Under the motto ‘Excellence At Every Stage’ GEA will present equipment & solutions on four main application expertise areas at IFFA 2019 in Frankfurt. Tempura coated nuggets is one of them. The chicken nugget in general is maturing. The tempura coating is one of the defining factors in this new gold rush. Market leaders in the fast food sector/market are in the process of demanding the so-called ‘golden standard’ nugget. Meeting these tougher demands means mixing and applying a tempura that guarantees a very consistent, high-quality end product.

With all our know-how about the tempura application, built up over the past 50 years, GEA is your partner to go for gold!

The secret about nugget processing is getting every process parameter and every single piece of equipment just right, with an excellent eye for detail.Martin Verhoeven, Application Specialist at GEA.

The secret is all in the mix

Perfect shaped nuggets

The way in which the product is mixed is critical to the success of the forming process. Through many years of developing mixing technology GEA has perfected the process. By measuring the torque within the GEA ProMix as the product is chilled, GEA engineers can help customers to hit the optimum level of chilling every time, taking the guess work away and allowing the GEA MaxiFormer to run continuously for many hours without clogging. If customers experience difficulties in getting the mix right, GEA Food Technologists will work with them, until it’s perfect. 

'It's all in the mix' also applies on the tempura batter mix as consistent tempura viscosity is essential for optimizing pick-up, therefore avoiding give-away and ensuring crunchiness of the product. With GEA TempuMixer II manufacturers can achieve that.

The secret is going for gold

Tempura nuggets in basket

GEA frying equipment helps you achieve crisp, crunchy and golden-colored nuggets. The formed and coated nuggets are flash fried in GEA EasyFry to stabilize the coating and give color. Designed to meet the highest safety standard, the fryer features low oil consumption, self-supportive oil filtration and recipe control and with our oil management solutions you can extend your oil lifespan up to 5 times! 

During cooking the goal is to fully cook the product to guarantee food safety and to achieve the desired yield and juiciness of the end-product. The flash-fried nuggets go through GEA CookStar three-phase spiral oven, where steam and heat is added. Steam has a lot of latent heat and is therefore very effective to transfer energy into the nugget. Due to the higher humidity less moist is lost, therefore achieving higher yields.

With GEA delivering all the equipment on the line we knew for sure that each element would fit together and be compatible.Per Ulrik Jørgensen, Product Technical Manager at Danpo.

The secret is complete line control

GEA installed the first fully automated chicken nugget line at Danpo A/S in Denmark, leader in fully cooked chicken products. On this line they produce a range of chicken nuggets under its ‘Your Chicken’ brand. The line includes the GEA MaxiFormer at its heart, providing high-quality nuggets in a fully automatic, high production process, using the minimum of labor. Watch the video to see how they grind, mix, coat, cook, fry, freeze and pack chicken nuggets day in, day out with only 2 operators.

The secret is GEA’s advanced technology

Tempura coated nugget line overview

Mixing, forming, coating, frying, cooking, freezing and packaging, GEA can supply the complete automated tempura coated nugget line. 

GEA PowerGrind

Pannello touchscreen PowerGrind 200
Pannello touchscreen PowerGrind 200

The GEA PowerGrind represents a new generation GEA grinders with improved capacity, hygiene and safety performance. These aspects are combined with high flexibility, robustness, and modularity, making the GEA PowerGrind a reference in its class. The PowerGrinds cover coarse (pre-grinding) to fine grinding, and are available for fresh meat, pre-broken frozen meat and hard frozen meat blocks.

GEA ProMix

GEA ProMix
GEA ProMix

The way in which the product is mixed is critical to the success of the forming process. The product must be chilled to precisely the right level of crystallization before forming. Through many years of developing mixing technology GEA has perfected the process in the GEA ProMix. This robust, reliable and flexible twin-shaft mixer creates the perfect nugget mix. 

GEA MaxiFormer

GEA MaxiFormer
GEA MaxiFormer

GEA’s MaxiFormer is the next step in high-capacity drum forming for the continuous production of perfectly formed nuggets. The unique patented, low-pressure portioning system in combination with the world-class vacuum filler from Handtmann, achieves more accurate filling with less wastage, creating a high-quality formed nugget with excellent structure retention using the minimum of power.

GEA TempuMixer II

GEA TempuMixer Module II
GEA TempuMixer Module II

GEA TempuMixer II is an automated tempura mixer that ensures a mix with consistent viscosity, composition and temperature. It features in-line viscosity measurement and automatic adjustment to ensure repeatable results. This is crucial for producing chicken nuggets that meet the golden standard.

GEA SmartPacker

GEA SmartPacker CX400
GEA SmartPacker CX400

To pack the nuggets on the safest way, the sanitary GEA SmartPacker is an available upgrade on GEA’s bestsellers, the SmartPacker SX400 and SmartPacker CX400. Main differences compared to the standard execution of SmartPackers are the Stainless-Steel film feed with sealed bearing rollers and sloping surfaces to allow water to come off easily.