There has been a wealth of recent research both on the importance of fruit and vegetable consumption to health and on new technologies to preserve the nutritional and sensory qualities demanded by consumers. Micronutrients, biologically-active, non-nutritive secondary metabolites may be preserved and even enhanced during food production, so the relative impact of processing have to be minimized: it is the case of mild-technologies. Before they are marketed and consumed, the fresh vegetables may undergo a series of technological treatments of mild intensity such as to ensure both their freshness and natural features, at the same time seeking to increase their value and convenience of use (Fig.1).
Drying of pasta
The use of raw material with good characteristics represents the key step for producing pasta of high quality. Nevertheless, the whole production chain greatly affects this quality: in the last decades, considerable progress has been made in identifying some phenomena that take place during processing, particularly in drying. In fact, the more advanced innovations in pasta manufacturing have been directed to optimize this process. Drying is the elimination of a liquid, normally water, from a substance or a solid body: if the water is inside it, the methods of drying will depend on the body’s physical and chemical properties, in particular on the characteristics of the body at issue. This is the case that concerns drying pasta, in fact drying is the most difficult and critical step to control in the pasta production process. The objective of drying is to lower the moisture content of the pasta from approximately 31% to 12-13% so that the finished product will be hard, retain its shape, and store without spoiling. However, the essential prerequisite for the pasta is not only to be dry, but also to have been dried properly; this means that, besides being dry, pasta needs to be “stable”: its internal moisture content must be remaining uniform. Since the outside surface of the pasta dries more rapidly than the inside, moisture gradients develop across the surface to the interior of the pasta. If dried too quickly, the pasta will crack, giving the product a poor appearance and very low mechanical strength. On the contrary, if the pasta is dried too slowly, it tends to spoil or become moldy during the drying process. When drying cycle has been successful, the pasta will be firm but also flexible enough so that it can bend to a considerable degree before breaking. So, the most significant physical states for pasta drying technology are the moisture and temperature of the air and the humidity and temperature of the product. Very briefly, drying pasta means modulating and properly controlling the evaporation of water from the product, using heat and ventilation. In general, the drying process can be realized by two different methods, that correspond to the plastic and elastic states of the product: the best results are obtained by applying a preliminary low drying temperature to reduce the pasta moisture, followed by a high drying temperature.
Plastic and elastic state of pasta
On leaving the die, pasta normally has a moisture content of approximately 31-32% and is in a “plastic state”. The dough in its plastic state is deformed by the action of the die and the shape obtained will not be altered when the pressure of the die has stopped. Pasta can then undergo even powerful drying without this causing any internal tension and the risk of damage; also the deformation suffered due to extraction of the water will be maintained. When, proceeding with drying, the product’s moisture content falls further (22-18%), the state of the pasta changes from plastic to elastic. In this new state the product’s behavior is totally different: pasta subjected to stress deforms, but tends to recover its original shape as soon as the stress stops. Besides causing deformation, stresses can then bring about tension inside the product: if the tension comes within the product’s specific limit of elasticity, it can be absorbed precisely by its own elasticity. These two different situations of the physical state of the product determine the subdivision of the process into the two fundamental phase, called pre-drying and drying; at the end, it is essential to stabilize the product.
Drying process
During the first phase, the moisture content of the product falls from 30-32% to 18-17%; the time this phase takes depends on a few variables: the temperature is the main. During pre-drying the water is extracted from the product with the highest rate. Also, this pre-drying technology makes it possible to gain different objectives: such as partial blockage of some enzyme activity and virtually total blockage of any product of fermentation; then it allows to uniform gluten distribution making possible the capacity of gluten to hold back the starch particles. Also, this pre-drying can decrease oxidation of the yellow pigments contained in the semolina and therefore give a brighter color of the dried product. Finally, this phase can provide a better shape stability and maintain the product’s capillarity, essential to redistribute the particles of water during the following steps of the process. The second step of drying must envisage alternating phases of water evaporation from the surface and of inside redistribution. Right now, ambient temperature and humidity normally decrease, clearly complying with the current temperature and moisture of the product. The speed of this phase is inevitably less than that of pre-drying, because of the structure of the product, passed on to the elastic state, has become more rigid, capillary action has decreased and so the migration of the remaining particles of water is slower. Putting these considerations into practice, there is the need to alternate phases of drying with phases of “re-hydration”. Thus means a long time, differently from the corresponding procedures implemented during pre-drying. The main aim is to avoid that the outside surface of the pasta dries up too much and too quickly, a result obtained by keeping the three components in functional balance: air temperature, air humidity, and ventilation flows.
Rollermill for cereals
Golfetto Sangati(Pavan组)提出了新版本的蜡膜al Rollermill:Synthesis, a rolling mill which meets the strictest hygiene standards. It’s precise in the grinding regulation and maintenance is really easy, and also versatile thanks to modular construction that can meet every plant engineering need. With its sturdy but elegant structure, has a cast iron base, while all of the external parts that are in contact with the product are made of anodized extruded aluminum, with an internal cavity (double-layer), for thermal (steam) and acoustic insulation. The internal part is made up of electro welded or stainless steel.
Hard mixing: problem solving for high viscosity fluids and heterogeneous solids
Bakery and confectionery industries, among others, face the challenge of mixing high viscosity fluids (fats, syrups, etc.), mixing fluids containing high volumes of powders (pastes, doughs, covering batters etc.) or mixing together in the same recipe solids of different size, shape and density (ingredients for snack bars as cereal flakes, nuts, dried fruit, chocolate bits etc.). In these circumstances, having the right machinery is just a part of the picture: a deep knowledge or all ingredients is needed in order to decide the mixing equipment, length, temperature etc. and thus to achieve the desired result.
Mixing high viscosity fluids and high solids formulations
Examples of viscous liquids or high solids formulations are chocolate during tempering, nougat, confectionery bases, many bakery doughs, batters, pasta before extrusion, meat pâté, fats, etc. Machinery used for these applications can have a fixed body with moving internal mixer/blender/agitator, or both body and internal parts moving, usually in opposite rotary directions, in order to enhance the mixing effect. Machinery can be vertical or horizontal. Internal mixing parts can be shovels, helixes or turbine for medium-viscosity foods; for high-viscosity application, the internal organ will have high resilience, high diameter in all its parts an low rotation speed. Some mixers consist of a U-shaped horizontal trough and an agitator made up of inner and outer helical ribbons that are pitched to move material axially, in opposing directions, and also radially: this combination promotes fast and thorough blending, with speeds in the range of 300 feet/min (1). High solid formulations of medium viscosity can be prepared in single-shaft rotor/stator mixers or high speed dispersers. For products that undergo a high viscosity phase, multi-agitator and planetary mixing equipment are commonly employed. As viscosity rises, however, even a multi-shaft mixer arrangement will eventually fail to produce sufficient flow: the logical solution is to utilize agitators that move through the batch regardless of product flow; this is what planetary mixers and sigma blade mixers (kneader extruders) do: in a planetary mixer, two or more blades rotate on their own axes as they orbit on a common axis; the agitators continually advance into the batch and contact fresh product all the time. Helical blades allow double planetary mixers to handle viscosities as high as 8 million cP (centipoise) (2).
最终产品粘度是一个重要的参数:e.g. for batters and coatings, thickness is important to ensure success of coating process (on meat, fish, vegetables and so on) and furthermore to ensure coating remains on the product after cooking. Viscosimeters are used to control this parameter (3). Some more problems arise after production is finished and it is cleaning time. Many mixers/blenders have CIP (cleaning in place) systems that easily remove all food residues. High viscosity fluids or pastes, however, firmly sticks to walls and agitators, making it difficult to remove thoroughly all residues; often a manual intervention using brush, steam, compressed air and/or high pressure water spray is needed. This difficulties can endanger not only microbiological safety but also allergen safety between batches containing different ingredients (cross-contamination risk). A well designed mixer/blender/agitator has no “dead zones” where residues can accumulate, and the interior stainless-steel surfaces must be well-polished, welds included; optional end-plate scrapers may be used for materials that tend to cake or pack. A flush plug discharge valve also reduces stagnant areas in the trough and simplifies cleaning. Some companies produce mixers with completely and easily removable agitators, allowing a high speed product changeover: use of a flat-flange clamshell coupling will allow operators to raise the agitator out of the mixer/blender without moving the end shafts, bearings or seals; this feature adds cost to the machinery purchase, but can save hours between batches, so it is paramount for plants preparing batches with e.g. different allergen profile (4).
Mixing (or not?) heterogeneous solid ingredients
While for fluids it is possible to reach a complete mixing, this is not the case for solids. The mixing degree that is possible to reach depends on size, shape and density of particles, their tendency to aggregate, moisture content, surface and flowing characteristics of the different materials, mixer efficiency, and so on. Mixing length of time is also an important parameter: heterogeneous materials reach a maximum of mixing uniformity after a certain amount of time, after which prolonging mixing can cause segregation of the different components. There are many different mixers for dry solid foods, some with fixed body (e.g. cochlea mixers) other with moving body (e.g. V-mixers) (5). Some products contain such a mixture of very different ingredient types that trying to mix them is not an option: e.g. instant soups may contain assorted dried vegetables in pieces, noodles or other pasta shapes, dried meat powder and/or other powdered soup bases as bouillon etc. It is impossible to premix such a mixture in an early stage and ensure a consistent proportion off all ingredients in the final pack, since the ingredients will always separate according to their densities and geometries. Such products need a separate filling station for each ingredient, unless two or three ingredients have very similar proprieties (e.g. different vegetable pieces but of the same size and shape, dried meat powder and other powder ingredients). Also mixed solids and liquids, such as canned legumes or vegetables, are similarly filled at two stations: one for the solids and one to top up the fluid portion (6). Properly weighing and accurately delivering the ingredients without manual intervention can result in many process advantages such as fewer mistakes, better accuracy, lower bulk costs, improved product quality and savings in manufacturing costs (especially if handling precious ingredients like probiotics and vitamins).
称量带式给料机系统分配的组合ring of different components into a mix prior to the packaging line are available: by utilizing a high accuracy feeder mechanism, the enduser can be assured of ingredient cost control and high product quality. These feeders are used for continuous controlled gravimetric feeding of bulk materials, they feature a primary weighbridge and offer an optional secondary weighbridge that provides continuous online auto tare, reducing maintenance and frequency of calibration. In most blend applications, ingredients are delivered to the ingredient bins via bags, boxes, drums or supersacks; once these ingredients are transferred to the product bin, a slide gate at the bin discharge is opened to allow flow of the product to the feeder hopper below. Each individual component is metered upon a predetermined recipe, and discharged to an horizontal conveyor; the product is then sent e.g. to a carousel type packaging machine; in principle it is possible to start and stop each ingredient line. The remaining belt feeders then discharge their ingredients sequentially, in accordance with the programmed sequence of operations, thus creating a layered mix. The number of belt feeders can vary depending upon the number of component in the mix (7).
Bibliografia
2) From Charles Ross & Son Company white paper on mixing high solid formulations
3)www.FoodViscosity.com;www.brookfildengineering.com;www.mpequipment.com
5) Lerici C.R. and Lercker G., Principi di Tecnologie Alimentari. Editrice CLUEB
6) Soroka W., Fundamentals of Packaging Technology. Institute of Packaging Professionals, 4th edition
Beverage world hosted at Sacmi
More versatile design, more flexible material choice and management. And that is not all, its outstanding efficiency allows the costs of plastic material to be reduced by up to 20%. This is the new modular Formsleeve+ labelling machine, the latest “creation” by Sacmi Labelling proudly presented today at the open house held at Sacmi Imola before an audience of international operators arriving from 21 countries and 4 continents. A great opportunity to preview a live demonstration of the Sacmi made technological jewel at work, thanks to a guided tour that allowed specially selected visitors to enter the group’s R&D lab, where the latest prototypes are developed and tested.
Cream industry, developments and technology solutions
The main leitmotiv underlying technology evolution in the field of creams for confectionery industry may be summarized as follows: modern machinery, aimed at increasing production profitability. Considering only cost-benefit analysis, however, would be restrictive, because in this area several considerations are to be made. First of all, it is not possible to ignore the potential risks for human health associated with the consumption of hygienically unhealthy creams. In this regard, a particularly pressing legislation allows such considerations to be properly inserted in plant design. R&D departments are mainly working in this direction.
Handcrafted with the latest technology
Producing high-quality dairy products with the most innovative technological systems for refrigeration and cooling water production.
Founded in 1987 and based in Caronno Pertusella (near Varese),CTM Refrigerazione Industrialehas developed a long experience in the field of industrial refrigeration. The company, operating in the system and industrial sector, both in Italy and abroad, designs and assembles complete systems for industrial refrigeration, employed in many fields, including milk and dairy. CTM offers advanced technological solutions such as: screw compression units, direct ice-cold water production plants and with ice accumulation, sanitized equipment and electrical switchboards. Moreover, the company provides “turnkey” solutions, post-warranty technical assistance, programmed assistance, and assistance in the regulatory framework.
The installed plant
CTM has recently installed at 3B Latte dairy factory a glycol refrigeration system that includes two distinct preassembled Brine Chiller modules and a Falling Film Chiller plant for cooling water production.
Brine Chiller
Each pre-assembled Brine Chiller group, which cools the glycol as an intermediate fluid, consists of two screw compressors and an evaporative condenser that ensures 400,000 kcal/h cooling capacity. Glycol is stored at -6 °C in a tank from which it is sent to the plant by special pumps, via two loop circuits to feed the cold utilities (such as cells, curing) and to ensure sanitized refrigeration and air-conditioning in the working rooms. The glycol in a 400,000 kcal/h Falling Film Chiller also cools water at -0.5°C temperature, being necessary to the process: the milk must always be kept at 4°C during all stages of production. The Brine Chiller groups, used for the cooling of intermediate fluids, are designed to work continuously and for the most demanding applications. Main characteristics: monoblock configuration; R 507 ecological gas screw compressors with evaporative condensers; a design aiming at maximum energy savings. The electric motors of the driving compressors, evaporative condensers and pumps are controlled by an inverter and, therefore, they ensure a progression of cooling capacity which adapts to production needs. All main functions are also controlled by a sophisticated system of centralized supervision.
Single-head ink-jet
EBS-6200is an industrial single-head ink-jet printer designed for labelling objects moving on a factory conveyor without requiring direct contact. They are based on moving printhead technology, where the print-heads are controlled manually or automatically. Prints are produced with coloured dye-based inks, i.e. homogenous non-pigment inks. Printers on offer differ in maximum print height (MPH, the maximum height of a vertical row) which can be 16, 25 or 32 dots, and it does not need to be supplied from a compressed air system. Products fromTutto Per L’Imballo打印机可以产生持久的和清晰的主要ts on a variety of surfaces, including smooth, porous and also uneven materials of irregular shapes, such as cables, tubes, insulation sleeves, furs or extruded packing. Non-contact print technology is applied to avoid problems when printing on curved surfaces (there is a significant distance of
up to 30 mm between the print-head and object).
Growth and innovation with the focus on sustainability
In line with thePavan Group‘s philosophy,GolfettoSangatiinvests in clean energy today, confirming the attention to the balance of our planet as a necessary step to support balanced growth. The photovoltaic system installed on the roof of the production unit in Quinto di Treviso (Italy) was recently inaugurated. With an energy production of 926000 kWh/year obtained by means of 3442 modules spread over an area of approximately 6,000 sqm, the investment ensures the Pavan Group plant a significant reduction of environmental impact. During the sunniest months production activities can be sustained entirely by solar energy, avoiding any resorting to polluting energy sources, with the yielding part of the production to the grid.
Processed cheese
IMAmachines are carefully designed and tested to guarantee the quality of product. Due to wide range of technologically advanced solutions for the processing and packaging, can choose the type of machine most suited to requirements. TheUMSK 24是t的一部分he Universal Machine range which handle almost all the tasks involved in the production of processed cheese, convenience products and confectionary: from mixing and chopping, emulsifying and vacuum deaeration to heating and cooling. The Universal Machines are available for batch sizes from 2.5 up to 170 litres, and all share one important characteristic: versatility. They follow the inique Stephan principle (all-in-one) and can be relied upon to carry out the entire process with all production steps.