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Maker - Product Challenge

Products

Technologies

About us

Changemakers

Technology Supplier ProXES

ProXES is the result of the merger of three industry leaders: FrymaKoruma, Stephan Machinery, and Terlet. FrymaKoruma, established in 1949, excels in machinery for the food, pharmaceutical, cosmetics, and chemical industries. Stephan Machinery, founded in 1953, specializes in equipment for convenience food, dairy, meat, and confectionery. Terlet, dating back to 1917, is known for high-quality components and turnkey plants for liquid product processing. Together, these companies form ProXES, combining extensive expertise and innovation to lead the industrial equipment market.

ProXES is renowned for its cutting-edge technology and quality, earning a spot in the WirtschaftsWoche 2023 world market leaders ranking. This success is due to its innovative, customer-centric product portfolio and co-creation approach in the food sector. ProXES' start-up program, "Processing Ideas," fosters continuous innovation. As a member of the European Hygienic Engineering & Design Group (EHEDG), ProXES upholds the highest quality standards, promoting safe food production with advanced hygiene technology and design.

About ProXES

New recipes are often created on kitchen counters. This is also true for innovative vegan specialties: They frequently go back to unique recipes developed by a single cook or kitchen team.

But translating a small-scale recipe, developed in a food lab environment, into an industrial product without altering the formula is a challenge. A manufacturing plant introduces a whole set of variables absent in kitchen-counter production.



<strong>Letting the processing experts chew on it</strong>

This is when Jens Thiele and his technology experts at ProXES come in. They help producers chart new processing terrain by designing commercial-scale manufacturing lines that keep the original recipe intact.

In the case of an artisanal producer of vegan cheese, the engineers designed custom solutions for milling the raw material, such as cashews or almonds, into fine particles. This approach gave their customer greater control over the base structure, enabling them to create the exact textures they envisioned.

“We determined the ideal particle size for the customer’s specific product type – down to a minimum of 30-40 microns,” explains Thiele. Anything smaller produces a clumpy mouthfeel, while a coarser grind leaves a gritty sensation.

<strong>Playing with water to define texture</strong>

But food texture is not dictated by particle size alone. Moisture content is another critical factor. Water regulates particle interaction: whether they can hold together and what pressure breaks them off.

Moisture levels, though, vary per material. Distinctions exist even between the same class of ingredients. For instance, caution is advised when producers use a combination of drupes like cashews and almonds for bases. “The oily almond requires different moisture treatment from the dry cashew,” the processing specialist at ProXES points out. “Almonds can be ground into very fine pastes if the nuts are dry enough. Cashews, on the other hand, must be processed with water as they have a lower oil content.”

<strong>Expertise in ingredients and processing</strong>

ProXES combined expert knowledge of food and processing technology, to help the manufacturer grow from lab to industrial scale, co-creating  new categories of plant-based specialties along the way. The vegan cheese producer adapted the manufacturing process to obtain distinct creaminess, stretchability and bite textures.

But the true recipe for success is the delicious synergy between the food companies and the processing experts. It can transform even homemade recipes into a marketable range of plant-based foods.

From the kitchen counter to industrial production: How to master texturing of vegan specialties

Picture this: mixing whipped cream at larger bakeries can take from 18 up to even 40 minutes using a standard planetary mixer. As the clock ticks, so does energy consumption, presenting a significant challenge in an era where energy costs soar higher than ever.

With plenty of manual work and different machines involved, the quality of the batch of whipped cream still heavily depends on the skills of the machine operator.

To dive into these whipping challenges, we spoke with Product Manager Marcel Menkveld from ProXES, a German solution provider in mixing and processing systems.


<h2>Whipped cream, not butter – Gentle force and temperature control</h2>
The primary challenge is to get the right volume by incorporating air bubbles into the cream and creating a light and soft texture. These air bubbles expand the volume and provide stability to the cream. But maintaining consistency can be difficult as the cream may deflate or lose volume over time.

“<em>Knowing when to stop is paramount. Overpowering the mixer introduces too much energy, leading to overmixing and a decline in volume,” </em>says Marcel.

So in place of whipped cream, you’ll find yourself with butter.

Temperature affects the viscosity of the cream, and whipping it at the right temperature facilitates the formation and stabilization of air bubbles.

“<em>A temperature control function to maintain the ideal temperature, supported by a double jacket system for precise heat regulation, ensures consistent conditions for whipping cream, preventing uneven temperatures that can affect texture and stability</em>,” explains Marcel.
<h2>Go slow to go fast; how low speed can result in faster production</h2>
Good things take time. Marcel highlights that they worked on developing a dedicated machine with a specialized bakery and pastry tools for a year and a half.

“<em>With our Universal Machine, a full batch of whipped cream can be produced</em>” – wait for it – “<em>under two or up to two minutes. And the best part is that we don’t use high speeds</em>.”

High speeds mean high temperatures, resulting in volume loss. In addition, controlling temperature becomes challenging as speeds increase.

But operating at slower speeds and lower temperatures, there is more time for adjustments. This is where frequency converters come into play. With them, you have complete control over the speed, offering a wide range of speed levels beyond just slow or high.

“<em>Being fast yet with low speed involves three factors: specialized tool development, an inclined bowl geometry - 10° for whipped cream - and a profound understanding of the application translated into the machine via the recipe control function</em>,” concludes Marcel.

So, who is ready to decelerate with <a href="https://www.proxes.com/en/" target="_blank" rel="noopener">ProXES</a> for extra productivity and make more batches of tasty whipped cream?

Whipping your cream at lower speeds for faster results

If you are looking for ideas on how to make mayonnaise production better, look no further!



<a href="https://www.proxes.com/de/">ProXES</a> is hosting a webinar called <a href="https://go.proxes.com/en/webinar-mayonnaise-real-to-light">"Mayonnaise: Real to Light"</a> on the 6th of March, where you can learn about the advancements in both cold and hot processing. The webinar introduces how the ProxxD® can help you make the production of your mayo even better.

Webinar: master mayo-making

ProXES Expertise

To make smooth batches of mayonnaise or ketchup you need to use process equipment for stirring, heating, and cooling the emulsions. This can be a time- and space-consuming process and each technology comes with a different set of challenges from efficiency to cleaning.


<h2>Mixes, cuts, emulsifies, heats, cools, and deaerates your mixture</h2>
<span data-contrast="auto">The Stephan Vacutherm by ProXES is an adaptable and expandable all-in-one emulsion processing system. The system combines cutting, mixing, heating, cooling, and deaerating to ensure a compact and streamlined production of both hot and cold batches. </span><span data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span>

<span data-contrast="auto">With a double-jacket vessel and a rotor-stator homogenizer the Stephan Microcut, the equipment guarantees stable emulsions while emulsifying and homogenizing even chunky products. With the aid of the vacuum system and corresponding hoppers, extensive dosing options for solid, semi-solid, and liquid ingredients are possible.</span><span data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span>

<span data-contrast="auto">Fast and gentle heating is achieved by direct steam injection and can reach the maximum working temperature of 95C, or optionally 110C. It is also possible to use the double jacket for indirect heat cooking or cooling. The power of the equipment ranges from 1600 to 3600 l/h. </span><span data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span>

<span data-contrast="auto">What is more, the Vacutherm operates under an inclined working position of 70 degrees</span><span data-contrast="auto"> </span><span data-contrast="auto">without any residue buildup, thanks to the scrapers that follow the contour. </span><span data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span>

All-in-one system for making emulsions

Emulsions enhance foods with a creamy mouthfeel and richer flavors. But the immiscible nature of oil-and-water mixtures makes it challenging to maintain consistency in textures and taste across batches.


<h2>Versatile, powerful, and reliable</h2>
The ProxxD® high-shear emulsifier from ProXES guarantees reproducibility batch after batch. The built-in proprietary automation system hands full control over the shear energy input and other critical parameters.

Droplet distribution impacts emulsion stability and the sensory profile of the final product. FrymaKoruma specializes in droplet size control and is the world market leader in emulsion-based food processing systems.  Its technology solution disperses fine droplets with precision to create superior-quality foods and extend their shelf-life.

The ProxxD® is a highly versatile system that is easily adaptable to match your exact processing needs. Besides emulsification, the ProxxD® performs a range of food processing functions, including dosing &amp; weighing, mixing, and vacuum deaerating.

The integrated unit has been redesigned with a small footprint but large capacities, reaching up to 5,000 kg/hour depending on the product recipe.

Batch processing system for emulsions and suspensions

From laboratory scale to large volume food or cosmetic production, it pays to have all-around equipment that can effectively cut, mix, emulsify, and even heat your products. Whether producing chocolates, processed cheese or beauty creams, a robust system that is flexible enough to handle products from different industries simplifies production steps while increasing overall productivity without compromising quality.


<h2>All-in-one processing system with direct or indirect heating of products</h2>
The Stephan Universal Machine from ProXES is an all-in-one processing system that includes cutting, mixing, emulsifying, and heating functions for food and cosmetics applications. The system is available as a tabletop or floor-mounted unit with frequency-controlled knives and with or without direct steam injection. Direct steam injection allows quick heating of products, like processed cheese, up to 95⁰C or 125⁰C, depending on the model. Various models are available for laboratories, R&amp;D, and industrial scale production with maximum batch sizes of 2.5 liters up to 170 liters. Finished products are discharged through a discharge valve or by tilting the bowl up to 90 degrees for highly viscous products. Various specially shaped tools and high-speed knives ensure quick mixing and cutting of products, making them ideal for most product applications. The system is equipped with either a soft touch keyboard or a touch panel for easy operation with an option of data recording via a USB stick.

Complete cutting, mixing, emulsifying and heating system

Buying pre-processed materials, such as flour, and handling and dispersing them to produce plant-based milk can be complex and costly. While it could be beneficial for smaller-scale production, working with big batches requires more control over material costs and consistency in product quality.


<h2>Efficiently pre- and fine-grinds grains, nuts, and legumes for making beverages</h2>
The MD Disc Mill &amp; MZ Toothed Colloid Mill from ProXES offer enhanced control over product quality when choosing in-house grinding over using pre-processed materials. It has a wider range of options, fine grinds, and long-term savings on raw material costs. The two-stage industrial-scale grinding skid pre-grinds the material and then fine-grinds it to an expected particle size ranging from 400 - 600 µm.

There are two grinding concepts: the first is using the hopper pump to continuously dose raw materials and water. It is suitable for high throughput applications, such as industrial soy and oat lines. It is also possible to dose raw material via the mill hopper and add water directly to the grinder. This ensures a higher level of flexibility with moderate throughput.

After grinding, the slurry goes through enzymatic treatment, where the large fibers are separated to make the correct formulation for the product. Follow-up steps include UHT treatment, as well as buffering and filling the cartons with the finalized plant-based milk.

The technology can be installed while upgrading an already existing processing line or designing a new one.

Energy efficient grinder for plant-based milk

High-viscosity products like hummus or chunky pasta sauces must be cooled down before filling them into containers. The process must be fast and gentle to make sure the taste and quality remain, but it can prove to be highly energy-consuming.


<h2>Cools the mixture efficiently with less time</h2>
<span data-contrast="auto">The Terlett Terlocool by ProXES is a cooling system that ensures a longer shelf-life but also preserves the taste and texture of cold-fill sauces, marinades, soups, and spreads. It is equipped with a double jacket which allows homogeneous and gentle cooling and inhibits bacterial growth.</span><span data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span>

<span data-contrast="auto">The bowl of the cooler is tilted, therefore the temperature is distributed evenly. In addition, the system has a special mixing tool with segmented scrapers that makes the heat transfer happen even faster, while also saving energy. For example, cooling a batch of ketchup from 95C to 5C would regularly take about 94 minutes, but with Terlocool it only takes 45 minutes.</span><span data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span>

<span data-contrast="auto">While the cooked mixture can be transferred straight to the cooling system, the cooker can be used again almost immediately. This creates additional process capacity by enlarging the availability of the </span><span data-contrast="none">cooker</span><span data-contrast="auto"> and immediate cooling increases flexibility. The cooler is available in different sizes from 600 – 1200 litres. </span><span data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span>

<span data-contrast="auto">CIP (cleaning-in-place) technology makes it possible to completely clean the Terlocool automatically without opening the lid. On top of that, an optional vacuum system provides even higher levels of hygiene, as well as a longer shelf life.</span><span data-ccp-props="{&quot;201341983&quot;:0,&quot;335559739&quot;:160,&quot;335559740&quot;:259}"> </span>

Energy-saving cooling system for vegan products

Delicacies such as meringue, ganache, and marzipan undergo various processes like mixing, whipping, emulsifying, heating, and cooling. Traditionally, each process requires different equipment and a lot of manual interventions that can lead to inconsistent product quality.


<h2>Preparing bakery creams and egg whites in a single system with easy tools changeover</h2>
The Stephan UM from ProXES is a versatile all-in-one processing system for the bakery market and includes different functions for cutting, mixing, whipping, emulsifying, heating, and cooling your bakery creams and pastries. The system can be coupled to application-specific processing tools and has vacuum support to produce even the finest professional-quality ganache. The integrated cooling function ensures cream stability and enhances shelf life.

The whipping process for creams and egg whites has shorter production times – up to 50% - with maximum throughput for different batch sizes. In addition, for mid and larger-scale bakeries, production costs of marzipan have proven to be 50% less than purchasing ready marzipan.

The mixing system is equipped with a tilting bowl for easy product and ingredient handling. The set of processing tools is specially designed for all bakery applications and allows easy, quick changeover. The UM family has a wide capacity range of 0.5 to 170 liters per batch. Its design allows easy water cleaning, which results in low energy costs. The different programming options for temperature regulations and recipe controls help reduce process time and ensure product quality.

Flexible mixing system for whipped cream and pastries

When processing alternative proteins or making products such as smoothies and sauces that require multiple production steps such as cutting and dispersing, having a single system that can combine the different processes in one, makes production more practical and efficient, saving costs and time.


<h2>Fine cutting and emulsifying of food products in one solution</h2>
The Stephan Microcut from ProXES is a multifunctional food processing system for fine cutting and homogeneous emulsifying. It can provide stable emulsions and disperse solids in liquids. The unit has a pre-cutter that can reduce product sizes of 100mm down to 1-2mm. It can be installed with a single or double cutting system consisting of cutting head(s) as the rotor, cutting ring(s) as the stator, and a feeding disc. The cutting rings are equipped with knives of specific gap sizes from 0.05 to 3mm, and the feeding discs are available in different designs. Product applications include meat emulsions, marinades, sauces, vegetable, and fruit grinding, and nut grinding. The system has a unique layout for cutting vegetables, fruits, frozen products, and rework of bakery products.

Multifunctional cutting and dispersing machine

In the food industry, when it comes to milling a wide range of products such as seeds and nuts and dispersing liquid, viscous and pasty products, having a fully versatile mill is a crucial factor. Whether for laboratory or industrial scale, a milling system that can mill multiple product applications with minimum product loss is necessary to achieve maximum productivity and improve your line efficiency.
<h2>Milling seeds and other grains through corundum grinding discs</h2>
The FrymaKoruma Corundum Stone Mills from ProXES is a milling system for various food processing applications. The system grinds the products at high speed using corundum stone discs with various grains ranging from 16 to 120 grit. The grinding gap between the rotor and stator discs is adjustable for flexibility in product size. It is sealed by an optional single or double acting mechanical seal with no dead spaces. The system is scalable according to production requirements from a laboratory scale to industrial use, with a throughput of 10 to 5,000 liters per hour. It offers multiple configurations such as vertical or horizontal designs with options of using a feeder pump or hopper with feed screws as inlets for the products to be milled. Other options include clamp and flange connections and different grinding tools for suitable product applications.

Versatile stone mill machine

ProXES Technologies

ProXES Videos

Vegan Burgers

Oat Milk

Ganache

Get in Touch

Experience unparalleled support with ProXES Service, where over 300 years of combined process technology expertise ensure the reliability and performance of your machinery. Our team of 80 dedicated service professionals is ready to provide fast, comprehensive assistance for over 100,000 machines globally, ensuring your operations run smoothly

Connect with the Experts

Consumers usually eat chocolate spreads along with bread, or other grain-based items, such as pancakes, biscuits, waffles, and others. Although one particular brand has dominated this market for more than 50 years, there is still a place for new, health-friendly innovations and production ideas using chocolate spread machines.

Chocolate spread

Foam kisses are known by different names, but their unique texture is unmistakable no matter what you call them. The chocolate mound with a frothy filling is an all-time favorite, but creating that crispy-fluffy contrast is no longer a job of approximation. Specialized foam kisses machines range from mixers to enrobers. But the magic of the delightful confection happens with aeration technology.

Foam kisses

Hummus processing begins by blending chickpeas, tahini, lemon juice and olive oil to create the simple yet versatile dip loved by so many around the world. To prove their love for hummus, the Lebanese, in 2010, made the largest plate of hummus that weighed over 10 tonnes! To produce hummus industrially, you need a hummus production line that includes processing equipment such as cookers, industrial grinders, pasteurizers and packaging equipment.

Hummus

Although the first association with almond milk might be the modern plant-based lifestyle trend, it is dated even back to the Middle Ages when it was used as an alternative to cow milk during Catholic fasting. Once harvested, almonds undergo a series of treatments in almond milk manufacturing equipment, such as bleaching, peeling, and grinding, to get the delicious final product for breakfast and desserts.

Almond milk

Ketchup processing begins with tons of tomato paste that is mixed and heated together with sugar, vinegar, and spices in a cooking kettle. After cooking, any remaining fibers and particles are filtered out. Once it reaches the right viscosity, your tomato ketchup production process is finished and ready for packaging and transport.