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Maker - Product Challenge

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Stirring Technologies

Batch

Industrial

Producing high-quality kettle-style potato chips can be challenging due to the need for consistent cooking times and temperatures. Traditional methods for frying often result in chip clusters, uneven cooking, and oil wastage, impacting both the quality and cost-efficiency of production.
<h2>Automatically control frying and stirring processes</h2>
The Batch Fryer by Heat and Control is designed for producing kettle-fried potato chips with consistent quality. It features a fully automated PLC system that controls potato feed, frying, stirring, and unloading of finished chips, ensuring repeatable quality. The fryer includes the optional Chip-Stirr system, which stirs the slices during cooking and prevents slice clusters, thereby maintaining uniform chip quality. The under-pan fired design eliminates the need for heat transfer tubes, allowing cooking with as little as 4 inches of oil, which is continuously managed by an automatic oil level control system. This efficient oil management reduces waste and improves the overall cooking process, making it suitable for producing kettle-style potato chips at production capacities of up to 360 pounds per hour.

Batch frying system for kettle-style potato chips

Blending

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

Industrial feeding systems allows you to control the flow of solid bulk materials throughout the manufacturing line. After loading your material onto the vibrating hopper, a screw at the base drives it out in uniform doses to the next stage of processing. New feeding technologies are designed to deal with challenges of powders clumping together in the hopper (bridging and ratholing) that interrupt the outflow. Common feeder systems include centrifugal feeders, vibratory feeders as well as elevator, linear and pneumatic feeders.

Feeding

Frying was an early method for preserving food. The most common technique, immersing foods in boiling oils, dehydrates the items and decreases microbial growth. But even with alternative decontamination and preservation methods, frying remains a popular cooking technique. The oils add complexity to the natural flavors and textures of foodstuffs. One of the main challenges of fried products is maintaining oil freshness. Industrial frying equipment processes large volumes of food homogeneously by strictly controlling the temperatures in the frying chamber. However, oil efficiency is also crucial, and temperature control must balance oil levels in the line.

Frying

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

Stirring

solid

When working on R&D projects or university applications, precise control over fermentation processes is essential for reliable and reproducible results. This includes maintaining specific environmental conditions and scaling up experiments effectively without compromising data integrity or process efficiency.
<h2>Enable precise control and efficient scaling.</h2>
The RALF fermenter from Bioengineering is a versatile lab-scale fermenter designed to support batch, fed-batch, or perfusion processes. It features autoclavable glass vessels with sizes ranging from 1.3 to 4.5 liters, and a direct top drive system for enhanced stirring options such as Rushton, propeller, or pitched-blade stirrers. Temperature control is managed using heating pads and cooling fingers or through a heated circuit integrated into the vessel walls. BioSCADA software ensures customizable, flexible control compliant with 21 CFR Part 11. This fermenter is ideal for scaling up studies due to its consistent system design and minimal space requirements. Bioengineering's RALF is perfect for applications in biopharma, food, beverage, and cosmetics industries, ensuring robust and reproducible results.

Lab-scale fermenters for research and development

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

The fermentation process stimulates enzymatic activity in organic substrates to transform their chemical composition. Fermentation is aided by storying the biomaterials in anaerobic environments, allowing the microorganisms to decompose their nutrient structures. The process is integral to some of the most popular products throughout time such as wine, beer, cheese, and kimchi. But besides the food sector, fermentation is also an important stage in the industrial manufacturing of chemicals, pharmaceuticals, and biofuels.

Fermentation

<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

Industrial measurement equipment is used as a crucial step before products leave the production line. These measuring instruments check for correct dosage and standards. Equipment for measurement and control employs a wide range of technologies to detect inconsistencies in volumes, sizes, weights, and fill levels as well as to inspect goods for quality against a set of criteria. Specialized measuring tools allow you to minimize the probability for error to its lowest possible, ensuring that both products and packaging meet your benchmarks.

Measurement &amp; Control

liquid

When working in R&D or university labs, efficient and scalable bioreactor systems are essential for accurate experimentation and development. The challenge often lies in finding compact and reliable solutions that facilitate both scale-up and scale-down processes without compromising on quality and compliance.
<h2>Supports flexible bioprocesses with modular design</h2>
The NLF by Bioengineering is a bioreactor designed for small production volumes, offering high reliability and space-saving features in a modular unit. Equipped with several automation levels, it is ideal for both low-budget and high-budget production scenarios. The system adheres strictly to FDA and GMP standards, which guarantees compliance for preclinical applications. The design of the NLF makes it optimal for scale-up and scale-down studies, assisted by matched system designs that reflect larger production environments. The bioreactor is constructed with robust, long-lasting components and includes the BioSCADA control software, which ensures precise data collection and analysis. Available in various configurations, from single fermentors to multi-configurations or as part of larger production plants, the NLF meets versatile production needs. With features like automated sterilization (SIP) and cleaning (CIP), and multiple ventilation, stirring, and gas module options, it promises efficient and flexible operation.

Modular bioreactor for low-volume production

Aerators are devices used for mixing air (oxygen transfer) with a liquid such as water or oil to form a homogeneous product. Selecting an industrial aeration system involves choosing a suitable mixing head and considering the desired input and output flows, temperature, level of aeration, properties of the liquid phase, and the degree of automation and pressure control. Aerators are used in the food industry for the production of fat-based center masses and crèmes and in the chemical industry for wastewater treatment. When it comes to water treatment, surface aerators are most commonly used.

Aeration

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 industrial kitchens, precise temperature control, consistent mixing, and the ability to handle a wide range of ingredients are essential for efficient production.
<h2>Automate stir-frying with temperature control and stirring</h2>
The BFK-10 Stir Fryer by ANKO is an industrial-grade appliance tailored for cooking a broad spectrum of ingredients, including fried rice, noodles, and various dried meats. It features automatic temperature control and a sensor for precise heat management. The built-in scraper and stirrer ensure that ingredients are evenly mixed and do not stick to the cooking surface. This stir fryer can operate with either LPG or natural gas, with a consumption rate of 355,000 BTU/hr for LPG or a variable rate for natural gas. The unit's capacity is 60 liters, making it suitable for large-scale food production. Additionally, the frying pot can tilt up to 90°, facilitating easy removal of cooked food. Adjustable stirring speeds add to its versatility, making it ideal for various industrial cooking applications.

Stir fryer for industrial food production

In chemical laboratories and industrial facilities, safe and efficient synthesis reactions often require the use of reactors that can operate under controlled temperatures and vacuum conditions. This becomes particularly crucial when dealing with flammable solvents and volatile reactions.
<h2>Safe synthesis with controlled temperature and vacuum</h2>
The 50L jacketed glass reactor from Across International is designed for synthetic reactions of various materials in a controlled environment. This reactor features an explosion-proof motor and controller, ensuring safe operation with flammable solvents such as ethanol and methanol. The dual jacketed design allows for vacuum drawing from the outer jacket to maintain precise temperature control and prevent frost formation. Constructed with high borosilicate glass and PTFE sealing components, the reactor is resistant to heat, cold, and corrosion. It includes an adjustable stirring rate for high torque or speed and a built-in condenser for material recovery. The system is supported by a heavy-duty stainless steel frame with lockable casters for easy mobility.

50l jacketed glass reactor with explosion-proof motor

Powder

Continuous

In laboratory settings requiring precise synthetic reactions under varying temperature and vacuum conditions, traditional reaction vessels may prove insufficient. These scenarios often involve handling sensitive materials that demand consistent stirring and controlled feeding rates.
<h2>Manage synthetic reactions with tight temperature control</h2>
The Ai 20L Single or Dual Jacketed Glass Reactor from Across International is designed for synthetic reactions of various materials. It features a high borosilicate glass vessel that is both heat and corrosion-resistant, making it suitable for a wide range of temperatures from -110°F to 400°F. The system is equipped with adjustable stirring speeds and a constant pressure feeding funnel for uniform material addition. Its dual jacketed design allows for vacuum drawing from the outer jacket, providing optimal recirculating fluid temperature control and preventing frost formation. A built-in condenser with dual cooling coils ensures efficient material recovery. The reactor's robust PTFE sealing components offer long-term durability, while its stainless steel supporting framework with lockable casters provides stability and mobility. The included Welch Pump further enhances operational efficiency.

Large capacity jacketed glass reactor

Purification is the removal of contaminating substances and by-products to increase the level of purity of the desired substance. Considerations for choosing a suitable purification system in the industry, include the physical state of the mixture, the desired product, required level of purity, the type of mixture, heat sensitivity of the product, number of purification steps needed, and the production volume. Industrial purification systems are used for the production of pure water in the food pharmaceutical and biotech industries.

Purification

Recovery

Pilot

In laboratory settings, precise control of reaction conditions is crucial for the synthesis of various compounds. Researchers and engineers often face challenges in maintaining consistent temperature, pressure, and mixing during complex reactions.
<h2>Control temperature and pressure for synthetics</h2>
The Ai 20L Single or Dual Jacketed Glass Reactor Systems With Air Motor from Across International is designed to facilitate synthetic reactions under controlled temperature and vacuum environments. The system features adjustable stirring speeds and a constant pressure feeding funnel for uniform material addition. The built-in condenser enables material recovery at a controlled rate. The reactor is constructed from food-grade high borosilicate glass, making it resistant to heat, cold, and corrosion. Equipped with a solvent-resistant PTFE stirring rod and stainless steel frame, this reactor provides durability and stability. It operates within a wide temperature range, from -110 °F to 400 °F, and offers high efficiency with features such as a large condenser cooling surface and an optional double-jacketed model for superior vacuum control. The unit's air motor allows use in C1D1 environments without requiring expensive EX retrofits.

20l jacketed glass reactor

In chemical and pharmaceutical industries, conducting reactions under precise temperature and vacuum conditions is essential. Uncontrolled environments can lead to unwanted side reactions, material loss, and safety hazards, particularly during synthetic reactions that require stringent control and reproducibility.
<h2>Perform controlled reactions and filtrations efficiently</h2>
The 20L Single/Dual Jacketed Glass Reactor System by Across International is designed for synthetic reactions involving different materials under controlled temperature and vacuum conditions. This system allows for both single and multi-step reactions and filtrations within the same vessel, minimizing material transfers and losses. Equipped with a built-in condenser and adjustable stirring speeds, this reactor ensures precise control over reaction parameters. The use of high borosilicate glass provides chemical resistance and durability, while PTFE components guarantee long-term operation. Additionally, the system includes a constant pressure feeding funnel for uniform material addition, and it supports a wide range of temperatures from -110°F to 400°F.

20l jacketed glass reactor for controlled chemical reactions

Industrial filtration equipment separates solid matter from liquid by using a filter medium. The filter allows only the fluid to pass through but retains the solid matter. The choice of filtration equipment depends on the particle size, the consistency of the mixture, and the nature of your product.

Filtration

In pharmaceutical and chemical laboratories, precise temperature control and uniform mixing are crucial for successful synthesis reactions. Managing these parameters can be challenging without the right technology, particularly when working with varying material viscosities and reaction requirements.
<h2>Efficiently manage temperature and mixing in reactions</h2>
The Across International R100 series jacketed glass reactor is designed for synthetic reactions of various materials under controlled temperature and vacuum conditions. This system includes adjustable stirring speeds and a constant pressure feeding funnel, ensuring uniform addition of materials to the vessel. The built-in condenser recovers materials at a controlled rate, aiding efficient processing. Featuring solvent-resistant PTFE on all seals, the reactor provides durability for long-term use. Digital speed and temperature displays offer clear operational visibility. The heavy-duty stainless steel supporting framework with lockable casters enhances both mobility and stability. This jacketed glass reactor is compliant with UL, CSA, and CE standards, making it a reliable choice for laboratory applications.

100l laboratory jacketed glass reactor

When producing kettle-style potato chips, uniform heating and consistent quality are crucial. Traditional frying systems can struggle with maintaining these standards, leading to issues like chip clusters and uneven frying.
<h2>Ensures uniform frying and reduces chip clusters</h2>
The MasterTherm Kettle Fryer from Heat and Control is designed for batch frying kettle-style potato chips with high accuracy and consistency. This thermal fluid heated kettle frying system features unique thermal fluid heat transfer tubes immersed in the oil, delivering uniform heating with fast heat response and no burning of chips. It reduces thermal stress by allowing the heat exchanger tubes to move independently. The Chip-Stirr system automatically stirs slices during cooking to eliminate clusters, ensuring consistent chip quality. The full-length hood improves safety, energy efficiency, and oil quality by reducing heat loss and purging oxygen.

Kettle fryer for batch potato chips

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