Potato processing Perfect potatoes from beginning to end Portioning Marinating Coating Cooking
One stop for all your potato further processing needs Further processing of potato specialities In the potato processing industry there is also a growing interest in convenience foods and ready-made products. The increasing demand for processed potato products can be met by industrial production machines and systems. Systems that meet the high requirements of the food processing industry. Form, colour, taste, hygiene and quality are important starting points, as well as capacity, efficiency, reliability and production output. Townsend Further Processing develops, produces and installs such systems; complete lines for processing potatoes into appetising products with significant added value. As full line supplier Townsend Further Processing supplies machines for all the functions in the line, including: Portioning Coating Heat treatment Cooling and freezing. 2 3
Portioning A perfectly portioned product is the right starting point for an attractive snack, a tasty meal component or ready-made meal. Portioning your potato mass into products is a possible first step in your further processing process. Of course you want products that keep their consistency, products that are accurate in weight and shape. And for most processors flexibility and the ability to produce a wide variety of products are crucial. TEX-10 units Using the TEX-10 as a master, several different units can be attached to it to make a wide variety of different products. Pommes duchesse Townsend Further Processing offers various portioning systems for low pressure portioning that enable you to produce high quality products whilst retaining the structure and texture of the raw material. TEX-10 how it works Potato mass is deposited into the hopper where it is pressed into the machine by a special auger that scrapes the mass off the sides of the hopper after which gravity keeps it moving downwards. A second, screw-shaped auger takes care of the further transport through the TEX-10. It also put the mass under low pressure. A forming unit is mounted easily onto the TEX-10 using a fast coupling system, where the mass is processed under low pressure into a specific form. TEX-10 benefits Pommes Duchesse (or Duchesse Potatoes) consists of a seasoned purée of mashed potato which is piped into a round, peaked shape through a forming machine with 12 heads. The twisted topside can be provided in a left or right-hand turn but also with a variable number of ripples. In order to change the appearance of the product, different types of extruder nozzles can be used. The unit is extremely easy to operate and clean. Forming plate The forming plate can be used to form all kinds of products, including rösti products such as hash brown and triangles. The potato mass is pressed into the forming plate and a knock-out mechanism ejects the shapes, keeping the structure of the product. It is easy to operate and the forming plates can be easily changed to form other products. TEX-10, flexible forming and portioning The TEX-10 low pressure pump is designed for the low pressure portioning and forming of mashed potatoes with a good homogeneous structure. The TEX-10 can be equipped as an intermittently or continuously operating extruder with a coupling of various forming units such as a diaphragm, extruder, mould plate unit and pommes duchesse forming unit. These specific forming units can be used to make a wide range of end products such as pommes noisettes, croquettes, figures, triangles, pommes duchesse etc. Physical coupling of the forming units to the TEX-10 is very simple, as is the control unit: the TEX-10 recognizes the coupled forming unit, which automatically results in the corresponding menu of the forming unit appearing on the machine s touch screen. Easy change to different forming units Automatic recognition of forming units Recipe control by means of PLC/Touch screen Minimum of mechanical parts Easy to clean. Extruder The extruder can be used to make croquettes. A continuous flow of mashed potato is produced and a specially designed elliptical cutting mechanism sees to a precisely straight cut for each croquette. Many different combinations of length and diameter are possible, producing a variety of flat-ended croquettes. Diaphragm In order to make spherical products, the diaphragm unit can be coupled to the TEX-10. Available with 6 or 14 heads, potato mass is pushed through the diaphragm opening, after which the diaphragm closes, forming a variation of spherical products. By simply programming different curves in the software, different forms can be made such as balls and pear-shapes. There is also a separate rolling machine available with two moving plates, between which balls can be rolled out to form round-ended croquettes that look home-made. 4 5
Marinating RevoPortioner, perfectly low pressure portioned products Our RevoPortioner makes perfectly portioned products at low pressure whilst retaining the texture and structure of the raw material. Using special software, the RevoPortioner can be coupled onto the TEX-10 pump so that the RevoPortioner is used as a forming unit. Each product will always have the same shape, weight, size and be of uniform quality. The system can release products using only air or limited water. This leads to better product consistency and quality and an optimum control of the remaining processing steps. There is virtually no leakage of the potato mass. Marinating your products adds extra flavor to them or intensifies their natural flavor and often gives them a different appearance. Marinades are usually seasoned liquids, consisting of a liquid to which oils, herbs and spices are added. Some marinades are dry and are made up of salt and dried herbs and spices. Marinating slows the growth of harmful bacteria, increasing food safety. Also, marinades will help lock in moisture so your products won t dry out. ValueDrum, marinating the smart way ValueDrum how it works RevoPortioner how it works From the TEX-10 potato mass is brought at low pressure into the distributor housing. There the cavities on the continuously rotating portioning drum are filled with the product mass. A pressurized side plate keeps the filled cavities under pressure ensuring consistent product shape. At the blow-off position the portioned products are blown from the portioning drum using limited water. Products move on a discharge belt to the next process step. RevoPortioner benefits Suitable for all kinds of potato mass Preserves texture and structure and gives the best possible mouth feel Consistent, highly accurate shape and weight Very low maintenance costs Limited water necessary for (sticky) product release, which benefits quality. The ValueDrum utilizes an in-line concept that does away with the need for many of the product handling operations surrounding a traditional marinating and massaging process. By adopting the principle of working in-line the ValueDrum works more efficiently than traditional tumblers. This has a positive effect on the distribution of additives and on the speed of the process. Although high capacities can be reached, the ValueDrum has the smallest footprint of any inline marinating systems on the market. End products are quickly in their final packaging thanks to the in-line principle and short process times. The ValueDrum was designed for in-line massaging and marinating. Its unique design makes it possible to achieve the desired yield by first adding and massaging brine into the product in a single process step before adding flavor using a marinade. The ValueDrum can be configured in various numbers of segments to match your production capacity. Furthermore, modules for the automatic dosage of dry or wet additives can be chosen per segment. Finally, the product can be garnished with other material. The ValueDrum can also marinate frozen products right before packaging, without the need to defrost them first. Its extensive marinating possibilities mean the ValueDrum is an excellent system for developing new products. ValueDrum benefits Uniform distribution of additives Less product damage Savings in labor costs and product handling Improved product shelf life Easier tracking and tracing. 6 7
Cooking Coating A coating influences your yield and will largely determine the bite, taste and presentation of your end products. Attractive presentation of your end product can convince consumers to buy it. A coating adds value to your product Frying Frying is an important step in your production process. If a coating has been used, it is fixed and your products acquire their attractive, golden crispy finish and taste. ValueFryer, value for your money Cooking is another way of adding value to your products. The complete cooking of product in oil results in high oil absorption and in moisture loss. Because of the increasing demand for healthy products, more and more processors choose the combination of deep-frying and oven cooking. Of course you can also cook products without frying, such as marinated wedges. Coating enhances taste and texture and increases yield. It also protects products from damage during freezing. With a coating, your products look good. The number of possible coatings is many. Will your choice be for wet or dry, or rather a combination of both? The process sequence will depend on the end product you choose. Regardless of which coating you choose, Townsend Further Processing is able to supply the appropriate system for virtually all types of coating. The breadcrumbs produce a nice brown color after frying and also give it a crispy bite. Not only the form is important, the proper coating can make the product look even more appetizing with an added value. The ValueFryer offers adequate frying capacity for high production volumes and ensures a uniform supply and flow of oil. It is a high quality machine allowing you to produce continuous top quality products. In a fryer, oil and energy consumption and the ability to process consistently are of the utmost importance and the ValueFryer steps up to the challenge. ValueFryer how it works A conveyor transports the products through the frying oil. An optional upper belt keeps them continuously immersed in the oil. The machine heats up the frying oil electrically or using thermal oil. An oil management system ensures that oil temperature remains constant throughout the whole frying process and together with the energy management system gives you a lower cost of operation. ValueFryer benefits Gives value for money Superior oil management High capacity Uniform and consistent fried products Safe and easy operation, cleaning and maintenance. SpiralOven for steaming, cooking and grilling The SpiralOven is a hot air system with a unique 3-in-1 concept allowing product to be steamed, cooked or grilled. It is now possible to process a wide range of products in one system at the same time giving them all the correct color, bite and flavor. SpiralOven how it works The SpiralOven is a system which makes for extremely accurate regulation and control of air flow and air velocity. Heat transfer yield to the products is particularly high. Each production tier has flow and counter flow and a hood encloses the oven s conveyors in the best possible way to prevent the occurrence of blind spots. This creates an ideal environment around the product in the oven allowing products to be made which perfectly and time after time satisfy requirements for core temperature, yield, color, crispiness and flavor. The climate in the oven is divided into macro and micro climates. By micro climate we understand the required air temperature, air humidity and air velocity directly round the product. This micro climate will therefore interact directly with the product unlike the macro climate, which is the climate in the oven more than two centimeters away from the product but which interacts with the micro climate. Around the macro and micro climates are climate generators, which determine it heat, moisture and air velocity. The SpiralOven is built around this total process of climate control. SpiralOven benefits Product of a consistently uniform quality Temperature and air speed distributed uniformly over the whole width of the belt Improved yield as a result of optimum air flow Easy to clean Minimum heat up time and efficient energy use. 8 9
Freezing Batching In order to protect and preserve the quality and freshness of your product over a longer time, freezing is an important next step in your production process. During the batching process, your finished products can be mixed and weighed into portions that can be packed into a wide variety of packaging. Fast, efficient freezing Freezing how it works Multihead Weigher for reliable batching We provide a wide variety of freezing solutions using the latest advancements in freezing technology in order to meet your demands for higher quality end-products. Our freezers range from upwards/downwards running Spiral Freezers to Superflow Easyclean Tunnel Freezers with impingement technology. Our continuous innovation in freezing technology has enabled us to constantly develop new space-saving, energy efficient and more importantly, cost-effective freezing concepts which allows you to focus on what matters the most maximizing your profit potential. The patented Superflow Easyclean Freezers freeze the product in a uniform manner, in the fastest possible time. On the conveyor belt, the product is led past the high velocity impingement airflow called Superflow, which is a turbulent vertical airflow that blows the air stream directly on to the product where after the air stream will change direction, becoming a combination of vertical and horizontal airflow, before returning back to the evaporators. The rapid horizontal airflow - Arcticflow is another one of our innovations in freezing concepts. In this configuration, the end-product is led past high horizontal airflow which directs the air over and under the products and continuously through the evaporators. The low temperature associated with Arcticflow ensures a rapid and homogenous freezing resulting in a fine quality end-product. Freezer benefits Shorter freezing times Less product weight loss Less energy consumption due to the horizontal airflow principle Less downtime due to minimum defrosting requirements Less water consumption. The Multihead Weigher deals with all infeed, mixing and weighing requirements. It automatically portions and packs food products into virtually any kind of tray, thermo pack, bag, can, glass or box. Multihead Weigher how it works The infeed transports your product to the top of the Multihead Weigher, where vibrating feeders dispense it gently into the weighing hoppers. The hoppers will by combination create exact portions, after which they will be packed. Multihead Weigher benefits Suitable for a wide range of products Extremely low giveaway Low maintenance Very hygienic Easy to operate and clean. 10 11
At your service When you choose Townsend Further Processing you choose for a future of operational reliability. Townsend Further Processing always stays closely involved with its customers and thinks along with them about production processes and end product possibilities. Townsend Further Processing can train your staff, offers tailor-made maintenance contracts and is available to you 24/7 via its expert help desk. It has a worldwide network of supporting technologists and service engineers. Townsend Further Processing would welcome your visit to its DemoCenter in Boxmeer in the Netherlands. Here we are able to mimic your production facility under the guidance of our food and process technologists and a professional master chef. We give you an insight into various products and production processes, which we will demonstrate live to you. Contact details Townsend Further Processing Design, manufacture, worldwide sales and service of further processing systems for portioning, marinating, coating, heat treatment and sausage-making for poultry, red meat and fish. Potato-Jan13-ENG Marel Townsend Further Processing B.V. P.O. Box 233, 5830 AE Boxmeer The Netherlands T: +31 485 586 122 F: +31 485 586 655 E: info.townsend@marel.com marel.com/townsend Townsend Further Processing is a trade name of Marel Townsend Further Processing B.V. Copyright Marel Townsend Further Processing B.V. The Netherlands, 2010: all rights are reserved. Any reproduction or modification, of all or part of this brochure, regardless of the method of reproduction or modification used and regardless of the carrier used, is strictly prohibited, unless written authorization by Marel Townsend Further Processing B.V. has been obtained beforehand. Those acting in breach of this notice expose themselves to criminal and civil prosecution, in accordance with the international conventions and copyright laws. The data published herein answer to most recent information at the moment of publishing and are subject to future modifications. Townsend Further Processing reserves the right to modify the construction and the execution of their products at any time without any obligation on their part to modify any equipment delivered before accordingly. The data mentioned are meant as an indication only. Townsend Further Processing assumes no responsibility for errors or omissions in the data published or use of the data published. The publication of these data may not be interpreted as a warranty or guarantee of any kind (either express or implied).