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Maker - Product Challenge

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Changemakers

The Pasteurization process is the method of subjecting liquids to mild heat at a specific temperature and time, and quickly cooling them down again in order to destroy pathogens in your fermented or semi-fermented products. Thus, increasing the shelf life of the manufactured products. Untreated microorganisms may lead to diseases, spoilage, or unwanted fermentation. Most pasteurization equipment operate in a continuous method using plate heat exchangers to keep a uniform level of high efficiency sterilization.

Pasteurizing

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.

Ketchup

In the beverage industry, beverages need to be pasteurized in order to destroy pathogens, and increase their shelf life while retaining their quality and freshness. A simple and energy efficient solution is required for the pasteurization of beverages when both the package and the product get pasteurized.


<h2>Efficient, reliable and economical pasteurizer for packaged beverages</h2>
Petek Proces’s Tunnel technology comprises of a tunnel pasteurizer, cooling tunnel, cooling tunnel with pasteurizing zone, and heating tunnel. The process involves taking cans or bottles filled with your beverage and running them through a hygienic stainless-steel tunnel where hot water is sprayed onto the finished product.

The tunnel pasteurizer for beverage, pours the liquid into bottles and cans, which are then moved into an enclosed conveyor. Heat exchange is then provided by recirculation of water inside a closed cycle by recuperating the energy through various, automatically controlled temperature zones. Its optimized nozzle system allows extremely good heat exchange between the water and your product.

Tunnel pasteurizing is a complex process, combining functions such as pasteurization, re-cooling and warming which consume a lot of energy. This solution comes with an in built central hot water unit along with a water saving system. Thus all excess water produced during the operation is collected in the pasteurizer saving both water and energy while maintaining high hygienic standards.

Tunnel pasteurization isn’t typically used with kegs because of their compact size. However, in comparison to flash pasteurization this process is not as cumbersome. Tunnel pasteurization does not require different processes and stages depending on the type of beverage. Therefore, it can be applied in the beer and beverage industry, fruit and vegetable processing, making sauces and jam etc.

Tunnel pasteurizer for beverage

When producing jams and marmalades, preserving the natural flavours, aromas and colors of the fruit can be challenging if no gelling agents or sugars are added. This is something important to consider when you are choosing the right jam making machines and equipment for cooking and sterilizing your products.


<h2>Vacuum Cooking and Sterilizing Your Fruit Jam and Marmalades</h2>
The BM50 Top Multifunction Bench from Frigojollinox is a complete marmalade and fruit <a href="https://making.com/jams/">jam</a> processing system. The vacuum cooker consists of two tanks working autonomously and automatically. Comprising of the sterilization of raw materials and the other, vacuum cooking of the product.

Vacuum cooking method cooks the jam at a lower temperature and at a shorter period. Thus, helping retain the natural flavors, aroma, and colors while saving time. This processing machinery features stainless steel tanks with a non-stick finish. This prevents the products from sticking to the bottom or to the wall of the tanks.

The Vacuum tank for cooking has a capacity of 54 liters and the Stery tank for sterilization has a capacity of 70 liters. This is the perfect processing machinery for a complete jam production line. All the way from with start with the raw materials, to the final end product, the MB50 is the ultimate processing and filling machine.

This machine has a touch screen control panel and intelligent control features that manage the system through wireless connections such as smartphones and tablets. This allows you to control the machine with out being physically present at the production line.
<h3>More Than Just a Jam Processing Machine</h3>
Besides for the ability to process jam from start to finish, the MB50 can also fry and braise. This makes it not only good for the production of marmalades and fruit jam, but it can also be used to <a href="https://making.com/fruit-juice/">produce fruit juices</a>, as well as sauces such as ketchup, soups as well as various other condiments. The functionality that this jam making machine provides makes it a great investment to any food production plant.

Marmalade and Jam Processing Machine

Microorganisms and pathogenic forms in fresh fruit jams can shorten storage time. In small food industries like canteens and cooking centres that preserve jams or other food liquids which are stored in cans, lengthening the shelf life of these products is necessary.


<h2>Pasteurizing by immersing the product in heated water</h2>
Fixpan of Firex is an industrial pasteurizer for preserves that pasteurise products like sauces, jams, liquids and semi-liquids, but can also cook. The jars that are filled with the product are put in a basket, lowered down in the machine and immersed in water, where a needle probe detects the temperature at the core of the product, during the pasteurisation process. The process of pasteurisation involves heating the product for a set amount of time in order to kill the vegetive form of bacteria harmful to the product. Depending on the product, the pasteurisation time and the temperature is set accordingly. A forced circulation system of running water (that is optional) allows to keep the temperature homogeneous in all areas of the tank. It also comes with a valve, to discharge liquid or semi-liquid products, or to connect with automatic dosing systems.

There is an electric, gas and steam version of the pan. They all come in versions that hold 100, 150, 200, 300 or 500 litres. The electric pan has the heating controlled by the electronic board with automatic insertion of the minimum 2°C before the setpoint, and by the pressure switch. The electric one has armoured heating elements in “Incoloy 800” alloy, installed inside the cavity. The steam pan has feeding (from the user circuit) via a minimum/ maximum modulation valve, controlled by an electronic board.

Jam pasteurizer with temperature control

An autoclave is a must-have machine for canned food production lines. It performs sterilization, which ensures a longer product shelf-life and eliminates the risk of contamination. However, autoclaves typically generate high water and energy consumption, which in the long run also means very high operating costs.


<h2>Sterilizing canned products with a separating compartment while saving water and energy</h2>
The Industrial Autoclave from Ghizzoni is a patented sterilizing system for canned products. It is a cylindrical autoclave that has a separating compartment for products that will be treated. Thanks to this separated space, the total volume that needs to be heated or cooled is reduced, and so is the time of the sterilization process and the amount of energy used. The system also features indirect heating and cooling of the products, so there is no need to worry about the cross-contamination risk. The water used for each batch in heating and cooling is reused for the next batch to save time and energy. This system is applicable for canned fish products, vegetables, ready-made food, baby food, pet food, etc.

Autoclave sterilizer for food cans and jars

If you want to pack into unique bag styles like Quad-seal and Doypack, but you don’t require acceleration &amp; deceleration, you can save costs by choosing a bagger with a mechanical drive.


<h2>Steady speed vertical form fill sealing</h2>
The VikingMašek Intermittent Bagmaker series (M250, M400, M500 ) are high-performance vertical form fill and seal machines. Its rugged construction and enclosed jaw drive enables hassle-free packaging in dusty or wet environments.

It can accommodate multiple bag designs and dimensions with high speed and accuracy. It can produce maximum up to 70-100 bags per minute and handles bag sizes from 50 x 60 mm (M250) up to 500 x 600 mm (M500).

This vertical bagger is perfect for packaging quad seal, flat bottom, doy style, brick fold down/tape down, and pillow bags, snacks, candy, coffee, fresh and frozen fruit and more.

Bagger with mechanical driven jaw actuation

If you are looking for a compact packing machine that packs multiple smaller packs in one master bag; this automated product is exactly what you need.


<h2>Compact bag-in-bag machine for packing applications</h2>
The VikingMašek Intermittent Bag maker (M250 BiB) is a machine for all types of bag-in-bag applications, from airline/hotel single serves coffee packs to multiple smaller packs in one master bag. This Bag-in-Bag machine has enclosed, direct jaw drive, that provides you with years of smooth maintenance and free operation.

This vertical Bag-in-Bag machine is perfect for packaging from small to large bags of snacks, coffee, pet food, hardware products and more.

Bag-in-Bag machine

If you are looking for a compact packing machine that fits into tight space and tight budgets, proven basic bagging technologies may be your solution.


<h2>Compact and economic vertical form fill sealing</h2>
The VikingMašek Intermittent Bag maker series (E250, E400) is the most compact and economical bag maker for the packaging of small to large bags. It can produce maximum up to 50-60 bags per minute depending on the series of machine. Bag size can vary from 50 x 60 mm (E250) up to 400 x 600 mm (E400).

The robust, stainless steel, open-design frame is easy to access for maintenance. This vertical bagger is perfect for packaging small to large bags of snacks, coffee, pet food, hardware products and more.

Bagger with rotary jaw drive actuation

If you want to pack into gusseted and pillow style bags and packing speed is important for your packaging process, a continuous bagger with twin sealing jaws could be a good investment.


<h2>The world’s fastest vertical form fill sealing machine</h2>
The VikingMašek Continuous motion bag maker velocity is capable of high speed production up to 300 bpm. The unique center mounted filling tube and natural counterbalanced sealing profiles are designed to provide vibration free, extremely smooth operation at all speeds.

The Velocity is also extremely versatile, handling package sizes up to 300 mm wide and multiple package styles. Patented, independently phased, twin sealing jaws separate the velocity from all other high speed machines and virtually eliminate lost cycle time. This is the world´s fastest bagging machine on the market that has no competition.

Continuous bagger with twin sealing jaws

If you want to pack into eye-catching 4-side sealed sachets between 40x50 mm and 250x200 mm in size, investing in a reliable sachet machine will be a good investment.


<h2>Fast and flexible solution for your sachet needs</h2>
The Sachet Machine series SA 300 &amp; SA 600 by VikingMašek are continuous motion multi-lane sachet machines. They make eye-catching 4-side seal packets using just one roll of packaging film that can seal your product with high speed and efficiency.

The versatile multi-lane sachet machines can accommodate from 1 to 6 lanes (SA600) or from 1 to 10 lanes (SA600) to form sachet pouches, running as fast as 80 cycles per minute.

Designed to pack powders, dense, fine, loose and particulate materials as well as liquids and semi-liquids into 4-side sealed sachets and to accommodate different bag shapes including tear notches and easy-open system. They can be fitted with servo auger fillers &amp; volumetric fillers for powder applications, and two different liquid fillers for sauces or creams.

Sachet Machine

If you are looking to pack your product into stick packs from 17 x 40 mm to 100 x 200 mm in size, you may benefit from the experience from the largest manufacturer of stick pack machines in Europe.


<h2>Benefit from the experience from Europe’s leading producer</h2>
This multilane Stickpack Machine series (ST200, ST400, ST560, ST800, ST1200 ) by VikingMašek can accommodate a large variety of different shapes of stickpack pouches with high efficiency and flexibility.

The versatile multi-lane stick pack machines can accommodate from 1 to 20 lanes, running as fast as 80 cycles per minute.

They are designed to pack powders, dense, fine, loose and particulate materials as well as liquids into StickPack bags and to accommodate different bag shapes including pour spouts, tear notches and easy-open system.

Semi- or fully automated cartoning solutions are also available for individual or bulk cartoning.

Stickpack Machine

VikingMašek is a global leading manufacturer of vertical baggers &amp; multilane packaging solutions.

Due to the fact that meal-kit subscription delivery companies deliver the box of ingredients that they assemble in the kitchen, their business models seem more sensible compared to the food delivery business which depends largely on the affiliated partners. Some restaurants, which only offer dine-in options before, have started to take similar measures to deliver half-processed meals to the end consumers. From kitchen to the consumers' table at home, there are a lot of considerations and challenges regarding the packaging of the food.


<h2>The driving forces of meal kit subscription services and restaurants joining food delivery</h2>
Since cooking at home can generate the sense of being in control during this out-of-control time, <a href="https://www.adweek.com/brand-marketing/meal-kits-had-their-chance-covid-19-has-given-them-another-one/">meal kit subscription businesses have taken initiatives to capture this quarantine-driven momentum.</a>  Meanwhile, the COVID-19 pandemic has also shown us that restaurants which do little takeaway or delivery business have adjusted to expand these capacities to maintain same level business due to the stay-at-home order.

Consumer behaviour is currently changing short term. However, when the consumers become more comfortable with order-in and meal kit preparation, chances are that their behaviours could be impacted long-term.
<h2>Packaging challenges and solutions for food delivery service</h2>
Either to deliver fresh food meal kit or to send fresh-cooked food, the process involves complex logistic and packaging challenges to bring the products across the city to the end consumer. The manufactures need to consider how to keep the ingredients fresh, how to prevent the liquid such as soup or sauce from leaking, and how to save employees' time if the food is packed manually.

While packing all the ingredients in the meal could not be perfectly automated in the standardized serving size, here are some most-requested food delivery packaging automation solutions:

<strong>- Meat, fresh-cut fruits and vegetables</strong>: Putting the ingredients in the sealed bag protects the food go wrong quickly. <a href="https://vikingmasek.com/packaging-machines/vertical-form-fill-seal">Vertical form fill seal (VFFS) machines</a> ensure high packaging speed and accuracy.

<strong>- Spices and sauces</strong>:  <a href="https://making.com/equipment/sachet-machine">Sachet</a> and <a href="https://making.com/equipment/stickpack-machine">stickpack machines</a> automatically form, fill, and seal small packets of ingredients like spices and sauces.

<strong>- Cold packs</strong>: Another emerging application is the packaging of cold packs for shipment of the ingredients to consumers' homes.

https://www.youtube.com/watch?v=JoIHv73s2zY

Packaging solutions for meal kit and food delivery

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.

Frigojollinox is an Italian company specialized in the manufacturing of equipment for the canning, dairy, fishing, confectionary, and cosmetic industries.

There was a period when ketchup bottles looked more like poster colors than condiments. The fad filled retail shelves with edgy ketchup palettes of purple, blue, green, pink. But the introduction coincided with a growing appetite for unprocessed food ingredients, and producers quickly reverted to red ketchup.

Most consumers will not be aware of lycopene, the compound that gives tomatoes their pigment. However, they know that the natural color of ripe berries is a rich red. The era of multicolor ketchup was, alas, short-lived.

But ketchup is more than tomato sauce. The classic recipe combines vinegar, sugar, and seasoning into the base sauce. Cooking combines the aromas and reduces the sauce into a denser liquid. But while it enriches the taste and texture, the rise in temperatures turns the glowing red of the tomatoes into a fading brown.


<h3>Natural pigments on red alert</h3>
“Conventional industrial cookers subject the ketchup mixture to temperatures up to 100°C,” explains Maurizo Pettini from Frigojolinox. The elevated heat diffuses the natural pigmentation and makes the orange and yellow undertones of lycopene more pronounced.

The discoloration can be corrected with food-grade additives, often Allura Red AC (E129 / FD&amp;C Red 40). However, preserving the original red pigment of the tomato sauce minimizes the degree of color adjustment required.

The trick is to balance temperatures with atmospheric pressure. Cooking the ketchup mixture under a vacuum reduces the thermal stresses considerably, circumventing the 'burn’ effect caused by traditional high-heat cookers.

“Vacuum cooking is conducted at around 50°C and removes a significant measure of the thermal burden from tomatoes,” Maurizio tells us. The decreased pressure lowers the boiling point of the moisture content in the sauce and the water in the vacuum cooker.
<h3>Take the pressure off color, texture, and taste</h3>
Lycopene perishes under intense heat, but the vacuum technique treats them gently. While the ingredients combine and thicken into ketchup, the tomatoes retain vivid redness.

But that is not the whole story, Maurizio points out. Besides the color, vacuum cooking develops other organoleptic qualities. It controls the extraction of water which regulates the viscosity levels. Meanwhile, the low temperatures prevent the caramelization of sugars that often produce off-tastes.

The vacuum technique protects the natural color of tomatoes and produces more authentic ketchup hues. However, that is no guarantee that the polychromatic craze will not make a comeback.

Ketchup shows its true colors with vacuum cooking

Sauces bring personality to a dish. From a spicy, dense Zhoug to a tangy, runny Suero, sauces add an extra dimension of flavor, texture, and mouthfeel. But developing recipes into industrial products with long shelf lives and consistent tastes is a complex process. Specialized sauce making equipment prepares and combines the ingredients into delicious, high-quality foods. The result is a sauce ready to elevate meals.

Sauce

Find production technology for Ketchup pasteurizing, and connect directly with leading machine manufacturers worldwide

Ketchup pasteurizing

Which ketchup pasteurizing equipment do you need?

Tunnel pasteurizer for beverage

Marmalade and Jam Processing Machine

Jam pasteurizer with temperature control

Autoclave sterilizer for food cans and jars

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