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Maker - Product Challenge

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Processing viscous foods

Do you have a multi product line that you wish could handle high and low viscosity masses with just one depositor? A flexible multi-purpose depositor designed to handle a wide range of viscous mass will increase production volumes and reduce costs.


<h2>Dynamic depositor for caramels, jams and toffees that adapts to your needs</h2>
The Aasted ETX is a centre depositor designed specifically to handle difficult high viscosity masses including caramels, toffee and "dry/viscous" chocolate. It's also able to deposit chocolate chips with speed and accuracy.

Flexible design means lighter liquids like jams and liqueurs can be handled equally well.

Fully tailored to your requirements, the Aasted ETX can be fitted with either a booster or a traditional stirrer, and options include built-in mould lifting or oscillating hopper movements during deposit.

Depositor for caramel, jam and toffee

For the production of chocolate paste based on refined or icing sugar, the decision whether to use a mixer or a kneader depends on the fineness of the sugar.


<h2>Optimized mixers for chocolates pastes</h2>
The Thouet Mixer Type DMS &amp; Kneader Type DMK from Royal Duyvis Wiener are used in the production of chocolate paste based on refined or icing sugar. The mixing and kneading times, as well as the decision whether to use a mixer or a kneader depends on the fineness of the sugar.

If refined sugar is required, the DMS mixer is the perfect solution for mixing your ingredients into a homogeneous paste. On the other hand if finely ground icing-sugar is used in your recipe, a kneader from the DMK series will be your perfect solution, due to chocolate made with icing sugar is a highly viscous paste, which requires more energy during the mixing and kneading process.

Mixer and kneader for sugar based recipes

When producing liquorice and other sticky or viscous food products, during the cooling or heating process, components in the product might stick to the machine surface. This leads to fouling and loss of heat exchange, which is inefficient and should be avoided for obvious hygienic reasons.


<h2>Using scraper blades to ensure transfer of heat when cooking liquorice</h2>
The MCE Cotator from Mattoc Confectionery Engineering is a food safe, scraped surface heat exchanger to cook, pasteurize or cool viscous masses like liquorice, fruit paste, caramel, mashed potatoes or marshmallows. It is designed with stainless steel scraper blades and a stainless steel heat exchange surface that comply with hygiene standards. At the start of the process, the product is pumped into a heat exchange tube where there is a rotational shaft carrying blades that scrape the tube surface. A geared motor drives the rotor to match the viscosity of the product. For heat exchange, a second tube surrounds the first and contains either steam or oil for heating or water for cooling that travels in the opposite direction to the product. The blades continuously remove the food product from the wall of the tube to ensure a thorough and even transfer of heat from the heating or cooling medium to the food. The food exits from the opposite end of the tube via a temperature probe and pressure control valve to maintain the correct heat exchange conditions for the process.

The machine is available in 600, 1,200 and 2,000 mm length, depending on the desired production capacity. It is designed to handle both viscous and heat sensitive products at rates between 100 and 2,000 kg/hr with motor powers between 3 and 15 kW.

Licorice cooker

Processes including homogenization, dispersing, suspension, emulsification and dissolving benefit with the addition of a dispersing rotor/stator system to the functionality of traditional overhead stirring equipment.  With traditional equipment, achieving desired results in high viscosity media is often difficult and slow and issues such as sediment formation and air inclusions are common.  Adding a high speed rotor and jet pipe in close proximity to the mixing vane greatly enhances the process and helps avoid many of these issues.
<h2>Fast and efficient agitation of highly viscous fluids</h2>
IKA's Rototron RTS is a line of agitators that uses jet-flow technology to speed mixing processes while avoiding many of the issues seen when more traditional equipment is used.  The jet flow agitators use a high speed rotor and jet pipe in close proximity to the mixing vanes to disperse and circulate products within a vessel while avoiding inefficiency caused by back flow, air inclusions caused by a static whirlpool effect, and the need for flow breakers caused by continuously rotating mixtures.  The circulation mechanism also avoids the common issue of sediment formation when being used to produce emulsions.  The units can be used with open and pressurized vessels and mounting options exist to accommodate a wide variety of vessels and configurations.  With this equipment, no seal material makes contact with the product and food or pharmaceutical grade versions are readily available.  Motor sizes are available from 2,2 to 15 kW with max batch sizes from 1.000 to 20.000 liters.

Jet flow agitator for high-viscosity media

<span style="font-weight: 400;">Coating cereal products adds variety, interest and value to breakfast products. The addition of syrups, frostings, glazings and coatings needs to be accurate and consistent to maintain top product quality. An easily expandable, specialised and fully automated syrup and coatings cooking, mixing and coating system increases quality and consistency whilst reducing costs.</span>


<h2>Modular systems for high quality automatic coating of cereal products</h2>
<span style="font-weight: 400;">The Baker Perkins range of syrup preparation and coating systems offer highly consistent and accurate coating solutions for a range of cereal-based product.</span>

<span style="font-weight: 400;">Options available are extensive, from glazed and glossy coatings through to frostings and chocolate coatings. To address the need for healthier products, all coatings can be made as sugar-free alternatives.</span>

<span style="font-weight: 400;">Advanced process control systems mean that preset parameters for sugar dissolving and evaporation are </span><span style="font-weight: 400;">accurately maintained. Fine control of final solids ensures that the coatings adhere evenly, are not sticky and provide the required appearance and texture every time.</span>

<span style="font-weight: 400;">Baker Perkins coating systems use double coating drum systems. This means one drum can always be operational whilst the other is being cleaned. This reduces your line downtime to an absolute minimum.</span>

<span style="font-weight: 400;">All components are designed specifically for the required coating task, but are completely modular. This allows for simple and cost-effective expansion. Systems are available from batch dissolvers to continuous, skid-mounted systems. This flexible set-up means each system can be specified to meet individual product requirements.</span>

Fully-automated syrup cooker, mixer and coater for cereals

<span style="font-weight: 400;">The production of accurately proportioned and homogenous slurries is a vital first step before cooking in many confectionary processes. Traditional volumetric measurement devices are prone to errors due to temperature, humidity and density variations, leading to inconsistencies and reduced product quality. A purpose-built weight-based mixer provides consistent highly accurate results, improving product quality and reducing costs through wastage.</span>


<h2>High accuracy ingredients weigher and homogenizer</h2>
<span style="font-weight: 400;">The Baker Perkins Autofeed unit is a compact, fully automatic unit that can weigh and dose up to 8 different dry and liquid ingredients. It then thoroughly mixes them into a uniform homogenous slurry that is ready for feeding into any of the specialist cookers in the Baker Perkins range.</span>

<span style="font-weight: 400;">The Autofeed takes ingredients fed sequentially from bulk handling systems into a combined weighing and mixing tank. The use of a single weighing hopper ensures correct proportions are maintained, irrespective of calibration.</span>

<span style="font-weight: 400;">All ingredients are mixed during the programmed fill cycle, and the order in which they are added can be easily changed as part of the recipe programming to ensure the highest levels of slurry consistency.</span>

<span style="font-weight: 400;">The highly sensitive weight measurement system produces a class-leading accuracy of 0.1% in each 180kg (200 litre) full batch. An easy to use touchscreen HMI shows full process visualisation, storage for up to 20 recipes, alarm handling and data logging, plus per-batch reporting of ingredients usage. Level control of the reservoir tank, and the weighing and mixing sequences is fully automatic, with no manual intervention required.</span>

<span style="font-weight: 400;">The Autofeed can also provide effective cost control. Thanks to its comprehensive reporting output for each batch its possible to produce highly accurate ingredients usage statistics on a regular basis.</span>

<span style="font-weight: 400;">Finally, an impressive range of options is available to tailor the Autofeed to your exact requirements, including efficient clean in place system, heavy duty upgrades for high viscosity slurries, twin tanks to avoid contamination across recipes, sugar-free syrup unit, and more.</span>

Automatic weigher and mixer of confectionery ingredients

Cool your product to the temperature required for further processing. This is a continuous cooling unit for chewy and caramel masses designed to take output directly from a cooker and spread it evenly over the surface of the rotating drum for even and efficient cooling.


<h2>Consistent and even cooling with no sticking</h2>
The Cooling Drum line from Hosokawa Ter Braak is a continuous cooling drum with output levels of 300 to 600 kg/h of soft caramel. It is designed to evenly and consistently cool hot substrates in preparation for further processing. Efficient cooling is achieved without product sticking by continuously lubricating the inner wall of the drum's cooling jacket upon which the product is evenly spread. Careful distribution of the chilling liquid inside the cooling jacket ensures maximum cooling with minimum input chilling energy. The line is part of Hosokawa Ter Braak’s line of continuous caramel processing equipment that has developed a strong international reputation for product quality and strong technical support to field applications.

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Cooling drum for soft and caramel mixtures

Do you need the highest quality single mass products? Traditional machinery can be too aggressive to achieve perfect results, often overworking the mass resulting in lower quality. You need a gentle single-mass solution that has been designed specifically for smaller volume high quality production.


<h2>Compact, gentle single-mass depositor and extruder for small volume production</h2>
The Aasted Alice is an innovation breakthrough for small volume production of high quality confectionary. Designed with delicate masses in mind, the Aasted Alice ensures gentle handling from input to output stage, applying the absolute minimum of work and shear as it passes through the machine.

The modular design means you can start simply with a single head extruder, and yet at a later date add further extrusion modules to produce increasingly intricate and exciting product. The large range of die tools provides a large range of possibilities for output.

Alice has been engineered to handle a vast range of masses including nougat, marzipan and almond pastes, peanut butter, aerated fillings, caramels, praline centre masses and much more. With individual temperature control of hopper and dies you can tailor Alice to give perfect results every time.

For hygienic cleaning or production changeover, the Alice is the first extruder depositor that allows complete hosing down off-line. All parts are easy to handle, lightweight and offer quick release/disassembly features that all combine to minimise downtime.

Compact extruder for bakery masses

<span style="font-weight: 400;">Batters, creams and other delicate sauces and emulsions take time to mix, reducing production efficiency. The technology employed by centrifugal mixers speeds up the production time of these products without impacting on quality. This improves throughput and increases return on investment.</span>


<h2>Flexible centrifugal mixer for fast production of lighter bakery and confectionery mixes</h2>
<span style="font-weight: 400;">The Tonelli Centrifugal Mixer-MU has been designed specifically for the high efficiency production of batters for cakes, meringue premixes, and the homogenization and mixing of creams, sauces and mayonnaises.</span>

<span style="font-weight: 400;">Centrifugal mixing technology allows for thorough mixing or emulsifying at much higher speed than traditional mixers without compromising on quality.</span>

<span style="font-weight: 400;">Suitable for a wide range of production environments, the Centrifugal Mixer-MU has a variable operating capacity from as little as 10kg up to 400kg. This makes it extremely flexible as well as providing the ability to increase capacity as future production volumes grow, removing the need to acquire new machinery.</span>

<span style="font-weight: 400;">Centrifugal Mixer-MU has a range of ingredient loading options, including manual load, volumetric and pump dosing, as well as loading cell scales.</span>

<span style="font-weight: 400;">Adding even more versatility the Centrifugal Mixer-MU can also be used as a scraps mixer, improving the return on investment even further.</span>

Centrifugal mixer for batters and creams

Cutting sticky products in the food sector is not always an easy process. Small scale producers that want to start automizing and speeding up their production process, without losing accuracy in cutting the products, an ultrasonic food cutting machine can help make the process more efficient.


<h2>Small capacity ultrasonic cutting of food products</h2>
The UFM3500 is a machine developed by Cheersonic that is able to cut food products such as cakes, marshmallows, pizza, pie or dough using ultrasonic technology that ensures very precise cutting. 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. Despite having a small capacity, the only knife can slice circular and rectangular product with its two cutting modes, which can be easily chosen or adjusted with the touch screen control interface.

The product is placed in a conveyor belt and pushed forward by a bar. While the product is moving forward, the knife will cut it in slices. On the other hand, in rotation mode, the product is kept in position by two holding plates. In this case, the knife rotates and cuts the round product, for example a pie or a pizza, in triangular pieces. The machine can achieve a cutting speed up to 60 cuts per minute.

Inline ultrasonic food cutting machine

Do you work with viscous foods like sauces, chocolate mass, soups or starches? Then you know all about working with viscosity. Viscosity plays a role in nearly all production stages in the food sector. Viscosity is normally compared to water. Water has a viscosity level of 1 and each number above is how many times the thickness of water that item is in a melted state.

So, for example, a 30 viscosity is 30 times the thickness of water, while a 125 viscosity is 125 times the thickness of water. Liquid media ranging from aqueous to pasty are pumped carefully through pipelines towards their next destination. This can be a next processing step or the filling into the package – ready for consumption.

We have experience with a broad range of process equipment designed for dispersing, milling, filling, extruding, drying or evaporating of viscous food. Viscosity is critical in most production stages as it determines the flow properties of a liquid food. It also influences the appearance and the consistency of your product.

Processing viscous liquids comes with a unique set of challenges. Because it is sticky, clean-ability may be an issue and you need to take special care to guarantee the hygiene of your production environment. As temperature changes will affect the flow properties this needs to be monitored and controlled carefully. No matter what viscous food you’re into, make sure to browse some of our solutions below.

Equipment for sticky foodstuffs

Find technology for processing viscous foods and connect with a global network of leading machine manufacturers.