The secret of perfect brine distribution and retention?
GEA's solutions for fresh enhanced enables impressive long term brine retention, guarantees the smallest possible variances and reduces brine losses. All while improving product appearance and juiciness.
Examples of fresh enhanced poultry products
Evolving from hand-cut chunks of chicken breast to formed poultry filet mix, either fry-cooked to cook-fried, during production manufacturers continuously look for consistent product quality, maximum yield, food safety and attractive appearance. But how to achieve this? If you really wants to go for the so-called ‘golden standard’ nugget, you need to excel in every stage of the production process, starting from the ingredients and their preparation, moving to forming and tempura mixing, up to cooking, frying, freezing and packaging. With all the know-how about the tempura application, built up over the past 50 years, GEA is the partner to go for gold.
The secret is all in the mix
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
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.
The secret is GEA’s advanced technology
Mixing, forming, coating, frying, cooking, freezing and packaging, GEA can supply the complete automated tempura coated nugget line
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.
製品および技術
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Defrosting & Tumbling
Whether you defrost, melt or thaw using a refrigerator, heating your product or add cold water. It is very hard to control the way your product is reacting and you usually need long time frames to do it.
インジェクタ
赤身肉、豚肉、鳥肉、魚加工品のいずれを生産する場合でも、塩水を注入すると、利益を上げ、お客様に受けるさまざまな製品を開発する機会が得られます。
塩水プラント
マリネを成功させるための第一歩は、均一に、制御された条件下で、塩水またはマリネードを混ぜて保存することです。
熱成形包装システム
エントリーモデルから高性能自動化ラインまで、GEA PowerPakシリーズは、精密性、柔軟性、信頼性を備えた包装のパワーをお届けします。食品、医療、非食品など幅広い用途に対応するよう設計された当社の熱成形機は、廃棄物や資源の消費を抑えながら、安定したパック品質を保証します。より薄いフィルム、リサイクル可能なモノ素材、繊維ベースのソリューションを可能にする技術により、PowerPakシステムは、パフォーマンスを損なうことなく、生産効率と持続可能性の目標との調整を容易にします。
Discover a typical fresh enhanced poultry process
The starting point for successful marination is a homogeneously mixed brine. Carefully formulated brine that is mixed and stored under tightly controlled conditions will enhance the value, consistency and safety of the end product.
Accurate brine injection needs a little finesse. GEA offers injectors with very dense injection patterns and smooth vertical movement to optimize 'Time-in-Meat' that is further evolved since the beginning in 1969. The more injection points, the better the brine retention. GEA MultiJector's injection head sets needles close to the product for maximum distribution with adjusted pressure. The unique 2mm OptiFlex needles are at the heart of the injector and are stronger than traditional stainless steel and have the superior property of recovering their shape over and over again instead of being deformed or bent. A brine cooler alongside the injector offers exact temperature control, keeps brine circulating and avoids sedimentation. And the GEA MultiShakers in combination with the flip-over drip-off conveyor at the outfeed, shake-off excess brine from both sides of the product and start the activation of proteins, which also close the remaining needle marks.
Packaging with our thermoformers
