Bring out the best in your process

Transcription

1 Bring out the best in your process

2 Company profile A chain is only as strong as its weakest link! Reducing downtime and maximising output capacity depends greatly on the continuity and reliability of your process. Kiremko offers solutions for each of the processes and integrates them into a complete processing line with all the required attention and care. A strong chain with the highest reliability, tailor made for your process. Kiremko develops, manufactures and installs all machinery required for the automatic and semiautomatic processing of potatoes into French fries, snack products such as chips, pellets, tortilla chips and other potato by-products like flakes, granules, salads and mash. Furthermore, we supply machines for processing (root) vegetables, not only for fresh but also for the deep-frozen and chilled market. Kiremko s processing technology includes the design and manufacture of machines for: destoning, washing, peeling, cutting, blanching, drying, coating, frying, cooking, forming, pasteurising, sterilising, cooling, freezing, (optical) sorting, transport, distribution, seasoning, weighing and packing: Kiremko can deliver it all, from the infeed of the product as raw material up to the outfeed as ready-made, packed final product. The individual machines form a chain in which every link is an example of inventiveness and reliability. Kiremko supplies a range of standard machines, but in most cases manufactures machines or complete production lines, which are tailor made to the specification of the customer. This is our major strength, the more complicated the wishes of the customer, the more the manufacturer has to prove itself through know-how, engineering, quality, inventiveness and a good pre- and after-sales service. The equipment is installed worldwide with approximately 85% of our sales being exported. Benefit from strong cooperation Kiremko B.V. was founded in 1965 as an offshoot of a trading company named Kiréma who supplied equipment to snack bars and restaurants. Before that time the snack market was an American phenomenon largely unknown in Europe. Kiréma was quick to break into the new market and began firstly by selling pre-frying lines and quickly followed by supplying automatic pre-frying lines. As the market kept growing, production lines with higher capacities were in demand and Kiremko was founded as a separate company to achieve this goal. Kiremko became independent in 1983 and personnel and turnover have continued to grow impressively ever since. These days Kiremko is an important worldwide player in the market for food processing equipment. Since 1978 Kiremko has had a partnership with its associate in the United Kingdom, Kiremko (U.K.) Ltd.. In 1996 the company joined forces with Idaho Steel Products Inc., a well-known manufacturer of high quality food processing equipment in the United States. This move strengthened Kiremko s presence in the North American market. In July 2005 Idaho Steel Products Inc., acquired all the available stock of REYCO Systems Inc.. This company supplies a complimentary range of industrial equipment for the food processing industry. Furthermore, Kiremko enjoys the benefit of cooperation with several technological partners that are considered the best in their particular field, especially with regard to product pumping, automated process control, flavouring and seasoning, high speed weighing and packing, energy supply and waste treatment. The cooperation between Idaho Steel Products, REYCO Systems, Kiremko and their partners offer customers worldwide an excellent source for all their food processing equipment needs.

3 Processing lines Mashed potato processing lines Processing lines French fries Potato chips Tortilla chips Potato flakes Formed potato products Mashed potato products Snack pellets Pre-cooked potato products Root vegetables Processes A processing line is built up from different processes. Kiremko s processing technology includes the design and manufacture of machines for: destoning, washing, peeling, cutting, blanching, drying, coating, frying, cooking, forming, pasteurising, sterilising, cooling, freezing, (optical) sorting, transport, distribution, seasoning, weighing and packing. Kiremko can deliver it all, from the infeed of the product as raw material up to the outfeed as ready-made, packed final product. The individual machines form a chain in which every link is an example of inventiveness and reliability. Kiremko supplies a range of standard machines, but in most cases manufactures machines or complete production lines, which are tailor-made to the specification of the customer. Kiremko has vast experience of turnkey projects worldwide with a dedicated, engineering oriented approach to all projects. All equipment is engineered and manufactured under one roof and built in compliance with the local statutory standards, and incorporates all the latest processing techniques available in the market. Destoning Washing Peeling Cutting Blanching Drying Coating Frying Cooking Processes Forming Pasteurising Sterilising Cooling Freezing Sorting Distribution Weighing Packing As long as man has cooked potatoes, it has been known that a cooked potato can be transformed into mash. For many years mash has also been the basis for formed potato products. In the last decade mashed potatoes, frozen or fresh, have become popular as a stand alone product. It is used as an important component for the production of ready meals or as a straight forward potato product in meals served in restaurants, canteens or institutionalised kitchens. More recently it has been a rapidly growing product in the retail sector. Kiremko has been involved in all aspects of the development on processing lines for mashed potatoes. We have the ability to deliver small, medium and large processing lines in all the defined market groups and can also assist in the development of customised products. Where necessary a number of different washing and peeling techniques can be employed depending on capacity and cost. We can supply cutting stations where the raw material is size reduced prior to cooking. The product can be blanched, cooled and or cooked before being gently and effectively converted to a puree. Once the mash is produced, it can be mixed with other components to add flavours or colours before it is packed, cooled or frozen. The equipment is designed for high capacities, ease of operation and maintenance and particular attention is given to hygiene and ease of cleaning, so all equipment is in compliance with European safety and hygiene standards.

4 Formed potato processing lines Coating lines There has been a trend over the last few years to develop formed potato product lines to accompany more traditional cut potato process lines such as French fries or cut roast potato lines. The formed potato products can be made from potato mash or from shredded potato. Some processors use formed potato product lines to use rejected potato from traditional process lines and thereby improve the overall yield of the processing facility, where others have developed stand alone lines to produce a wide array of products for the retail, catering and fast food markets. Many different products and shapes can be made, such as hash browns, croquettes, waffles, rounds, triangles and more complicated shapes. The products can be delivered fresh chilled or frozen and also coated and pre-fried or not. Rotary former Kiremko has been involved in all aspects of these developments and has the ability to deliver small, medium and large process lines in all the defined market groups and can also assist in the development of custom products. Kiremko manufactures all the necessary components to complete this process, from washing and peeling lines, cutting systems, blanchers, coolers and cooking equipment, mixing and mashing systems, forming, coating and frying lines up to the final packing and cooling solutions. The machinery is designed for high capacities, ease of operation and maintenance and in compliance with European and worldwide safety and hygiene standards. In the ever changing world of potato product developments, new varieties of French fries and other potato products are always high on the agenda. The market for French fries can be divided roughly into two main segments: the retail market and the catering trade for fast-foods, restaurants, institutions and hotels. This last category prefers relatively large, quantities of French fries from which they can serve a number of portions. These multiple servings should stay in perfect condition for a long period of time. The retail market does not require such a long shelf life, but is always interested in new products with different tastes or shapes. Recognising these demands, Kiremko decided to develop equipment to meet these requirements. Kiremko designs, manufactures and installs equipment, which coats the French fries with a special coating. This special coating can alter the texture, crispiness, colour or even the flavour of the French fries and other products after frying. This new Kiremko coating system is designed to handle different kinds of fried potato products, like sticks, slices and wedges. The coating which is applied may vary from a watery solution to a thick viscous batter. Depending on the customer s preference, the coating system could be installed between the dryer and the fryer or between the blancher and the dryer. The Kiremko coating system consists of a feed vibrator for even distribution of the product over the width of the enrober, which consists of a high speed transport belt with coating distributors. This transport belt moves the product through curtains of coating fluid and/or a dipping bath, where the product is covered evenly from all sides. A mixing tank is placed close to the enrober to prepare the mixture to the specific recipe. After the enrober, a drip-off belt is used to remove the excess coating fluid from the product. This dripoff belt has two sections in order to have the coated product tipped-over and has two air knives, mounted above the belt, reaching all sides of the coated product. The drip-off belt drops the enrobed product on a specially shaped belt, which feeds the product smoothly into the next machine, mainly a fryer, making sure that each potato piece stays singlulated during the next operation to prevent them sticking together. COATING MATERIAL The most common coating material is a starch mixture which will cover the surface of the pre-dried product and will give the crispy effect after final frying. In this coating a glazing agent can be added. Other types of coatings are much thicker and form a separate layer around the potato stick. A protein rich liquid, mainly flour, is often used but it is also possible to include other flavours and herbs. Coating line z Forming z Frying z Coating z Frying

5 French fries processing lines Kiremko was formed in 1965 to service the needs of the growing French fries industry. This product was then and is still today a core part of our business. We have continuously been involved in the design, production and installation of French fries processing lines worldwide. Over the years we have gained a huge knowledge of processing potatoes into French fries using the latest technology and techniques. From small start up lines with outputs of kg/hr to complete industrial process lines of over kg/hr capacity, Kiremko can offer cost effective solutions to individual process requirement and also complete turnkey packages to suit all capacities and budgets. Kiremko is at the forefront of developing and applying technology for coating and flavouring of French fries. We also deliver byproduct lines, such as hash brown or flake lines, which are commonly installed to compliment French fries lines. Our processing lines are specially designed for the production of top Blancher quality French fries complying with the strictest possible quality requirements. The lines are equipped with the latest processing techniques. Effective washing and de-stoning lines and single or twin brine separators can be used for separating the potatoes on density and removing floating matter such as straw or wood. Steam peeling systems with condensate separation and removal systems can be incorporated to achieve the lowest possible peeling losses. Optical sorters can be used to control the quality of the raw potatoes, cut and final product and also to remove foreign material and defects. Our Quadraflow hydro cutting lines with switch-over systems guarantee our customers a perfect cut and an interruption free operation of their cutting process. To process the perfect fast food style French fries, we supply our customers our blanchers (belt or screw type), innovative Delta-X dryers, coating systems and fryers that will give French fries their famous golden colour. Kiremko can now offer the advanced Oil Miser system for effective removal and recovery of superficial fat after frying alongside more traditional fat removal systems. To complete the process line, we can offer standard or customised cooling, freezing, distribution and packing lines. Belt dryer French fries fryer Fryer infeed vibrator All the lines can be delivered with SCADA systems for automatic control and continuous process monitoring and data logging. They are built to the latest European safety and hygiene standards and can be built to comply with local regulations and demands. Kiremko has installed French fries lines all over the world, also on a full turnkey basis, and can customise the designs to suit local needs and conditions. Brine separator STRATA steam peeler Quadraflow water knife Length grader z Destoning/Washing z Peeling z Cutting z Optical Sorting z Blanching z Drying z Frying z Cooling/Freezing z Packing

6 Potato chips processing lines For more than 150 years, potato chips have been the world s favourite type of savoury snack. The recipe has changed little over the decades and, although today the process is automated and on a much larger scale, a potato chip is still basically a fresh potato, delicately sliced, lightly fried in vegetable oil, then sprinkled with flavouring. Kiremko has built chips fryers since the early seventies. Because the demands of our customers are continually developing, we put a lot of effort into optimising the design of the machines in our lines to improve production efficiency, sanitation and maintenance. Our production lines are specially designed for the production of top quality chips complying with the strictest possible quality requirements. The latest innovations in manufacturing, control and monitoring are included in our designs. Modern techniques for motor speed and process data control can be incorporated. All the lines can be delivered with SCADA systems for automatic control and continuous process monitoring and data logging. They are built to the latest European safety and hygiene standards and can be built to comply with local regulations and demands. The most common potato chips are flat chips but in addition to this, our production lines are also suitable for producing crinkle cut and v-cut chips in a standard capacity range of 100 to kg/hr with customised designs available to suit all requirements. Lines begin with a potato reception area where the raw material is unloaded, washed and gently separated from stones. The product is then lightly peeled using one of the several peeling techniques depending on cost and capacity. The product is then cut, washed and sometimes blanched to produce the perfect slice before it is evenly fed into a continuous fryer to finish the perfect potato chip. After frying, Kiremko delivers complete and integrated flavouring and packing solutions, meaning that we are one of the only companies in the world that can truly deliver the complete package. Feed vibrator peelers To compliment our exceptional process and packing lines, we can deliver optical sorters for quality control of the raw potatoes or final product and to remove foreign material or defects when necessary. Frying line Abrasive peeler Roll sizer Visionair optical sorter z Destoning/Washing z Peeling z Sorting z Cutting z Blanching z Frying z Sorting z Flavouring z Packing

7 Snack pellet processing lines Tortilla chips processing lines Over the last decade the snack pellet market has grown massively worldwide and Kiremko plays a major role in being able to supply equipment incorporating the latest technology in the field of snack pellet processing to meet the exacting standards of our customers around the globe. There are many different raw materials which can be used for pellet production such as; potato, rice, wheat, corn etc. The pellets are divided into two basic categories, those made from grain (rice, wheat, corn) or those made from potato. The latter being the only one to give the authentic potato taste to the finished product. Pelletised snacks are produced when the raw material is extruded into a recognisable shape, this can be done using a process known as direct expansion or alternatively using a process known as indirect expansion. The direct expanded pellets are produced in a one step extruder and are ready for consumption following the extrusion process. Maize products are processed into a wide variety of snack products, one of them being tortilla chips, which accounts for a large percentage of the capacity delivered by the snacks industry. The processing starts with the maize being mixed with water to form a dough, which is then pressed using rollers into sheets of approximately 1.5 mm thick. The sheets are passed through a rotary former which cuts out the triangular shapes. The shapes are pre-dried in a direct fired oven. After ambient air cooling on an equilibration and cooling belt, they are fried in vegetable oil in a tortilla chips fryer. The indirect expanded pellets are extruded and then generally sold on as a semi-manufactured product to companies who finish the process by frying them in hot oil then dosing them with flavouring or seasoning before packing. This is often the most affordable set-up into industrial production of savoury snacks for newcomers in this segment. Often as an alternative to potato chips, still by far the snack with the largest Pellet snack frying line market share, for those countries where fresh potatoes of the right variety are not available like the Middle East, Central America or South East Asia. Kiremko manufactures and supplies complete snack pellet frying lines starting from the bunker belt, that feed the fryer, the fryer itself, flavour dosing system, discharge and transport equipment to the packaging lines with a capacity range of 100 to kg/hour. Depending on the capacity required, the fryers are either electrically heated or indirectly heated through a steam/thermal oil heat exchanger. Tortilla chips fryer Kiremko can supply in cooperation with its partners complete turn key solutions right from the dough production through the sheeting and cutting, the dryer and fryer and into custom built packing lines. The tortilla chips fryer is designed to incorporate the latest technology to produce homogeneous, high quality tortilla chips. Flavour applicator z Infeed raw material z Frying z Flavouring z Packing z Cutting z Pre-drying z Frying z Flavouring

8 Processing lines for fresh cut and preserved potatoes Frozen French fries, potato chips and dehydrated potatoes are the best known processed potato products worldwide. However, the ever increasing demand for convenience foods, easy to prepare and with healthier and better nutritional characteristics has driven potato processors into diversifying their product range. In recent years the segment of the so called preserved potato products has grown massively. Depending on the required shelf life, the product can be preserved in several ways. From a fresh peeled and cut potato vacuum packed with of shelf life approx days. To a cooked / chilled product (30 days), or blanched and pasteurised in vacuum pack ( days). Finally a sterilized product in can or jar (720 days), obviously depending on critical factors in the process and distribution requirements. STRATA steam peeler Stainless steel product pump Final product Kiremko is active in this market segment offering complete This segment basically consists of whole, halved, quartered, sliced and diced potatoes which are offered in both industrial applications as well as retailed products. Due to consumer demands, the potato products are offered in a wide variety of different packs, flexible packs, vacuum bags, thermoformed and sealed trays, cans, glass jars, and others with diverse recipes, which may include sauces, herbs, vegetable mixes and even minced meats. Blanching-cooking line Continuous pasteuriser processing lines including density separators, abrasive or steam peeling lines, mechanical and/or hydro cutters, optical sorters, blanchers, steam cookers, cooling tunnels and continuous pasteurisers as well as sterilisation equipment. Lines are available from 500 kg/hr to kg/hr output and higher. Cyclone destoner Dry brush machine Ciris optical sorter z Gravity separation z Peeling z Optical sorting z Cutting z Cooking z Packing z Pasteurising z Cooling

9 Potato flake processing lines Potato flakes were first produced industrially in the USA lines with the most efficient processing techniques, focussing on improvements in energy and water consumption. back in the 1950s and have since developed into a food ingredient of massive importance and countless applications. Potato flakes are nowadays an extremely cost efficient part of Potato flake lines are usually set up in one of two ways, the recipes for end products such as stackable chips, extruded first is a primary process the second being a line to use snacks, baby foods, bread and pancake mixes, formed meat reject potato from another primary process line such as a products, and even as non-food applications such as plastics. French fries line. Potato flake lines, manufactured by Idaho Steel Products In the first instance a specialized potato flake line is developed to convert potatoes that have been specifically sourced and Kiremko offer maximum efficiency, cleanliness, and durability. Our commitment is to deliver the highest quality for manufacturing flakes. Potatoes are washed and stones are automatically removed before the product is peeled using the most suitable technique depending on capacity. The product is then size reduced using custom built cutters before it goes on to the flake making process. surface of the drum where the moisture from the potato is quickly and efficiently driven off leaving an almost dry sheet of flake. The moisture is carried away as vapour by extract fans whilst the flake is broken into manageable pieces and transported to the packing area. The coarse flake is then milled down to the correct size for the customers needs before it is packed in a number of different ways, once again depending on the end users requirements. Kiremko can supply individual components to enhance existing lines or complete state of the art new lines to meet the challenges of this market place. The drum dryers which are at the heart of this process are a well proven design manufactured by Idaho Steel Products in the USA for more In the second instance a flake line is installed along side an existing process line, for example a French fries line. The reject potato from the French fries line is used as a raw material to convert it into a saleable quality of flakes. This method is a very good way of improving the overall yield of a processing facility as material, which previously would have been discarded as waste, is now converted into a saleable product. The cut product or rejects from another process line is either blanched, cooled and cooked or simply just cooked depending on the type of flake required. The cooked potato is then converted to a coarse mash which is transported to and evenly distributed over the flake drum. Applicator rollers on the drum allow the mash to be spread evenly over the hot Drum dryers than 30 years, they are now fabricated in stainless steel, which has brought a marked improvement to industry standards. These Super Drums first introduced in 1995 have been installed in many flake plants in North America and around the world. Available in sizes from 5 x 8, 7 x 20 and 7 x 24 and with approximate capacity ranges of 500 lbs (225 kg) per hour finished up to 2,200 lbs (1.000 kg) per hour finished product. Major advantages are gained by integrating our Visionair optical sorters in our flake lines, which results in a great improvement to the quality of the end product. The Visionair optical sorters are worldwide the preferred sorters for the flake industry. Idaho Steel and Kiremko work closely together, creating one of the only partnerships in the world capable of design, layout, manufacture, and installation of complete potato flake processing lines. Blancher z Destoning/Washing z Peeling z Blanching z Cooling z Cooking z Drying z Optical Sorting

10 Colofon This brochure is a publication of: Kiremko B.V. Compilation & editing: Nicole Peters With the cooperation of: Idaho Steel Products REYCO Systems Packo Technisch Bureau Lindhout B.V. and others. D.T.P. & Print: Comm Unity, The Netherlands References For many years Kiremko has been a leading light in the production of potato and vegetable processing equipment. Our reference list reads like a Who s Who of the processing industry and we are proud of the fact we have equipment working not only in Western Europe and North America, which accounts for the major part of the world s processing industry, but indeed in all five continents of the world. In fact, Kiremko is active in all major potato growing countries, which have an existing or potential processing industry. In many emerging markets, Kiremko was the first to identify the need for processed potato products and the possibility to produce these locally, such as in China, India, Iran and Brazil. Kiremko is not only a preferred supplier to the multinational corporations in the food processing industry, but is also first choice to medium sized, family owned processors and even regional oriented fresh cut operations. We continue to deliver new and innovative systems all over the globe. January rd edition No part of this brochure may be reproduced: stored in a database or retrieval system, or published, in any form or in any way, without written permission of the publisher. The data published in this brochure, answers to the most recent information at the moment of publishing and are subject to future modification. Kiremko reserves the right to modify the construction and execution of their products at any time without any obligation on their part to modify any equipment delivered before accordingly.

11 Strategic alliances For many years Kiremko has actively encouraged reliable manufacturers of specialist machinery and components to join forces with us in order to offer the client the best and latest developments available in the market. Through close and intensive communication between all parties the individual desires of the client can be met to the highest level possible. Furthermore, these cooperation s enhance the flexibility and speed of our service and the delivery of machines and components. Your process will benefit from our proven reliability The continuity of your process depends greatly on reliability. A chain is only as strong as its weakest link. Kiremko offers solutions with a proven reliability for each of the processes and integrates them into a complete processing line. With all the required attention and care and tailor-made for your process. Assuring the reduction of downtime and the maximum output capacity. Kiremko B.V. Tasveld 7 P.O. Box ZG Montfoort The Netherlands Tel: +31 (0) Fax: +31 (0) kiremko@kiremko.com Internet: Kiremko (UK) Limited LN8 Armstrong House The Finningley Estate Hayfield Lane Doncaster, DN9 3GA United Kingdom Tel: +44 (0) Fax: +44 (0) sales.uk@kiremko.com