food processing innovation
Transcription
food processing innovation
www.dcnorris.com food processing innovation Introduction For over 40 years DCN has been at the heart of the food processing industry. We provide our customers with flexible, efficient and innovative solutions to meet the full range of food processing needs - from stand alone items to fully automated processing lines. As acknowledged market leaders, we are continually looking ahead, planning to meet the needs of the future through active research and development. FROM DESIGN THROUGH TO INSTALLATION Customer satisfaction is our mission; we involve our customers at every stage of manufacture working closely with you from design through to installation to ensure that our solutions work. Using stateof-the-art 3D modelling design software, we can create an on-screen simulation of a new plant, enabling a walk through before it’s even built. DCN has over 60,000 square feet of manufacturing space with overhead cranes and the very latest CNC manufacturing and laser cutting machines. All our equipment is manufactured in-house at our premises in the UK by fully trained engineers, and meets our exceptionally high standards. We ensure that our equipment is ideally suited for the application, meets all HACCP regulations, and complies with a customer’s own quality assurance and product traceability systems, integrating with existing equipment as necessary. The result is a system that will deliver many years of reliable, cost-effective service backed by superb aftersales support. Our experienced engineers draw upon a comprehensive spares stock to ensure down time is kept to an absolute minimum. PRODUCT DEVELOPMENT KITCHEN Testing and product development is crucial to the success of your business, and to demonstrate our commitment to you DCN has invested heavily in a test kitchen facility. This features stand-alone equipment and a full production line as well as a kitchen/leisure area which can be used for tasting, training and discussion. Here we can rigorously test and trial customer products in a food factory environment. With our experienced team we are able to assist with recipe development and give customers the opportunity to fully assess equipment before they decide to order. 03 www.dcnorris.com DCN are specialists in manufacturing high quality food processing and packaging machinery. Our range of equipment is second to none, and can BESPOKE EQUIPMENT produce a wide range of convenience foods. These include soups, sauces, pasta, rice, vegetables, fish, fruit and desserts. MANUFACTURED IN THE UK We work together with our customers on a day-to-day basis designing equipment to suit their individual needs. We are continually developing RELIABLE COST EFFECTIVE SOLUTIONS ground-breaking innovations, and take great pride in sharing our knowledge throughout the world to meet the food needs of the future. TEST KITCHEN FOR RECIPE DEVELOPMENT THE POSSIBILITIES ARE ENDLESS! DCN has manufactured some of the largest food processing plants around 3D MODELLING DESIGN SOFTWARE the world, including projects in Europe, USA, Russia, Middle East, China, Brazil, South Africa and Australia. MEETS ALL FOOD SAFETY REGULATIONS • Concepts • Bespoke Equipment • Turnkey Projects AFTER SALES SUPPORT • Product Development & Trials • Design • Project Management • Manufacturing • Software & Control • Installation WORLDWIDE EXPERIENCE AWARD WINNING COMPANY • Commissioning of Equipment CE COMPLIANT • Service • Spares High Performance Processing Equipment & Expertise For The Food Industry: • • • • • • • • • • • • • 04 Food Manufacturers Restaurant Chains Military Foodservice Catering Companies Hotel Foodservice Institutional Foodservice Supermarkets Schools Foodservice Hospital Foodservice Speciality Food Producers University Foodservice Casinos/Resorts Olympics / World Cup / International Events 05 www.dcnorris.com DCN COOK CHILL BENEFITSS Skeleton Conveyor Recipe Manager Control System Savings of 5-10% are possible from increased meat yields, control of ingredient inventory and use of standard recipes reducing food waste Tumble Chiller Production can be scheduled to meet sell-by-date requirements, allowing advance ordering or just-in-time delivery of meals Builds up a stock of quality food for future use Consistent quality of finished product by the use of controlled production techniques System ideally suited for HACCP controls Both large and small particulates can be processed without damage All products are packaged at pasteurisation temperatures Hygiene – no direct human or utensil contact during the cooking or the packaging Saves on labour costs Food safety Production can be centralised for operations where food is distributed to off-site locations Pump Fill Station Steam Jacketed Cooking Kettles Operator Platform Tote Bin Hoist DCN Cook-Chill System has become an industry benchmark delivering cooked and cooled food of the highest quality. Food retains the taste, texture and aroma of freshly prepared ingredients with a shelf life of up to 45 days. The system is based on specially designed cooking, packaging and chilling equipment capable of processing both small and large volumes of ingredients with the minimum number of operators. With the Cook-Chill System you can make up to 250,000 meals a day or more. User friendly control systems monitor production and product status at all stages of the cook-chill process in order to ensure delivery of a reliable, safe, refrigerated product. Pumpable Kettle Cooked Food Types Ready Meals HOW DOES COOK-CHILL WORK? COOK CHILL SYSTEM KETTLE COOKED FOODS AND COOK TANK FOODS Soups / Chowders Cook-Chill follows a logical fully documented production cycle, and delivers a range of important benefits. The key to safe extended storage of foods is to heat your products to pasteurisation temperature and then rapidly chill through the ‘danger zone’ to retard bacterial growth. This is how we do it: Ethnic Cuisines 1: Cooking: Using any of the range of DCN Steam Jacketed Kettles or Sous Vide Cook Tanks (dependent on product) which can be fully recipe driven or manually controlled. The system ensures that all times, temperatures and quality parameters are constantly monitored. Dressings & Dips 2: Packaging: When the cooking cycle is complete, a specially designed DCN Pump Fill Station or fully automated Form Fill Seal Machine transfers food at 85-95°C from low to high-risk areas – this avoids particulate damage, and allows metered delivery into specially formulated laminated bags. The bags can be filled with different volumes subject to requirements and are then sealed, dated and labelled. Beef / Pork Joints / Ribs 3: Chill: Bags are conveyed into a DCN Tumble Chiller, they are then gently tumbled in chilled water to rapidly drop the temperature from 95°C to below 5°C in under an hour (product dependent), with cooling times and temperatures fully logged. Sealed casings are then placed in chilled storage at 1°C and can be stored for up to 45 days. Lamb, Goat & Veal Cuts Sauces / Gravies Pie Fillings Casseroles Dessert Products - custard / chocolate Cook Tank - Sous Vide Cooking Chicken Breasts Turkey Breasts Ham Joints Fish Duck / Pheasant / Quail 4: Heating and Serving: If the product is required for immediate consumption (e.g restaurant/hotel), the bags can be transported to various locations, reheated and served and will retain the quality and taste of a fresh meal. If destined for a supermarket shelf, bags will be emptied into a depositor and product portioned on a filling line into packaging such as Ready Meal trays. It can then be transported to the outlet and is ready for presentation to the consumer. 06 07 www.dcnorris.com JET COOK SYSTEM (patent granted) We have developed a new system incorporating all the best features of DCN cooking technology to cook and heat at incredible speeds. This innovation can be installed into new kettles / Cook-Chill Systems or retro-fitted into existing equipment. Jet Cook Nozzle steam injection system looks like a jet engine and performs in the same way; it heats and pumps drawing product through the internal jet stream. Products are then cooked and heated at incredible speed atomising steam to extract the maximum energy. Jet Cook Globe Head agitation system uses the same principle except steam is drawn externally around the outside of the head and draws product through it without any clogging, making it ideal for vegetables, pasta and I.Q.F Products. Jet Cook Station Following on from the success of our Jet Cook System, we have developed a Jet Cook Station which heats and cooks directly into existing transfer vessels or tanks. This enables customers to improve their production times and cook at incredible speeds whilst utilising existing equipment. KETTLE SYSTEMS DCN have a number of patents on their kettle features including: DCN cooking equipment is second to none, ideal for cooking and blending the widest variety of products including soups, pie fillings, sauces, vegetables, fish, fruit and desserts. • • • Stainless steel, scraped surface steam jacketed kettles are available in a wide range of sizes from 50 to 5000 litres. These can form part of the DCN Cook-Chill System or be used as independent units. With bespoke designs to suit each customers individual requirements, they are available with a huge range of features and accessories. Kettles can be integrated into existing processes by utilising the range of outlet options that can be fitted to the base of the kettle. These include manual or automatic ball valves and EHEDG certified air operated flush fitting drop down valves. Caramelising system for onions and meat In-vessel homogenisers Shovel scraper blades designed to lift and fold product and are clean-in-place (CIP) - a method of cleaning without disassembly Our kettles are designed using the one piece pressing method to ensure even heat distribution across the cooking area resulting in rapid heat up times. Kettles are available for very high temperature cooking with steam pressure up to 10 bar. • • • • Fully aseptic kettles are available throughout the size range Kettles for atmospheric, vacuum or pressure cooking are also available Fully fabricated kettle systems are installed on our own, specially designed support gantry and flooring using the DCN Stardeck Treadplate Designed and tested to PD5500 CAT 3 / ASME Section VIII Div 1 or equivalent European or worldwide codes BENEFITS Fast cooking times • Uses approximately half the energy of standard cooking methods resulting in huge savings Emulsification and powder entrainment - less wastage occurs as starches are activated without any damage. Oils, purees and powders can be drawn in using the vacuum created by the Jet Cook • Built-in homogeniser for pureeing Reduced cleaning times • Odour extraction unit High quality product • Caramelisation system for cooking onions & searing meats Elimination of burn-on • Inclined agitator for keeping product in suspension Great taste, texture, appearance • Recipe management Quiet in Operation We offer fourteen different agitator combinations in either fixed or tilted fittings. These enable a gentle lifting, folding or heavy duty contra-rotating of ingredients. The variety of off the shelf agitators allows fast precise customisation. Application specific agitators are also available. DCN are also agents for Joni Foodline manufacturers of Electric Kettles and Bratt Pans. 08 09 www.dcnorris.com WOK STYLE BRAISING PAN High Temperature Braising Pan used for frying/ cooking/simmering – ideal for small batch ethnic/ready meals products. The DCN Model 2700 Wok is a versatile, high performance steam jacketed braising pan, capable of reaching high temperatures in half the time of conventional kettles. • • • • • • • • All stainless steel construction Tilts both ways (high/ low risk) Programmable agitation Variable speed Temperature logging (optional) 150 litre capacity Easy remove agitator Stainless steel or plastic blades COMBINATION COOK/ CHILL EQUIPMENT Traditional Steam Heated Bratt Pans are also available Hoist Operated Vessel & Basket Cook Quench Chill DCN offer combination cook/chill equipment for those food manufacturers who require a compact two-in-one design. COOK QUENCH CHILL MACHINE ROOT VEGETABLE COOKER Continuous Cooking System for mash potato and root vegetables such as carrots, parsnips and swede. Designed to produce up to 2 tons per hour continuously. A typical system may include the following items however the process can be adapted to suit requirements. • • • • • • • • • • In-feed auger conveyor Vegetable auger cooker Product chute Solia style shredder Ribbon blenders Milk, butter and hot water system Access platforms Load cells Recipe system control Remote monitoring The DCN Cook Quench Chill machine is designed to cook rice, vegetable and pasta products in tipping baskets using three stages. We have several versions available to suit each customer, including Continuous Automatic with Tipping Baskets and a Hoist Operated Vessel & Basket System. The initial stage of the process heats and cooks the product in water in the first basket/tank. The product is then transferred to the second quench tank containing cold (ambient) water to take the bulk heat out of the product, stop the cooking and refresh the product. The final tank contains chilled water and completes the cooling process. The baskets containing the product can lift and lower in the water to give a gentle agitation in each of the three stages. The final exit of product is usually into a de-watering vibrating conveyor. Models are heated either by direct steam injection or steam jacket and have a water overflow rim incorporated into the water tanks to prevent spillage onto the production floor and cross contamination between high and low risk areas. It can also be used to remove starch from the product. A new unique Wave Pump Agitation system is available, which provides the perfect agitation for 'long' pastas. We offer both Linear and Rotary Cook Quench Chill Systems, which follow the same cooking process as the original versions but have a smaller footprint/design to suit a more compressed factory production/area. Continuous automatic with tipping basket 10 • • • • • • • • Available as 2,3,4 or 5 basket machines Basket capacity sizes - 75, 200 or 300 litre Glycol chillers Easy to use HMI - stores recipes Loading/ unloading by tote bin lift or conveyor Food safe and hygienic components Distinct low risk/ high care division Unique water heating system on fully auto machines 11 www.dcnorris.com DA COOLER DCN cooling systems offer process innovation and excellence with minimum batch times. For processes requiring large batch cooling in stand-alone vessels, DCN offer an extensive range of static DA Coolers with unique, scraped surface agitators. Their large surface area to product ratio allows rapid cooling times, without damage to particulates or adverse effect on quality or taste. Product is gently transferred to the Coolers using our vacuum transfer system and the cooling cycle is closely monitored to eliminate the risk of thermal shock and separation. Once cooled, product can then be over-pressured with sterile air into transfer vessels before being taken to the filling line for depositing, avoiding product damage and keeping losses to a minimum. TUMBLE CHILLER As part of the DCN Cook-Chill system, filled bags of kettle-cooked product are conveyed into a purpose built rotary tumble chiller. This process reduces the temperature of cooked food to below 4°C in under an hour (product dependent), with cooling times and temperatures fully logged. Sealed casings are then placed in chilled storage at 1°C and can be stored for up to 45 days. COOK TANK TUMBLE CHILLER The CTTC was originally designed for outlets such as schools and care homes who are required to produce a steady supply of meals which can be re-heated and served. It gave them the ability to slow cook solid items (beef/chicken/ fish) overnight unattended and then rapidly cool their liquid products (soups/ sauces) during the day. The machine has an internal drum that doubles up to be used stationary for Cook Tank mode and rotating for Tumble Chiller mode. This Cook-Chill method ensures that pasteurisation of the product is achieved and therefore delivers the benefit of an extended shelf life. Whilst in Cook Tank mode, solid items are cooked sous vide style in a water bath. Products are vacuum packaged in specially formulated plastic bags and then placed in the drum to be cooked over a long period of time at a low temperature. After cooking, the hot water is replaced with ambient water that is then chilled and evenly cools the product to below 4°C. The sous vide method ensures fresh tasting and extremely tender foods without losing any of the original colour, flavour or texture. Yields are also vastly improved as shrinkage is minimised. During Tumble Chiller mode, the internal drum holds hot filled bags of kettlecooked product which are gently rotated in chilled water. This delivers all the benefits of our larger scale Tumble Chiller. (see page 13) 12 COOLING • Savings of 5-10% from increased meat yields, control of ingredient inventory and use of standard recipes • Increased shelf life • Retain product integrity, nutrients and vitamins • Enhances meat texture, tenderness, colour and aroma • Consistent quality of the finished product by the use of controlled production techniques • Preparation of multiple portions in a single batch • Unattended overnight cooking and cooling • Accurate temperature control • Simplified storage If the product is required for immediate consumption (e.g restaurant/hotel) the bags can be transported to various locations, reheated and served and will retain the quality and taste of a fresh meal. If destined for a supermarket shelf, bags will be emptied into a depositor and product portioned on a filling line into packaging such as Ready Meal trays. It can then be transported to the outlet and is ready for presentation to the consumer. • • • • • • • • Available in 300, 500, 750 and 1000 litre capacities All stainless steel design Microprocessor control Large or small batch sizes Easy to use HMI E-terminal data logging (optional) Cleaning cycle Surge tank for water recovery (optional) • • • • • • Standard batch sizes range from 300 to 1000 litres Vessel is capable of taking a vacuum to allow filling of product without the need for transfer pumps Insulated with a conical bottom and stainless steel cladding Vertical product zone with scraping surface type, variable speed agitator fitted with replaceable food approved plastic blades Fixed lid design with manway for incorporating into CIP cleaning systems, or: Full diameter, counter balanced, domed top lid for complete access to product zone (optional) VACUUM COOLING A DCN Vacuum Cooling System is amongst the fastest and most efficient methods of sauce/product cooling available today. Cooling options include vacuum, chilled water, glycol and pumped/scraped heat exchangers. Manual, semi-automatic or fully automated control is offered. 13 15 www.dcnorris.com SOFTWARE CONTROL SYSTEMS Excellent kettle control is essential if both the equipment and processing line are to maintain optimum efficiency. DCN design all software systems in–house using the latest technologies and up–to–date software. A full system analysis and close consultation with the client is conducted to ensure that they get the exact control and support that is required. Our software expertise doesn't end at system control. We have also produced our own Data-logging and Recipe Management software. RECIPE MANAGER Recipe Manager Software package provides a simple to use and flexible method of controlling a recipe driven production process. Working closely with our customers to understand and identify what they require, we have developed the very best system in the market. The user friendly system allows customers to create ingredient listings, step–by–step procedural recipes and user access security with all recipes stored to a relational database. The system maintains full records of kettle yields, allowing bar code identification from preparation through to packaging, and ensures all HACCP controls are met. • • • • 14 Temperatures, cook times and motor speeds are automatically controlled by the recipe Visual display of plant layout and fault notification Records all weights, temperatures, sequences, deviations and errors Creates batch reports in text and graph formats VIRTUAL CHART RECORDER • • • Piped additions are batched in automatically and verified by either load cell or flow meter Touch screen for operator use DCN Software Engineers can log in remotely utilising a local broadband connection and make any updates to your system or assist with queries DCN Virtual Chart Recorder software has been designed to record in real time data produced by your system. This allows customers to log information relating to temperature changes in any cooking or cooling process. The software stores this data to a database ready for you to quickly produce historic cycle process records and trends to your customers. • • • • • • • • Data logging can be seen running in real time Relational database Date Time (start, finish, total) Batch number numerical Operator ID Products ID Reports generated and printed against selected database records 15 www.dcnorris.com ADDITIONAL FOOD PROCESSING EQUIPMENT DCN can supply and install all the equipment needed to create an efficient food processing factory including: • • • • • • • • • Can Openers – stand alone, semi – and fully automated, allowing a throughput from 100 to 800 cans per hour Can Crushers Conveyor Systems – belt or fully automated slatband A comprehensive range of mixers, from small pilot plant cutter/mixers to large industrial models. They can slice, mix and transfer ingredients, ideal for processing products such as sauces, preserves or dips. They feature speed control, are vacuum steam jacketed and also offer product unloading. Accessories include in-line homogenisers and a top-mounted version Jacketed or non-jacketed paddle mixers for gentle blending of volumes from 300 to 3000 litres Ribbon Blenders Star Deck Tread Plate for Gantries Depositors and Form Fill Seal Machines Retorts All items in our preparation range can be load cell mounted, with metered ingredient addition to provide consistent processed batches. VACUUM PRESSURE TRANSFER SYSTEM DCN were the first to introduce the Vacuum Pressure Transfer System to the food industry to replace the traditional use of pumps. This method uses the pressure vacuum to gently transfer products from the cooking stage to depositing. Product quality is maintained as it removes the problem of product breakdown and losses which occurs when pumps are used. HOLDING TANKS/ TRANSFER VESSELS We manufacture a large range of transfer tanks utilising the vacuum pressure transfer system as well as standard storage/holding vessels (Daleks). Both can be provided with either fixed legs for forklift transportation, or with wheels for in-factory operation. A wide variety of accessories are available, all designed for CIP operation if required. Tanks and vessels are ideal for products such as milk, yoghurt, sauces, fruit purees and dips and are available from 100 to 3000 litres. ACCESSORIES • 16 • • • • • • • • Portable agitators On-board heaters Fully opening lids Temperature indicators Fully insulated equipment / or single skin Heating or cooling jackets Manways Vacuum or pressure Stackable 17 www.dcnorris.com Case Studies & Testimonials Béchamel Sauce Goal: Improve the emulsification of the sauce and reduce the noise of the customers current system. Method: All ingredients added together and cooked using the patented Jet Cook Nozzle. Result: 500kg of sauce reached 95°C in 8 minutes greatly reducing production times. The customer is achieving a far better emulsion with the béchamel sauce and therefore improved taste and texture. Vibration and noise was reduced dramatically and the customer replaced his existing equipment with a Jet Cook System. AFTER SALES SERVICE ENGINEERS & SPARES DCN is committed to providing excellence − not only in the products we sell − but also in our after sales service. It is our aim to continue to improve upon our levels of product quality and customer service to exceed customer expectations. Our service engineers are friendly, courteous and have a high degree of expertise and knowledge on all equipment that we supply. They can visit your site to assist with any technical issues, advise on the best parts for your equipment and carry out any required installation. They are backed up by a comprehensive stock of spare parts which are available for immediate dispatch to anywhere in the world. Chicken Korma HEALTH & SAFETY Goal: Improve taste and texture of Korma produced by Customers are guaranteed a dedicated and experienced support team to ensure that they get the highest quality performance from any DCN equipment once purchased. With expert technical support available in-house, DCN can respond quickly to any faults or problems you may have with your equipment. We are committed to maintaining your equipment at optimum efficiency, thus reducing the risk of process downtime and increasing productivity. All our engineers are trained in Health and Safety and will arrive on-site ready to face the food and drink safety issues that go with our industry sector. All DCN engineers are issued with a passport photo card identifying them and the specific areas they have been trained in. All site welders are Zurich coded welders and all of our electricians are certified and up–to–date with I.E.E regulations. a leading Indian Curry Manufacturer. Method: The sauce was cooked using the patented Jet Cook System and cooling was achieved using glycol through a jacketed vessel. Result: Cooking and cooling times were exceptionally faster when compared with those recorded using standard equipment. Results collated from a taste test showed that the cooling process eliminated fat crystallisation in the korma, resulting in enhanced taste and texture of the final product. The trial showed a massive energy saving compared with conventional cooking systems. Cheese Sauce Goal: To reduce overall cooking batch times, minimise the level of ‘burn-on’ and maximise product consistency without compromising the quality of flavour. Method: Using the DCN Cook-Chill method, the cheese sauce was cooked in a DCN Steam Jacketed Kettle. Once the ingredients were added, the kettle was brought up to temperature using the Jet Cook. The product was then homogenised to create a smooth texture. Once ready, we transferred the sauce into CookChill bags using the Pump Fill Station. They were then cooled in a DCN Tumble Chiller. Result: The sauce was cooked in a third of the normal time. Once emptied, the kettle revealed absolutely no burn-on. 18 Bighams chose to work with DCN for the quality of the equipment and because of the very knowledgeable team with a “can do” attitude. The project went very smoothly from trial, through specification, order, delivery, commissioning and training. We were working on particular tight deadlines and were pleasantly surprised by the speed and the quality of the system developed for us. Boris Pucelle – Operations Director, Bighams I worked on a large project together with DCN to bring the Cook-Chill concept of food production to Russia to supply meals to schools, universities and the armed forces. I would have no hesitation in recommending DCN for supply of similar projects, their professionalism, knowledge and enthusiasm for their business is refreshing and they provide the necessary information and assistance to ensure client satisfaction. Duncan Black - Project Consultant It has been a real pleasure working with DCN. They have a great service-oriented team and innovative equipment that has allowed us to make unique and delicious products. We now have a customized, state-of-the art cooking and cooling system that has allowed us to successfully launch a new range of products into the UK. Paul Schiefer - Operations Director, Amy’s Kitchen UK Bar and Restaurant foods have worked with DCN as their preferred cooking and cooling vessel supplier for over 13 years. As times have changed DCN have modified and adapted their equipment to offer the latest technologies and advances. Technical advice and help is readily available and spares holding and supply very good. In short the choice of DCN as a preferred supplier has proved to be a good one, and one that I am sure will continue for many years to come. Tim Lewis - Engineering Manager, Bar and Restaurant Foods Ltd I am happy to say that every project we have embarked on with DCN has been a success. The latest project was the installation of a Cook Quench Chill System, which was delivered to specification and on time. The commissioning was also provided expertly at a time which suited our operation. This is all something that we have come to expect from DCN. Richard Cooper - CEO, In2food We have been very impressed with DCN's performance and flexibility from the outset with our very demanding expansion project which has now been completed on time and to budget. The cook teams are very impressed with the new kettle system which they feel is an immense improvement on the current kettles. Andrew Gordon – Projects Director, British Pepper and Spice 19 www.dcnorris.com D C Norris & Company Ltd Industrial Estate, Sand Road, Great Gransden, Nr Sandy, Bedfordshire, SG19 3AH United Kingdom T: +44 (0) 1767 677 515 F: +44 (0) 1767 677 851 E: [email protected]