Trade fairs
PROSWEETS
Come visit TFT: Hall 10.1 - C61
Tanis to reveal new line for marshmallow extrusion at low temperatures
Dutch food equipment manufacturer Tanis Food Tec specialises in process lines for bakery fillings and confectionery products. On display in their stand at ProSweets will be the Roto MallowPlant: a new marshmallow production machine that combines cooling, aeration and extrusion of the product at a low temperature.
Keeping the product in shape after extrusion always was a key problem as the required higher temperatures during the aeration process made the product rather fluid. Shape loss was inevitable, giving the brands a hard time to control and maintain the look of their product. Tanis has solved this by integrating a cooling device between the aerator and the manifold extruder.
Manufacturers benefit as they can now make and replicate their marshmallow product exactly conform its design. A round marshmallow will remain a 100% round instead of flowing out into an egg-shape. Enabling the brand to distinguish itself and increase consumers’ recognition of and dedication to their special product.
Another added value of extrusion on lower temperatures is that the final cooling line can be a lot shorter. Consequently the production line as a whole will now take up less valuable space in the facility, saving can be as much as 10 to 15 mtrs.
The extruded marshmallow process at low temperatures is basically as follows. Sugar glucose syrup is cooked to the correct dry solids. A whipping agent solution is prepared separately. Then the cooked slurry is pumped continuously through the Tanis RotoTemp scraped surface heat exchanger and then cooled to aerating temperature. This flow is measured. Now the whipping agent is pumped at a correct ratio into their RotoPlus preblending chamber together with the sugar slurry and blended together. This mixture is then aerated to the correct final density. After which it will run through a secondary RotoTemp where it is cooled to extrusion temperature. If necessary the marshmallow can now be coloured and flavoured, then extruded on a starch bed.
This whole operation is done by one RotoMallowPlant. The same skid also incorporates all water circuits that form an integral part of the recipe structure.
Tanis Food Tec at ProSweets: Hall 10.1 – stand C61
Biscuits & Snack Seminar
The Academy of Sweets (ZDS) organised it on 8 & 9 november at it's own location in Solingen.
During which Mr Peter TANIS lectured on the current trends in the processing of fillings for bakery products:
"In grownup consumer markets most bakery products are of a complex nature, meaning they contain multiple components that provide a layered taste and texture experience. The majority of these components are liquid and semi-liquid fillings such as chocolate, cream, marshmallow, jelly, caramel and nougat. These can not be used straightforward as delivered by the ingredients supplier. They need to be processed to accommodate the well developed expectations of consumers.
Processing fillings earns the manufacturer several benefits. By tempering and aerating we can change the molecular structure of the product. This can work out for the better or, if not done correctly, for the worse. At its best the new product structure leads to a stable filling with a longer shelf life, the right bite, mouth feel, flavour and texture.
The processing of fillings equally provides industrial food manufacturers with the opportunity to create original products and distinguish their brand from others in the supermarket. Once established the ability to replicate the appearance and quality of a brand product becomes essential. To allow for line efficiency the replicating should be done with a minimum use of ingredients.
Although the processing of fillings is a rewarding and therefore worthwhile addition to a food production line it should not be treated lightly. It is in fact a fine balancing act to first create then keep the right crystal structure when bringing in a gas (usually air) by a movement into a product. Absolute control over the whole process is therefore a necessity as it can come as close as a tenth of a degree.
To this end a recently introduced fillings processing system sets a new standard for the market. The RotoFlex of Dutch company Tanis Food Tec (TFT) is a compact one-frame unit that processes combinations of fillings simultaneously on one production line. Several functions give the user complete control over such process parameters as recipe, capacity, density, crystal structure, viscosity, pH level, deposit, and product and water temperatures to help reach product objectives. One PLC control panel operates them all.
In depth knowledge of the base products used in a recipe is vital, too. To gain full understanding of the chemical characteristics of a base product TFT cooperates with ingredient providers. That know-how gets engineered into equipment to create the fitting process for a manufacturers’ recipe.
Semi-liquid fillings will be cooled in a scraped surface heat exchanger and brought below melting point so the fat part will start crystallising. This is a fully controlled tempering process. The now crystallized filling then runs into the aerator and gas is injected into it. The amount of gas is adjusted as a percentage of the pumping capacity, allowing very precise control over the density of the product. Changes in pump capacity are automatically compensated, maintaining the set gas percentage. The benefit of this full viscosity control is a continuously consistent final product during production that allows for deposit control.
For the production of a jelly filling a plate heat exchanger can be used to heat the jelly. The desired pH level is acquired by accurately controlled injection of acid. Other injection systems allow for inserting colour, flavour and fruit pulp into the product. Integrated control of product temperature is obtained by water tempering circuits that can be individually adjusted from 10 to 90°C.
In order to process mallow the base product first needs separate cooking to transform it into dry matter, normally between 75 and 81% Brix. This then is passed through the RotoFlex to cool to depositing temperature and aerated to the required final density. Caramel needs no cooking and can be tempered and aerated to prepare for depositing.
A processing device like the RotoFlex is particularly useful for confectioners and biscuit makers creating aerated creams and mallows combined with jelly, or jelly filled marshmallows, caramel with cream or praline bar-type products, and centre filled chocolates. The current trend for product variety to surprise consumers asks for flexibility of production lines with quick changeovers to minimize loss of production time. It was with this in mind that TFT developed the multi fillings processor.
Other important demands on today’s fillings processing technology are the need for food safety, a small footprint in the processing facility and durability. Food quality and food safety start with best choice equipment to ‘get it right first time’. As a member of the EHEDG – the European Hygienic Engineering and Design Group – TFT designs her equipment according to strict criteria. A leading worldwide provider of continuous food processing equipment, their product portfolio covers all aspects of process control from weighing ingredients to Cleaning in Place.
TFT is part of a network of leading equipment manufacturers that together offer turnkey solutions, each bringing in their own expertise. From raw material mixing via the making of wafers, biscuits and cakes to processing and applying fillings, and the final baking of the product. Tanis Food Tec’s expert knowledge is in the field of processing fillings for bakery and confectionery purposes: creams, chocolate, marshmallows, pectin jellies and jam, caramel, nougat, and dulce the leche. Their processes include mixing, tempering, crystallizing, aerating and depositing. Major focus is on continuously replicating the exact same product with every deposit by total control of temperature, density, crystallization and thus viscosity."
See for more information: http://www.zds-solingen.de/en/seminarsconferences/biscuits-snacks-2011/
May 12 - 18, 2011
Düsseldorf, Germany
Welcome - please come and visit TFT in Hall 3 - stand E39
Control your product
With two introductions:
- the RotoUniversal; one skid to run biscuit cream, praline mass, marshmallow or pectin jelly at the same time on one line
- new Sheeting concept; continuous sheeting system to make a new type of high fibre fruit bar with a cream or jam filling, or to make a new type of Maria biscuits with filling
Visitors are treated to two new machines that help them gain control over their product. In Hall 3, stand E39, Tanis Food Tec introduces firstly a multipurpose system to run biscuit cream, praline mass, marshmallow or pectin jelly at the same time on one line. The other innovation is a new sheeting concept to put a thin layer of cream or jam between two sheeted doughs, prior to the oven.
The multipurpose system is baptized the RotoUniversal. It gives manufacturers a very compact and easy to control skid when they need to combine two fillings in one product. This is especially helpful for the confectionery and biscuit industry. The RotoUniversal is very useful in combination with cookie sandwiching machines, cake bar lines, tea cake lines, shell moulding lines, and mallow lines.
Both centre filled chocolate articles and biscuit products can be made with it. Examples of products to process on the RotoUniversal are: aerated creams and mallows combined with jelly in one sandwiched product. In extruded or deposited marshmallow lines it will do marshmallow simultaneously with pectin jelly to make marshmallow with a jelly centre. And to make a bar type product caramel and cream or praline mass can go together at the same time.
The beauty of the system is in its versatility and that it gives complete control over temperature, density and viscosity of the products that are made with it. The RotoUniversal can contain the tempering, aeration, heating and/or cooling, automatic mixing of colour, flavour and acid. All of these functions are controlled with one central PLC on which the different recipes can be safeguarded.
The second introduction at Interpack is a new sheeting concept. It is the first system that can make a new type of high fibre fruit bar with a cream or jam filling. It can also be used to create a new type of Maria biscuits with a filling which can either be an aerated or non-aerated one. This machine can easily form continuous sheets of caramel, jams, cream, praline mass, pectin jelly, nougat, etc. The thickness of the sheet is adjustable from less than 1mm up to 15mm.
The machine is fully jacketed, including the feed roller and the (film)spreader roller. Therefore each temperature necessary for handling of above mentioned products are possible. The RotoSheeter is constructed for easy cleaning. Multiple units can be placed behind one another for the production of multi-layered products.
Another feature on show is a running RotoPlant to produce cream & jam on sandwiched cookies. The production unit combines aeration and tempering with acid injection and mixing. It demonstrates how to prepare density controlled cream and jam. These are then deposited on the cookies.
Celebrating their 20th anniversary TFT aims to share their experience of how to perfectly control the temperature, density and viscosity of a product with their visitors during Interpack. Offering customers innovative process solutions for product ideas is Tanis Food Tec’s objective. Our equipment includes mixers, aerators, tempering and crystallizing devices, and depositors for continuous production lines.