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Maker - Product Challenge

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Industrial drying machines are designed to remove moisture from your product. But the drying process must cater to variations in the state of matter and molecular structure of the input material. Industrial dryer technology exploits the modes of heat transfer (convection, conduction, radiation, evaporative cooling) to control the moisture content.

Drying

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, <em>true nuts. </em>Once harvested, the nuts are dried and ready to be processed in various hazelnut processing equipment.

Hazelnuts

In a Fluid Bed, a product or solid is made fluid by an upward moving flow of gas. The mechanical movement of the Fluid Bed strengthens this effect. Thus, the gas and product are intensively mixed so that high heat transfer and an optimum physical reaction speed are achieved.


<h2>Continuous fluid bed dryer for an energy-efficient drying</h2>
Ventilex Continuous fluid bed dryers apply world-leading fluid bed technology to high-throughput bulk processes. By choosing a good combination of gas speed and mechanical movement, you will be able to process granular products with a wide range of grain sizes while forming a minimum amount of dust.

A whole range of products can be processed in the fluid bed for long residence times, up to two hours per machine are possible. Ventilex Fluid bed dryer can function at temperatures from–15ºC to +600ºC. The gas speed can vary from 0.2 to 3m/sec.

Continuous fluid bed dryer

Traditional drying methods are often slow and can actively damage ingredients, reducing the final product quality. New infrared technology can enhance or replace traditional drying to increase throughput and improve ingredient and product quality.


<h2>Infrared drying solution to increase efficiency and improve product quality</h2>
The Kreyenborg FS-IRD uses cutting edge infrared technology and can act either as a standalone dryer or as a boost for your traditional convective unit. As a booster it can increase your capacity by up to 50%. When used as an end-dryer, products will be automatically sterilized and stock protected.

Infrared light instantly heats the product from the inside, driving moisture from the inside out in a gentle way that doesn't damage the look, smell or taste of ingredients, even the most delicate. The gentle but constant tumbling motion is perfect for mixing of multiple ingredients, as well as ensuring even drying.

The Kreyenborg FS-IRD technology can dry products to a precise residual moisture value in minutes, rather than hours, preserving key characteristics like colour and flavour, as well as protein and vitamin structure. The use of infrared and lack of warm-up time means the FS-IRD is one of the most efficient drying methods available.

The FS-IRD can also be used to roast and coat products like nuts, seeds and spices, providing enormous flexibility.

Infrared rotating drum dryer

For small scale production of cocoa beans and nuts, the use of traditional toasters is inefficient. Electrically powered infrared toasters allow small producers to toast nuts and cocoa easily, quickly and efficiently.


<h2>Smaller-scale, highly efficient electric nut toaster</h2>
The RI 700 from DSC is a highly efficient electric toaster for cocoa beans and nuts. Using infrared technology and enhanced insulation, the thermal performance of the RI 700 is excellent, reducing energy consumption and toasting time.

The toasting chamber is fully computer controlled, ensuring optimal temperatures that toast nuts evenly and from the centre, while gently moving the product without damage. Loading of the chamber can be automated by using optional elevators.

Once the toasting is complete, the nuts or cocoa beans move to the cooling chamber. Cocoa beans, pistachios or almonds are quickly and gently cooled, while peanuts and hazelnuts are also peeled and cleaned.

The throughput of the unit is 9kg to 25kg per hour, depending on the raw product, and the average toasting time is 25 to 35 minutes.

The entire unit is constructed of AISI 304 stainless steel for strength and easy cleaning and maintenance.

Entry-level infrared nut drying machine

Moisture considerably depletes the shelf life of nut products. At the same time, however, manufacturers want to retain the oil content that gives nuts their aromas and nutritional benefits. Keeping a precise temperature control that ensures both qualities is a primary challenge in nut roasting processes.


<h2>Accurate temperature control and efficient roasting for different types of nuts</h2>
The TFS Series by Tecno 3 comes with 3 different nut roasting stages (drying to eliminate moisture, roasting, and cooling down). Thanks to independent drying and roasting chambers, the nut is treated in a delicate manner to preserve its structural characteristics.
Built for vertical functionality, the machine is compact and offers easy accessibility. Moreover, the roasting and drying processes can be automatically managed by the PLC. The machine reaches a maximum capacity of over 2 tons/hour and starts at 100kg/h.

Industrial Nut Roaster

Manufacturers requiring big bag packaging have specific sizes, shapes, and material requirements to ensure their products can be handled safely during transportation and storage. However, the FIBC manufacturing process is only sometimes considered sustainable since these big bags are made of polyethylene, which is difficult to recycle. An ideal solution would be working on preventing waste by producing custom-made big bags of the exact right sizes and shapes required by the manufacturer to save on excess offcuts and material costs and minimize production waste.
<h2>Preventing 10-20% of waste by producing big bags in custom shapes, sizes, and material</h2>
Masterpack Group, a leading expert in innovative packaging solutions for bulk materials, designed custom big bag containers used as packaging that provide increased protection, prolong product shelf life, and optimize storage space. FIBCs are available in different shapes, such as circular or U-shape. They can be equipped with specific liner materials like conductive, aluminum, anti-static, dissipative, metalized OPP, or whichever is best for your product. Liners also help protect products from oxygen, moisture, and other possible contaminants while providing safe filling and discharge. The FIBCs are hygienic, and the PE films used as liners are designed and fabricated according to the correct size, not cut to shape from a big tubular PE film. This method minimizes waste in the production of each liner.

Modified Atmosphere Big Bags

When sealing large bags containing bulk products, a sealer must be reliable to keep the MAP safe in order to avoid products going to waste due to subpar sealing quality. Manual operation for sealing is still very common in the industry, but it is prone to error and inconsistent output. Automating the sealing process can minimize operator error and produce consistently secured sealing.


<h2>Automated complete sealing by single-button operation</h2>
The Automatic Spout Sealer, from Somsix, is a sealing system for large bags used in industrial applications. The system features automated, user-friendly controls where the sealing settings can be preset for a consistent output in every cycle. This method significantly reduces operator error over manual hand-operated sealers. The operator simply positions the spout in the seal mouth and presses one button to execute the sealing process, including the cooling necessary after heating for a complete and secured seal.

Automatic FIBC Sealing machine

Products packed in large bulk bags, such as FIBCs, require vacuum pressure and accurate oxygen or nitrogen content control. Modifying the atmosphere inside the packaging by lowering oxygen levels to 1% or less can protect the products from molds and other microorganisms, as well as insects and rodents, resulting in a prolonged product shelf life.


<h2>Creating an atmosphere with oxygen levels below 1% inside your bulk bags</h2>
The Vacuum and Gas Injection Machine, from Somsix, is a system used to create the optimum atmosphere conditions inside FIBCs or large bags during the packaging of bulk products. The unit allows the operator to create a vacuum and insert the necessary gases in a single cycle to increase productivity. The procedure is done by removing air from a sealed container before injecting essential gases like oxygen, nitrogen, or carbon dioxide into that container. It can also reduce oxygen levels in FIBCs down to 1% or lower in a very short time.

The system has an integrated leak test at the end of each cycle to automatically check for possible leaks in every bag. This feature prevents costly and time-consuming errors. The entire system is built based on food-grade standards guaranteeing hygienic operation.

Vacuum and Gas Injection System for FIBCs

Every year, more than 200 million FIBCs are filled with food for storage and transport. Products must be kept in the ideal conditions to maintain their quality from production up to packaging, storage, and delivery. By controlling oxygen levels during packaging and continuously monitoring the conditions in each package, food manufacturers can benefit from less waste within their supply chain, where up to 40% of the food waste occurs.


<h2>Remote monitoring of conditions inside each modified atmosphere bag to prevent waste</h2>
The Modified Atmosphere Sensor, from Somsix, is a monitoring device for oxygen levels and other conditions inside bulk packages. The device is available in 3 monitoring categories. The first category is called modified atmosphere (MA) sensors for FIBCs. It features remote monitoring of oxygen, temperature, and humidity wherever the FIBCs are located. The second category is a custom sensor, which monitors specific data or packaging applications based on client requests, while the third category is called basic manual probe, where a probe and a set of MA sensors are used for monitoring.

These sensors are mainly developed to allow monitoring of modified atmospheric conditions inside the packages in the most non-invasive and cost-effective way. All sensor caps are easy to install, provide accurate analysis, and monitor each bag every 6 hours. Data collected are sent directly to the operator through a software portal. The monitoring system also allows certification of product quality from departure to arrival.

Sensor for Modified Atmosphere FIBCs

Masterpack Group is a leading developer of high-end packaging solutions for big bags, and flexible intermediate bulk containers (FIBCs) used to protect, store and transport bulk and delicate goods worldwide.

What do Turkey, Italy, Oregon, Azerbaijan, Chile, and Georgia have in common?

Surely they are all on someone's must-see list -<em>definitely on ours</em>- but some have been lucky enough to visit all these beautiful countries. More than someone, we should say something.

We are talking about the sweet fruits of the hazel tree: hazelnuts.



Hazelnuts are great travelers; just think they travel many miles every day before reaching their destination market. For instance, 3,453.8 is the number of kilometers they have to cover to get from Turkey to the shelves of Dutch supermarkets.

The main problem with hazelnuts, and fresh products in general, is the long-term storage; one may wonder how they are still fresh and possess all the organoleptic qualities after such a long journey.

It’s not as simple as it sounds; generally, it has been estimated that up to 30-40% of fresh food may be wasted along the supply chains due to storage conditions.
<h2>What causes rancidity in hazelnuts when stored for a long time?</h2>
Having a high oil content - about 65% of its kernel weight – and being rich in unsaturated fatty acids, hazelnuts are highly sensitive to rancidity. Rancidity occurs when the fats inside the nuts, especially the unsaturated fats, get oxidized. This means that the hazelnuts were stored for a long time in the presence of air.

Rancidity is also stimulated by the product’s humidity, which causes the deterioration of the oils in the hazelnut (oleic and linoleic acids), thus producing fatty acids that lead to increased auto-oxidation of the product.

Not only does this lead to food waste and subsequent loss of business money for the companies involved, but rancid hazelnuts can have harmful impacts on your body.

But how can we ensure that hazelnuts do not go rancid when stored for so long?
<h2>Store your hazelnuts under Modified Atmosphere to fight rancidity</h2>
We raised the topic with Tim De Winter, Managing Director of Masterpack, a Dutch company specializing in creating Modified Atmosphere packaging. With its sustainable technology, the company won Packaging Innovation Contest De Gouden Noot (The Golden Walnut) in October 2022.

“<em>Hazelnuts stored at low oxygen concentrations (under 1-2% O<sub>2</sub>) are much less affected by rancidity because low oxygen avoids autooxidation of the fats in the kernel</em>,” Tim explains.

“<em>Using Masterpack Modified Atmosphere technology, manufacturers can reduce and control the oxygen levels within the packaging to create the right environment for an extended product shelf life</em>.” Tim continues.

You can also monitor the oxygen level during the whole transport without damaging the packaging film, thanks to their non-invasive sensor technology. Because the packaging is left intact, your hazelnuts are prevented from being exposed to air while avoiding contamination risk.

By preserving the product and extending the shelf life, the Modified Atmosphere technology help to reduce food waste in the supply chain.

Say no to food waste. How to protect your hazelnuts from going rancid along the supply chain

Food

Our food chain starts in the soil, growing crops and livestock. But between the fields and the stores, there is a line of industrial food processing equipment. Processes may be as minimalistic as cleaning fruit and as complex as homogenizing milk alternatives made from pressed legumes. In each case, processing technology is an important link in the food production chain.

A fresh salad with a walnut oil dressing or a peanut butter sandwich? A bag of roasted cashews or a pack of almond cookies? The common thread among these tasty treats is nut processing equipment. Not all nut ingredients are indeed nuts, botanically speaking. But the machinery that transforms shelled fruits, legumes, and drupes into fried snacks or a paste is similar. As for the food products, there is a nut recipe for every mood and occasion.

Nuts

Find production technology for Hazelnuts drying, and connect directly with leading machine manufacturers worldwide

Hazelnuts drying

Which hazelnuts drying equipment do you need?

Continuous fluid bed dryer

Infrared rotating drum dryer

Entry-level infrared nut drying machine

Industrial Nut Roaster

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