food institute pilot plant - ge.mam.tubitak.gov.tr · the pilot plant was founded in 1972 to...

FOOD INSTITUTE

PILOT PLANT

FOOD INSTITUTE

PILOT PLANT

Gebze, KOCAELI

2018

TABLE OF CONTENTS

INTRODUCTION 1

HEAT TREATMENT EQUIPMENT 3

DRYERS 3

HEATING-STERILIZATION 11

EVAPORATION 18

EXTRACTORS and SEPARATORS 19

MIXERS and HOMOGENISATORS 35

GRINDERS 44

BAKERY PRODUCTION EQUIPMENTS 47

HAZELNUT PROCESSING EQUIPMENTS 53

MEAT PROCESSING EQUIPMENTS 63

TABLET PRESSING MACHINES 66

PACKAGING MACHINES 68

INDUSTRIAL KITCHEN 75

1

INTRODUCTION

The pilot plant was founded in 1972 to support food industry with research and product development

studies. Its physical infrastructure and equipments were renewed in 2006 and it was moved to a new

building in 2012.

The pilot plant, sited on 1700 m2 of floor space, has a total area of approximately 3500 m

2. The largest

part of the plant is the Production Hall where equipments for food processing are located. The hall has

a total area of approximately 1000 m2. Various food processing equipments have been located in the

area. In addition, the pilot plant has a total of nine separate units with a total area of 700 m2. The

equipments related to processing and packaging of fruits, vegetables, meat products, dairy products,

bakery products and dried fruit are located in these areas.

Next to the production hall, there are six cold rooms with different cooling capacities (from -40 ° C to

+15 ° C) those are suitable for storing raw materials and final products.

In the pilot plant, national and international research and product development activities are performed

for specific product groups. Some studies such as new product development, improvement and

process optimization in product formulation, testing different process conditions are carried out. In

addition, the plant is suitable for demonstration activities of food industry.

2

In the context of industrial services, the application and admission requirements for the routinely used

equipments in the pilot plant are described under the “Activity Areas” heading “ “Industrial Services of

Food Institute" at the following web page: http://mam.tubitak.gov.tr. Other requirements and

information about the pilot plant operating conditions can be accessed using the following contact

details.

Addre ss: TUBITAK Marmara Research Center Food Institute

P.O.Box. 21, 41470 Gebze-Kocaeli

Phone : +90 262 677 32 00

Fax : +90 262 641 23 09

E-mail : [email protected] r

This catalogue presents the food processing equipments including the properties and applications in

the pilot plant of Food Institute.

http://mam.tubitak.gov.tr/

mailto:[email protected]

Heat Treatment Equipments-Dryers

3

FLUIDIZIED BED DRYER

Properties:

Process Chamber : GF3 (1-5 L)

Starting material : 0,2-1.2 kg

Spray Speed : 2000 g/h

Fludization speed : up to 3 m/s

Compressed air pressureı : 6 bar

Applications:

Fluidized bed technology can be used in food industry in order to perform drying, granulation, agglomeration, coating and encapsulation processes.

Instant foods (coffee, soy milk,whey powder and cocoa that are easily dissolved in water or milk),

Dry soup mix,

Healthy food extracts,

Process aids (enyzmes,yeast,etc.),

Colorants,

Preservatives (acid and salts),

Nutrient supports (vitamin and minerals),

Aroma and flavour compounds (natural and synthetic),

Spices


4

SPRAY DRYER

Properties:

Feed rate : 7-15kg/hour

(changing according to product properties)

Nozzle head : Atomizer

Hot air system : Electric

(gradually 5 pcs, total 36 KW)

Particle size of final product : 5-100 micron

It is ideal for pilot scale studies.

Applications:

It is used for the production of dry solids in powder or formation of agglomerated particles from a liquid

feedstock. The feedstock can be in the form of solutions, emulsions, orpumpable suspensions. It is used for

the production of milk powder, coffee, tea, eggs, cereal, spices, flavourings, starch and starch derivatives,

vitamins, enzymes, colourings. It can also be used for the production of antibiotics, medical ingredients, and

additives.


5

MINI SPRAY DRYER

Properties:

Max. temperature input : 220 0C

Nozzle tip diameter : 0.7 mm

Possible particle diameter range:1 -25 µm

It allows working with acids, organic

solvents or mixtures of aqueous - and

organic solvents safely

Ideal for laboratory scale drying processes

Applications:

It is used for the purpose of drying, granulation, agglomeration, coating and encapsulation processes for wide range of applications such as to cut off contact of main material with outside (heat, light, O2, etc.), to

provide easy handling to product, to transform the liquids to powder form, to decrease volume, to increase the flow ability of powder products, to mask aroma and flavour compounds, to protect sensitive compounds, to prevent nutrition losses, to enable controlled release of compounds, etc.

This process is applicable in various fields such as pharma, materials, chemistry; food (instant food products, essential oil, flavour and aroma compounds, microorganisms, etc.) feed (enzymes), beverages,

etc.


6

NANO SPRAY DRYER

Properties:

Max.temperature input : 120 °C

Airflow : 80–160 L/min.

Air, N2/CO2 gas input press. :max.2 bar

Particle diameter range :300nm-5µm

It allows working with acids, organic solvents

or mixtures of aqueous and organic solvents

safely

Applications:

It is used for the purpose of drying, granulation, agglomeration, coating and encapsulation processes for

a wide range of applications such as cut off contact of main material with outside (heat, light, O2, etc.), to give easy handling to product, transform the liquids to powder form, to decrease volume, increase the flowability of powder products, to mask aroma and flavour compounds, to protect sensitive compounds, to

prevent nutrition losses, and to enable the controlled release of compounds, etc. This process is applicable in various fields such as pharma, materials, chemistry, food (instant food

products, essential oil, flavour and aroma compounds, microorganisms, etc.) feed (enzymes), beverages, etc.


7

FREEZE DRYER

Properties:

Lyophilisation speed : 24L/day (theoretical

value)

Number of shelves : 6

Drying Area : 1.03 m2

Temperature : -65 +80 C

Vacuum pump capacity : 20.50m3/h

Applications:

This device can be used to dry products in glass vial or bulk at very low temperatures under vacuum. It can

be applied to dry fruits and vegetables and to dry liquids to obtain powders.


8

DRUM DRYER

Properties:

Feed rate : Variable

Rotation speed : Variable

Operating condition : Pressurized steam

Applications:

It is used for drying liquids. It is available for drying of insensitive heat treatment foods. Some

products where drum drying can be used are starches, breakfast cereals, baby food, instant

mashed potatoes, milk powder to make them cold water soluble.

http://en.wikipedia.org/wiki/Starch

http://en.wikipedia.org/wiki/Breakfast_cereals

http://en.wikipedia.org/wiki/Baby_food

http://en.wikipedia.org/wiki/Instant_mashed_potatoes

http://en.wikipedia.org/wiki/Instant_mashed_potatoes


9

TUNNEL DRYER

Properties:

Feed rate : Manuel

Operating condition : Pressure steam (max.:150°C)

Fixed-speed dual-carrier

Conveyor (stainless)

Applications:

It is used for drying all kinds of fruit and vegetables, and some animal foods. It is available for sterilisation and

pasteurization of packaged food. It can also be used for cleaning of packaging materials (glass, plastics, metals

etc. ) which are insensitive to heat treatment before filling treatment.


10

CERAMIC MEMBRANE FILTRATION

Properties:

Membrane area :0,29 m2

Operating prsessure : 2-10 bar

Max.Operating Temp. : 150 oC

Max. Cleaning temp. : 80 o

C

Allowable pH : 0-14

Solvent stability : Unaffected

Applications:

Liquide-solid seperation

Liquide-liquide seperation

Heat Treatment Equipments- - Heating&Sterilization

11

THE VACUUM PROCESSING UNIT WITH EXCHANGEABLE HOMOGENIZER

Properties:

Processing vessel volume : 3 L-12 L (totally15 L)

Homogenizer : 600-5000 rpm /50Hz

Scraper agitator : max.50 rpm/50 Hz

Temperature : 0-140°C

Air humidity : 0-80%

Applications:

It is used for the manufacture of all semi-solid products such as suspensions, emulsions and gels. It is ideal

for the development of new recipes from formulation to full production as well as for scale up of a wide

range of semi-solid products such as suspensions, crèmes, emulsions, gels, sauces or dressings.

Heat Treatment Equipments- Heating&Sterilization

12

MULTIFUNCTIONAL PROCESSING SYSTEM

Properties:

Tank capacity : 40 L

Scraper agitator : Max. 3000 rpm

Vacuum : Max.-980 mbar

Product Temperature : up to 120°C

Pressure : Max.+800 mbar

The main unit consists of double jacketed bowl, stainless steel body, lighting and touch screen.

Applications:

It is a multifunctional machine for preparing foods. It cooks, cools, concentrates, kneads, refines, cuts,

mixes, homogenises, and pulverises all types of food products. It is used for making custard and any kind

of cream, chocolate-based products, spreads, pastes jellies, candied fruit and mixtures, tomato puree,

concentrates, ready-made sauces, vegetable creams, mayonnaise, homogenised products for baby food

and special diets, mixtures.


13

AUTOCLAVE

Properties: The static water cascade type retort system is equipped with an automatic temperature and pressure

control system. Foods can be sterilized or pasteurized at max 4 bar pressure and 120 °C.

Applications: The retort can be used to sterilize or pasteurize foods which were packed with heat resistant packaging

materials (metal, glass, plastics). The core temperature of packed food can be monitored during heat

treatment by the help of Ellab temperature probes. The retort has only one basket and the amount of

product which can be treated at each trial depends on the packaging size.


14

BATCH PASTEURIZER

Properties:

Capacity : 150 L

Temperature: max. : 95°C

It has an agitator paddle, double-jacketed boil, digital display screen which is possible to pre-set 4

different product recipes.

Applications:

It can be used for the pasteurization and the production of all kinds of products, such as milk, cream,

yoghurt, liquid egg, fruit juice, etc.


15

PLATE HEAT EXCHANGER

Properties:

It consists of feeding tank, chilli cooling unit, heat exchanger and pump.

Capacity : 50 L/hour

Filling : Manual

Programmable board

Applications:

It can be used for the pasteurization of milk and milk products, clear fruit and vegetables juice.


16

DOUBLE JACKETED BOILER UNITS

Properties:

It is available for cooking and pasteurization under steam.

Feeding : Manual

Capacity : 250 L and 50 L boilers

Double jacketed units

Heat control unit

Applications:

It is available for blanching and cooking of fruit and vegetables and brewing of herbs.


17

BRINE TANK

Properties:

Manual filling

Steam Heating

Ciller cooling

Applications:

It is available for preparing various brines. It can be used for the pasteurization of packaged products

Heat Treatment Equipments-Evaporation

18

FALLING FILM EVAPORATOR

Properties:

Feeding : min 40-50 L

Flow rate : 40-100 L/hour

Steam double jacket system

Heat control unit

Evaporation under vacuum

Applications:

It is used for concentration of liquids like milk and fruit juice.

Extractors and separators

19

SUPERCRITICAL CARBON DIOXIDE EXTRACTION SYSTEM

Properties:

Max. extraction temperature : 120 0C

Max. extraction pressure : 500 bar

Modifier pump : Available

Extractor volumes : 1 L solid extractor, 2 L liquid extractor

For pilot scale studies

Applications:

It is possible to obtain high value-added products with no petroleum solvent and no toxic substances by this

“Green Technology” extraction system. Pilot scale extraction of herbs, spices and fragrances,

pharmaceuticals/nutraceuticals, nicotine and caffeine, pesticides, oil from oil seeds, and natural colour

substances are the examples for the applications of this technology.


20


Properties:




Extractor volumes : 5,10 & 24 ml

For small scale studies

Applications:

It is possible to obtain high value-added products with no petroleum solvent and no toxic substances by this

“Green Technology” extraction system. Extraction of herbs, spices and fragrances,

pharmaceuticals/nutraceuticals, nicotine and caffeine, pesticides, oil from oil seeds, and natural colour

substances are the examples for the applications of this technology.


21


Properties:



Max. CO2 heater temperature : 180 0C

Extractor volumes : 300 ml, 1L


Has aroma capture unit.

Applications:

It is possible to obtain high value-added products with no petroleum solvent and no toxic substances by this “Green

Technology” extraction system. Extraction of herbs, spices and fragrances, pharmaceuticals/nutraceuticals, nicotine and

caffeine, pesticides, oil from oil seeds, natural colour substances and aroma compounds are the examples for the

applications of this technology.


22

SOLID LIQUIDE EXTRACTION DEVICE

Properties:

Extraction Temperature Range:

room temperature-100 oC

Evaporation capacity : 75 kg/h

Extraction tank volume: 150 L

Vacuum evaporation

Applications:

Extraction for plant materyal (tea etc.)

Concentration under vacuum for extract


23

ROTARY EVAPORATOR

Properties:

Bath capacity: 20 L

Distillation capacity (ethanol): up to 13.5

liters/hour 3600 W heater

Temperature range: room temperature up

to 180 o

C

Rotation speed: 5-140 rpm

Pressure in the glass assambly: 0 mbar to

ambient pressure

Applications:

Recycling of solvents

Performance of extractions

Concentrating of active agents

Separating of substance mixtures


24

REACTOR/FILTRATION/DISTILLATION UNIT SYSTEM

Properties:

Glass reactor: Volume: 5 L Temperature: -60°C/+200°C

Pressure: -1/+ 1 bar Volume of Receiver : 4 L (for distillation)

Agitator Speed: 0-600 rpm

Nutch filter

Volume: 10 L, Temperature: -60°C /+200°C

Pressure: -1/+ 0,5 bar

Filters: mesh size 20, 60 ve 100 micrometer

Applications:

The reactor / filtration / distillation unit system is suitable for extraction, filtration, distillation,

purification, phase separation for azeotropic mixtures, multi-component reactions, and

crystallization processes.


25

JACKETED GLASS REACTOR

Properties:

Volume: has two separate glass

chambers of 5 L and 20 L

Temperature: (-110°C) - (+230°C)

Jacketed for heating and cooling

Applicable vacuum: -Up to 0.095

MPa

Speed: 40 – 1200 rpm

Digital speed control

Mixer type: PTFE Propeller (Teflon)

Leak-proof bottom flush valve

Applications:

The reactor is suitable for extraction, distillation, purification, phase separation for azeotropic mixtures, multi-

component reactions and crystallization processes.


26

ULTRASOUND EXTRACTION SYSTEM

Properties:

Operational frequency : 20 kHz

Amplitude control : %50 - %100

Applications:

There are no limits of applications of the ultrasonic processor in biology, medicine, chemistry and

technology. Dispersing, homogenizing, deagglomeration, particle size reduction, emulsifying, cracking of

bacteria and sonification of liquids in flow or batch operation processes can be studied with the system.


27

CONTINUOUS EXTRACTOR

Properties:

Product feed rate : 7-14 kg/hour

Water flow rate : 27-140 L/hour

Extract flow rate : 10-28 kg/hour

Slope : Adjustable

Double helicoidally screw design

Applications:

It can be used to have instant tea from tea leaves, instant coffee from coffee seeds, water soluble extracts

from fruits and vegetables.


28

PRE BLANCHING MACHINE

Properties:

Conveyor : Single screw

Filling : Manual adjustable tilt

Screw feet rate : 2-10 cycles/ min

Temperature and time control

Double-jacketed steam heating

Applications

It is used for pre-heating and blanching of fruit and vegetables.


29

REVERSE OSMOSIS – ULTRAFILTRATION UNIT

Properties:

Product flow rates :9-15-18-30 L/min

Permeate flow rate : 5-50 ml/min

Feed tank capacity : 15 L

Permeate tank capacity : 15 L

Membrane module tube volume: 75 ml

Can be used at pressures up to 55 bars

Applications:

It can be applied for concentration, clarification and fractionation of milk, whey, fruit juice and vegetable

juices. It is also suitable for processing liquid wastes, enzyme, antibiotics and organic acids.


30

SEPARATOR-1

Properties:

Product feed : Automatic

Centrifuge speed : 10.000 rpm

Product feed rate : Min. 30, max. 150 L/hour

CIP system

Applications:

It can be used for the extracts of fruit-vegetable, herbal tea. It is not suitable for high viscous samples.

It can also be used for milk and for liquids with a viscosity close to that of milk and a particle size below 20

microns such as fruit and vegetable extracts and herbal tea.

.


31

SEPARATOR-2

Properties:

Product feed : Manual

Centrifuge speed : 7.900 rpm

Product feed rate : Min. 20, max 140 L/hour

Applications:

It can be used for the extracts of fruit -vegetable, herbal tea, milk and liquids which have viscosity close to

milk and particle size below 50 microns.


32

PACKING PRESS for FRUIT and VEGETABLES

Properties:

It consists of 3 main parts: Shredder, grinder, press

Manual filling

Hydraulic press (1-15 tons adjustable)

Shredder : Constant speed

Grinder : Constant speed

Applications:

It is used for shredding, grinding and pressing of fruits and vegetables.


33

PULPER

Properties:

It consists of two units: core separation unit, extraction units.

Applications:

This machine is suitable for extraction of pulp from most fruits and vegetables. It is used for separation of

core and shell of vegetables like tomato products. It is not available for hard-core or shelled products. It is

used for pasting of pitted olives.


34

OIL SEED PRESS MACHINE

Properties:

Capacity : 24 kg/h (mean value related to the products)

Yield of product : Changing related to the product

Applications:

It is used to press oily seeds. Oil is obtained by squeezing with no heat application, which keeps the aroma

and quality.

Used for:

Cumin seeds

Grape seeds

Canola

Coriander

Coconut

Daphne seeds

Apricot kernel

Sesame

Hazelnut

Peanut

Walnut

Sunflower seeds

Opium seeds

Flaxseed

Almond

Mustard seeds

Urtica seeds

Pepper seeds

Black cumin

Tomato seeds

Rose Seeds

Squash seeds

Cacao seeds

Melon seeds

Soybean seeds

Pistachio nut

Mixing and Homogenizators

35

HIGH PRESSURE HOMOGENIZATOR

Properties:

Inlet reservoir capacity : 0.3 liter

Flow rate : 120 ml/min (at 30.000 psi)

Maximum working pressure: 30.000 psi

Interaction chamber : H10Z ve H30Z

Applications:

It can be used to produce dispersions and emulsions (water in oil) and to reduce the particle size of various

foods and chemicals homogenously. It can be used for food, nutraceutics and pharmaceutics industry.


36

ANNULAR GAP MILL

Properties:

Max. operating temperature : 80°C

Capacity : 500-800 L/hr

Inlet : max. 25°C

Outlet : max. 60°C

Product chamber pressure : 2,5 bar

Double jacket pressure : 2 bar

Effective grinding chamber volume: 0,467 L

Grinding beads : 1,0-1,3 mm, ZrO2-Toray

Applications:

The ANNULAR GAP Mill is used for fine milling of suspensions and high -viscosity products. The product is fed to the milling chamber by an external variable-flow pump. The milling action is created in the gap

between the conical working vessels the stator and a conical rotor. This system can be used to produce suspensions, emulsions or dispersions. Grinding can be achieved at sub-micron range and products

particles can be reduced from 200m’ to 5 m, even to 0.5 m. The particle size distribution of the finished

product is homogeneous. It can be used for products such as pastes, chocolate, sesame (tahina), peanut butter, nuts pastes, pigments, etc.


37

ROBOT COUPE VERTICAL CUTTER MIXER (HOMOGENIZER)

Properties:

Bowl capacity: 20 L

Manual filling

Two levels of speed (1500 & 3000 rpm)

Bowl-base blade assembly with three detachable and height -adjustable blades

Applications:

The vertical cutter-mixer allows cutting and mixing of nuts with or without shell, cutting and mincing of

vegetable and fruits and finally homogenization of the foodstuffs. Solid or viscose type of foods can be

mixed with water and cutting can be obtained. According to type of food detachable and height -adjustable

blades can be arrange to ensure a perfectly uniform consistency, ensuring total homogeneity of processed

foodstuffs, even when small amounts are involved.


38

HIGH SPEED MIXER

Properties:

Manuel

Velocity : 2000 Rpm

Capacity : 0,5-10 L

Setting time

Applications:

It is used for mixing of sensitive powder products. It is used for mixing and homogenization of ingredients

with a high speed.


39

BATCH MIXER

Properties:

It consists of two main parts: mixer and pulverising units .

Rotation speed : Adjustable

Capacity : 0,5-10 L

Liquid pulverising

Manual filling

Applications:

It is suitable for various applications including development of recipes and product development of pure dry

mixes, addition of liquids into dry materials and pure liquid mixes. Also possible is a gentle product

treatment for homogenization of sensitive material through to breaking down of agglomerates by using a

cutting rotor.


40

TUMBLER MIXER (THREE-DIMENSION INVERSION)

Properties:

Tumbler mixer with maximum 20 L filling capacity uses three-dimension inversion kinematics

Available with 20 and 10 L steel drum

Adjustable timer and speed control

Working speed range : 5 - 30 rpm

Working time range : 1 min - 99 h 59 min

A mechanical lock prevents opening of the safety hood when the machine is running

Applications:

It can be used for solid-solid, liquid-liquid mixing and also liquid and solid product homogenization. It is ideal

for homogenization of powders, solids, liquids, suspensions and particles of any size, sheer, viscosity or

weight by gentle treatment of the ingredients. Using three-dimension inversion kinematics, it has been used

in a variety of industries such as food and nutritional applications, pharmaceutical applications, chemical

and petrochemical applications.


41

HIGH SHEAR MIXER (HOMOGENIZER)

Properties:

Solid-liquid mixer and homogenizer

Capacity : 30 kg

Speed : 3000 cycle/min

Interchangeable rotor/stator mixing head

Cutting and homogenization simultaneously

Manually adjustable, mobile hydraulic floor stand

Applications:

Generally it is used for cutting and mixing of solid foodstuffs with water and homogenizes them, apart from

the ability of liquid-liquid mixing and homogenizing properties. Especially for mycotoxin analysis slurry

homogenization of nuts and dried fruits (with/without shell) are performed with using high shear mixer which

is accepted by legal and scientific authorities. With the easily interchangeable work heads, it can be adapted

to perform a wide range of mixing operations including emulsifying, homogenizing, disintegrating, dissolving,

dispersing, blending, particle size reduction and de-agglomerating.


42

HIGH SPEED HOMOGENIZER

Properties:

Capacity : 2 L

Rotation rate : 10.000 rpm

Feeding : Manual

Height : Adjustable

Blade types : Change

Applications:

It is used for mixing, grinding and homogenization of liquids, soft products and viscous liquids. It is available

for mixing two or more liquid products having similar densities. .


43

LIQUID-LIQUID HOMOGENIZER (Colloid Mill)

Properties:

Manual filling

Rotation rate : 2000 rotation/min

Capacity :15 L

Particle size : 5-10 micron

Applications:

It is used to reduce the particle size of a solid in suspension in a liquid, or to reduce the droplet size of a

liquid suspended in another liquid. It is also used to increase the stability of suspensions and emulsions, but

can also be used to reduce the particle size of solids in suspensions.

http://en.wikipedia.org/wiki/Solid

http://en.wikipedia.org/wiki/Suspension_(chemistry)

http://en.wikipedia.org/wiki/Liquid

Grinders

44

GRINDER

Properties:

Standard capacity : 30-100 kg/hr (wet) and 1-10 kg/hr (dry)

Grinder diameter : 150 mm

Applications:

The products below can be grinded in dry or wet form by using the appropriate stones and particle size

reduction can be performed,

soft materials such as fruits, vegetables, rice, peanuts etc.

hard materials such as egg shell, minerals, bones etc.

herbs, species, powder tea leaves, etc.

Cooling water jacket prevents the products from heat dissemination caused by the grinding process.

Grinders

45

HAMMER MILL

Properties:

It is high speed machine, working with sieving system.

It shreds the products with hammers

Manual feeding

Rotation rate : Constant

Particle size : 0.50 mm and up

Applications:

It is used for shredding all kinds of dry foods.

Grinders

46

BLADE MILL

Properties:

It is high speed machine, working with sieving

system

It shreds the products with rotating steel blades

Manual feeding

Rotation rate : Constant

Particular size : 1 mm and less

Applications:

It is used for shredding all kinds of dry foods

that does not contain core and a hard shell.

Bakery Production Equipments

47

MINI DOUGH CUTTING AND ROLLING MACHINE

Properties:

Dough weight : 40-120 g

Applications:

It is used for production of small bread, doughnuts, cookies and

pizza. It eliminates the differences due to hand shaping in product

development studies and research studies for different processing

techniques and formulations.


48

CONICAL ROLLING MACHINE

Properties:

Capacity : 2500 pieces/hour

Dough weight : 100-1000 g

Applications:

It is used for giving round shape to the dough with its aluminum cones and spiral arms and prepares the

dough for second fermentation.


49

LONG SHAPING MACHINE

Properties:

Shaping capacity : 2500 pieces/hour

Shaping weight : 100-1000 g

Applications:

It is used for giving long shape to the dough rolled in the conical rolling machine.


50

OVEN

Properties:

Cooking area : 2.88 m2

Shelf number : 3

Inside width : 1200 mm

Inside height : 800 mm

99 cooking programs

Fermentation cabin

Steam control

Applications:

It is used for bread production under controlled fermentation and cooking conditions. It is also suitable for

other pastry products and pizza production.


51

EXTRUDER

Properties:

Screw diameter : 25 mm

Maximum screw speed : 550 rpm

Maximum temperature : 400°C

Maximum pressure : 300 bar

Capacity : 0.6-50 kg/hour (changes according to the raw material)

Applications:

It is used for extruded snack production with different flour mixtures.


52

VACUUM COATER

Properties:

Absolute pressure : 200 mbar

Motor : 0,37 kw

Main Voltage : 230 V AC

Frequency : 50Hz

Rotation Motor : Manuel

Nominal Capacity : 25 m3/h

Ultimate vacuum : 10 mbar

Applications:

Laboratory Vacuum Coater is a fully automatic rotating vacuum coater for laboratory purposes. The

machine is based on the very well proven Rotating Vacuum Coating Technology. It is used for product

development in research programs, quality control and scale-up purposes.

The complete cycle consisting of spraying, core coating and rotation can be executed fully automatic. The

Vacuum Coater (manual rotation – or automatic) is specially designed for the needs of the Fish, Feed and Pet Food Industry to develop new processes incorporating the latest post -extrusion technologies. Vacuum Coating Technology permits to add vitamins, flavours, colours, fat, Omega-3, medicine, pharmaceuticals,

antioxidants etc. deep into the kibbles (pellets) without the need to over formulate. The addition of these heat and pressure sensitive ingredients after the extrusion process results in significant savings for quick return of investment

Hazelnut Processing Equipments

53

HAZELNUT PROCESSING LINE

Hazelnut Processing Line has 50-80 kg capacity. Hazelnuts can be shelled, blanched, roasted and grinded to

make puree at pilot scale. Effect of processing conditions can be determined using only one bag of hazelnuts

The equipment can be listed as:

1. Sizing system

Unshelled hazelnuts (9mm-15mm)

Shelled hazelnuts (8mm-15mm)

2. Cracking

3. Shell removal

4. Roasting

5. Blanching (skin removal)

6. Grinding


54

IN-SHELL HAZELNUT SIZING (VIBRATING EIEVES 1, 2)

Properties:

Sieve 1 : 1175 x 885 x 965

Sieve 2 : 980 x 885 x 965

Main Inlet : 380 V – 50 Hz

Motor Power : 2 x 0,10 Kwan,

Applications:

In-shell hazelnuts can be classified in two parts with 2 sieves into 9mm -11mm in part 1 and 13mm-

15mm in part 2. Rubber balls in 20mm diameter makes the sieving easier. There are 3 outlets at each

part and 6 different sizing can be achieved.

1. Part

1. outlet : 9mm & <9mm

2. outlet : 11mm & >11mm

3. outlet : <11mm & >9mm

2. Part

1. outlet : 13mm & <13mm

2. outlet : 15mm & >15mm

3. outlet : <15mm & >13mm


55

HAZELNUT CRACKING

Properties:

Capacity : 50 kg/hr

Size : 610 x 905 x 1580

Main Inlet : 380 V – 50 Hz

Motor type : 3 Kw, 400 d/d

Applications :

In-shell hazelnuts classified according to their size are cracked by frictional movement of two stone discs.

The distance between the two discs are adjusted according to the size of the in-shell hazelnuts.


56

SHELL REMOVAL (VANTILATOR)

Properties:

Capacity : 50 kg/hr

Size : 980 x 730 x 2390

Main inlet : 380 V – 50 Hz

Motor Type : 1,1 Kw, 1500 rpm

Applications:

Shell of the hazelnuts are removed by the help of a ventilating fan. Air speed can be adjusted with a flap.

Shells and un-shelled hazelnuts are collected in to bags from two different outlets.


57

UN-SHELLED HAZELNUTS (Vibrating Sieves)

Properties:

Size : 1230 x 1795 x 1460


Motor Power : 1,1 Kw, 940 rpm

Applications:

Un-shelled hazelnuts are sieved through 8 sieves and classified as 8mm, 9mm, 10mm, 11mm, 12mm,

13mm, 14mm, 15mm according to size of the kernel. This sieve is set on four springs which has one

directional movement and has two outlet chambers.


58

BELT TYPE HAZELNUT ROASTER

Properties:

Belt : Cr-Ni net, adjustable belt speed

Electric power : 2 kw

Temperature : max 200°C

Three Parts : Temperature can be adjusted for each part separately

Applications:

Nuts, fruits and vegetables can be dried and roasted.


59

HAZELNUT PEELING/BLANCHING MACHINE

Properties :

Capacity : 50 kg/hr

Size (mm) : 790 x 650 x 1726


Motor type : 0,75 Kw, 200 rpm

Applications:

After roasting, skin of the sieved un-shell hazelnuts are removed by frictional movement of two rubber

discs. The distance between the two discs are adjusted according to the size of the hazelnuts kernels.

Skin of the hazelnuts is removed by the help of a ventilating fan.


60

ROTATING ROASTER

Properties:

Capacity : 1 kg

Roasting Temperature : max. 240°C

Equipment is consisting of an electricity panel board, 6 heating resistance, rotating chamber with a

mixing scraper and a motor.

Applications:

Granular and round type food stuff such as nuts and their granular forms can be roasted homogeneously.


61

BALL MILL (Hazelnut Paste Machine)

Properties:

Capacity : 1 kg


Motor type : 2,2 kW, 1420 rpm

Applications:

Roasted hazelnuts are chopped and fed to the ball type grinder to form paste. The system in consist of a

reduction motor, mixing shaft and grinding tank. Grinding tank is made from AISI 304 quality stainless steel

sheets and has double walls, where heating and cooling water is transferred in the outer wall.


62

COATING PAN

Properties:

Single-walled

Manual filling

Applications:

It is used for coating of nuts such as almonds, hazelnuts. etc.

Meat Processing Equipments

63

STEAM HEATER

Properties:

Pressure : 0-2,5 bar

Time : 0-30 min

Applications:

It is suitable for preparing various meat products. It is used for steam cooking of meat products.


64

SAUSAGE FILLING MACHINE

Properties:

It has two filling heads with the different diameters.

Filling head diameter : 1.5 cm / 2.2 cm

Applications:

It is used for filling of meat products such as sausages, salami.


65

CUTTER

Properties:

Capacity : 65 kg

Velocity : Two-stage (slow, fast)

Time : 0-60 min

Temperature : 0-100°C

Applications:

It is used for grinding of meat and preparing emulsified meat products.

Tablet Pressing Machines

66

SINGLE PUNCH TABLET PRESS MACHINE-1

Properties:

Maximum tablet diameter : 25 mm

Maximum tablet capacity : 60 t/min

Maximum pressure : 50 KN

Maximum filling depth : 20 mm

Maximum tablet thickness : 0.5-8 mm

Applications:

It is used for making tablets from powder or granule forms of the sample.

Tablet Pressing Machines

67

SINGLE PUNCH TABLET PRESS MACHINE-2

Properties:

Maximum tablet diameter : 20 mm

Maximum tablet capacity : 60 t/min

Maximum pressure : 30 KN

Maximum filling depth : 20 mm

Applications:

It is used for making tablets from powder or granule forms of the sample

Packaging Machines

68

PLASTIC EXTRUDER

Properties:

Twin screw extruder.

Extruder has two different dies:

Blown film die

Sheet, tape and ribbon die

Applications:

It can be used to produce plastic films from various polymers. Different additives can be dispersed in

polymeric matrices and various plastic films can be produced for R&D purposes.

Packaging Machines

69

VACUUM PACKAGING MACHINE

Properties:

Horizontal packaging machine:

Foods can be used : Solid foods.

Packaging materials : Flexible plastic packs.

Packaging dimensions : Max. 40x40 cm

Modified atmosphere packaging : Yes

Vacuum packaging : Yes

Capacity: It can be changed according to the food dimensions and vacuum time.

Gas flow rate and mixing of different proportions of inert gases can be adjusted

Applications:

This machine can be used to make the vacuum and modified atmosphere packaging of foods. Different

vacuum levels and gas mixtures can be applied for different food products. It can be used to pack the

foods for shelf life and storage studies.

Packaging Machines

70

INCLINED VACUUM PACKAGING MACHINE

Properties:

Foods can be used : Foods in liquids or oils, such as cheese in brine or olive in oil.

Packaging dimensions : max. 40x40 cm

Packaging materials : Flexible plastic packs

Capacity : It can be changed according to the food dimensions and vacuum time

Applications:

Machine can be used for vacuum packaging of foods in liquids or oils.

Packaging Machines

71

TRAY SEALER

Properties:

Machine has two different size tray moulds:

Small tray mould : 190/140 mm

Big tray mould : 275/175 mm

Trays and packaging film should be supplied separately to work with the tray sealer.

Applications:

It can be used to package the foods in trays. It is possible to give N2, CO2 or mixed inert gases and to

perform high oxygen atmosphere in trays.

It can be used for modified atmosphere packaging of various meat products, dairy products, olives and dry

foods.

Packaging Machines

72

VERTICAL PACKAGING MACHINE

Properties:

Capacity : 40-1000 g.

Packaging rate : 30-45 package/min. (for 1000 g. dry beans)

Packaging materials : OPP, OPP+PP, PP-A, laminated flexible films, etc.

Package length : min 60-max. 310 mm

Package width : min. 75-max. 210 mm

Package type : Pillow type

Applications:

It can be used for packaging of dried powder foods, such as spices, tea, coffee and various food additives.

Packaging Machines

73

SEMI AUTOMATIC MACHINE FOR FILLING AND CLOSING

Properties:

Filling amount :100g-1000g

Bottle height :100 mm-300 mm

Bottle width : 30 mm-200 mm

Filling nozzle number : 1

Filling type : Volumetric

Capacity : 500 /hr (for 1000 g)

Lid type : Screw lid

Closing of lid : Screw press

Lid type : Aluminium lid

Closing nozzle number : 1

Applications:

It can be used to fill the liquid and semi-liquid foods into glass and plastic bottles and to close their lids.

Industrial Kitchen

74

CAN SEALING MACHINE

Properties:

Cans with the different sizes can be sealed.

Applications:

It is used for sealing of the filled can with lid.

Industrial Kitchen

75

INDUSTRIAL KITCHEN

Properties

The equipments used for to prepare pilot scale of food production are given in below:

Range oven/gas operated

Steam Convection oven (electric operated)

Pastry-pizza oven (heat resistant bottom of refractory bricks)

Pasta cooker

Fat fryer (gas operated)

Grill (½ smooth + ½ ribbed)

Fish preparation unit

Electronic vegetable washing machine (washing capacity: 4 – 20 kg; drying capacity: 2-10 kg)

Mixer (25 L capacity)

Dough kneading machine (25 L capacity, flour capacity: 10 kg)

Upright refrigerator (-2/+8 0C cooling capacity, 700 L)

Upright deep freezer (-10/-25 0C, 700 L)

Microwave oven (25 L capacity)

Blender

Applications:

It is available for R&D studies for ready to eat meat sectors, productions and studies on developments of

new products and like that.

76

TÜBİTAK Marmara Resarch Center

Food Instutite

P.O.Box. 21, 41470 Gebze-KOCAELI TURKEY

Phone: +90 262 677 32 00

Fax: +90 262 641 23 09

Web: http://ge.mam.tubitak.gov.tr/

http://ge.mam.tubitak.gov.tr/

food institute pilot plant - ge.mam.tubitak.gov.tr · the pilot plant was founded in 1972 to...

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