Steam Infusion Buyers' Guide

Transcription

1 Steam Infusion Buyers' Guide steaminfusion.oalgroup.com OAL's Development Chef, Chris Brooks and Process Apprentice, Kyle Constable at the Steam Infusion test centre at the University of Lincoln.

2 Introduction Do you need to expand your soup, sauces and ready meals production? Or perhaps your company is facing growing pressure from governments to reduce fat, salt and sugar in products, but reformulating products has been an obstacle. Equally, meeting consumers demands for convenient yet healthy foods is another constant challenge. To remain competitive, food manufacturers need to be flexible and adaptive, embracing new technologies and innovations. Steam infusion may well be the answer to winning new business, increasing cooking capacity, and meeting government and consumer requirements. A growing number of food and drink manufacturers have come to recognise the outstanding value of this technology which shortens cooking times, avoids high operating costs and creates fresher-tasting, healthier food products. Choosing the Right System However, not all Steam Infusion systems are created equal, nor are they interchangeable. A wide range of businesses from cooking system suppliers to multi-national component suppliers now offer their own steam injection and infusion solutions. Their products vary widely in terms of process, performance, compatibility and usability, meaning that the right system for one manufacturer may be unsuitable for another, and vice versa. For this reason, we have put together the following guide to help would-be buyers make the best possible purchasing decision in their steam infusion journey. 2 Steam Infusion Buyers' Guide

3 Performance One of the key business drivers for adding steam injection or Steam Infusion to your cooking vessels is to speed up cooking and increase capacity. As a manufacturer, you want to introduce energy into your products quickly whilst minimising any losses to the atmosphere, and will be looking for the solution that provides this most effectively. All steam injection and Steam Infusion systems directly inject steam into food products. However, the process by which they introduce the steam differs significantly, changing the performance of the technology. From a simple sparge pipe to a more sophisticated steam injector, it s important to consider how the process works. Steam Injection Direct steam injection will either add steam through apertures around the skin of the vessel (a steam jacket), through a lance positioned inside the vessel or a recirculation loop. A series of steam bubbles are then discharged into the product (though they can easily break the surface and escape into the atmosphere) and a turbulent zone within the steam injector body is created to help mix the steam and product. Steam Infusion The Steam Infusion Vaction Pump s patented design uniquely creates a partial vacuum within the device, generated by momentum transfer of the accelerated steam into the product. This is profoundly different to how traditional steam injectors operate, and is fundamental to its ability to condense large volumes of steam into the product. Factors to consider when choosing a steam injection or infusion system: How much energy can your steam injection/infusion process add to your product? How does the device ensure all steam energy is condensed into the product? Can you vary steam pressure to change operating conditions? Can your supplier demonstrate cooking times and speed, reliably and with repeatable results? 3 Steam Infusion Buyers' Guide

4 New Product Development Cooking quickly is important, but to win new business you also need to create new products that attract consumers and stand out on the shelf. And in the medium to long term, new technology can unlock profitable new development areas. Directly adding steam to your product using a Steam Infusion system is different to non-direct steam jacket or heat exchanger cooking. As such, some level of product matching will need to take place initially, usually by trials or based on experience. The level of food science required for this process depends on the operating conditions created by your new technology. Scientifically Proven For instance, the Steam Infusion Vaction Pump heats, mixes and pumps simultaneously, offering unique cooking conditions. During its development, we found that the speed of cooking enabled flavour enhancements. But for a food scientist, this evidence isn t strong enough. Recognising this, we have taken the time to scientifically understand the processing environment via two governmentfunded Nutrition for Life projects. These projects have ensured that repeatable, reliable results can be obtained so that products can be optimised by the use of this technology. Considerations for Product Development: Is a demonstration of the technology available? Does your supplier offer development support? Are your supplier findings scientifically proven and not anecdotal? Does your supplier offer trial facilities in factory environments? 4 Steam Infusion Buyers' Guide

5 Compatibility Considerations Factory Compatibility If you re adding steam injection or Steam Infusion to an existing kettle, it must be compatible with your existing cooking vessels and factory services. Whether it s possible to retrofit a new steam system to existing equipment depends on a number of factors. Adjustments may be required to the existing kettle and cooking vessel depending on their age and type, and the steam capacity that you will require. Steam Compatibility For both steam injection and Steam Infusion, steam is added directly to your product. As such, it s essential the steam is of culinary quality. The most common method to achieve this requirement is by complying to the 3A Standard method of producing filtered culinary steam. Essentially, this means that the steam must be free of entrained contaminants, be relatively free of water in liquid form, and be suitable for use in direct contact with food products. This standard not only refers to the design of the system, but also includes the requirements for boiler treatment chemicals which in general are already widely used by the UK food industry. For peace of mind, you can download and read the standard here. If you don t already produce culinary grade steam on site, you will require a steam filtration set. A typical steam filtration set comprises a steam separator, a steam strainer, hygienic filter, pressure regulation system and insulation. The set can be sized according to use, so greater steam requirements will need a more expensive, higher capacity steam filtration set. As an example, a single Steam Infusion Vaction Pump requires steam at a rate of 750 kg per hour, at a pressure of 6.5 bar at the point of use. Multiple Steam Infusion Pumps will increase this requirement, so that higher capacity filtration sets are needed. Steam of culinary quality means steam that is free of entrained contaminants, is relatively free of water in liquid form and is suitable for use in direct contact with food products. 3-A Standard Definition of Steam of Culinary Quality Vertically Orientated Agitator Inclined Agitator 5 Steam Infusion Buyers' Guide Start your Continuous Improvement Journey 5

6 Boiler Capacity Another consideration when introducing Steam Infusion is boiler capacity. Steam Infusion can quickly become cost prohibitive if your existing steam boiler is unable to generate the required steam demand. The only way to increase this capacity is with a new steam boiler. This is a significant investment for a food manufacturer, so it s important to check this before committing to a new Steam Infusion system. A single Steam Infusion Vaction TM Pump requires 750 kg per hour of steam at peak usage. Questions to ask when assessing steam injection or infusion pumps: 1. Do you have enough steam capacity for the device you are considering? 2. Is your steam already culinary grade, or will you require a filtration set? 3. Is the pump capable of being retrofitted to your existing equipment? For example, can you keep your existing agitator? 4. What size vessels do you need, and is the system compatible with your current cooking vessels? 5. Can more than one pump be fitted per kettle, and what is their lifespan? 6. What software systems are required, and do they integrate with my current systems? 6 Steam Infusion Buyers' Guide

7 Supplier Track Record With such a wide range of companies offering steam injection and infusion systems of some form, it can be difficult to know who to trust. Some companies are primarily industrial equipment component suppliers, while others are first and foremost cooking vessel manufacturers. Whichever path you choose, it s vital to ensure that your supplier has the right industry knowledge and track record to make your steam infusion transition a success. Proven for Your Industry An important point to look for is a proven track record of delivering steam cooking systems, as opposed to steam pumps for healthcare, pharmaceutical or other industries, for example. While many of the pumps for these industries may be suitable for use within food manufacturing, it s likely that the supplier may not understand your particular needs and challenges. These pumps may not be optimised for faster cooking times, and the product team may not understand the importance of reducing burn on and Maillard reactions, for instance. Research and Development When you do find a steam system manufacturer you are interested in, look for evidence of development. Can they provide facts about the reduction in cooking times, the average reduction of fat within products, or typical energy consumption? Ensure that you can find substantiated, numerical, and relevant facts as opposed to vague statements. Production time for three batches of Béchamel Sauce 7 Steam Infusion Buyers' Guide

8 Testimonials Another point to consider is evidence of satisfied customers from your industry. Customers outside your industry will be facing different challenges, so ensure that there are reviews from companies who are tackling the same issues as you. Whatever your needs, probably the most important factor is the ability to discuss your challenges and requirements in detail, with knowledgeable staff who can help you identify potential opportunities. Steam Infusion has reduced the production time of our soups and sauce by more than 50% as well as reducing energy whilst still maintaining our exceptional product quality. Jan Kusters, Operations Director, Larco Foods (NL) Positive indications that your Steam Infusion supplier should be able to meet your needs: They can demonstrate a proven track record in your industry. They can provide references from happy customers who also work in your industry. They have a vision for the future based on trends like health, convenience and digital technologies. Our latest Steam Infusion white paper in partnership with the University of Lincoln. 8 Steam Infusion Buyers' Guide

9 After-Sales Care and Support Finally, it s highly likely that during the steam system s lifetime the products you manufacture will change and the systems will require some level of engineering support. When choosing a supplier, it s essential that they can deliver the right level of product development and engineering support to maximise your technology s lifespan and give you the greatest return on your investment. Continuous Development One of the ways to assess this is the level of investment that the company is making into the system. For instance, is further work being undertaken to develop new applications for the technology, or to identify additional health benefits that can be obtained from its use? Evidence of added investment and research is a reassuring sign that the manufacturer will continue to support your product and help meet your product development goals. Local Support The available local support network is also a valuable indication of the level of after-sales service you can expect. If a company has created a large support network, then it s likely they plan to continue to refine their systems for some time. In addition, training on the new system should be easier to arrange with a local support team in place. Good local support can give you the peace of mind that should any problems arise such as product development issues or equipment difficulties you will have help to resolve them. Questions to ask the prospective supplier of your Steam Infusion Pump: What level of support can you offer? (Training, product development, maintenance, and troubleshooting?) Is on-site support available? Do you offer additional training, beyond the initial set up training? Do you keep your customers informed of the latest developments, applications and product ideas? If so, how? What additional research and development are you undertaking for this system? 9 Steam Infusion Buyers' Guide

10 Join Our Steam Infusion Revolution With over 25 years of experience supplying the food industry and a cooking technology which is the result of over 15 years of development, OAL is a trusted leading supplier of Steam Infusion cooking systems for the food and drink manufacturing industry. The revolution is spreading, and now, over 40 food manufacturers use multiple Steam Infusion Vaction TM Pumps to cook over 237,000 kilograms per hour of soup, sauces and ready meals across the UK, Europe, USA, Africa and Australasia. OAL s Steam Infusion improves efficiency while unlocking product development opportunities in key product areas. Our scientifically-proven technology offers a range of significant benefits, such as: Elimination of burn on and Maillard reactions. Reduction of fat in dairy products by up to 20%. Creation of a creamier, more indulgent mouthfeel. Substantial reduction of cooking and cleaning times, typically by 50%. Reduction of energy consumption by up to 15%. Easy product matching of existing recipes. Your Trusted Supplier With a global network of system partners providing full product installation and after-sales care, you can be assured of seamless integration of Steam Infusion into your existing cooking processes. Our unique design allows the Steam Infusion Vaction Pump to be retrofitted to existing equipment, reducing the amount of investment required. Our regular cooking classes, continually updated knowledge base, and ongoing research into Steam Infusion technology means that you will always be at the forefront of the latest product developments and information. Ready to find out what our Steam Infusion technology could do for your food business? Get in touch with one of our Steam Infusion experts for a free demonstration of all that our Steam Infusion technology can offer your business. 10 Steam Infusion Buyers' Guide

11 Where to buy from: We have a global network of approved system integrators ready to integrate Steam Infusion into your cooking processes. All are supported by OAL s engineering and product development teams. For more information, contact OAL at: Tel: sales@oalgroup.com Web: steaminfusion.oalgroup.com