Convenience products of the highest quality

„Consumer demand for value-added convenience products is on the rise. In addition to end-products such as nuggets and hamburgers, consumers want more variation in flavors and appearance. To meet this demand, producers of convenience products need to be able to produce a limited number of high volume products, as well as a wide variety of small volume products. Marel’s coating portfolio combines high production capacity with the flexibility to produce a variation of end-products, without compromising product quality,“ accordin to Marel‘s homepage

New coating equipment

Presentation plays a key factor in the consumer’s choice for a product, so it is of vital importance to get your coating right when producing convenience products. Coating influences yield and will largely determine the appearance and bite of an end-product. The options for possible coatings are numerous. Will your choice be pre-dust, wet or dry coating, or rather a combination of these steps?

The coating process depends on the end-product you want to produce. Regardless of which coating you choose, Marel can supply the appropriate system for virtually all types of coatings, to make every conceivable coated end-product.

Laying the foundation

Marel’s Active Flour ApplicatorActive Batter Applicator and Active Tempura Applicator lay the ideal foundation for a flawless layer of crumb. Flouring is a common first dry-coating step. The fine layer of flour that is applied to the mass serves as a binder to allow other coatings to adhere better. Subsequently, a layer of batter will ensure that breading fully adheres to the product. Marel’s Active Batter Applicator and Active Tempura Applicator provide an excellent distribution of batter over products, can remove and reuse excess batter, and are suitable for a wide range of capacities.

Both wet-coating solutions, the Active Batter Applicator and Active Tempura Applicator, have the option to create an active bottom bed, a unique feature that positions a product directly in the batter when entering the machine. This results in a perfectly even coverage of both the top and the bottom of the products. Improved control over the amount of crumb that is added to a product, also referred to as pick-up, and the ability to handle thicker batter at high-speed allows processors to produce a substantial volume of high-quality products in a shorter amount of time.

Master the art of coating with revocrumb

The new RevoCrumb system produces perfectly coated products with optimum crumb distribution over all surfaces of the product. With an innovative crumb-management system, producers can control the flow of coarse and fine crumbs to the top or bottom bed. The crumb-management system ensures optimum coverage that meets the customers’ requirements.

RevoCrumb allows for high-speed processing while guaranteeing perfect coverage of the product on both the upper and bottom side. The sophisticated crumb management enables various kinds of crumb distribution including uniform coverage or a specific crumb distribution over top and bottom.

RevoCrumb has a built-in transport mechanism featuring a revolving water-wheel that carefully transfers the crumb, unlike the more commonly used grinding augers. As the RevoCrumb does not grind or crush crumbs, the crumb structure remains intact during processing, making the solution particularly suitable for very vulnerable crumbs such as cornflakes and panko.

Dual-mode revobreader

The all-new RevoBreader is a flexible machine that offers a flatbed and drum-mode all in one system. Switching from one mode to another is easy. In the flatbed position, the RevoBreader guides products through a bottom bed of crumb, while covering the top layer of the product with a gently falling layer of crumb. The result is high-quality, uniformly coated products. In the drum position, a high pick-up of crumb and optimum home-style coverage of the product is guaranteed, and producers can be certain of high retention of crumb to the product during the frying process.

Production insight

For centralized process control, Marel’s new convenience line can be connected to Innova Food Processing Software. With Innova, processors can control and monitor their process and gain insight into the production line’s effectiveness. Innova provides real-time data for performance monitoring and enables processors to maximize their yield and throughput, while complying with the strictest food safety, quality and traceability standards.

 

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