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Thermo-Compound-Installation

Thermo-Compound-Installation. Semi-continuous combination of Hot Smoking and Cooking Installation with an Intensive Cooling Installation. Thermo-Compound-Installation. Content. The concept AEROMAT Intensive Cooling Installation Thermo-Compound-Installation (TCI)

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Thermo-Compound-Installation

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  1. Thermo-Compound-Installation Semi-continuous combination of Hot Smoking and Cooking Installation with an Intensive Cooling Installation

  2. Thermo-Compound-Installation

  3. Content • The concept • AEROMAT • Intensive Cooling Installation • Thermo-Compound-Installation (TCI) • Glowing Smoke Generator H 504 • Management and Documentation System (LDS)

  4. 1. The concept AEROMAT Hot Smoking and Cooking Installation Reddening, drying, smoking, cooking and boiling Intensive Cooling Installation Showering, Cooling, Drying

  5. 2. AEROMAT AEROMAT Hot Smoking and Cooking Installation Reddening, drying, smoking, cooking and boiling

  6. 2. AEROMAT Combined Hot Smoking andCooking Installation

  7. Functions & processes • Reddening • Drying • Warm and hot-smoking (glowing, friction, steam or liquid smoke) • Cooking / Boiling • Hot-air curing • Cooling (showering) • Baking Flexible solutionfor different functions

  8. Applications • Cooked and smoked sausage, i.e. fine and coarse cooked sausage, Wiener, Bratwurst • Cooked sausage and ham • Fish • Pet Food • Fruit & vegetables • Cheese Flexible solutionfor different applications

  9. Basic data • Temperature range The temperature can be set from 10°C to ambient temperature to a maximum of 95°C • Relative humidity Depending on the chamber temperature set and type of humidification, relative humidity can be adjusted between 65 % and 98 % at process temperatures of over 40 °C • Fresh air condition Maximum 30 °C and 60 % relative humidity

  10. Benefits Top energy efficiency • Highly-insulated chamber with 82 mm-thick chamber elements insulated with CFC-free hard polyurethane foam reduces heat loss by up to 40 % compared to walls insulated with rockwool • The central circulation fan achieves a higher degree of efficiency than conventional individual fans • Our air change flap system enables us to reduce circulating air and thus save a significant amount of energy • The special dynamic form of air distribution minimizes the overall flow volume of the fan, so only low fan capacities are required • Pre-heating fresh air with the EcoCon heat recovery unit allows energy requirements to be reduced by up to another 30 % Optimizedenergyefficiency

  11. Benefits Absolute consistency • The tried and tested air change flap system achieves dynamic air circulation which generates the same qualities as conventional horizontal flow systems even on products which are lying flat. This means the installation can be used for products which are both lying and hanging • Fast and constant cooling down provide shorter process times and lead to a higher product flow • Compared to conventional installations weight loss is reduced by a dynamic air circulation Absolute consistency in process & products

  12. Air flow by air change flap Dynamic circulationtoachievegreatconsistency

  13. Benefits - chamber structure Captivating quality Inner panels 1 mm 1.4571 (AISI 316TI) Wall and ceiling elements linked by screwed connection Outer panels 1mm 1.4301 (AISI 304) Chamber assembled from the inside out PU hard foam insulation (CFC-free) K value 0.3 Silicone seal on screwed connection 82 mm-thick chamber elements Wall and floor element linked by screwed connection Captivatingquality & outstandinghygiene U-profiles to reinforce the area of the chamber floor where the smoke trolleys run Option „Pagel“ concrete floor element (smoke trolleys of 350 kg upwards or for Installations let into the floor)

  14. Benefits Captivating quality & outstanding hygiene • The installation can be dismantled and can thus be used in a different location • We fit a 3-point latch to make the door absolutely smoke-proof • Cleaning results are guaranteed to be reproducible with minimal use of chemicals by means of the automatic CIP system included in the scope of supply. This system can be linked to a customer's foam-cleaning system Captivatingquality & outstandinghygiene

  15. Design • Chamber single-row • Machine position attached to rear wall • Chamber width 1750 mm or 1920 mm • Chamber double-row • Machine position attached to roof • Chamber width 3300 mm Individual design

  16. Process scheme

  17. MICROMAT C7-100 • Freely programmable SPSs based installation control based on latest Siemens S7 technology • 9 inch comfort panel, widescreen, touch, 16 million colours • Clear display of all relevant process data • Display of all control signals • Direct operation of all set-point values • Operator log in with password • RFID-login as an option

  18. Options • EcoConheatrecovery • Central Managing & Documentation System (LDS) • Ethernet connection • Type ofheating • Fullautomatic CIP system • Drain options • Entry options • Cold-smoking facility • Automaticfloorconveyor • Door window • Chamber light • Backingfacility • Risingandfallingdoororrollingdoor • Transit design • Hangingtrolleys • Smoke Generators Different optionsfor individual design

  19. 3. Intensive Cooling Installation Intensive Cooling Installation Showering, Cooling, Drying

  20. 3. Intensive Cooling Installation

  21. Functions & aims • Even core temperatures independent of product diameter • Very short throughput times enabling the products to go straight to packing • Reliable process control • Reduction of process times • Weight loss is reduced • Rapid, even cooling leads to small window of opportunity for bacteria Absolute consistency, captivatingquality, outstandinghygiene

  22. Basic data • Processes Showering Cooling down with cold air (approx. +1°C air temperature) Cooking (cooking facility as an option) Cold water circulation system (as an option for big calibre products and presstower) • Products Packed products Products with natural casing Big calibre products Presstower

  23. Benefits Top energy efficiency • Highly-insulated chamber with 82 mm-thick chamber elements insulated with CFC-free hard polyurethane foam reduces heat loss by up to 40 % compared to walls insulated with rockwool • A high rate of air circulation with a cooling capacity of 13 kW per trolley results in very short throughput times, enabling the products to go straight to packing. The number of areas, cooling chambers and smoking products required can thus be reduced • Rapid cooling times guarantee reduced loss of water and therefore of weight Optimizedenergyefficiency

  24. Benefits Absolute consistency • The tried and tested air change flap system achieves dynamic air circulation which generates the same qualities as conventional horizontal flow systems even on products which are lying flat. This means the installation can be used for products which are both lying and hanging • Rapid, even cooling leads to shorter process times and thus to a higher product throughput rate • Weight losses are reduced compared to conventional installations as a result of dynamic air fl ow around the product Absolute consistency in process & products

  25. Benefits Quality • The installation can be dismantled and can thus be used in a different location • 82 mm-thick walls achieve a sable construction Captivatingquality

  26. Benefits Outstanding hygiene • Minimal cleaning eff ort for cooling areas, smoke trolleys and accessories. • Small window of opportunity for bacteria, as the critical temperature range of +40 °C to +15 °C is passed through quickly • The central air-conditioning unit provides ideal conditions for simple cleaning • Optional components such as a sterilization facility and fresh air fi lter improve hygiene • Combined cooling with cold air and water increases cooling rates, as a higher rate of cold transmission is achieved Outstanding hygiene

  27. Process scheme

  28. MICROMAT C7-300 • Freely programmable SPSs based installation control based on latest Siemens S7 technology • 9 inch comfort panel, widescreen, touch, 16 million colours • Clear display of all relevant process data • Display of all control signals • Direct operation of all set-point values • Operator log in with password • RFID-login as an option

  29. Options • Cooking facility • Cold water circulation system • Door variants • Fully automatic CIP system • Automatic floor conveyor • Automatic conveying of suspended trolleys • Type of cooling medium (ammonia, Freon or glycol) • Central Managing & Documentation System (LDS) • Ethernet Different optionsfor individual design

  30. 4. Thermo-Compound-Installation AEROMAT Hot Smoking and Cooking Installation Reddening, drying, smoking, cooking and boiling Intensive Cooling Installation Showering, Cooling, Drying

  31. Benefits TCI Safety • Loading and unloading by only one person • Continuous transport from the hot smoking to the cooling zone • Automatic transition • Small window of opportunity for bacteria, as the critical temperature range of +40 °C to +15 °C is passed through quickly • No contamination of products after the hot smoking zone • Shelf life is extended • Minimized weight loss • Reproducability Productandprocesssafety

  32. MICROMAT C7-700 • Freely programmable SPSs based installation control based on latest Siemens S7 technology • 9 inch comfort panel, widescreen, touch, 16 million colours • Clear display of all relevant process data • Display of all control signals • Direct operation of all set-point values • Operator log in with password • RFID-login as an option Included in delivery

  33. 5. Glowing Smoke Generator H 504 Availableas an option

  34. H 504 - Overview Smoke flow control system Agitator ofchips Extinguishing device Hopper Woodchip hatch Fresh air Smoke washer Smouldering chamber Combustion air fan Ash collectingbox Drain smoke washing

  35. H 504 - Dimensions Hopper Ø 1000 mm • Hopper volume 280 L • Quantity of smoke 250m³/h Height 2000 mm Length 800 mm Width 1400 mm

  36. Benefits • Maximum userfriendliness & simple operation • Absolute consistency • Outstanding hygiene • User-friendly compact control • We achieve short process times by using a high level of smoke intensity which is provided at a constant rate • Temperature monitoring with an integrated extinquishing device and water pressure check, together with optional smoke/volume flow monitoring allow us to guarantee maximum operational reliability • The integrated smoke washer provides clean smoke for perfect products • The sophisticated hygienic design of the smoke generator ensures easy access for cleaning and maintenance Summaryofbenefits

  37. 6. Managing & Documentation System (LDS) Availableas an option

  38. The concept • The LDS is for recording data and managing programs on several production installations • The system reduces complex production processes and a wide-ranging distribution of installation components to a reliable and convenient general overview for the operator • MICROMAT control systems will automatically be recognized and integrated • Das LDS complies with the EU regulations 178/2002 article 18,19, traceability of foodstuffs in the food industry Maximum userfriendliness & simple operation

  39. Screenshot LDS – Hot Smoking Installation

  40. Screenshot LDS – Intensive Cooling Installation

  41. Screenshot LDS – TCI

  42. Program management I • Every window has a subwindow for the transfer of programs via two buttons • List of programs opens automatically • A user program can be chosen • Transfer is released by clicking the right button • Right after the transfer, the name is listed Reliable & convenient

  43. Program management II Transfer ofprogramsfromtheinstallationcontrolunitstothe LDS • Duringtransmissionyousee a message on the LDS • The program will automaticallybestored in theinstallationsfolderofthe LDS • Itisavailablefortransmissiontoothercontrolofthe same type Flexible & convenient

  44. Program editor Editors todevelopprogramsfor different installationcontrolsystems • Universal symbols • Convenientoperation • Print andstorage in the form of a PDF file

  45. Historical data • Relevant process data are stored in a SQL database • Recording period is determined by the capacity of the hard disk • Values such as chamber temperature, rel. humidity, process and core temperatures, respectively speed of the circulating fan and control data can be displayed Reliable & convenient

  46. Batch management

  47. Batch management Every startof an installationleadsto a batchgenerationwithinthe LDS incl. thefollowinginformation: • Start andstoptimes • Runtime (min.) • Operator • Programname • Productcode • Min. coretemperature • Max. coretemperature • F-value • Rack information • Energydata • Status ofbatches • Manuallymeasuredcoretemperature

  48. Batch management • Relevant process data is stored • Values are displayed • Recorded process parameters are shown • Every value can be shown with a ruler • Print and storage of the chart in the form of a PDF file Reliable & clear

  49. Service area • Password protected private area • Parameters can be retrieved and changed • Communication of control systems can be supervised Safety in theservicearea

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