Modern smoking and process air-conditioned climate curing systems are designed for the different types of smoking and curing methods, thereby offering the possibility of a broader product range as well. Depending upon specific needs and requirements, processing customers can base their decision on hot, warm or cold smoking, whether with smoldering, friction, condensate or liquid smoke, and irrespective of whether performed with high or low pressure steam. And also irrespective of processing customers’ different plant sizes, smoking systems manufacturers’ range is wide enough for all customers from small craft-rooted businesses all the way to large industrial plants to satisfy their specific needs. And when it comes to heating systems, customers can again choose among those based on electric power, gas, steam or heating oil.
As for the smoking process itself, the finished product’s quality depends on a number of factors: For one thing, smoke must uniformly distribute itself within the chamber, while smoke development must always come with the right intensity for the respective product; and it also important to note that temperature and air guidance are factors of influence with respect to smoked products’ taste and consistency as well.
The individual process steps of drying, curing and smoking are governed and monitored by easy-to-handle computer control systems, so that standardized production runs become a practical reality. As part of the control systems, microprocessors afford simple control data recording in line with the HACCP concept, with on-screen indication of trouble or mistake reports intended to guarantee smooth production runs.
In view of the current climate debate, the exhaust air topic has meanwhile assumed a higher place on the ranking scale as well. Given that fact, lawmakers are placing higher requirements on afterburning systems for smoking gas purification in terms of their CO2 emission. Which means that equipment manufacturers are constantly striving to develop smoke destruction systems that are environmentally friendly, while minimizing costs at the same time.
Efficient curing process
- picture: Bastra These process air-conditioned curing/smoking systems are suitable for curing, drying, smoking and after-curing uncooked as well as long lasting meat products. full size
Industrial Line is the brand name of production systems from Bayha & Strackbein GmbH of Arnsberg, Germany, which have been specifically designed and laid out to fulfill the needs and requirements of those in the meat and sausage producing industry, as the manufacturer points out. Among other units, this product line comprises multi-cart hot smoke as well as multi-cart universal cooking and smoking systems (temperature range: up to 130 °C, capacity: up to ten carts), process climate air-conditioning systems (temperature range: 10 to 30 °C, capacity: up to 42 carts) and follow-up aftercuring equipment (temperature range: 10 to 20 °C, capacity: up to 150 carts). As an option, these process climate conditioners can optionally also be operated in combination with smoke refining/upgrading systems, for which purpose all customary process smoke production technologies are available.
Switching cabinet and operating elements with Bastra touchscreen control type TS 800 KR form their own independent units and can, as the manufacturer states, be individually positioned to fit in with room and space conditions present and available. The operating element itself includes a separately operating safe temperature control function for automatic disconnect in case the temperature limit is exceeded, and the humidity measuring device is equipped with automatic water infeed. In addition, an optical and acoustical alarm system is also there, alerting operators to such troubles as malfunctions and deviations from preset limit values.
The ventilator unit, as such separate from the mixing chamber, is mounted for vibratory attenuation, while a frequency converter is there to assure infinitely variable ambient air velocity control.
Depending upon design and room size, two blow-out ducts and two central suction ducts are provided, with the ducts’ blow-out exhaust nozzles and resuction openings separately adjustable in an infinitely variable manner as well. All ducts and forming elements come with control openings, with the changeover valve for air guidance pneumatically activated.
In case of process air-conditioned curing/smoking systems, mixing chamber, ducts and smoke pipes are cleaned by way of a semiautomatic cleaning system. As a final note, the manufacturer also points to the fact that in order for better all-out foaming of the smoke process resin removal to be obtained, compressed air can be added in further support the cleaning agent being used.
Sprinkling systems offer benefits
- picture: Red Arrow The SpeedSmoke smokehouse cart sprinkling system lets the sprinkling technology become a useful option for plants with individual charge-based smoking systems as well. full size
In the past, practical use of sprinkling systems where an aqueous solution of purified smoke condensate is showered over the surface of food products scheduled for smoke treatment was reserved for processing plants with equipment for continuous production runs already in place. But sprinkling as such was essentially still limited to small caliber products like small sausages in peel-off casings.
More recently, however, Bremen, Germany-based equipment manufacturer Red Arrow has developed a new process with its SpeedSmokeRauchwagen (Speed Smoke Smoking Cart) sprinkling system designed to allow plants operating with single-charge smoking systems to make practical use of the benefits coming with sprinkling technology as well. As such, complete smokehouse carts are treated inside a sprinkling system with a predefined smoke solution for up to two minutes in such a way that, within a few seconds only, complete moistening of the product surface is achieved by a simple rinse process already. After a subsequent drip-off phase, the smokehouse cart is moved from the sprinkler to the smoking station, where heat treatment comprising drying and cooking phases takes place. As a result of that process, typical smokehouse color and taste develop, as do the product-preserving and texture imparting properties typical of smoke treatment. In addition, the result of smoke processing can be influenced by selecting the type of smoke, concentration of the smoke solution, smoke treatment time as well as the subsequent heat treatment.
With its development of novel smoke treatment products, Red Arrow has for several years now offered the option of producing large caliber products like bellies, Kassel-type rib spears or ham, with technological sprinkling equipment as well apart from small sausages in peel-off casings. The essential advantage of the sprinkling technology being that an exact volume of smoke is introduced to the smokehouse products, meaning that smoke treatment color, taste, product keepability or shelflife, and texture can be precisely reproduced. As such, the stipulated standard quality for the respective products is obtained with each and every manufacturing charge.
By subjecting fresh products to smoke prior to heat treatment already, new conditions for that specific heat treatment can also be stipulated. As a result, product surfaces must no longer be prepared for smoke reception so that, as the manufacturer indicates, heat treatment with higher temperatures and an increased drying rate can start immediately. This, in turn, allows these processes to come with time savings ranging from 30 to 50 percent.
When sprinkling is applied, smoke solution, and with it smoke constituents, are being consumed. But these are automatically reintroduced to the smoke solution by way of an automatic redosing system, so that constant smoke treatment results are being obtained. Frequently of customer-specific design, sprinkling equipment units come with controls allowing operation with optionally different smoke solutions. Which means that, in this way and manner, different products can receive system treatment in line with individually specified qualities, needs and requirements. Smoke composition and follow-up dosage are stored in a product-specific manner, being called up by pertinent program selection. For the sprinkling system to be cleaned, the smoke solution is pumped from the operating into the storage tank, while connection to an existing CIP system is also possible.
As Red Arrow furthermore states, the sprinkling technology can replace the entire smoking process, with exhaust air emission and the load on waste water being reduced to a considerable extent. It is also in this context that the EU Guideline 96/91/EC on integrated prevention and reduction of environmental pollution (IVU guideline) requires all manufacturers to employ processing technologies affording the best possible environmental protection. In which context, the manufacture of smoke products is already coupled with the objective of placing as little a load as possible on the environment. In stating its reasons for the EU guideline 2065/2003 for regulating the use of aromatic smoke substances in foodstuffs or on their surface, the European lawmaker advocates the use of aromatic smoke substances which, as a result of their fractionalization and cleaning, are viewed as posing less of a human health hazard.
In addition, nonexistent hazards of fire and explosion make the sprinkling technology-based operating process controllable and consequently safer. But over and above that, there is also the possibility of combining conventional smoking processes with the sprinkling technology, meaning that processing times can at least be substantially curtailed.
Complete industrial-type solutions
- picture: Maurer-Atmos Complete solutions are in demand when it comes to thermal meat products treatment. full size
With its home base in Reichenau, Germany, the Maurer-Atmos manufacturing company has completely modernized its product range, positioning itself as a complete solutions supplier for the processing industry. So the manufacturer’s slogan “complete control of the thermal meat or meat processing process” can be seen as a summary of the above statement. Down to more detail, this first of all applies to the thawing, cooking, pasteurizing, smoking, cooling, baking, and curing of meat and fish. The most recent customer projects put in place in South America, in Germany or in Italy confirm what the manufacturer specifies as its company’s incomparably high level of technical know-how.
As such, the Maurer-Atmos product range comprises smoke generators for all directions of taste as well as charge- or batch-type units and semi-continuous equipment systems or continuously operating systems coming with an output capacity ranging from 100 to more than 5,000 kg/h. These present-day systems operate efficiently while also saving on water and energy, doing so as a result of ice water circulatory or thermal afterburning systems coupled with heat recovery. In addition, these equipment units are also emphasized for what is stated to be their fascinating control, documentation and data recording functions as well as their automated transportation mode.
In a more generalized context, Maurer-Atmos follows the objective of turning adaptations to the most recent challenges, as placed by the industry and the entire market, into practical reality in a fast and flexible manner. Given that effect, customers can raise their success to a higher level thanks to better resource utilization and shorter processing times, as the company underscores in its final statement.
Reducing cost and emissions
- picture: KMA Umwelttechnik The exhaust air filter type UV4000 with a filtering capacity of up to 3,200 m3/h is suitable for connection to a continuous-flow frying system. full size
Translating climate protection measures into practice is on the government’s political agenda this year. For companies in the production field, this translates to extra load factors in the form of CO2-specific taxes or other environmental fees. As a result, afterburning systems used in many meat processing plants for exhaust air cleaning are going through an additional operating cost explosion. It is against this backdrop that KMA of Königswinter, Germany, intends to offer the industry a climate-gentle and cost-saving alternative: With its Airmaxx smoke gas filtering system, as such honored with a premium award from the German Agricultural Society DLG, energy costs and greenhouse emissions can be drastically reduced for exhaust air purification, to quote from the manufacturer’s own statement.
More to that point, KMA is presenting numerous novelties within its Airmaxx exhaust air filtering systems production program. For one thing, capacity has undergone upward expansion in order for large exhaust air volumes of more than 10,000 m3/h to be cleaned in central filtering units in a cost-favorable manner. In the future, these systems will also be available in a model version that can be installed in the open air.
The filtering systems themselves are of a modular design concept and can hence be accurately adjusted to fit in with the utilization purpose planned (for instance in combination with smoke treatment smoke, or exhaust air from regular or hot air deep-frying systems); and for the latter, a new filtering system with electrostatic fat separation and odor filtration, based on UV technology, is also available.
As the manufacturing company furthermore points out, frying/deep-frying or smoking systems equipped with thermal or catalytic afterburners can also be upgraded by being remodeled at a later date. With such remodeling, all energy-devouring exhaust air combustion systems can be replaced. With that done, the production system’s CO2 emission is stated to be reduced to a considerable extent, since no fuels like oil or gas are being burned. And as KMA further points out, monthly reduction in CO2 emissions, as such a climate load factor, are achieved in the order of more than 25 tons. Over and above that, such an exchange results in energy savings of more than 80 percent, so the new filtering system already pays for itself by way of cost savings reflected in the oil and gas invoice, as the manufacturer explains, while additionally pointing out that financing with the assist of public support funds can also be applied for.
Upgrading in the traditional manner
- picture: Travaglini S.p.a. Fine meat and sausage specialties are being produced with these systems. full size
It is for three generations now that the manufacturing company Travaglini S.p.a. of Milan, Italy, has been putting out process air conditioning systems for the manufacture of fine meat products and specialties like Parma ham, Jamòn Serrano, noble salami varieties, Bressaola or similar high-quality products.
And the company’s equipment systems types, specifically configured for the respective processing phases, are as different as the products listed above. As such, when raw ham is being manufactured, equipment systems must satisfy different requirements, starting with the ones posed by the salt phase, and continuing with those of the burning phase, fermentation and drying, and all the way to long-term curing.
Already rich in different details, this requirement profile receives yet another dimension when products are being manufactured in a lying or hanging position, in which case horizontal flow systems must be used in order for the necessary product uniformity to be assured with high-structure assembly systems as well. Particularly where long processing times require a large storage capacity, the standard smoke treatment truck is no longer in demand because of its low level loading capacity. And it is at this particular point, however, that structures up to five meters in height, in themselves affording space-saving practical use, do require a different systems configuration.
Turning to equipment types intended for salami manufacturing, the variation range is similarly wide, with the spectrum extending from the small two-cart chamber to fully automized systems where racks are moved by robots. While production itself is in progress, the robots are busy with filling chambers and expediting them further. During the night, redistribution of the racks from the preliminary to the after-curing chambers is performed, so that, when a production work shift gets started the next morning, everything necessary has already been prepared. Only one person in the workforce is needed for system surveillance because the robots, themselves operating under a low energy level, move over to the loading station, dock onto it and return when loaded, with all that done in full automation.
Even though modern technology is being used, Travaglini strives to observe traditions incidental to the manufacture of fine raw products. As an example, natural air streams and wind cycles can be simulated with the various control types. For some tradition-bound clients, classical use of natural air is a point of such importance that outside conditions are permanently monitored. And in case these are in the “green light spectrum”, the windows’ blinds automatically open, air-conditioning systems stop, and natural fresh air streams through the climatized processing rooms. And only when outside conditions no longer correspond to those that are optimum, the windows will close, with the process climate conditioning system taking over again. That, in turn, saves on energy while imparting products so produced with an individual note and character. Turning to Germany, lots of energy can also be saved by utilizing the outside air, at least during the cold season of the year. Enthalpy, in other words the energy content of the air, is used as a measuring standard. Based on permanent monitoring of temperature and air humidity in the open, and by way of comparison with pertinent process parameters, the system decides whether a usable difference between the energy content of the outside air and the air inside the chambers exists, with digital probes transmitting the respective data to the control system. And it is at this point that the decision is made with respect to how high the share of outside air may be when the process air is being conditioned. In case of optimum external conditions, that share is 100 percent.
For the growing bio products market, the company’s product range also offers systems which, thanks to slow and gentle curing, allow raw sausage production without the use of nitrite pickling/curing salt, in which particular case static cooling, interconnected with pulsating heat input, is carefully put to use.
Over and above all that, the equipment manufacturer also offers systems for air conditioning of complete production areas, extending all the way to the slicer department’s clean room technology, and also including all associated hygiene junctions and rapid freezing tunnels for an optimum product cutup temperature to be obtained.
That typical taste of smoke
- picture: Wiberg With high-quality aromatic smoke flavors as well as smoke-impregnated sausage casings, delicious specialties coming with a delicate touch of smoke can be produced in a simple and safe manner. full size
In the manufacture of further refined and upgraded meat and sausage products, smoke has always played a significant role; and apart from its contribution to taste, odor and color, smoke treatment is also one of the oldest processes used to make products durable. In this day and age, however, the conventional method of firewood smoking is ever more frequently replaced by currently popular smoke treatment methods like the use of aromatic smoke flavors and liquid smoke.
The benefits resulting from such use speak for themselves: clean production areas without wood shavings and ash, a uniformly stable taste of smoke in the finished product, as well as a reduction in operating costs thanks to savings on time and expensive cleaning jobs, to name just a few examples. In cooperation with the Red Arrow company, Wiberg of Salzburg, Austria, offers a whole range of first-class products for smoke generation and direct smoke addition. With smoke generation in a closed system, stable processing smoke is created. And turning to the water-based liquid smoke products SmokEz, Enviro 24, and SmokEz Classic 5100, a perfect smoke curing color as well as the finest taste of smoke are guaranteed, as the manufacturer promises, also pointing out that adding aromatic smoke flavors directly to the input meat emulsion, or to the brine, is as simple a method as it is an efficient one; and for it to be used in practice, the overall Wiberg assortment offers an optimum selection of liquid as well as dry aromatic smoke flavors. As such, Fumaro and Smoke OG are intended to impart the ready-prepared sausage input meat with a well-rounded touch of smoke flavor, while Fumaro Kirschholz (cherry wood) is stated to be suitable for both, sausage input meat and brine.
