Hazelnut Processing Equipment

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In Ancient Rome, hazelnut plants were valuable gifts as it was believed to bring happiness. In modern days, hazelnuts still bring happiness, mainly in the form of Nutella. While most nuts are botanically classified as fruits, hazelnuts are, along with chestnuts and acorns, true nuts. Once harvested, the nuts are dried and ready to be processed in various hazelnut processing equipment.

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The hazelnut journey: from a plant to hazelnut processing equipment

It is estimated that almost 700 000 tones of hazelnuts are harvested yearly. A hazel or a filbert tree, which is a slightly larger species but often interchangeably used with hazelnut, becomes productive at the age of 7 and can produce nuts for approximately 80 years. The ideal time to harvest is before or during autumn, as soon as they become loose – hazelnuts fall from the tree once they are mature – to minimize the risk of animal predation. If left on the ground for a long time, rain can cause discoloration of the shell.

That’s why hazelnuts should be collected as soon as possible after falling. Sometimes this means that hazelnuts must be post-ripen. It can be done manually or by using suction machines, for instance, “finger wheel” or straddle-type harvesters, usually used for all commercial harvests, which perform the initial cleaning of the nut and dumps them into a harvest wagon. High-capacity machines (about 1000kg/h) are used for the more detailed cleaning process, followed by sorting nuts by quality, considering the moisture content, kernel size, kernel/nut ratio, and the degree of mouldiness and rottenness.

Hazelnuts may nut be moist: the drying process

In order to meet commercial standards, hazelnuts, which have a high moisture percentage of around 35%, must undergo the following processes: debuding, impurity removal and drying. Drying is a vital process for preservation due to the risk of fungal attacks, as nut trees are the perfect substrates for fostering microorganisms and meeting quality and food safety standards.

Although some confectionery companies require hazelnuts to be dried to 6% of moisture, since the lower water percentage prevents oxidation which changes the taste, 8%-10% is a universally acceptable level of hazelnut moisture content. Hazelnuts can be sun-dried or spread in well-ventilated but safe locations and turned 1-2 times a day. Mechanical dryers such as prune driers or small dehydrators can be used during this process. However, there are also larger drying machines that significantly reduce the drying time of hazelnuts by continuously mixing them while exposing them to a hot blast of air reaching up to 40°C. This dying process can be finished within a day.

So fresh it’s nuts: the proper storage and quality

Although generally non-perishable and can be stored for long periods, hazelnuts must be stored properly to maintain freshness, aroma and taste. It is ideal to store hazelnuts in cold storages with around 0°C and relative humidity of 65-70%. In such conditions, they can stay fresh for up to a year. Hazelnuts can even be frozen for later use as they tolerate temperatures as low as -10°C. Improper storage can result in auto-oxidation and rancidity. It happens when oils and fats are exposed to air, light and bacteria, which changes nuts on a molecular level, leaving them with a “stale” taste and smell.

Furthermore, storing hazelnuts inappropriately can lead to insect pests and molds, which makes the nuts unsafe for consumption. Modified Atmosphere Packaging is an effective method to preserve hazelnuts and significantly prolong their shelf-life. This method entails storing nuts in intact bags and containers with controlled levels of oxygen and other gases. In case of large quantities, a steel or concrete silos is a practical solution: nuts are protected from mechanical damage, and the storage parameters are monitored precisely.

The hazelnut journey continues: processing hazelnuts for various applications

Once harvested, dried and stored properly, hazelnuts are ready to be sold to customers or factories for further treatments in hazelnut processing equipment. Firstly, the hard shell must be removed in a process called shelling or cracking. There are two possible processes: compression cracking in plate crushers or impact cracking by throwing the nuts against hard surfaces. Using a hazelnut shelling line, nuts are separated from the remains of the shells and grouped into classes based on size and quality.

According to the customer’s preference or requirements for the byproduct, hazelnuts can be roasted to various degrees in rotary tunnel ovens in order to improve the flavor and texture. By finely grounding, hazelnuts can further be made into grains, flour or pastes.

NUThing to waste: from hazelnuts shells to sustainable panels

While the nuts can be used in various snacks and delicacies, many shells go to waste. However, a Washington State University scientist developed an innovative idea for producing durable panels for cabinets, tables, and furniture using hazelnut shells. They are naturally sustainable and ideal for such products due to their strength, performance, and beauty with their rich reddish-brown color. The key is preventing degradation by restricting the release of carbon while maximizing the amount of natural fiber but minimizing the amount of resin.

In conclusion, hazelnuts are a popular and versatile ingredient used in a variety of food products. They are harvested by growers and sent to processing lines, where they are sorted and cracked to extract the hazelnut kernels. Nut processing machines like crackers and calibrators are used to separate the kernels into different sizes for different applications. Proper storage is crucial for maintaining the freshness, aroma, and taste of shelled nuts, and they can be frozen for later use. While hazelnuts are the focus of this discussion, almonds and walnuts are other popular nuts that are also commonly processed and used in the food industry.