Industrial Grinders for Food Processing: A Comprehensive Guide
Industrial Grinders for Food Processing: A Comprehensive Guide
Industrial grinders play a crucial role in the food processing industry, providing efficient and effective solutions for various grinding needs. In this comprehensive guide, we will explore the functionality, types, selection considerations, maintenance and safety, as well as the impact of industrial grinders on food quality.
Understanding the Role of Industrial Grinders in Food Processing
Industrial grinders are powerful machines designed to reduce food ingredients into smaller particles, enhancing their usability and aiding in food preparation. These grinders are commonly used in the production of spices, herbs, grains, and other food products.
When it comes to food processing, industrial grinders play a crucial role in ensuring that the ingredients are finely ground to achieve the desired texture and consistency. Whether it’s grinding spices for a flavorful curry or pulverizing grains for baking purposes, these machines are essential in the food industry.
The Basic Functionality of Industrial Grinders
Industrial grinders utilize a rotating mechanism to grind food ingredients. The grinding process involves the interaction between the rotating blades or discs and the food particles, resulting in the reduction of particle size.
These machines are equipped with powerful motors that drive the rotating mechanism, ensuring efficient and consistent grinding. The blades or discs are strategically designed to create a vortex-like motion, pulling the food particles towards the center and grinding them into smaller pieces.
Depending on the desired particle size, industrial grinders offer adjustable grinding settings. This allows food manufacturers to have control over the final product’s texture, ensuring that it meets the specific requirements of their recipes.
Key Features of Industrial Grinders
Industrial grinders are designed with various features to optimize performance and facilitate efficient food processing. Some key features include adjustable grinding settings, durable construction materials, and user-friendly controls.
One of the key features of industrial grinders is their ability to handle large quantities of food ingredients. These machines are built to withstand heavy-duty usage, making them ideal for commercial food processing facilities.
Furthermore, industrial grinders are often constructed using durable materials such as stainless steel. This ensures that the machines can withstand the rigors of continuous grinding without succumbing to wear and tear. The robust construction also contributes to the longevity of the grinders, reducing the need for frequent repairs or replacements.
In addition to their functionality, industrial grinders are designed with user-friendly controls. This allows operators to easily adjust the grinding settings, monitor the grinding process, and ensure optimal performance. The intuitive interface and clear instructions make it easier for operators to operate the machines efficiently, minimizing the risk of errors or accidents.
Overall, industrial grinders are essential tools in the food processing industry. Their ability to efficiently grind food ingredients into smaller particles not only enhances the usability of the ingredients but also contributes to the overall quality and consistency of the final food products.
Types of Industrial Grinders for Food Processing
When it comes to food processing, having the right equipment is crucial for achieving optimal results. Industrial grinders play a vital role in breaking down food ingredients into smaller, more manageable sizes. There are several types of industrial grinders available in the market, each with its specific features and advantages. Let’s explore some of the commonly used types:
Disc mills, also known as attrition mills, are versatile grinders that use a series of rotating discs to grind food ingredients. These discs can be made of various materials, such as stainless steel or stone, depending on the specific application. One of the key advantages of disc mills is their ability to offer precise control over particle size. By adjusting the gap between the discs, operators can achieve the desired fineness of the final product. Disc mills are commonly used for grinding oily or wet ingredients, making them ideal for applications such as peanut butter production or wet spice grinding.
Hammer mills, as the name suggests, utilize high-speed rotating hammers to pulverize food ingredients into smaller particles. These hammers are attached to a rotor, which spins at a high velocity within a chamber. The food ingredients are fed into the chamber and are repeatedly struck by the hammers until they are reduced to the desired size. One of the key advantages of hammer mills is their ability to handle a wide range of materials. From grains and spices to fibrous materials like meat or vegetables, hammer mills can effectively process them all. Additionally, hammer mills are known for their ability to generate consistent particle sizes, ensuring uniformity in the final product.
Pin mills, also known as universal mills, are specialized grinders that use narrow pins or needles to reduce particle size. These pins are evenly distributed on a rotating disc or plate, which creates a high-speed impact on the food ingredients. Pin mills are often used for fine grinding, where a high degree of particle size reduction is required. They are particularly suitable for fragile or heat-sensitive food ingredients, as the grinding process generates minimal heat. This helps to preserve the quality and integrity of the ingredients, making pin mills a popular choice in industries such as pharmaceuticals or confectionery.
Choosing the right type of industrial grinder for food processing depends on various factors, including the specific application, desired particle size, and the characteristics of the ingredients being processed. By understanding the different types of grinders available and their unique features, manufacturers can make informed decisions to optimize their food processing operations.
Selecting the Right Industrial Grinder for Your Needs
Choosing the appropriate industrial grinder for your specific needs is crucial to achieve optimal grinding results. Consider the following factors when selecting an industrial grinder:
Assessing Your Grinding Needs
Identify the specific requirements of your food processing operation. Consider factors such as desired particle size, processing capacity, and the types of food ingredients you will be grinding.
When assessing your grinding needs, it is important to consider the desired particle size. Different food products may require different particle sizes for optimal results. For example, if you are grinding spices, a fine particle size may be desired to ensure even distribution of flavor. On the other hand, if you are grinding meat for sausage production, a coarser particle size may be preferred to achieve the desired texture.
Processing capacity is another important factor to consider. How much food do you need to process in a given time frame? This will help determine the size and capacity of the industrial grinder you require. If you have a high-volume food processing operation, you will need a grinder that can handle a large amount of food at once to ensure efficient production.
The types of food ingredients you will be grinding also play a role in selecting the right industrial grinder. Some grinders are better suited for specific food products. For example, if you are grinding oily ingredients like nuts or seeds, you may need a grinder that is designed to handle these types of materials without clogging or overheating.
Grinder Size and Capacity Considerations
Ensure that the industrial grinder you choose has the appropriate size and capacity to handle your intended workload. Consider factors such as available space, production volume, and future growth potential.
Available space is an important consideration when selecting an industrial grinder. Measure the area where the grinder will be placed to ensure that it fits properly and allows for easy access and maintenance. It is also important to consider the layout of your food processing facility and how the grinder will fit into the overall workflow.
Production volume is another factor to consider when choosing the size and capacity of an industrial grinder. If you have a small-scale operation with low production volume, a smaller grinder may be sufficient. However, if you have a large-scale operation with high production demands, you will need a larger grinder that can handle the workload.
Future growth potential should also be taken into account. If you anticipate your food processing operation expanding in the future, it is wise to choose a grinder that can accommodate increased production needs. Investing in a grinder with room for growth can save you the hassle and expense of upgrading to a larger grinder down the line.
By carefully assessing your grinding needs and considering factors such as desired particle size, processing capacity, available space, production volume, and future growth potential, you can select the right industrial grinder for your specific requirements. This will ensure that you achieve optimal grinding results and maximize the efficiency of your food processing operation.
Maintenance and Safety of Industrial Grinders
Regular maintenance and adherence to safety protocols are essential for maximizing the lifespan of your industrial grinder and ensuring a safe working environment. Let’s explore some key considerations:
Routine Maintenance Practices
Implementing a regular maintenance routine is crucial for the optimal performance and longevity of your industrial grinder. Cleaning, lubrication, and inspection of critical components should be included in this routine. By following the manufacturer’s guidelines, you can ensure that your grinder operates at its best.
Cleaning your industrial grinder regularly is important to prevent the buildup of debris and contaminants. This buildup can affect the performance and efficiency of the machine. Use appropriate cleaning agents and tools to remove any residue or dirt.
Lubrication is another crucial aspect of maintenance. Proper lubrication of the moving parts reduces friction and wear, extending the life of your grinder. Consult the manufacturer’s recommendations to determine the appropriate lubricant and frequency of application.
In addition to cleaning and lubrication, regular inspection of critical components is necessary. Check for any signs of wear, damage, or misalignment. Replace any worn-out or damaged parts promptly to avoid further issues and potential breakdowns.
Safety Measures and Precautions
Prioritizing safety measures is of utmost importance when working with industrial grinders. By implementing the following precautions, you can minimize the risk of accidents and injuries:
1. Personal Protective Equipment (PPE): Ensure that all operators and maintenance personnel wear appropriate PPE, including safety glasses, gloves, and hearing protection. These protective measures help safeguard against potential hazards such as flying debris, noise, and hand injuries.
2. Safe Operating Procedures: Establish clear and comprehensive operating procedures for the use of industrial grinders. Train all employees on these procedures and ensure that they understand and follow them diligently. Emphasize the importance of proper machine setup, correct tool usage, and safe work practices.
3. Training and Education: Regularly provide training sessions and educational materials to employees regarding the safe use and maintenance of industrial grinders. Keep them updated on any new safety guidelines or procedures. Encourage open communication and reporting of any safety concerns or incidents.
4. Machine Guards and Safety Features: Ensure that your industrial grinder is equipped with appropriate machine guards and safety features. These include protective enclosures, emergency stop buttons, and safety interlocks. Regularly inspect and maintain these safety devices to ensure their effectiveness.
5. Hazard Identification and Risk Assessment: Conduct regular hazard identification and risk assessment to identify potential hazards associated with the use of industrial grinders. Implement appropriate control measures to mitigate these risks and regularly review and update them as needed.
By following these routine maintenance practices and safety measures, you can maximize the lifespan of your industrial grinder while creating a safe working environment for all employees.
The Impact of Industrial Grinders on Food Quality
Industrial grinders have a significant impact on the quality of food products, influencing factors such as nutrient retention, texture, and consistency. Consider the following aspects when using industrial grinders:
Ensuring Nutrient Retention
The grinding process may expose food ingredients to heat and oxygen, leading to potential nutrient loss. Minimize nutrient degradation by selecting an industrial grinder that operates at lower temperatures and with minimal exposure to air.
Texture and Consistency Control
Industrial grinders allow for precise control over the texture and consistency of ground food ingredients. Adjust the grinding settings to achieve the desired particle size and ensure uniformity in your final product.
Industrial grinders for food processing provide essential grinding solutions for various industries. Understanding their functionality, types, selection considerations, maintenance and safety, as well as their impact on food quality, is crucial for optimizing their use and achieving desired results in your food processing operations. So, whether you are grinding spices, herbs, grains, or other food ingredients, make sure to choose the right industrial grinder and maintain it properly to ensure efficient and safe food processing.
Corenco teamed up with Flottweg, the leader in separation technologies and solutions, to discuss higher yields in juice and food processing based on the guide we just published in April 2021!
Whether it’s fruits, vegetables, or other products that you are processing, waste is the enemy of profit. The food processing industry in general (and size reduction specifically) is an exercise in waste management.
The company that can produce the highest yields and maintain the highest quality will always win; however, there is a delicate balance between profit and processing. How do you get the highest yield and highest profit? Watch the Webinar and learn more…
The key focus will be about maximizing yield while reducing waste – which is critical no matter what process you’re using. We will also discuss getting a better understanding of the balance that can be achieved with some small changes so you don’t continue to throw your money away.
Industrial food grinders for the food processing industry – there’s a lot of confusion around these unique pieces of equipment. Specifically, many people don’t understand what they are and what they’re not, and how to tell whether using one would benefit an organization. This is especially true for organizations that have since relied on batch equipment and aren’t sure when they should make the switch to industrial machinery. With that in mind, we’re going to spend this blog talking about what commercial food grinders are and what they’re not, and how to decide when you need to purchase one.
What an Industrial Grinder is Not
Anindustrial food grinder is not a piece of equipment used for short-batch processes that are manually intensive. You would not find one in the home kitchen, for example. These are large, industrial-grade pieces of machinery that deliver output and uniformity. As a general rule, these grinders tend to exist in highly automated and controlled processes. They’re popular in settings where companies are trying to create uniform products in uniform batches. This makes them perfect for commercial food production, for example. They’re also a popular go-to in the world of continuous processing, where they stand toenhance productivity. While not everyone needs an industrial grinder, most operations reach a point where their old batch-style machines can’t keep up, so they decide to introduce some more powerful equipment.
When to Invest in an Industrial Grinder for Your Operation
How do you know when it’s time to purchase an industrial grinder? How can you tell when this equipment would benefit your organization? Here are a few signs it’s time to make the change:
You’re running multiple commercial pieces of equipment. If you want to consolidate yoursize reduction operation, adding a single commercial food grinder can be a great option. In many cases, this industrial system does the job of several pieces of equipment in one. Byimproving the versatility of your operation, you stand to save time, money, and effort.
You’re wearing out your commercial equipment and have begun buying more batch-style equipment. Batch-style food processing equipment is an excellent option, up to a point. Eventually, however, most commercial food production operations start to outgrow their batch equipment. When you realize you’ve started adding additional equipment to meet production requirements, it’s a great time to add an industrial grinder. Adding industrial equipment, rather than duplicating your existing batch equipment, will help level up your output, while also mitigating issues like a lack of uniformity.
Your rate is too slow. If you need to go from hundreds of pounds of production an hour to thousands of pounds of production an hour, it’s time to invest in an industrial food grinder. Not only will this machine increase your output, but it will result in a higher-quality product that can also increase your sales.
You need more sanitary equipment.Sanitation is an ongoing concern in the food processing industry. If you need more sanitary food production equipment, an industrial grinder is a great option. Designed not only for efficiency but also for sanitation and ease of use, these pieces of equipment make compliance easy.
You need a higher quality product. Industrial grinders can enhance the quality of your product and generate more sales for your company. This, in turn, builds your bottom line and makes it easier to grow your operation accordingly.
Choosing the Right Industrial Grinder for Your Needs
If you’re going to invest in an industrial grinder, quality is essential. After all, the point of an industrial mill is to streamline and simplify your operations. You don’t want a piece of machinery that’s going to break down or require lots of expensive upkeep. Additionally, the size and variety of grinder you choose will depend on the ingredients your operation processes, and what you want to achieve in terms of output. While many people believe bigger is better, a too-large grinder will be just as problematic as one that’s too small for your operation to use effectively. As such, it’s smart to work with a company that has a reputation for producing high-quality commercial grinders and industrial food processing equipment. That’s where Corenco comes in. Since every company’s food production equipment needs are different, our customized service is here to help you find the option that works best for you.Contact us today to learn more about our equipment, or to speak with a skilled tech who can help you find the perfect piece of equipment for you.Wet grinding is a critical part of commercial food production in the United States. Unlike dry processing, which involves no moisture, wet processing requires water activity, both in the products and during the processing of them. This water activity may come in the form of water circulation, steam, pasteurization, or sterilization.Utilized to developpet foods, as well as foods for human consumption, wet processing involves mixing ingredients and packaging them in a can, pouch, or tray, where they will later be cooked before distribution. While wet food processing has many benefits, one of the largest is that it allows materials to remain shelf-stable for the entire life of the product or until the container is opened.
What Do You Need to Begin Wet Grinding?
If your organization is considering expanding or entering the wet food grinding industry, you may be wondering what kind of equipment you need to begin. Here’s a breakdown of the five pieces of wet food processing equipment we recommend every manufacturing operation should have:
Dicers are commonly used to make prepared foods, such as veggies and toppings. Take prepared, pre-chopped chicken, for example – it goes through a commercial-grade dicer outfitted with circular blades. This system offers outstanding precision, high output, and less waste. Dicers also produce visually appealing food products, which can help increase a company’s sales. By supporting faster, more sanitary food production, dicers have quickly become a favorite tool in the commercial food production industry.
Shredders are a critical part ofsize reduction equipment. Used to produce materials with uniform thickness, shredders are particularly popular in manufacturing the ingredients for pre-packaged salads and the like.Designed to grate vegetables and other food products rapidly and at scale,shredders can take large blocks of material and quickly reduce them to a size that’s easy to process further. One of their primary applications is in the production of MREs, or Meals Ready to Eat. Shredders make quick work of the various wet ingredients so they can then be packaged and prepared for further production.
Slicers are used to reduce vegetables like whole carrots. A critical part of the wet food production industry, slicers are some of the most flexible types of food production equipment and can go a long way toward increasing the output of your processing program.
4. Comminution equipment
Today, many wet food products are pureed. This puree process requires the inclusion ofComminution equipment. Today, comminution equipment is prevalent in the tomato processing industry, for example, and is an integral part of the production of tomato paste, tomato puree, tomato sauce, and more.
In America, food ishomogenized to make it shelf-stable for human consumption. Here’s how theEncyclopedia Britannica defines homogenization:Homogenization is the process of reducing a substance, such as the fat globules in milk, to tiny particles and distributing it uniformly throughout a fluid, such as milk. When milk is homogenized correctly, the cream will not rise to the top. The process involves forcing the milk through small openings under high pressure, thus breaking up the fat globules. Cream and other food products, such as peanut butter, may also be homogenized to produce a stable emulsion, i.e., one in which fats or oils will not separate from other elements. A similar process is used in the manufacture of some cosmetics and pharmaceutical products.As you can see, homogenization is a complex process, and it requires a complex piece of equipment. This is where the role of commercial homogenizers comes in. Designed to serve as the final step in the production process of liquids, including milk, ketchup, mayonnaise, and baby food, homogenizers help protect foods, extend their shelf-life, and deliver value – both to the producer and the consumer.
Putting Together a Functional Wet Grinding Operation
Wet grinding is a critical part of the overall food production industry. If you’re interested in enhancing your wet food processing equipment, these five crucial pieces of machinery are here to help. Designed to provide a high-quality finished product, improve output, and more, these five pieces of wet food processing equipment are a must-have for any operation. Not sure what you need for your wet food processing operation?Contact Corenco’s reps. Our team specializes in helping operations identify the most useful pieces of equipment for them, and will be happy to walk you through our selection of products. Let us help you build the wet food processing lineup you need to grow your business. The disintegrator machine: it’s durable, strong, and meant to process tough material easily and efficiently. Because of these traits, most people think they can buy size reduction equipment, dump material into it, and just walk away. In some cases, this assumption isn’t unfounded – many food processing experts are familiar with batch equipment which allows you to do just that.For continuous food processing, though, like the processing of cheese for pizza toppings, that’s not the case. Instead, you need a metered feed. In this piece, we’ll dive into the importance of a metered feed, and how to create it for your size reduction equipment.
Two Primary Benefits of a Food Disintegrator Metered Feed
Generally speaking. Most pieces of size reduction equipment require a metered feed. This is true for the following reasons:
More efficient material processing. If you dump material into a food disintegrator, the grinder will consume as much product as it has the horsepower to consume. If you drop a barrel of onions into the disintegrator, for example, it will try to process all of those onions in a millisecond. However, usually the machine doesn’t have sufficient HP to do that, so it will typically jam, causing it to stall completely. Metered feeds, on the other hand, allow the food disintegrator to process material entirely and efficiently at a prescribed or ‘metered’ rate, rather than becoming overwhelmed by a large batch of material all at once.
Improved consistency. Metered feeds improve product consistency. Instead of creating product-on-product grinding, metered feeding results in consistency and diminishes product kickback and heat-related issues.
How to Create Metered Feeding
The traditional way to facilitate a metered feed is to have a person do it. To put this another way, to have someone hand-feed the machine from a five-gallon bucket is the easiest way to facilitate metered feeding. Unfortunately, it’s also not the most efficient, and it doesn’t scale well when production starts to increase. This approach won’t work in large factories, for example. As a result, most people use mechanical feeding options. You can pump into a machine, like an in-line orangle disintegrator, for example, or use belt conveyors, screw conveyors, or vibratory feeders to create a continuous feed. These feeding methods allow you to maintain a consistent feed rate and free your team up to do other things.When you find the right mechanical feed tool and run it at the right speed for your material, you can conduct your food processing operation at optimal efficiency. Even better, the inclusion of a feedback loop between the grinding equipment and the variable speed feeder drive allows you to modulate feeder rate with increases or decreases of the RPM of your grinding machine.
How Variable Frequency Models Work
Ideally, in a process line, you’d have feedback between the grinder and the feeder. This is particularly helpful in continuous situations. If you have a feeder that is set up on a programmable logic controller (PLC), for example, you can have a feedback loop in the mill that tells the feeder what the load is on the grinder. For example, if the grinder is running at 50%, the mill tells the feeder it can process more and that the feeder should speed up. Variable frequency models are the most efficient way to feed a disintegrator machine and have become much more widely deployed in the food processing industry. This variable frequency model allows your equipment to adapt intelligently to products, processing capacities, and production demands, creating a more efficient operation for you.
Corenco: Your Source for Metered Feeding for Your Disintegrator Machine
If you need help making decisions about how to feed your disintegrator machine,give us a call. We can help. Our team will provide individualized recommendations based on your specific product, need, and application. If you’re not feeding your machine fast enough or running at full load, you’re not getting the available capacity out of your equipment. We’ll help you use your machine to its full potential and avoid easily-avoidable production interruptions, both now and in the future. For decades, paint has caused issues in food production. Thousands of food production companies struggle each year with painted or coated equipment and the myriad of issues they bring. While paint related issues can be a difficult problem to solve, there are several sensible approaches modern food and beverage processors can take. The simplest solution is the implementation of stainless steel motors which eliminates the risk of chipping paint.
The State of Food Processing Motors: Then and Now
While stainless steel motors seem obvious in the world of food production, for years they were relatively unavailable, especially with motors above 10 horsepower.While washdown-duty motors have been available (motors specifically designed for use in food processing and other applications where the equipment is routinely exposed to washdown, chemicals, humidity, and moisture,) they were all painted.Food processing standards have been increasing over the years. Today, the industry has very high standards for both food safety and cleanliness. The widespread demand for stainless steel motors grew from these sensibly high standards and process equipment manufacturers can now affordably offer these options.
How Paint Chips Happen
Obviously cleanliness is essential in food processing and the chemicals used to sanitize these environments must penetrate and permeate adequately to sanitize. Today’s ultra-stringent standards and regulations lead to cleaning agents that strip paint from food processing equipment, possibly leading to paint that flakes into product during processing.Most painted motors don’t last more than two months before chipping and flaking begins. When the flaking does start, people scrub the affected motors in an attempt to clean them. This chips the paint more creating an unending cycle of greater uncoated metal and resulting rust.The presence of rust represents a red flag for inspectors, who may imparthefty related issues fines if they see flaking has begun. Traditionally, the method for fixing the problem is to paint the motor regularly. Unfortunately, each additional coat of paint added to the motor has an increased propensity to crack and flake, which only exacerbates the problem.While some motors arrive from the factory already painted, very few manufacturing plants will tolerate factory-issue motor paint that is not white. White paint shows imperfections and wear more easily. As a result, manufacturers are trying to paint their new motors white. Unfortunately, white paint will often not adhere to a factory-issue undercoat, and this approach creates a higher risk of chipping and wear.
Stainless Steel Motors and RTEs
Today, ready-to-eat foods (RTEs) have become very popular. As a result, food processing plants around the world are producing them, including meats, cheeses, and more. While these foods are popular and delicious, they also contribute heavily to an environment providing ideal growing conditions for bacteria, including Listeria monocytogenes which can cause Listeriosis which is a serious infection. There are many ways to prevent bacterial growth in RTEs, and one of the most effective is simply maintaining smooth surfaces throughout a food production plant, including the walls, floors, and all food preparation surfaces. When these surfaces are flat and flush, they’re easier to clean and less likely to harbor bacteria. Stainless steel motors make an excellent contribution in the battle against RTE related issues, since they perpetually maintain a smooth surface, resist corrosion and cracking, and are not painted so there is no flaking.
How Stainless Steel Motors Improve Sanitation
Stainless steel motors possess several properties that painted motors do not. They:
Are easy to clean
Are impervious to cracking, and flaking
Withstand today’s food processing solvents and cleaners.
If you’re interested in investing in a stainless steel motor, you’ll find that they are easy to source up to about ten horsepower. In most places, you can buy them “off the shelf”. If you need a machine with more than 10 horsepower, you’ll essentially need to have a custom motor built for you. While customizing a motor is expensive, it is a long-term investment in that you won’t have to contend with the paint issues we just discussed above.Because these stainless steel motors are mostly custom-built, they’ve also been evaluated carefully. Any time you order one of these motors, you can generally trust that there is a real person in the USA looking over every component of your motor. This creates a higher-quality product that would be expected to last longer than stock options. Additionally, there’s no difference in cleaning the stainless motor- use exactly the same solvents and pressure washers without worrying about paint issues. If you’re interested in investing in stainless steel motors, contact Corenco. Our team will help you understand our various options and find the right machine for your needs.In the world of commercial food production, grinding is a critical part of many manufacturing processes. Single pass food grinding on it’s own is not enough to produce many of the products we know and love, here’s why:The amount of work you can do in a single pass on size reduction equipment is limited – both by the properties of what you’re feeding and by the target size of the material. Because of this, some material requires double pass grinding. In this post, we’ll discuss the benefits of double pass grinding; where it’s used in commercial food production, and which machines are best for companies who require double pass grinding.Let’s dive in.
First Things First: Why Double Pass Grinding?
Sometimes, food grinding can’t be a “one and done” process. When it comes tosize reduction, the laws of physics dictate that you can only do so much work in a single pass.A classic example is in the reduction of a twenty-pound wheel of parmesan cheese. Say you need to grate this large wheel of cheese for pizza topping. Pizza topping requires a nice, fine grind with no chunks or large clumps of product. If you try to reduce the entire wheel in a single pass, though, you’ll end up with one of two outcomes: you’ll either overheat your material or destroy your machine. Instead, begin by reducing the wheel of cheese into small pieces via an initial grinding pass – chunks of 0.75”, for example. Once you’ve made a single pass and reduced the material to 0.75”, you can take this output and grind it once again, through a different machine, to create a smaller particle size. This is called double pass grinding. While double pass grinding is common in commercial uses, it’s also utilized by at-home chefs grinding meats and other products. The process of double pass grinding is essential for a few reasons. The first and most obvious is that it reduces the load on both machines during passes. The amount of load it takes to process a large product directly into its final form factor can be massive. For example, the rotating imbalance of flinging around a 20 pound block of material is enormous and potentially damaging. The objective for companies is to get the material through the mill as quickly as possible without negatively impacting the product or the machinery. Double pass grinding can greatly increase the efficiency of the size reduction operation. This consideration is especially critical for a product which will melt under high heat loads.
Which Foods Require Double Pass Grinding?
Double pass grinding is more widespread than you might imagine. Even machines that grind things to super-fine dimensions (think chemical and pharmaceutical processing, for example) requires a head start. As powerful as some machines are, they often can’t take a massive piece of material and grind it down to something superfine in a single pass. Theflour industry is a perfect example of the need for multiple pass grinding. Some flour mills use seven-passroller mills, for example. These mills process the same material again and again, at an increasingly finer particle size, until it reaches the desired granularity. Additionally, double pass grinding is exceptionally useful in reducing clumps, lumps, and leftover large particles in many different foods.
Can You Double Pass on the Same Machine?
It is possible to double pass a product on a single machine. The only consideration is that you cannot undergo the second pass with the same sized screen if you want a finer product. Instead, you must switch to a finer screen, which will effectively deliver the same results as a multiple pass machine, processing the material at an increasingly smaller particle size until it reaches the desired consistency.
Double Pass Food Grinding: A Critical Addition to Size Reduction Processes
In the world of grinding, double passing is an important and common approach to creating a super fine finished product. By running material through several food grinding machines or using progressively finer screens on successive passes, manufacturers can create the particle size they want for their product without causing excessive heat or load on their machines during the process. If you’d like to learn more about double pass food grinding, or which machines are ideal for double pass food grinding,contact Corenco today. Our staff will be happy to help.
55-gallon drums are a convenient way to acquire frozen product, but can be a pain in the neck to deal with. Not only are these drums large and unwieldy to move around, but they take a long time to thaw. At most plants, food processing companies deal with this problem by leaving drums of material outdoors to thaw.
The big issues with that solution are that they don’t let them thaw out long enough and the center remains frozen. Alternatively, companies let them soften too long, risking spoilage.If you have a frozen kernel in the middle of the drum, the core will mostly be water.
Orange juice concentrate is a great example: the water freezes before the sugar, so you wind up with a frozen drum of juice that’s mostly sugar on the outside with a hard kernel of ice in the middle. To transform it back to orange juice, you then have to break up the ice ball, add water, and mix. Introducing size reduction equipment not only dramatically speeds up the thawing process, but also prevents damage from under-thawed material in downstream processes.
Thaw 55-gallon drums of Material
The easiest way to deal with these large drums of material is to conduct the entire process while the material is still frozen. Unfortunately, there’s not much equipment out there that can do it. Most rotary chippers designed for this are ineffective and slow. Other pieces of equipment, like the Reitz Extractor, for example, serve different purposes. The Extractor is a large, stainless steel, high-capacity, meat grinder. While the machinery is robust, it is too expensive or unsanitary for many companies.
Because of that, some companies use Crushers, which is what we manufacture here at Corenco. Crushers are a less costly method of processing large amounts of frozen material, from 5-gallon buckets to 55-gallon drums. Thaw 55-gallon Drums of Frozen Product – These Crushers reduce content down to softball-sized or smaller chunks. Many companies utilize a subsequent milling step to further reduce their material to a “snowcone,” or a pumpable, slurry.
Why Crushers Are So Helpful
Crushers are versatile machines that were designed specifically for reducing large bulk products to manageable sizes. This allows manufacturers much more flexibility in their downstream processes. By running your materials through a Crusher or Grinder, you can streamline production and increase capacity.For an example of these machines at work, check out thisvideo of a Corenco C24 crusher grinding a 55-gallon drum of frozen juice.As you can see, running the ingredient through the size reduction equipment takes a process that would require hours to thaw naturally and reduces it to just a few seconds. The product will then thaw out evenly and be ready for additional processing.
Thaw Frozen Food the Easier Way
Size reduction improves the efficiency and productive capacity of processing lines that involve large bulk/frozen products. Corenco’s Crushers can be found all over the world tirelessly performing size reduction with minimal upkeep and maintenance. Our technology helps streamline the thawing process and ensures faster processing times for our customers, andCrushers by Corenco will go a long way to improve and enhance your product thawing efforts. If you’re interested in investing in machinery that could streamline your thawing or bulk product size reduction process,contact Corenco today. We manufacture many lines of durable, reliable size-reduction equipment meant for a wide variety of applications. We’re happy to help you navigate our selection and find the products that are perfect for you.
In the past several years, nut products have become all the rage. An excellent alternative to dairy products, nut milk, butter, and paste offers a higher nutrient content, less fat, and fewer allergens than standard milk products. And thanks to advanced nut processing equipment, they’ve become more popular than ever before. In fact, the global peanut butter market was worth a staggering $3 billion in 2017, and it’s only grown since then. What’s more, the average American consumes about 6 pounds of nut products each year, with about half of that being some form of nut butter. If you’ve ever wondered how nuts are processed, and whether it’s possible to make nut milk from butter or paste, here’s what you need to know:
Why People Love Nut Butters
When we process nuts by grinding them to make them into nut butters, we change the way people consume and interact with them. Grinding the nuts makes it easier for people to consume them, digest the nutrient content of the nuts, and incorporate them into their daily diets. In addition to being convenient and easy to consume, nut butters also pack a dense punch of nutrients. Nut butters are high in fiber, micronutrients, anti-inflammatory fatty acids, and omega-3 fatty acids, to name a few. They’re also excellent sources of protein, and are the perfect grab-and-go snack for people who need something healthy and filling in the middle of a busy day. Today, the average 2-tablespoon serving of nut butter typically contains about 190 calories, 16 grams of fat, 6 grams of protein, and carbs between 0-8 grams. Whether it’s cashew butter, almond butter, or even hazelnut butter, a growing number of people enjoy these tasty treats.
What is Nut Milk?
Nut milk is, in essence, exactly what it sounds like: milk made from nuts instead of dairy products. Today, most commercial nut milk contains about 5%-15% almonds, soy, or cashew matter, with the rest of the mixture water, sweeteners, binding agents, and thickeners added. Homemade nut milks generally have a slightly higher concentration of nut products. Usually, homemade nut milks are made up of about 30% nut products. These mixtures have no additives unless the home cook has included them. Home cooks can make nut milks with a mixture of 1 1/2 cups water and three tablespoons nut paste. The resulting drink will have about 12% nut matter, if the cook leaves it unstrained.
Dry Roasting: Batch vs. Continuous
Before nuts can be processed, they must be roasted. Dry roasting is either done by the batch, or via a continuous method. Here’s a breakdown of each:
In the batch method, peanuts are roasted in massive lots in a large, moving oven that reaches temperatures of 800 degrees Fahrenheit or higher. The amount of time the peanuts are roasted depends on the size of the batch and the desired purpose.
In the continuous method, peanuts are fed into a hopper, where they’re roasted, cooled, and ground into peanut butter. This method is quick and less labor-intensive. It also creates a more uniform roasting.
The batch method allows for the different kinds of nuts or nuts meant for separate applications to be roasted separately, which is a positive for companies making nut blends. Batch roasting is also popular since peanuts and other nuts include lots of different moisture levels and may need special consideration throughout the roasting process, which batch roasting can deliver.
While batch roasting may work for some production goals, continuous roasting is better for others.
A Note on Granulating
Granulating is another important niche method of nut processing. Granulating refers to the process of making nuts into an ingredient which most people have seen used for the top of ice cream cones. It involves grinding nuts to uniform size and not making a paste. The key to granulation is not producing a lot of fine material. While that seems straightforward, there are not many nut processing equipment technologies available for this. While dicers are applicable and practical, companies also use Angle disintegrators.
Investing in the Right Nut Processing Equipment
Nut processing equipment is critical to ensuring proper nut processing. Investing in the right materials is also essential. When you partner with a company likeCorenco, you know you’ll get high-quality, durable nut processing equipment you can rely on. When it comes to food grinding, there are dozens of different methods to choose from, and dozens of food grinding machines to do it on. Whether you’re grinding material for food production or preparing ingredients, these types of food grinding are most popular:
Juice processing is one of the most common applications in fruit and vegetables industries. While many people imagine that juice production involves the juicing of whole food items, that’s not always the case. In fact, many whole food products must be ground or crushed before they can be juiced. This, of course, requires the assistance of food grinding machines, specifically crushers and angle disintegrators, even for large, difficult-to-move items like apples or pineapples.
Food Powder Production
Dehydrated powdered material is a major product for the food industry. Food powders are used as baking additives, drink additives, supplements, nutraceutical supplements (any food supplement that doesn’t require FDA approval), whey powder, potato starch, and more. Food powders and dehydrated ingredients are also popular in certain military and survival applications. Powdered and dehydrated foods are common in Meals Ready to Eat (MREs), which are widespread throughout the military and backpacking communities. Because the food powders are so diverse, the methods of producing them are equally diverse. The machines used to create these items include roller mills, pin mills, and hammer mills for milling powders and flour. It all comes down to product characteristics and demands of the system.
Flour is a critical ingredient in baking, cooking, and more throughout the U.S. and the world. When it comes to ready made baking mixes, deglomeration of ingredients is an important consideration.Deglomeration refers to the process of breaking up oil chunks in things like baking mixes that include oil sometimes called “prills”. Deglomeration breaks up the combination of oil and flour and makes for a consistent mixture.
Aside from juice production, grinding is also used to prepare ingredients to be made into a paste, to produce products like canned baby food, and to process certain food additives and ingredients. Finally, grinding is an important part of oil production. Before they can be made into oil, olives, avocado flesh, and seeds must be crushed to release and extract the natural oils within the casing of the ingredient. This second process is sometimes called “expelling”.
Choosing the right type of food grinding machine depends substantially on your budget, process, and production needs. No two applications are created quite the same, and no two setups should be, either. Here are a few tips for finding the right fit for you:
Think about output. What do you need in terms of production? Organizations that need larger output quantities will benefit from choosing a machine that can keep up with performance requirements. Smaller operations, meanwhile, may benefit from smaller equipment that doesn’t provide the same level of capacity. Since this equipment is also likely to be less expensive, it’s more affordable for small companies.
Consider your budget. Budget is, of course, a significant consideration when it comes to finding an excellent grinding machine. While you can find a wide selection of food grinding machines, they’ll come at prices ranging from a few hundred to thousands of dollars. Make sure you’re shopping machines that work for both your application and your pocketbook.
Grind needs. Do you need to grind your items once or take two passes at the material? If you need to make two passes, you’ll need to find a machine that can suit this. Generally, it’s possible to make two passes through most devices, although you may need to change out screens to do so.
Finding Your Ideal Food Grinding Machine
Once You know what type of food grinding you’ll be doing, you can invest in a food grinding machine that will support it. By shopping with a reputable manufacturer, you can secure high-quality equipment that will serve your company and your needs for many years to come. Need some additional assistance finding the food processing machine of your dreams?Contact Corenco today.