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Maker - Product Challenge

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TVP heating Equipment

<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

Vegan meat alternatives and plant-based foods have rapidly grown in popularity over the last decade. Many people are switching to meat substitute food products. Your body does not discriminate between proteins and calories coming from meats and those coming from plants. From a nutritional point of view, they all have the same value. But chewing on a portion of veggie pumpkin protein does not feel the same as a cut of meat - the texture is completely different.

Textured Vegetable Protein

For the small and medium food industry, economical use of time, space and human resources is critical whilst still maintaining product quality. This industrial sauce pan may be just the solution for you.


<h2>Cook and mix automatically in programmable bratt pan</h2>
Cucimix by Firex is a truly versatile, compact all-in-one multi-functional industrial sauce maker. Without requiring constant attention from kitchen staff, the electric tilting bratt pan has direct heating and a built-in mixer with full monitoring and electronic control throughout the process. With a 70 liter capacity pan, yet only occupying less than 2 cubic meters of kitchen space, the Cucimix is available in electric and gas versions.

Industrial sauce pan

Cereal and grain bars are increasingly popular, both as snack foods and as functional foods using natural ingredients. Traditionally, a higher-quality softer bar has been difficult to produce economically in small-to-medium production environments. Additionally, standard machines have only been able to produce either moulded dry-grain based bars or extruded dried fruit paste-based bars, limiting production flexibility. A modern, purpose-designed machine that can address these issues is therefore an attractive proposition.


<h2>Flexible bar machine for grain or fruit paste-based products</h2>
The Bar 2 from DSC is a flexible entry-level machine for the production of extruded or moulded soft cereal bars.

For dry cereal mixes, the product is dosed onto a conveyor which passes it through a laminating roller to assert the initial thickness. A further laminating roller then produces the final product dimension.

For dried fruit pastes, two specially designed rollers shape the pre-mixed product into a fully adjustable extrusion.

For both product types the final stage is to cut to final product size. Cut dimensions can be selected by means of the built-in touchscreen control interface.

The HMI allows the creation and storage of multiple product recipes for easy recall, meaning simple one-person operation.

The whole machine has been designed to be simple to clean, with all product contacting surfaces easily accessible for hot water washdown.

Entry-level cereal bar making machine

When producing liquid and viscous products such as mayonnaise, sauces, dressings and ketchup it’s vital to achieve thorough emulsification and homogenization to ensure product quality. Traditional homogenizing solutions can be slow and difficult to clean, increasing downtime between batches. A modern vacuum-based system offers the flexibility to produce a wide range of products quickly, with exceptional quality and short cycle time.


<h2>Vacuum processing plant for emulsions, suspensions and gels</h2>
The MultiVacH from Enoop is a state-of-the-art processing plant for the production of high-quality sauces, mayonnaise, <a href="https://making.com/ketchup/">ketchup</a> and other liquid and viscous products.

Designed to be completely flexible, MultiVacH can be used whenever liquids or powders need to be thoroughly mixed and offers both cooling and heating to suit all production methods.

Ingredients are circulated via vacuum pump to a high-shear mixing element, then recirculated. This allows for extremely fast processing, as the circulation of product provides additional macro-mixing.

Downtime associated with batch or product changes is reduced to an absolute minimum thanks to fully pumped emptying via the recirculation line. In addition, rotating clean-in-place nozzles speeds up cleaning, allowing the MultiVacH to be used in multi-recipe environments.

Heating and cooling are via a double-jacket system, with direct steam injection available for high-temperature recipes.

Control is via a Siemens PLC with 12” touchscreen display, allowing observation and control of all parameters. Production can be manual, semi-automatic or fully automatic to your requirements.

Vacuum based homogenizer

Batch cookers can be highly inflexible and inefficient, relying on maximum fill levels to operate well enough to ensure quality. By installing a modern flexible batch cooker with multiple operation options and varying batch sizes you can quickly enhance efficiency and flexibility. A flexible solution allows multi-product batch cooking, enhancing return on investment.


<h2>Flexible batch cooker with vacuum and overpressure cooking</h2>
The MultiCook from Enoop is a highly innovative tilted vertical vacuum batch cooker for the widest range of food products, including jams, soups, sauces, ready meals, baby foods, fruit fillings, and many more.

As well as being completely constructed of stainless steel and complying with all HACCP hygiene requirements, the MultiCook has a tilted design to improve mixing and emptying, reducing batch times.

The body of the cooking vessel is double-jacketed and externally thermo-insulated, and it is heated via saturated steam and cooled with cold water. The heating/cooling is divided into 3 zones. This enables processing of different batch sizes without risk of burning smaller volumes of product.

In addition to the heated jacket, the MultiCook has an internal heated cone. This further reduces cooking times and increases productivity.

Available in two sizes to meet your requirements, MultiCook features frequency controlled speed of impellers to allow even delicate mixing to preserve fruit pieces. Teflon-coated scrapers improve mixing capability and heat transfer.

Industrial vacuum cooker

When producing fruit-based products such as marmalades or ice cream toppings, the process of cooking fruits needs special attention, as it can directly affect the organoleptic features of the final product. If the fruits are cooked for a long time at a high temperature, they may lose its flavor and discolor. Cooking under vacuum and below 80 °C helps preserve the flavor, color, but also vitamin content of the fruits in the most natural way possible.


<h2>Vacuum cooking fruits at low temperatures while keeping their natural taste</h2>
The Concentration Boule, from Ghizzoni, is a vacuum cooking system designed specifically for the preparation of fruit or vegetable-based products. It has a vertical cylindrical boule equipped with a scraper that prevents products from sticking to the vessel sides or burning. The vacuum cooker also features a double bottom wall for the indirect steam heating of fruits and vegetables. The vacuum technique reduces water content in the product through evaporation at low temperatures. This makes it possible to cook jams and concentrates evenly while preserving the natural taste of the product and requires less time compared to traditional cooking methods. The system has a safety feature that stops the stirring automatically when the lid is opened while cooking. This unit operates as a batch system with a capacity range from 20 kg to 7000 kg.

Vacuum and pressure cooker for fruits and vegetables

What does a $300,000 burger taste like? Meat. The first lab-grown burger took two years and 20,000 strands of muscle tissue to produce. But with rapid advances in cultivated meat processing technology, non-animal meat alternative products can now take a lot shorter to prepare. And cost much less.

Cultivated meat

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

With the protein transition, both more sustainable plant- and animal-based solutions are advancing. We excitingly met Tobias Gaiser and John Sheehy from <a href="https://www.coperion.com/en/home">Coperion</a> who have <span class="ui-provider a b c d e f g h i j k l m n o p q r s t u v w x y z ab ac ae af ag ah ai aj ak" dir="ltr">key technology and know-how for the protein transition. We had a very insightful talk at</span> <a href="https://anugafoodtec.com">Anuga FoodTec</a> about the future of protein.



Among other processes, Coperion specializes in industrial extruders with their expertise in making texturized vegetable proteins (TVP) and high-moisture meat analogs (HMMA). They also have know-how in <span class="ui-provider a b c d e f g h i j k l m n o p q r s t u v w x y z ab ac ae af ag ah ai aj ak" dir="ltr">precision fermentation and other key processes for making cultivated meat</span>.

John, who is the Global Key Account Manager for Alternative Proteins, took the time to detail all the varieties and making processes of <span class="ui-provider a b c d e f g h i j k l m n o p q r s t u v w x y z ab ac ae af ag ah ai aj ak" dir="ltr"> plant-based and insect protein in addition to cultivated meat. He </span>explained that cultivated meat can not always compete with real meat in terms of texture and flavor. Therefore it is now being mixed with TVP, which has a special very meat-like texture. "The extrusion process creates these specific fibers within the TVP," adds John. These products should reach the market within a few months.

Tobias explained that TVP can be made from soy, pea, or wheat protein, but the list of alternatives is growing over time. Therefore the possibilities are endless. He emphasized that being plant-based is not just a statement, but many of their employees actually follow that course.

We're grateful for this talk with Coperion and are enthusiastic to see what innovations are coming our way in the protein revolution!

#Changemaker: how about a cultivated TVP fish or meat burger?

Food

Protein

With consumerism comes great responsibility. More and more are switching their diet towards vegan and vegetarian alternatives, varying from dairy to meat. As more plant-based meat technologies are being invented, the production is rising in popularity. Ever wondered which challenges come with that?

Plant-based meat

I’m high in fiber, proteins, and minerals. What are your superpowers?

Lentils are one of the oldest crops ever, and you’ll be surprised how versatile this humble legume can be. They are higher in proteins than beef and have other essential nutrients. That’s why they are the new "old" superhero or, more accurately, superfood.



Martin Jager and Cassandra Winter know it well. Martin and Cassandra are the founder of <a href="https://www.easyvegan.at/en/easyvegan-is-loved-by-everyone/" target="_blank" rel="noopener">EasyVegan</a>, ready-made frozen products relying on the power of lentils.

The Making.com team met them at Free From Amsterdam 2022 where Cassandra shared how everything started. Cassandra is a <em>burger lover</em> but wanted to create something tastier than the tofu and veggie burgers already on the market. So after many experiments in the kitchen with lentils, she found the right combination for a burger that - we assure you - is a wonderful explosion of flavors. So she bought a sales trailer and traveled through Austria and Bavaria, selling her vegan products at city festivals, culinary events, sporting events and concerts. EasyVegan was then founded in April 2017 with the life partner Martin to make the lentil products accessible to a broad mass.

EasyVegan products such as lentil sliders, lentil sticks, lentil balls, and lentil patties are sustainable, purely natural, lactose-free, gluten-free, GMO-free, preservative-free, and palm oil-free products. Moreover, they are SUPER tasty!

<a href="https://making-tst.imgix.net/2022/11/WhatsApp-Image-2022-11-23-at-10.55.28-3.jpeg"><img class=" wp-image-60450 aligncenter" src="https://making-tst.imgix.net/2022/11/WhatsApp-Image-2022-11-23-at-10.55.28-3-225x300.jpeg" alt="" width="366" height="488" /></a>

&nbsp;

#Changemaker: The plant-based burger made of lentils you didn't know you needed!

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.

<span style="font-weight: 400;">Shaped and filled extruded products are extremely popular with consumers, but can be complex and inefficient to manufacture on a large scale whilst maintaining high consistency and quality. A dedicated extrusion solution designed from the ground up for high level production provides consistency while delivering reduced costs.</span>


<h2>Twin screw extruder with enhanced quality and production flexibility</h2>
<span style="font-weight: 400;">The SBX Master Extruder by Baker Perkins has been designed specifically to enable the production of a range of high quality extruded snacks. Its integrated design allows for the easy addition of flavouring and colours, and the SBX Master is capable of producing complex multi-ingredient premium product, as well as more standard designs such as expanded corn balls, multigrain rings and shaped designs.</span>

<span style="font-weight: 400;">The SBX Master is built for flexibility. A modular barrel design allows the perfect length to be chosen to exactly suit the product required, maximising quality, and advanced features are available such as super-cooling to allow the production of fine extruded flakes.</span>

<span style="font-weight: 400;">Set up, recipe selection and full condition monitoring are available through an easy-to-use HMI with graphical representation. The open frame design means all areas of the machine are easily accessible for cleaning and maintenance, and AC motors are used throughout which are maintenance free and consume less power than DC equivalents.</span>

<span style="font-weight: 400;">Another key aspect in reducing costs is the SBX Master’s capability for rapid product changeover. Face-cutter blades are able to be changed quickly, without the need for the extruder to be brought to a complete stop, and fully automatic start-up and shutdown cycles have been designed to minimise waste between production runs.</span>

Extruder for large-scale production of TVP

Baker Perkins supplies technology for the bakery, biscuit, confectionery, supplements, snack and breakfast cereal sectors, The company's production machines are based on over 100 years of experience in the field.

Soya, peas, beans or cereals are low in fat, high in fibre and protein content, and therefore a nutritious and healthy base for new meat analogues. The global shift away from meat leads to an increased demand for these TVP textured vegetable proteins (TVP) that can be often purchased in the form of dry chunks or flakes.


<h2>Higher moisture content for a meaty result</h2>
How is TVP made? Vegetable protein isolate from for example beans or peas is passed through an extruder. In this <a href="https://making.com/plant-based-meat">plant-based meat process</a> it is steamed, heated and – still hot – squeezed out of the machine nozzle. As soon as the substance cools, it changes into the desired form.

To achieve fibrous, chewy and meat-like TVP for veggie burgers it needs to be extruded at far higher moisture content of 50-70% . For sausages and for example nuggets only 20-30% is required. The moisture level facilitates forming, enabling a fibrous structure which can look and taste like natural meat.
<h2>Extrusion equipment for meatless meat</h2>
So the extrusion process begins with making a premix from soy beans, wheat, peas, lentils, etc. This mass is then transferred into a <a href="https://www.bakerperkins.com/news/developing-new-technology-for-commercial-production-of-meat-substitutes">double screw extruder,</a> where by the means of steam heating, shear, as well as presence of water, the meat-like structure is formed. When the material exits the extruder die, the structure is ready and can be further processed with different dyes or flavours, depending on the final product. The dye shape plays a significant role here, as it determines the final product - e.g., a circular cross-section tool for sausage-like products or a square cross-section for chicken analogues. Below a video of a TVP extruder from Baker Perkins. They have a cool R&amp;D centre to help their customers fine tune new recipes with for example seaweed and algae and further improve their meat-like taste and appearance.

[embed]https://www.youtube.com/watch?v=0B5RiyxijDI[/embed]

How to produce textured vegetable protein TVP?

Find production technology for TVP heating, and connect directly with leading machine manufacturers worldwide

TVP heating

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TVP heating Equipment

Which tvp heating technology do you need?

Industrial sauce pan

Entry-level cereal bar making machine

Vacuum based homogenizer

Industrial vacuum cooker

Vacuum and pressure cooker for fruits and vegetables

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