control included in basic version 6 The design of the freezelite. and blizzard. already consider the latest development in terms of service life extension (production time without defrost). A modified air flow through the air cooler optimises the distribution of frost and ice on the fin surface. Thus, the process time available before pressure loss due to snow building and defrost of the air cooler, can be increased considerably. packfrost. the multi level buffer freezer for highest demands - capacities up to 500t/d - for already packed products either in cartons or plastic boxes - for cooling and freezing at the same time in the same system - modular system design with four different product shelves and a free scalable total height and depth - different retention times each level - air flow in counter current, co-current and cross current direction - servo driven motors for high dynamic and special sensors with integrated heating for highest reliability - PLC controls with field bus technology for best operating comfort - options like feeding and discharging conveyors, frequency controlled fans, energysav system, laser scanner system - heavy duty industrial execution made of hot dipped galvanized steel and stainless steel for a long lifetime and low maintenance costs The flexible shelve system for cooling and freezing of products at the same time as well as storing of products, especially for higher volumes is used as an ideal solution especially in the poultry, meat, fish and ice-cream industry. packfrost. new and different. With its packfrost. system HEINEN Freezing offers abattoirs and meat processing factories one of the most efficient opportunities in the market today to cool and/or freeze - at lowest cost - products already packed into cartons or semi-finished products held in plastic boxes for intermediate storage. During the thermal process the products are stored on special product shelves which allow air to circulate around them at temperatures down to -35 C. In general, the packfrost systems are designed for taking up the quantity of a daily production. The products are frozen during the night and discharged when feeding another daily production quantity the next day. Capacities up to 500 tons/day are possible. The packfrost can be used both for shift- and continuous operation and is able to reach a capacity up to 40 tons/hour (depending on the product). Another advantage of the packfrost is the complete independence of the conveyor system from the type and/or size of packing. As the products are conveyed on shelves, even sensible cartons can be handled without damage. It is also possible that differently packed products are cooled and frozen at the same time. With the free programmable retention time each level cooling and freezing of different packed products at the same time is also possible.

7 7 The sequential defrost system for the air coolers of the packfrost extends the production time without defrost, thus assuring a continuous operation up to one year without interrupting production. The packfrost. can be operated in shift mode or in continuous mode and achieves freezing capacities up to 40 tones per hour - depending on the product. Connection to a production planning system via ethernet or field bus technology as well as the control of the product flow by a laser scanning system allow an integrated data management. In the focus of the Heinen Freezing design specialists has been also for this series the reduction of the energy consumption as well as increasing the reliability. Now all movements of the elevators and of the pusher are realized with servo driven motors. All servo drives are connected via a field bus and can be monitored very closely. The servo drives, made by SEW Eurodrive are equipped with special Hiperface incremental encoders which do not need to do a reference run after power faliure. In addition to that with using incremental encoders a multitude of normal sensors have been replaced and the reliability increased. The remaining light barriers and sensors have been equipped with heating elements for assuring a long lasting function. For reducing the energy consumption Heinen Freezing offers now the standard option energysav also for the packfrost. series. The reduction of the energy consumption will be achieved at first with reducing the energy loss with a higher thickness of the insulating enclosure. With a thickness of 170 mm there can be already an improvement of 20% in the heat-transfer coefficient (U-value, W/m2*K) achieved. The next step is then reducing the base (heat) load of the electrical motors. Heinen Freezing offers here the high efficient energy saving motors from SEW-Eurodrive, which are more than compliant with European Regulation EFF1. The optimised use of the refrigeration energy in the air cooler finally leads to some more energy saving. A special fin spacing and the change to a controlled air circulation in relation to the temperature difference reduces the energy consumption of the fans. All energy saving measures require a higher investment in technique and technology, but the do pay back depending on the daily operation time in very short time mostly. the freezing people. Customers that choose Heinen not only acquire a high performance plant that fulfils highest quality standards, they also invariably acquire state-of the-art technology from one of the leading mechanical engineers in the trade. The large numbers of returning customers in past years are evidence for the truth of our claims. More than 30 years of experience from more than 500 plants installed all over the world today s technology for tomorrow s products. This is the expertise that enables Heinen to meet the specific needs of its customers with specific solutions the expertise of the freezing people.