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THERMO-COMPOUND-INSTALLATION

THERMO-COMPOUND-INSTALLATION. Flexible solution. Intensive Cooling Installation Shower, cool, and dry. AEROMAT Hot-Smoking and Cooking Installation Redden, dry, smoke, cook and boil. Door between hot-smoking and cooling section. Details – Material. 82 mm chamber elements

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THERMO-COMPOUND-INSTALLATION

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  1. THERMO-COMPOUND-INSTALLATION

  2. Flexible solution Intensive CoolingInstallation Shower, cool, and dry AEROMATHot-Smoking and Cooking Installation Redden, dry, smoke, cook and boil Door between hot-smoking and cooling section

  3. Details – Material 82 mm chamber elements PU foam isolation Improved heat conductance values

  4. Details – Material • High quality stainless steel 1.4301 (AISI 304 ) and 1.4571 (AISI 316 TI ) • No hygienical weak spots, because transition to the wall has been raised by 60 mm (tray – shaped) • Easy dismantling to be relocated

  5. Details – Isolation PU foam (containing no CFCs) gives the sandwich – style design a high degree of stability and rigidity. Heat conductivity values for the walls PU foam, thickness 80 mm 0,225 kcal/m²h°C ( 0,262 W/m²K ) VEMAG Mineral wool , thickness 80 mm 0,425 kcal/m²h°C ( 0,494 W/m²K ) others Mineral wool, thickness 60 mm 0,567 kcal/m²h°C ( 0,659 W/m²K ) others A lower heat conductivity signifies a lower loss of heat, i.e. lower energy costs.

  6. Details – Isolation Isolation by means of mineral wool is problematic: Danger of condensation due to high temperature differen-ces between inside of chamber and ambient temperature. The damp mineral wool goes down, isolation decreases about 60%. Heat conductivity is worse. Lack of isolation = loss of energy The special VEMAG isolation with PU-foam containing no CFCs guarantees a stable, long-lasting thermal transfer.

  7. Details – Automatic CIP-Cleaning CIP Cleaning pipes CIP Cleaningwith foam

  8. Details – Heat exchanger • Compact flat tube air heater made of stainless steel 1.4301 (AISI 304) • Optimized air flow (flat design) • Heat-up times minimize by up to 10% • Reduction of fan power, because of slighter pressure loss • Economical energy demand • Optimum cleaning in the hot-smoking section due to lack of fins • Result: consistant product quality • minimum loss of weight

  9. Details – Air flow 1. Smoke chamber 2. Injection channels 3. Suction channel 4. Fan 5. Change air flap 6. Heat exchanger 7. Exhaust air fan 8. Exhaust air flap 9. Exhaust air 10. Steam connection 6 bar 11. Fresh air 12. Fresh air flap 13. Condensate connection 14. Smoke Generator Smoke flap

  10. Details – Air change flap Irrespective of size of the chamber or quantity of trolleys, the central air conditioning unit produces the desired condition. By our air change flap, air is conducted through two injection channels into the chamber. Due to a continuous shift of air flow, an optimum vertical and horizontal air circulation is guaranteed. Thus we have an exact constancy.

  11. Details – Air change flap Right Middle Left 30% 70% 50% 50% 70% 30%

  12. Details – Air change flap • Air flow without air change flap. • Left and right side of the chamber is fed with an air quantity of 50% of total volume. There is a higher air flow in the middle of the trolley. • Disadvantage: • - Uneven drying • - > drying in the middle • - > weight loss • > drying time= quality loss

  13. Details – Advantages of the air change flap • A fast and constant drying assures: • Highest quality even for sensitive products • No colour differences • Constant core temperatures • Shorter drying times, i.e. lower weight loss • Shorter process times, i.e. higher product flow

  14. Transport system As soon as the heat treatment is complete, trolleys are automatically transported to the intensive cooling section. Controlled, safe and without time loss. With standard and popular load, lifting cylinders are driven with compressed air.

  15. Transport system • Example: Roller conveyor for ham • - Different automatic transport devices • - Use of floor or rail system • Automatic transport

  16. Transport system Precise engineering. Design according to hygienical demand; safe operating procedures. Pusher Interior

  17. Transport system • Summary of advantages • Batch and unloading can be realized by one person only • Smooth transport • No manual transport of trolleys • Automatic transport from the hot-smoke to the cooling section • Solid and precise design

  18. Intensive cooling • A distinction is drawn between: • Intensive cooling with fresh air and cooled air • Intensive cooling with cooled shower water, recycling system

  19. Intensive cooling with fresh water and cooled air The core temperature of the product is cooled down from 68°C – 74°C to 35°C – 40°C by means of a fresh water shower. The showering process can be fixed via the VEMAG control system as a steady shower or – as an alternative – as an intervall shower. In the second step the product is subject to an intensive air flow with a temperature of 0 – 4°C as long as the requested core temperature is reached.

  20. Intensive cooling via cooled shower water in a recycling system Water is collected beneath the installation right after showering. Using a pump it is transported to the cooler (cooling down to +0.5°C). Afterwards water is transported to a reservoir. By pumping down it goes back to the circuit.

  21. THERMO-COMPOUND-INSTALLATION Advantages • Minimum cooling times, faster turnover • Slight time of bacterial contamination, because critical temperature from +40°C bis +15°C is passed fast. • Only one person is needed to unload • No extra spaces for cooling the product • Minimum weight loss, cost saving • Slight cleaning of cooling area, trolleys and accessories • Quantity of trolleys, accessories and manpower is reduced

  22. Profitability – Space saving Space requirement without intensive cooling AEROMAT- Hot-Smoking Installation It is neccessary to have one orseveral cooling chambersSpace comes up to 150 m²to store production quantities. 15 batches are produced in 16hours to achieve a dailyproduction of 20.000 kg

  23. Profitability – Space saving Cooling area is reduced Quantity of trolleys is reduced Just In Time Production + Packaging Slight time of bacterial contamination Less cleaning

  24. Profitability – Space saving Example Product 60 g Wiener CSE Capacity per 20.000 kg Load per trolley 160 kg Packing temperature =< + 5 °C Production time 16 hours 125 trolleys have to be stored in a cold store. Further processing of the product without any temporary storage in a cold store can be realized with our Thermo-Compound-Installation.

  25. Profitability – Weight loss Example Product 60 g Wiener CSE Calibre 22 – 24 mm

  26. Profitability – Weight loss Example Product 90 g Bockwurst SD Calibre 28 – 30 mm

  27. Profitability – Weight loss Example Product 125 g Frankfurter CSE Calibre 22 – 24 mm

  28. Profitability – Costs Example Product 60 g Wiener CSE Calibre 22 – 24 mm Production 40 to / day Price 2,0 € / kg

  29. QUALITY, SAFETY and PROFITABILITY • Quality assurance at the highest stage • Short, constant, reproducable and gentle hot-smoking and cooling processes • Microbiological product stability • Cooling process: Minimization / Control of weight loss • Cost reduction (energy, transport, manpower) • Optimization of process- and production flow

  30. THERMO-COMPOUND-INSTALLATIONAccessories MICROMAT C7 – Control Systems with SIEMENSSimatic S7

  31. THERMO-COMPOUND-INSTALLATIONAccessories • Smoke Generators • Glowing Smoke Generator H504/C for woodchips and sawdust • Glowing Smoke Generator H 508/C for woodchips • Friction Smoke Generator H 501/D for wood beams • Steam Smoke Generator H H 507/C for woodchips • Liquid Smoke System H441

  32. THERMO-COMPOUND-INSTALLATION References • 30 pieces Denmark • pieces Finland • pieces Russia • 10 pieces Germany • 11 pieces Norway • 3 pieces USA • 1 piece Australa • 3 pieces Belgium • 9 pieces France • 1 piece Japan • 2 pieces Spain • 1 piece Trinidad • 2 pieces Chile • As at April 2007

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