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Cutting

Cheese is the most demanding food in the entire dairy family to emulate using non-animal and dairy free ingredients. The complex physical and taste profiles of animal-derived milk products make plant-based cheese manufacturing challenging to pull off. But the growing appetite for lactose-free and non dairy products is serving alternative platters of cheese.

Plant-based cheese

Accurately cutting food products in their desired shape, is a process that can take a lot of time and effort, especially when it comes to sticky products. To make this process faster while keeping the accuracy, more and more manufacturers decide to rely on ultrasonic cutting machines.


<h2>Accurate, consistent cutting in different shapes</h2>
The UFM6000 slicer produced by Cheersonic is a multi-slice food cutter. It can be applied to cut a variety of differently shaped products such as tiramisu, Swiss rolls, brownies, bread, pizza and sandwiches. Four cutting modes are provided: round mode, slice mode and two rectangle modes (square and triangle cuts). This ultrasonic cutter is composed of a transducer, a device that converts energy from one form to another, in this case ultrasounds in vibrations. The vibrating component plays a key role in the process, because it prevents the product from sticking to the blade. The machine is formed by plates on which the product is located. While cutting, the knife moves up and down. If the product has to be rotated, the plates turn the product while the knife is stationary. This type of food cutter can cut two products, such as two round cakes positioned on these two turning plates, at the same time. Cutting speed can reach 60 cuts per minute.

Stand-alone ultrasonic medium scale food cutting machine

Some cake items you may wish to cut can feature substantial amounts of cream. But that cream could smear and squeeze out of a cake during the cutting process while generating a lot of waste. Proper cutting accuracy is necessary for producing quality cream-based cakes without causing the cream to spill or spread.

<h2>Precision and hygienic cutting of creamy cakes using ultrasonic vibrations</h2>
The transversal ultrasonic cutter from TT Italy uses vibrating blades that cut your cake through quickly and precisely, preventing it from any damage or imperfections.
The cutter uses ultrasonic waves at a higher frequency than other traditional waves. The vibrations produced by these waves will create a frictionless cutting surface. The design also prevents waste, as the cake material is trimmed safely and effectively.

Cake ultrasonic cutter

Textured vegetable proteins made from soy, wheat, and oats are extruded into tubes or rods before being cut to the desired size. When cutting these extruded TVP tubes in large quantities, a guillotine cutter is required to cut multiple extruded products simultaneously and continuously to produce a uniform size.


<h2>Cutting multiple extruded foods to a controlled size and in uniform lengths</h2>
The Guillotine, from Mattoc, is cutting equipment that can simultaneously cut multiple extruded food products such as textured vegetable protein into a controlled size. The unit is driven by a servomotor which is placed at the end of the extrusion line. A belt carries the extruded product under the blade to be cut in uniform lengths based on the feedback of the conveyor belt drive. Cutting lengths of the extruded products can be controlled from 5mm to 1m or longer. It has a cutting speed of up to 350 cuts per minute for a cutting length of 20mm. Longer lengths would require slower speeds. The system is available in 4 cutting widths (400, 800, 1200, and 1600mm) and is supplied with a stainless-steel static blade or ultrasonic cutting blades for sticky or fragile products.

Industrial guillotine machine for extruded foods

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

ProXES machines and process lines are used to produce and process liquid and semi-liquid foods, cosmetics, and pharmaceutical products. ProXES together with its clients co-creates first ideas, develops tailor-made processing concepts and accompanies them until go to market.

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

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.

Caboc? Nope. Crowdie? Nope. Lanark Blue? Nope. Bonchester cheese? Nope. Oh, wait… Did we say Scottish cheese?

We meant the Scottish Sheese!



From the beautiful Isle of Bute in Scotland, <a href="https://www.buteisland.com/" target="_blank" rel="noopener">Bute Island Foods</a> was the first company in the UK to produce vegan cheese alternative Sheese in 1988. The company’s first vegan cheese was a cheddar style soya-based cheese alternative.

Made with coconut oil and without hydrogenated fat or palm oil, Sheese products are gluten and lactose-free.

Winning is hard work and determination, and that’s why, with over 30 years of experience, the company received more awards than you can imagine. One of the latest examples was the victory of Smoked German Style as the Best Vegan Cheese 2019.

Over the years, the company increased its range of Sheese blocks, Creamy Sheese, Grated Sheese, and Sheese slices with different formats and flavors.

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#Changemaker: From Scotland, the award-winning vegan cheese that is taking the market by storm

Drying meat was the prevalent method of conserving meat cuts when food could not be chilled. But dried meat products developed into delicacies and remained a culinary mainstay long after the functional need for preservation was answered with refrigeration. The ancient techniques have been replaced by dried meat processing equipment, but the time-honored recipes remain unchanged.

Dried meat

Making.com is a new online platform that helps makers find production technology quicker by grouping it around the products they make.

In Greek mythology, the people of ancient Attica chose Athena as their patron after the goddess gifted them the first olive tree ever.

The Athenians quickly discovered the multiple uses of the oily berry. But olives held more secrets yet. After years of research, <a href="https://polyhealth.gr/en/">PolyHealth</a> developed a way to extract molecules from the fruit and turn them into natural preservatives for foods.


<a href="https://www.linkedin.com/in/effie-lada-8b2099182/">Effie Lada</a> gave us a primer on the company’s ingenious method at the Free From Fair.

The result is a biological substitute for synthetic preservatives, ideal for delicate foods such as cured meats or plant-based spreads.

The flagship product, Medoliva, prevents oxidation and microbial growth without altering the natural flavors of products.

Thank you, PolyHealth, for this ground-breaking innovation. And thank you, Athena, for planting the first olive tree.

#Changemaker: A divine alternative to synthetic preservatives

Edible oils are fats that you can extract from various plants and animal tissues. The most popular sources are olives and sunflowers. You can use them for different cooking techniques, such as frying, baking, and other methods. Manufacturers are now finding ways to extract oils with a higher natural fat content efficiently using edible oil extraction machines.

Edible Oil

Essential oils are known as the liquid gems of nature. The sweet-smelling essences impact not just our senses but also our biochemical and cellular make-up. Besides aromatherapy, the products of an essential oil extraction system found applications in pharmaceuticals and foods.

Essential oil

Ancient civilizations discovered that plant extracts were useful for the treatment of pathologies. The origin of plant extraction cannot be specifically verified, but we can infer that the earliest attempts at plant extraction were more intuitive than scientific. Today, the extraction of compounds is a precise process with plant extraction systems complimenting traditional knowledge.

Plant extracts

Find production technology for Plant-based cheese cutting, and connect directly with leading machine manufacturers worldwide

Plant-based cheese cutting

Which plant-based cheese cutting equipment do you need?

Stand-alone ultrasonic medium scale food cutting machine

Cake ultrasonic cutter

Industrial guillotine machine for extruded foods

Complete Cutting, Mixing, Emulsifying and Heating System

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