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Maker - Product Challenge

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Deaeration Technologies

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Industrial

In the brewing process, controlling the amount of dissolved oxygen in the water is crucial. High levels of oxygen can lead to off-flavors and reduced shelf life of the final product, creating challenges for breweries striving for consistent beer quality.
<h2>Produce deaerated water for improved beer blending.</h2>
The Deaeration Plant by Easybräu-Velo is a specialized process module for generating high-quality deaerated water, essential for breweries. This water is used for precise blending into the main beer stream, followed by carbonation, ensuring the desired characteristics of the final product. The plant aids in maintaining a controlled environment by removing oxygen from the water, thus preserving the beer's flavor stability and extending its shelf life. The system is versatile, also allowing for the use of deaerated water in tasks such as line flushing and filter pre-coating. Part of the TMCI Padovan SPA group, Easybräu-Velo ensures that the plant meets rigorous industrial standards, making it robust and reliable for high-demand brewery operations.

Deaeration plant for beer production

Blending

Deaeration

liquid

In beverage production, oxygen presence can cause unwanted oxidation, affecting taste and shelf life. To ensure product quality, removing dissolved gases like oxygen from liquids is critical, particularly in the production of fruit juices, nectars, and soft drinks.
<h2>Ensures high-quality carbonation and mixing</h2>
The deaeration system by BLENDTECH (Omnia Technologies) is designed to produce high-quality deaerated water essential for manufacturing soft drinks, fruit juices, and nectars. The system removes dissolved gases in a single or double stage process, ensuring the water used for carbonation and mixing is free from unwanted gases. This process prevents oxidation, ensuring the flavor and shelf life of the beverages are maintained. The deaeration system can also be used for other purposes, such as flushing production lines and filter pre-coating.

Deaeration system for fruit juices and soft drinks

Industrial mixing equipment is used to combine two or more solid, liquid or gaseous segregated ingredients into a homogenous single product. The choice of mixing technology depends largely on the physical state of the ingredients and the desired final product. But the sensitivity of the ingredients, the process temperature, and pressure requirements are also critical factors. All these parameters result in a wide range of industrial mixers.

Mixing

When producing high-quality fruit and vegetable purees, maintaining nutritional integrity and preventing oxidation are crucial challenges. Traditional methods often compromise the freshness and nutrient content due to heat exposure and air incorporation during the process.
<h2>Extract and deaerate cold for superior purees</h2>
The Monoskid System by Bertocchi is a compact unit integrating cold Turbo Extractor and Cold Deaerator on a single frame. Designed for easy installation and operation, it handles fruits and vegetables at room temperature to create products such as pulpy juice with medium fiber content but low viscosity. The system uses a High Speed Rotopulse extraction method that preserves nutrients and freshness by operating at room temperature, making it suitable for subsequent cold pasteurization treatments like HPP. The Monoskid accommodates whole, chopped, or destoned produce including apples, pears, peaches, apricots, grapes, red fruits, tropical fruits, bananas, and various vegetables. It supports production capacities ranging from 500 kg/h to 32 t/h, suitable for uses in concentrates, baby foods, nectars, fresh juices, and pulpy juices.

Cold extraction and deaeration system for fruit and vegetable purees

Industrial extraction equipment unlocks the valuable compounds hidden away in natural materials. Automated extraction equipment is applied in the pharmaceutical and cosmetic industries to extract active compounds from medicinal plants or herbs. For example, extracting cannabinoids from cannabis plants. But the process is also fundamental to the food industry, recovering various components like aromas, oleoresins, and proteins.  Considerations for selecting suitable extraction technology include the type of plant material to be processed, the extract's heat sensitivity, and the production volume.

Extraction

In the preparation of fruit and vegetable purees, maintaining the natural flavor, color, and nutritional value while ensuring enzymatic deactivation can be challenging. Common issues include browning, nutrient loss, and microbial growth, which can degrade the final product quality.
<h2>Optimize cold extraction and deactivation processes</h2>
The EOS Revolution by Bertocchi is an enzymatic deactivation system designed to work in conjunction with a Turbo Extractor for cold extraction and deaeration of fruit and vegetable purees. This system immediately heats the product at the outlet of the screen inside the Turbo Extractor, ensuring rapid enzymatic deactivation. By implementing thermal shocking, the system minimizes nutrient loss and prevents unwanted microbial activity. The EOS Revolution simplifies the process by recirculating the hot product through the Turbo Extractor, internal to the enzymatic deactivation circuit. This method is ideal for processing various fruits and vegetables, delivering high-quality deactivated purees suitable for concentrates, single-strength products, baby foods, and nectars.

Cold extraction deaeration system for fruit and vegetable purees

In both the brewery and soft drink industries, ensuring product quality involves minimizing oxygen content in water. Excessive dissolved oxygen can negatively impact taste and shelf life, creating challenges for manufacturers aiming for consistent, high-quality products.
<h2>Produce high-quality deaerated water</h2>
The Alfa Laval Aldox™ Mini is a compact, fully automatic water deaeration module specifically designed for breweries and soft drink manufacturers with low capacity demands. This skid-mounted module can achieve dissolved oxygen levels down to less than 0.01 ppm in less than 5 minutes. It retains more than 95% of carbon dioxide, enhancing the final product's quality. The Aldox Mini employs a gas stripping process using specially developed internal packing material for efficient oxygen removal, while its integrated Cleaning-In-Place (CIP) program ensures easy, automatic maintenance. This system operates within a capacity range of 10-40 hl/h (4.4-17.6 gpm) and requires no heavy-duty or pressure rated vessels, optimizing both space and efficiency.

Water deaeration module for breweries and soft drink manufacturers

Industrial cleaning equipment is used to wash or disinfect machinery and the production/warehouse area. It may also be used to sterilize the product, equipment, tools, floor or work surfaces and to purify or clean the product by removing impurities. Choosing a suitable cleaning system depends on the type of product or equipment to be cleaned, the sensitivity of the product to heat, pressure, and chemicals, and the level of sterility desired.

Cleaning

In the production of beverages such as carbonated soft drinks, efficient processing is essential to maintain product quality and consistency. Challenges include accurate blending of syrups, maintaining desired carbonation levels, and ensuring minimal oxygen content in the final product.
<h2>Ensures precise carbonation and mixing</h2>
The EASY.Carbomix by A Due is an automatic premix system designed for the in-line preparation of carbonated and non-carbonated beverages. This system handles water deaeration, syrup dosage, and carbon dioxide dosage with precise control, ensuring consistent product quality. Featuring mass flow meters, it continuously monitors and adjusts the Brix degree and CO2 content, providing feedback correction. With a production capacity ranging from 5,000 to 60,000 liters per hour, the system is equipped with software and a refractometer for precise Brix control, and a flowmeter for accurate CO2 measurements. It supports rapid product changeovers with minimal waste and is suitable for both carbonated and still beverages, including soft drinks, mineral water, and diet drinks.

Beverage deaeration, carbonation and mixing system

Carbonation

Dosing systems are a line of hoppers, feeders, filling machines, and checkweighers that operate in sync to dispense materials accurately. Dosing is an essential feature of the packaging process, whether you’re filling shampoo bottles or tea bags. But dosing equipment is critical for formulations, too, particularly in the pharmaceutical and chemical industries. Imprecise dosing may cause quality degradation in the best-case scenario. In the worst scenario, it creates serious health risks.

Dosing

When producing a large quantity of bottled beverages, maintaining high efficiency, reliability, and minimal downtime is crucial. Challenges include ensuring consistent filling, sealing, and labeling while preventing contamination and oxidation.
<h2>Fill, seal, and label with precision</h2>
The GAI Macchine Imbottigliatrici bottling lines are designed to cater to a wide range of beverage industries, from wines and spirits to oils and beers. These systems handle up to 20,000 bottles per hour, offering extensive customized options for filling, rinsing, deaeration, capping, and labeling. The machines are optimized for high efficiency and low maintenance, utilizing both mechanical and electro-pneumatic operations. Specialized features like the 'Unica' electro-pneumatic spout for sparkling wines allow for automatic level adjustments and precise filling. The use of inert gas at various stages ensures the oxidation of beverages is minimized. The family of machines also boasts advanced sterilization capabilities, integrated vacuum corking, and secure labeling techniques, suitable for various bottle shapes and sizes. Designed by GAI Macchine Imbottigliatrici, these lines provide scalable solutions to meet both small-scale and large-scale production demands.

Complete bottling lines for beverage industries

Bottling equipment draws a measured quantity of your drink, food, or formulation from a holding tank and fills it into bottles. These bottles usually need to be checked, capped, labeled, and sealed for distribution. Bottling solutions differ in product metering system, sterilization level, and bottle type and sealing system depending on your production scale and product format and regulations. Bottling systems are utilized in a variety of industries. For example, in the food and beverage industry as well as in cosmetics and pharma.

Bottling

When looking for capping equipment, it is crucial to know first which type of capper your product requires. Do you want screw caps, twist-off caps, hand pumps, or push-pull caps on your bottle or container? If you require different cap types for format changeover times can be time-consuming. The bottle cap seals the top opening of a bottle to guard the product against leakage and spoilage and sterility and filling requirements depend on the nature of your product.

Capping

Labels provide customers with important information about both your product and your brand. Different labeling technology attaches the printed film to the packaging using a range of methods such as shrink wrapping, side sealing, and adhesives. For added traceability and protection, you may also use serialization coding equipment and anti-tampering labeling systems.

Labeling

Industrial sterilization processes are employed in different industries to completely eliminate all living microorganisms from the final product. For instance, in food processing, sterilization equipment is used to produce a stable product with a long shelf-life by eradicating harmful bio-contaminants. Instead, in the medical field, sterilization technologies aim to prevent the transmission of microbes to patients by sterilizing all the tools and medical devices that come in contact with the patient. Most sterilization equipment, such as autoclaves, employs high-temperature pressurized steam to destroy bacteria and disinfect surfaces from spores. Other methods include radiation sterilization or using chemicals such as hydrogen peroxide for disinfection.

Sterilization

In beverage production, ensuring consistent carbonation levels in products like sparkling water, beer, and cider is crucial. Traditional carbonating methods often result in fluctuating carbonation, leading to inconsistencies in the final product's quality and taste.
<h2>Achieve precise carbonation in beverage production</h2>
The Comac Saturation Unit is designed for precise carbonation of beverages, managing both deaeration and carbonation processes effectively. Its stainless steel frame provides durability, while the pump feeds the static mixer/carbonator tank regulated by a frequency converter. This ensures constant product inlet pressure. The unit includes a CO2 pressure reducer, product/CO2 static mixer, and a corrosion-resistant Aisi304 stainless steel storage tank with safety valve and min-max level probe. The unit is equipped with an electric control panel featuring an HMI touch screen and Siemens PLC logic controller for seamless operation. It is suitable for carbonating products like water, cider, and sparkling wine with levels up to 7/8 g/L.

Saturation unit for carbonating beverages

In the production of carbonated beverages, ensuring precise CO2 levels and consistent quality can be challenging. Standard methods often lead to variable carbonation levels and increased waste due to inefficient gas dispersion techniques.
<h2>Ensures precise carbonation and stable product quality.</h2>
The Premix system by Co.Mac is designed for the precise carbonation of beverages such as carbonated soft drinks, nectars, fruit juices, tea, isotonic drinks, and beer. The product enters the deaeration tank, where it is nebulized by a battery of diffusers under light CO2 pressure, replacing the air with carbon dioxide to ensure efficient deaeration. After deaeration, a high-prevalence centrifugal pump sends the water to the injection-mixing system to achieve the desired CO2 saturation. Components are dosed with flow rate meters and modulating valves, ensuring maximum accuracy and repeatability. The system also includes static mixers for fine gas dispersion and optimal mixing of components. Stabilization is achieved through a holding tube and buffer tank, with temperature control maintaining a fixed CO2 pressure. The system’s compact design allows for easy installation and integration into existing production lines.

Premix system for carbonated beverages

Producing high-quality carbonated and non-carbonated soft drinks requires precise control over the combination of water, syrup, and carbonation. Challenges include removing dissolved oxygen from process water and ensuring consistent carbonation levels.
<h2>Deaerates, mixes, and carbonates with precision</h2>
The Premix system by BLENDTECH (Omnia Technologies) is designed for the production of carbonated and non-carbonated soft drinks. It features a vacuum-type deaeration group for extracting dissolved oxygen from process water. The system includes a mixing zone with magnetic or mass flow meters to ensure accurate blending of aromatized syrup with deaerated water. For carbonation, it uses a CO2 injector controlled by either magnetic or mass flow meters, delivering precise carbonation levels. The unit is compact, built with a monoblock configuration, and equipped with a PLC for selecting production recipes. Optional online CO2 and Brix degree control enhance the production process, ensuring high-quality end products. The system integrates well with existing fillers and CIP interfaces via digital or BUS & NET signals, and it includes onboard pumps for filler delivery and CIP return.

Premix system for soft drinks production

In the beverage industry, ensuring consistent quality in the production of fruit juices and soft drinks is crucial. Challenges such as maintaining homogeneous mixtures and preventing contamination during blending processes are common concerns that necessitate specialized equipment.
<h2>Guarantees uniform blending for high-quality beverages</h2>
The BLENDTECH blending system by Omnia Technologies is designed specifically for the production of fruit juices and soft drinks. This system ensures a homogeneous mixture of ingredients by utilizing precise blending techniques. One key feature is its deaeration process, which removes air from the blend, preventing oxidation and preserving the flavor and quality of the beverages. Additionally, the CIP (Clean-in-Place) system integrated within the blending unit ensures minimal downtime and thorough cleaning, maintaining hygiene standards. Ideal for various types of juices and carbonated drinks, the system supports aseptic production lines, offering a flexible and reliable solution for beverage manufacturers.

Blending system for fruit juices and soft drinks

In the fruit juice industry, reconstituting juice from concentrates is a crucial step to deliver the final product. The challenge lies in achieving the right blend and consistency while maintaining shelf life and flavor.
<h2>Mix, deaerate, and pasteurize fruit juices</h2>
The Bertuzzi juice reconstitution line is designed for efficient processing of concentrated juices. It includes solutions for preparing and mixing sugar syrup with the concentrate, followed by homogenization and deaeration to enhance product shelf life and aroma. The line also features pasteurization and sterilization systems like ThermoFlash and SterilFlash for both hot and cold filling methods. The integrated CIP (Clean-In-Place) system, named CipMatic, ensures the equipment meets international food grade standards and is easy to clean.

Juice reconstitution equipment for concentrated juice

Homogenization is the process of reducing particle size in mixtures to improve the consistency, uniformity, and stability of the product. The choice of a homogenizer depends on the nature of the product, desired particle size, the physical state of the ingredients, and pressure requirements during the process. Homogenization is widely used in the biotech industry for cell lysis and in the pharmaceutical industry for the emulsification of creams and ointments; it also finds applications in the cosmetics and food industries for improving the consistency and uniformity of various products.

Homogenization

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

In the food industry, producing high-quality ketchup and vegetable sauces involves handling diverse recipes and strict hygienic standards. Ensuring consistent blending, homogenization, and pasteurization processes are crucial to delivering a final product that meets consumer expectations while maintaining production efficiency.
<h2>Ensures consistent and flexible sauce production</h2>
The Ketchup Production Line from Bertuzzi is designed to meet advanced technological and stringent hygienic requirements. This production line is flexible, allowing the processing of various recipes with or without thickeners, vegetable particles, or preservatives. The system includes several ingredient preparation groups customized to specific needs, such as tomato paste dilution, sugar and salt dosing, and spice blending. The blending section uses special horizontal mixing tanks for homogeneous mixing and high-performance recipe reliability. Additional processes include deaeration, high-pressure homogenization, and pasteurization using a tubular heat exchanger. The line can handle high-capacity plants with automated ingredient dosing systems and integrated cleaning through the Bertuzzi CipMatic system.

Ketchup production line

Producing high-quality fruit and vegetable smoothies at an industrial scale presents challenges, including maintaining the freshness and nutritional content of the ingredients while ensuring a consistent texture. The need for an efficient, automated process to handle different types of fruits and vegetables is paramount.
<h2>Automated frozen extraction and enzymatic deactivation</h2>
The Smoothies Line by Bertocchi is designed for the production of pulpy fresh fruit juices and smoothies through a frozen extraction process. This line includes systems for cold deaeration and ultrarapid enzymatic deactivation, ensuring the retention of nutritional content and texture. Integrated CIP washing systems facilitate easy maintenance and automation. It is capable of processing both whole and crunched fruits and vegetables without the need for modifications. Ideal for red fruit IQF, the line's thermal shock deactivation by EOS guarantees the quality and safety of the final product, providing a deactivated cold puree of fruits and vegetables. With a maximum capacity range from 1000 kg/h to 3000 kg/h, it is suitable for large-scale production, ensuring consistency across batches.

Smoothies production line for fruits and vegetables

Freezing

When producing high-quality fruit and vegetable purees, maintaining the natural color, flavor, and aroma is crucial. Traditional extraction methods can often damage the product through excessive heat and mechanical stress, leading to a loss of essential qualities.
<h2>Enhance puree quality through cold extraction</h2>
The EOS TT from Bertocchi is a system designed for cold extraction and enzymatic deactivation of fruit and vegetable purees. It features tube-in-tube technology combined with cold deaeration, which minimizes mechanical and thermal stress on the puree. This results in a final product with retained natural color, flavor, and aroma. The system can process a variety of fruits and vegetables, including apples, pears, destoned peaches, apricots, grapes, red fruits, tropical fruits, and even vegetables. The flexible capacity ranges from 1 to 12 tons per hour, making it suitable for different production scales. Ideal for producing both concentrate and single-strength purees, the EOS TT ensures that the puree can be packed hot, aseptic, or used in baby foods and nectars.

Cold extraction and enzymatic deactivation for fruit and vegetable purees

Creating high-quality fruit and vegetable purees requires technology that minimizes heat exposure to preserve natural flavors and nutrients. Traditional methods can lead to nutrient loss and a need for artificial additives.
<h2>Achieve ultra-rapid puree deactivation</h2>
The EOS System from Bertocchi is designed for the cold extraction and deaeration of fruit and vegetable purees. This system combines cold extraction with a patented ultra-rapid thermal shocking process for enzymatic deactivation, minimizing heat exposure and preserving the natural qualities of the products. The system efficiently processes various fruits and vegetables, whether whole, chopped, or destoned, such as apples, pears, grapes, and tropical fruits, ensuring high-quality purees suitable for baby foods, nectars, and concentrated products. With a capacity range from 1000 kg/h to 24 t/h, the EOS System is highly versatile. It guarantees top-quality deactivated purees without the need for added gases or antioxidants.

Cold extraction system for fruit and vegetable purees

In the production of carbonated beverages, maintaining precise mixing ratios and ensuring thorough carbonation are pivotal for product quality. Without the right mixing system, beverages risk uneven carbonation, incorrect flavor balance, and higher operational inefficiencies.
<h2>Ensure accurate mixing and high carbonation</h2>
The Automatic Carbonated Beverage Mixing System from Alps Machine is designed for accurate mixing and high carbonation of various soft drinks. It features a high-quality stainless steel structure that meets international food safety standards, making it suitable for carbonated beverage, soda water, and paste drink production. The system manages precise mixing with a water and syrup ratio ranging from 3:1 to 6:1. With advanced microcomputer controls, it ensures consistent and stable operations, automatically alerting and stopping in case of malfunctions. The system’s vacuum deaeration function achieves a deaeration rate above 90%, ensuring minimal air content and a CO2 content of 3.5 to 4.5 times. This results in evenly mixed beverages with high carbonation and minimal bacterial growth.

Automatic carbonated beverage mixing system

In food processing industries such as dairy, beverage, and plant-based drinks, safety and shelf-life extension of liquid products are critical. Effective pasteurization helps eliminate pathogens and deactivate spoilage enzymes, ensuring the product is safe for consumption and has a longer shelf life.
<h2>Ensures food safety and extends shelf life</h2>
The HTST Pasteurizer by INOXPA is a high-temperature-short-time thermal treatment system designed for liquid and low-viscosity foods. Utilizing plate or tubular heat exchangers, the system efficiently heats products to pasteurization temperatures (70-100°C) for defined durations (15-300 sec), ensuring pathogen elimination and enzyme deactivation. Its modular, compact design allows for the integration of centrifugal separators, deaerators, homogenizers, and mixing stations, enhancing its adaptability to various process requirements. The HTST Pasteurizer features automated temperature control, multiple thermal programs, and the capacity for heat recovery up to 95%, making it energy efficient. Constructed from AISI 316L and AISI 304 stainless steel, it ensures durability and high sanitary standards.

Htst pasteurization system for liquid foods

<span style="font-weight: 400">The heating process is a step of raising the temperature of food, pharma, cosmetics, and many other types of products. You may employ different heating solutions for this process, depending on the type of product you intend to manufacture. Selecting the appropriate heater machine for your product is quite important since various products require different ranges of temperatures and different ways of heat transfer using exchangers. Industrial heating equipment varies in two ways - the type of material it can process and the reaction you want to achieve.</span>

Heating

Batch

In laboratory settings, achieving fine particle size reduction rapidly and effectively can be challenging due to air entrapment, which often leads to inconsistent results and longer processing times.
<h2>Eliminate air entrapment while milling</h2>
The NEXGEN™ MICRO MILL from Hockmeyer Equipment is a rapid-flow vacuum milling solution designed to perform both milling and deaerating processes simultaneously. It is engineered to minimize processing times while increasing yield efficiencies and eliminating air bubbles. The micro mill's advanced design allows for nano-particle size reduction, with capabilities to handle media sizes as small as 0.03mm efficiently. Built for quick and easy cleanup, it includes sanitary fittings that comply with laboratory standards. Additionally, the mill ensures uniform batch temperature control through integrated cooling, making it suitable for laboratories requiring precise and pure particle size reduction and deagglomeration.

Laboratory vacuum milling for fine particle size reduction

Industrial cooling equipment varies according to the consistency and temperature conversion demands the material you are handling, but the process typically involves heat exchange treatment as your products are conveyed through a cooling chamber equipped with extraction fans or circulating water. Temperature control is a crucial aspect of your commercial production and cooling systems are applied to a range of industries.

Cooling

Milling machines are used to reduce the size of material by cutting, crushing, or grinding it. The choice of industrial milling equipment depends on the industry and the materials to work with. Besides, there is a significant difference between those aimed to remove layers from metal or other materials workpieces and those designed to reduce particle size for materials that come in bulk.

Milling

Powder

solid

In industrial food production, achieving consistent quality while maintaining high capacity can be challenging. Precise control over blending, cooking, and product consistency is crucial, especially for processed cheese, sauces, baby food, and pet food.
<h2>Blends, steams, and cooks with high precision</h2>
The FreeTherm 500 from Hochland Natec is a versatile batch processing system designed for a range of products, including processed cheese, sauces, baby food, and pet food. This system features independently controlled augers for gentle mixing, Natec Network's direct steam injectors for effective heating, and an integrated vacuum system to de-aerate the product. Temperature is precisely monitored using self-cleaning probes, ensuring accurate pasteurization. The FreeTherm 500 supports up to 2,000 kg/h with up to five 500 kg batches per hour and includes automatic programs for various uses and fast CIP for maximum uptime. The central control and surveillance system enhances operator comfort, while the insulated buffer tank with an agitator holds the processed product for downstream delivery. The system is adaptable with several options such as a bin lifter, level measurement, and integration with existing CIP systems.

Multifunctional batch cooker for various food products

Whether it is marmalade or pizza, sauce or hummus, chocolate or fruit puree, most food products undergo a cooking step during their production process. Cooking is nothing more than applying heat to food, but there are different methods to do it. For instance, baking, frying, and roasting involve cooking food without using water, unlike boiling or steaming. Industrial cookers such as vacuum and pressure cookers, industrial fryers, industrial ovens, and industrial roasters focus on specialized applications that meet the different needs of the food industry by helping producers achieve a homogeneous cooking process.

Cooking

In the food production industry, achieving consistent and high-quality results across various product types is crucial. Producers of processed cheese, sauces, baby food, and other specialized foods require reliable systems for blending, heating, and de-aeration to maintain product integrity.
<h2>Blend, cook, and de-aerate diverse food products</h2>
The FreeTherm 150 by Hochland Natec Network is a batch processing system designed to handle a wide variety of product types and viscosities, including processed cheese, pasta filata, sauces, purees, baby food, meat, and pet food. The system features two independently controlled augers that gently mix ingredients, while unique direct steam injectors provide effective heating without creating hotspots. An integrated vacuum system de-aerates the product, ensuring density control and color stability. The temperature is monitored by self-cleaning probes, and the processed product is held in an insulated buffer tank with an agitator before being delivered to downstream systems. Options for additional functions include a bin lifter for ingredient addition, level measurement for dosage accuracy, and a shear pump for spreadable cheese. The FreeTherm 150 supports a production capacity of up to five 150 kg batches per hour, translating to 750 kg per hour.

Batch processing system for processed cheese and various food products

Complex processes call for continuous tracking and monitoring systems that help you to keep the manufacturing operation under control. The technology analyzes the components in the production phase for divergence in behavior or changes in conditions. Based on advanced software applications, monitoring platforms make sure that your products satisfy the quality criteria while they are being developed.

Monitoring

In modern food production, maintaining uniform consistency and precise blending of ingredients is crucial for high-quality end products such as processed cheese and sauces. Traditional methods often struggle to provide the necessary control over variable viscosities and compositions, leading to inefficiencies and inconsistent output.
<h2>High-efficiency blending and heating</h2>
The FreeTherm 50 by Hochland Natec is a specialized batch processing system designed for versatile food production needs, including processed cheese, sauces, purees, and more. Featuring two independently controlled augers, it ensures gentle and precise mixing of all ingredients. Heating is provided by unique direct steam injectors, eliminating product hotspots and enabling consistent temperature control. An integrated vacuum system de-aerates the product for better density control and color stability. Post-processing, products are discharged into an R&D trolley or an insulated buffer tank for seamless delivery to downstream systems. The FreeTherm 50 stands out for its flexibility, allowing up to 5x 50kg batches per hour, and ensures high operator comfort through a central control and surveillance system.

Batch processing system for processed cheese and sauces

Producing high-quality processed cheese, sauces, and purees in various viscosities and compositions requires a versatile system. This includes challenges like maintaining product uniformity, efficient heating, and preventing excess aeration during processing.
<h2>Blend, cook, and de-aerate with high precision.</h2>
The FreeTherm 10 is a purpose-designed batch processing system from Hochland Natec for a wide range of products including processed cheese, pasta filata, sauces, purees, baby food, meat, and pet food. It achieves great flexibility by utilizing two independently controlled augers for gentle mixing. Direct steam injectors ensure effective heating without creating hotspots, while an integrated vacuum system de-aerates the product for better density and color stability. The temperature is accurately controlled with self-cleaning probes, and the processed product is later discharged into an enclosed catchment bin. Clean-In-Place (CIP) programs and a central control surveillance system enhance operator comfort and ensure product safety. Optional features like steam conditioning units and different auger executions are available for customization to meet specific requirements.

Multifunctional batch processing system for processed cheese

In the pharmaceutical, cosmetics, chemical, and food industries, achieving homogeneous, high-quality liquid and cream products can be challenging. Issues like inconsistent blending, air entrapment, and improper temperature control frequently arise during mixing and processing stages.
<h2>Homogenize, emulsify, and de-aerate with precision</h2>
The Bachmix R by Bachiller is an industrial vacuum mixer designed to handle liquid and viscous products up to 20,000 liters. It excels in homogenizing, emulsifying, and de-aerating processes, making it ideal for applications that require high-viscosity homogenization. The mixer operates under vacuum or pressure and supports washing and sterilization. Its internal and external homogenization capabilities ensure thorough mixing, while its design adheres to GMP and EHEDG standards, ensuring compliance with industry regulations. Suitable for a wide range of industries including pharmaceutical, cosmetics, chemical, and food, the Bachmix R offers a versatile and robust solution for complex mixing needs.

Vacuum mixer for liquid and cream processing

An emulsifier is used to mix two immiscible liquids. Heating or cooling requirements during emulsification, overpressure or vacuum requirements, the need for wall scrapers, design of the mixing head, the viscosity of the liquids, and the desired droplet size are all important considerations when selecting an emulsifying system. Emulsifiers are typically used in the food industry for the production of batters, creams, and sauces, in the pharmaceutical and cosmetics industry for the production of creams and lotions, and in the chemical industry for the production of paint and other emulsions.

Emulsifying

Industrial washing systems are used to clean and disinfect a variety of items in research and manufacturing facilities. Industrial washers use solvents and cleaning agents with mechanical action to remove deposits and residues from stainless steel machinery components, empty containers, and other soiled surfaces. The selection of an industrial or commercial washer depends on the type of items and surfaces to be cleaned, the type of deposits/residue that is typically present, whether drying is required after rinsing and the level of sterilization necessary. Manufacturers will have cleaning specifications and as a result, require washers to be engineered to meet these specs.

Washing

In softgel production facilities, achieving high-quality gelatins is essential for ensuring the integrity and consistency of the final product. Traditional melters often struggle with inconsistent mixing and aeration, leading to defects and inefficiencies in the production line.
<h2>Optimized mixing for consistent gelatin quality</h2>
The Gelatin Melters from Arbes Tools are designed to provide optimal and effective mixing of gelatin mass on a stainless steel platform, featuring both single and double melters. Unique agitator-paddle design ensures thorough mixing, surpassing conventional vertical single paddle melters. The control panel allows for precise adjustments of agitator speed, water jacket temperature, and vacuum pump operation, which can be further enhanced with an optional PLC-HMI setup. A specially sized vacuum pump, included in the utility skid, maximizes de-aeration, making the gelatin suitable for high-quality softgel production. Available batch sizes accommodate various production needs.

Gelatin melters for softgel production

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