Fessmann Smokehouses Brochure - Schellhas Food Technology

FESSMANN
LEADING IN SMOKING TECHNOLOGIES
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CONTENTS
EXPERIENCE THAT CAN
BE TASTED
FESSMANN − yesterday and today
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SMOKING SOLUTIONS PATENTS
Leaders in smoking technologies
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TURBOMAT 1900 / 3000
Quality from tradition
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INDUSTRIAL SYSTEM Ti 3000
We leave weight loss to others
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AUTOVENT
For profitable cooking
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ROTATHERM CARAT
The secret of baking is now revealed
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INTENSIVE COOLING SYSTEMS
Cooling for an improved shelf-life
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SEMI-CONTINUOUS
SYSTEM TF AND TFi 3000
A successful mixture
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CONTINUOUS SYSTEM TF 4000
Continuous progress
20
AIR CONDITIONING SYSTEMS
Favourable climate
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FPc 100 / ProCES CONTROL
Everything under control with
the FPc 100
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DETAILS
A closer look is worth its while
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EXPERIENCE THAT CAN BE TASTED
FESSMANN – YESTERDAY AND TODAY
FESSMANN was founded by Wilhelm Fessmann in 1924. Much has happened since then. The technology has improved, the processes have been
optimised and the family business has now become an enterprise whose
high-tech systems for smoking, cooking, roasting, baking, maturing and airconditioning are in use across the world.
What still remains is our insistence that our solutions must always be
more mature, better worked out and better thought out, so that your customers
get the best taste. Over 75.000 units supplied demonstrate that our customers
share our view and are our reason to constantly improve ourselves.
INCLUDED IN THE SERVICE
The process of buying a FESSMANN system starts long before the actual
purchase and does not stop with it. We support you in the project engineering, planning and adaptation of the correct solution for your requirements.
We have technical advisers and contact persons who will guide you through the
production process in word and deed.
You will rarely see our service personnel. That is however not due
to the fact that they do not have any time for you, but rather because our
systems are exceptionally low-maintenance and operate in a fail-safe
manner. Should you nevertheless require the services of our trained service
technicians, they will be quickly at your premises, fully
equipped.
We are conscious of our responsibility towards our customers and our environment. We are constantly developing our systems further, in order to be able to offer you
products, which are easy on the resources and your purse
even in future.
DATES AND FACTS
1924 Founded by Wilhelm Fessmann
1969 Delivery of the first TURBOMAT universal system,
over 75.000 units sold since then
1971 Development of the first semi-continuous system
1972 Development of the first transfer system
1976 The technical school at FESSMANN inaugurated
1982 Development of the first RATIO smoke generator
1993 The patented smouldering smoke generator
RATIO-TOP completes the RATIO family
1998 FESSMANN develops systems for cooking and
baking: AUTOVENT and RotathermCARAT
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FESSMANN SYSTEMS OFFER BETTER
Control of the smoke density for individual and
uniform taste
Patented smoke system for a uniform quality
of the entire batch
High economy due to minimum weight loss and
the best uniformity
Reproducible results thanks to FESSMANN control
Individual adaptation of the smoke generators
to your requirements
Durable due to the best materials and processing
The systems are flexibly expandable as a result of
modular construction
Energy-efficient due to the best insulation
Future-proof: Alternative heating using electricity,
high pressure steam, gas, thermo oil or oil possible
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SMOKING SOLUTIONS PATENTS
LEADERS IN SMOKING TECHNOLOGIES
Whether you wish to smoke, cook, bake or cool − FESSMANN has the correct
system for each job. Thanks to the modular construction, the system adapts
itself flexibly to your operating size. And with many well thought out details and
a choice between stand-alone or central units, the system can be combined to
suit your own exact requirements.
Our strength are our patented smoke generators: The sophisticated smoke
system strengths the best results in the shortest time. The variable smoke
intensities permit wide variety of smoke aromas and colour nuances. And the
FPc 100 control ensures that this first-class, uniform product quality in colour
and taste remains reproducible. Depending upon the requirements, you have
the choice between smouldering smoke generator (RATIO-TOP), friction smoke generator (RATIO-FRICTION) and liquid smoke generator (RATIO-LIQUID).
SMOKE GENERATION
SMOKE COMPONENTS
low-boiling components
for the colour
200° C
250° C
300° C
350° C
high-boiling components
for imparting taste and
preserving
400° C
450° C
SMOULDERING TEMPERATURE
APPLICATION SPECTRUM
Taste
RATIO-TOP
RATIO-FRICTION
RATIO-LIQUID
Preservation
Colour
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RATIO-TOP SMOULDERING SMOKE GENERATOR
Short smoking times thanks to rapid generation
of highest smoke concentrations
Variable smoke intensity
Wide variety of smoke aromas and colour nuances
TOP‘s selectable based on FPc 100-control:
– TOP 1: Light smoke
– TOP 2: Medium smoke
– TOP 3: Intensive smoke
First-class, uniform product quality in colour and taste
Low costs, economical consumption of smoking material
RATIO-TOP
OPEN SYSTEM WITH
REDUCED EXHAUST
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RATIO-FRICTION FRICTION SMOKE GENERATORS
Mild smoke aroma
Variable smoke intensities thanks to controllable smoke intervals
Integrated cleaner
low cost smoking material, beechwood beam, grade II,
80 x 80 x 800 mm or 120 x 120 x 1000 mm
Low consumption rate
low noise
Unparalleled service life of the friction wheel
Low power consumption of the motor
Includes a magazine for reserve beam
RATIO-FRICTION
CLOSED SYSTEM
RATIO-LIQUID LIQUID SMOKE GENERATOR
Low purchase costs
Top product quality: finest atomization thanks to the maintenance-free fuel
injection nozzle with highest availability developed in-house
Minimal consumption of liquid smoke concentrate
FESSMANN system: during the smoking process, the system works
as a hermetically closed system with a temperature control
RATIO-LIQUID
CLOSED SYSTEM
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TURBOMAT 1900 / 3000
QUALITY FROM TRADITION
The challenge faced by modern butcheries today is to produce large numbers of different products of the best and uniform quality as cost-efficiently as
possible. With a Turbomat from FESSMANN you can achieve both: quality
and productivity. The proven FESSMANN technology with multi-stage turbine
fan provides the finest smoking taste and accurately reproducible results.
Thanks to minimum weight-loss, fast process times and low maintenance and
operating cost, this universal system starts paying for itself in the shortest
period. The automatic control lets you have everything under control with low
deployment of manpower. And when your capacities increase, thanks to the
modular construction, the system also just grows with them. Model selection
and optional equipment features permit an optimal adaptation of the Turbomat
Universal System to your needs.
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TECHNICAL DATA
TURBOMAT1)
T 1900
DIMENSIONS
T 3000
1 TROLLEY
2 TROLLEYS
3 TROLLEYS
4 TROLLEYS
Base HP (W x D)
cm
126 x 109
151 x 127
151 x 237
151 x 347
151 x 457
Height with EL/ HP heating, corpus
cm
220
250
250
250
250
Height with gas / oil heating, corpus
cm
220
265
265
265
–
Minimum room height EL/ HP heating
cm
265
316
372
372
372
Recommended room height EL/ HP heating cm
275
333
397
397
397
Smoke-trolley dimensions (H x W xD)
cm
168 x 91 x 80
198 x 104 x 102
198 x 104 x 102
198 x 104 x 102
198 x 104 x 102
Max. stick length
cm
90
100
100
100
100
Connected load for HP heating
kW
–
37
74
111
148
Connected load for EL heating
kW
22.5
28.5
56.8
85.2
113.6
Connected load for gas heating
kW
25
37
74
111
–
Connected load for oil heating
kW
25
37
74
–
–
HEATING CAPACITIES
1)
These are summary specifications, and therefore not to be used for the
structural application. The complete dimensions and power connections
are to be taken from the respective latest dimensions sheets.
HP = high pressure-steam-heated, EL = electrically heated, oil = oil heated, gas = gas heated
ALL BENEFITS AT A GLANCE
Completely made of stainless steel with low
overall height
Automatic cleaning as standard
Different kinds of heating to select from
Optionally with climatic package for optimal maturing
Two to three-stage turbine fan for uniform smoking
climate in the entire system and the best smoking results
Standard equipment with one of our proven controls for
reproducible results
Modular construction for flexible extension of up to
8 trolleys. Each attachment with its own heating and
circulation for short production times with maximum
quality
SIDE VIEW T 3000
(WITH INDIVIDUAL UNITS)
Can be combined with all smoke generators of the
RATIO family
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ALL BENEFITS AT A GLANCE
Panel construction and central tender technology for highest air
and process capacities
Higher flexibility in the implementation of customized product requirements
thanks to infinitely variable fan speed
Higher system capacities thanks to faster process times = higher yield
Use of all well-known feed trolleys possible for the industrial application
Use of "extra long" feed trolleys and transport frames
Automatic door opener as standard
Automatic CIP cleaning systems as standard
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INDUSTRIAL SYSTEM Ti 3000
WE LEAVE WEIGHT LOSS TO OTHERS
With the Ti 3000 industrial system, you get over 1.5% more yield as compared to other systems
and that with proven FESSMANN quality as well. Completely made of stainless steel and produced
in panel construction, the Ti 3000 is universal and can be employed according to your specific requirements. The central unit technology also makes it flexible and cost saving including the highest
circulating air capacity with short process times.
Look forward to higher system capacities with decreasing weight-loss. A new fan technology with
central air circulation unit provides effective production processes and unparalleled fast smoking
with even faster drying times. All this with a very high degree of dryness, the best taste and the
highest quality. The Ti 3000 is an absolute multi-talent as far as the processing of your sausage,
meat and fish products is concerned. It can execute complete product manufacturing processes
with heating, drying, reddening, smoking, roasting, baking, hot-air refining and cooking as well as
optional shower cooling and cooling/dehumidification functions. The intelligent FPc 100 control is
intuitive and accurate to use and permits storage of 99 different product manufacturing programs
up to cold smoking processes.
VIEW OF Ti 3000
(WITH CENTRAL TENDER)
TECHNICAL DATA
INDUSTRIAL SYSTEM1)
Ti 3000
DIMENSIONS
3 TROLLEYS
4 TROLLEYS
5 TROLLEYS
6 TROLLEYS
Base (W x D)
cm
151 x 356
151 x 466
151 x 576
151 x 686
Height with HP heating
cm
421
421
421
421
Minimum room height HP heating
cm
450
450
450
450
Recommended room height HP heating
cm
500
500
500
500
Smoke-trolley dimensions (H x W x D)
cm
198 x 104 x 102
198 x 104 x 102
198 x 104 x 102
198 x 104 x 102
Max. stick length
cm
100
100
100
100
Connected load for HP heating
kW
135
180
225
270
Connected load for EL heating
kW
118.8
158.4
198
237.6
HEATING CAPACITIES
1)
These are summary specifications, and therefore not to be used for the
structural application. The complete dimensions and power connections
are to be taken from the respective latest dimensions sheets.
HP = high pressure-steam-heated, EL = electrically heated, oil = oil heated, gas = gas heated
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AUTOVENT
FOR PROFITABLE COOKING
AUTOVENT from FESSMANN is the optimal, patented system for high-quality
cooking processes with A1 product results. The system operates so accurately
that over-cooking and weight losses no longer occur.
The AUTOVENT system uses the natural dynamics of the low pressure steam
for air circulation and converts it into air speed and heat energy. It operates
completely without a circulation fan and thus has a maintenance-free operation.
This makes the AUTOVENT system very inexpensive to purchase and cheaper
to operate. It shortens the production times by approx. 10%, saves energy
thanks to the omission of air circulating fans and thus lowers your costs!
AUTOVENT WITH LOW
PRESSURE STEAM TECHNOLOGY
TECHNICAL DATA
AUTOVENT COOKING SYSTEMS1)
DIMENSIONS
AUTOVENT 3000
1 TROLLEY
2 TROLLEYS
3 TROLLEYS
4 TROLLEYS
5 TROLLEYS
6 TROLLEYS
Base (W x D)
cm
151 x 136
151 x 246
151 x 356
151 x 466
151 x 576
151 x 686
Unit height
cm
352
325
351
357
368
368
Minimum room height
cm
370
360
361
370
378
378
Recommended room height
cm
420
420
420
420
420
420
kW
70
140
210
280
350
420
CONNECTED LOADS
Connected load low
pressure cooking
1)
These are summary specifications, and therefore not to be used for the
structural application. The complete dimensions and power connections
are to be taken from the respective latest dimensions sheets.
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ROTATHERM CARAT
THE SECRET OF BAKING IS NOW REVEALED
Invaluable: uniform processing
In the RotathermCARAT® system, the entire feed trolley rotates slowly in the
horizontal hot-air or steam stream. The products are uniformly processed
from all sides. The spacing of the tiers can be freely selected in a raster of
75 mm.
Top-class: A1 quality products
Thanks to the optimal heat transfer and extremely high process temperatures,
perfect quality can be achieved during roasting, baking and cooking. This
means a decrease in the weight-loss of much more than 50% as compared
with conventional baking systems.
Money-saving: short production times
With shorter production times the RotathermCARAT® system ensures
enormous cost savings. For baking, the time is reduced by up to 25%. This
lowers your energy costs and processing time substantially!
TECHNICAL DATA
RotathermCARAT® 1)
DIMENSIONS
Base (W x D)
cm
198 x 187
Unit height
cm
251
Minimum room height
cm
311
Recommended room height
cm
311
Transportation dimensions (H x W x D) cm
311 x 218 x 189
Installation height (tilting dimension) cm
330
Installation height (H x W x D)
cm
198 x 103 x 104
ROTATHERM CARAT
TOP VIEW
HEATING CAPACITY
1)
Connected load for EL heating
kW
88
Connected load for gas heating
kW
80
+ EL additional heating
kW
24
Connected load for oil heating
kW
80
+ EL additional heating
kW
24
Connected load low
pressure cooking
kW
45
These are summary specifications, and therefore not to be used for the
structural application. The complete dimensions and power connections
are to be taken from the respective latest dimensions sheets.
EL = electrically heated, oil = oil heated, gas = gas heated
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ALL BENEFITS AT A GLANCE
Still faster cooling to packing temperature:
up to 75% shorter cooling times
Extended shelf-life thanks to the fastest
crossing of the critical temperature range for
microbial growth
Less loss in weight
Low water consumption
Less area requirement for showering spots and
refrigerating chambers
Additional steam cooking possible
Available with optional saltwater circulation
For processes with just-in-time production
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INTENSIVE COOLING SYSTEMS
COOLING FOR AN IMPROVED SHELF-LIFE
With FESSMANN intensive cooling, you can cool all cooked products with
water, air or brine or a combination thereof to packaging temperature in a
single work cycle.
°C
INTENSIVE COOLING
(NATURAL GUT CALIBRE 32)
70
60
SHOWERS
50
40
Showers with
intensive cooling
30
20
10
10
20
30
40
Final core temperature 20°C after 18 min
Final core temperature 8°C after 35 min
50
60
70
80
min
Final core temperature 20°C
after 60 min
SCHEMATIC DIAGRAM IK 3000
(LEFT)
SCHEMATIC DIAGRAM IKi 3000
(RIGHT)
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SEMI-CONTINUOUS SYSTEM TF AND TFi 3000
A SUCCESSFUL MIXTURE
The TF and TFi 3000 offer an economical combination of smoking, cooking and
chilling. Automated procedures increase the production capacity and lower
the operating costs. The freshly filled smoke trolley is driven manually to the
first storage place of the front chamber and pulled from there with the pneumatic transport system to the centre of the heating chamber. Subsequently, the
process control is activated and the specified processing routine is started. The
heating process now runs fully automatically. When this phase is completed, the
trolley is automatically carried into the cooling zone. The products are immediately cooled down to the packaging temperature according to their condition and
the intended packaging using continuous shower, intermittent shower and cool
air in a single just-in-time process. At the same time, the next batch can already
be processed in the scalding and smoking chamber.
Scalding and smoking chamber Ti 3000
Cooling zone IKi 3000
PRODUCTION STAGES OF TFi 3000
(WITH CENTRAL UNIT)
ALL BENEFITS AT A GLANCE
Production just-in-time, controllable process with
reproducible processing sequence
Substantially lower germ formation and contamination −
thereby longer shelf-life
Automatic transport system in the system
Production, packaging and delivery within the
shortest time
Lower requirement of refrigerating chamber capacities
Higher loading capacity as compared to comparable floor
mounted conveyor systems thanks to low construction
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ALL BENEFITS AT A GLANCE
Substantial energy saving
Unsurpassed hygiene, separate product entry
and exit (HACCP)
Ability to use all smoking systems
Only 25% of the space requirement of
batch processing systems − for maximum
returns on smallest area
Fully automatic control and monitoring of the
production processes
The temperature and humidity in each
processing zone can be regulated separately
using the control
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Outstanding quality results as regards colour
and taste with minimum weight-loss as
compared to batch processing systems
Option for the automation of loading and
unloading
Modular construction: Expansion of the system
capacity possible
Short assembly and commissioning times
CONTINUOUS SYSTEMS TF 4000
CONTINUOUS PROGRESS
The multi-functional TF 4000 from FESSMANN combines the basic elements of
meat product manufacturing: smoking, scalding, chilling. In the TF 4000 continuous transfer system, the products pass through the drying, smoking, cooking, shower and chilling areas in several heat treatment and cooling sections
and leave the system in a condition suitable for packaging. With all FESSMANN
systems, the heat treatment sections can be flexibly used for drying, smoking
and scalding. The cooling sections can be equipped with showers, air cooling
equipment, circulation fans or a brine shower.
With these systems, the workflows can be positively rationalised in operation,
and production costs can be lowered to a minimum. Work procedures such as
hanging, emptying or the transportation of feed trolleys and their cleaning can
be completely omitted. In principle, personnel are now required only for feeding and controlling the production workflow.
THE TEMPERATURE
AND HUMIDITY CAN BE
REGULATED SEPARATELY
FOR EVERY PART OF THE
CHAMBER
Drying
Smoking
Heat treatment sections
Cooking
Showers
Cooling
Cooling sections
PRODUCTION STAGES OF A TF 4000
(WITH INDIVIDUAL UNITS)
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AIR CONDITIONING SYSTEMS
FAVOURABLE CLIMATE
The sophisticated technology of FESSMANN air conditioning systems avoid
events and are reliable. Even under extreme climatic conditions, the
heating and cooling system ensure that temperature and humidity values
are accurately maintained. This lets you regulate the weight-loss and the degree of maturity of your products accurately. Your manufacturing processes
become accurately reproducible.
FESSMANN offers three types of systems: with and without smoke generators
for safe conditioning of meat and sausage products:
Climatic and maturing systems (KEW)
Systems for the production of naturally matured and smoked raw and cured
sausages as well as for raw pickled products. Depending upon the requirements and size of operation, the climatic maturing systems are produced in
various sizes ranging from single trolley manual systems to large industrial
systems. The FPc 100 control is very easy to operate and lays stress on process
safety.
Climatic post-maturing systems (KNR)
Systems, which are suitable for the post-maturing, post-drying and storage of
raw sausages, air-dried or smoked products and can be implemented in sizes
suitable for manual production and large industry. And with the easy to operate
DP 05 control, all processes can be centrally controlled and regulated.
Climatic storage rooms:
For long-term storage
ALL BENEFITS AT A GLANCE
Construction can be adapted to the requirements: Stainless steel
panels, insulation panels or installation in existing rooms
Flexibly adapts to existing rooms
Variable application of all smoke generators of the RATIO family
The proven ventilation principle is very energy-efficient and provides
reliable and uniform air conditioning and maturing of the entire batch
Air speed in the air-conditioning system can be customised for the
product independently of the speed
Optimal cooling and heating capacities for high dehumidification
performance of the product during fermentation
Automatic CIP cleaning systems as standard for KEW
Controller FPc 100 or DP 05 for regulated processes and
reproducible results
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ALL BENEFITS OF FPc 100 AT A GLANCE
Clearly arranged display with permanent display of the most important
parameters such as temperatures, humidity, time etc.
Anyone can start the product programs easily
Quick and easy change of product programs even during operation
for individual programs
Intuitively guided product program creation for easiest operation
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FPc 100 / ProCES CONTROL
EVERYTHING UNDER CONTROL WITH THE FPc 100
Use our know-how of over 80 years in sausage production and take time to
optimise your processes in the best possible way. The intuitive program
guide of the FPc 100 makes it possible for you to correctly program individual
programming steps without previous technical knowledge. The clearly
positioned display shows you all important data such as product program
duration and remaining time of the program, temperatures and humidity as
well as the status of the program used. The colour highlighted display makes
it easy for you to compare the set and actual values. The FPc 100 adapts
flexibly to your requirements: Thus, programmes can start even at night or
on weekend using the pre-selected times and the default program can be
customised as regards, e.g. colour or aroma.
The user friendliness, the ease of programming and high process safety
distinguish the FPc 100 in application for all thermal processes.
IMPROVE PRODUCTION AND SECURE QUALITY
The ProCES software documents, monitors and optimises all processes in the
meat, sausage, poultry and fish production.
HISTORY
THE RANGE OF SERVICES OF ProCES
AT A GLANCE:
Process monitoring
Process documentation
DATATRANSFER
Verification
MONITORING
Batch logging
Production optimisation
Program maintenance
Error management
System monitoring
EDITOR
Integration into EN ISO 9000 - 9004
Networks up to 32 systems, cooling and
storage rooms per PC
Minimum requirements for computer standard
commercially available PC (starting from
Pentium Processor)
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DETAILS
A CLOSER LOOK IS WORTH ITS WHILE
It is often the little things, which make the difference. Therefore we not only
ensure that the entire system functions optimally, but give particular attention to details. With careful processing and thoroughly thought out, partially
patented detailed solutions, we make the work easier for you. So you can enjoy
your FESSMANN system for a long time to come.
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1 The automatic door opener
is supplied as a standard
accessory with the Ti 3000.
1
2 The FESSMANN lifting hinge
ensures that neither smoke
nor steam can come out of
the system door and the door
gasket is protected.
The robust, skid-proof floor
plate can be fitted in existing
factory buildings and permits
hermetic sealing.
3
2
3
4
The pneumatic transport
system with higher loading
capacity provides smooth
operational workflow with
maximum loading of the trolley.
4
The innovative air
circulation provides fast
smoking and drying times
and can be customised
for all product types.
5
5
6 The CIP cleaning provides
reliable cleanness and hygiene.
The door-lock system made
of stainless steel for optimal
sealing prevents energy-loss.
7
6
7
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Subject to technical changes.
FESSMANN GmbH und Co KG
Postfach 360, D-71351 Winnenden, Telefon +49 (0)7195 701-0, Fax +49 (0)7195 701-105, [email protected], www.fessmann.de
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