The MultiDrum ticks all our operational boxes. Ian Dunn, Head of Process Development at Moy Park.
The secret is all in the flour
Maintaining flour condition is essential to get the authentic homestyle coating. It is important to keep the flour dampness consistent throughout the production run in order to deliver uniform product quality and maximum process efficiency. This is best achieved by keeping the flour level to a minimum and adding fresh flour at the same rate it is being consumed. The flour delivery system on the GEA MultiDrum manages this in the perfect way.
The secret is in the drums
To meet the challenges poultry processors face in re-creating homestyle, GEA has developed an innovative multi-drum breader. The patented GEA MultiDrum authentically re-creates homestyle breading and significantly reduces the need for manual labor. The tumble motion of a drum gives a homestyle appearance, but this comes at a price in terms of process steps, manning levels and other process drawbacks.
Before the MultiDrum you basically had to choose between an authentic look but with low production efficiency, or a non-authentic appearance with better efficiency. Thanks to GEA's innovative homestyle breader with multiple drums this is in the past. This unique multi-drum breading technology is only available on GEA coating machines. Tumbling the products in a drum ensures a homestyle appearance, and there are no augers in the design so the potential for blockage is minimized. After tumbling, excess flour falls through slits and is constantly cycled back into the machine. At the outfeed, products exit evenly spread across the belt and there is no need for additional spreading machines or manual workers.
The secret is to tick all operational boxes
Moy Park in Craigavon, Northern Ireland specializes in the production of fresh poultry products. The company was an early adopter of GEA MultiDrum breaders. Watch the video and find out how the MultiDrum is helping Moy Park to meet day-to-day challenges, develop new products and enhance productivity across the company’s extensive range of fresh chicken, made just the way customers like.
The secret is a complete innovative homestyle line solution
GEA has a full range of best-in-class equipment that can be incorporated into the homestyle coating line. The line starts with brine injection, massaging and tumbling to add value to the products in terms of enhanced flavor, more appetizing color, higher yield and an appealing bite. The next step is the coating process. During this process step, the products subsequently undergo pre-dust coating, batter coating and flour coating.
GEA’s technology is exceptionally successful in offering efficient use of ingredients, dust-free production and consistent and high-quality batter mixtures to ensure optimal coating pick-up and coating retention. After coating, the homestyle products need to be flash fried to set the coating. When frying coated products, the use of flour always influences the life and quality of the cooking oil. Frying is essential to set the coating, and flour will always be left in the oil. The GEA EasyFry can be fitted with the high capacity Oberlin Oil Filter that filters out particles down to one micron in size. It is a fully automatic, continuous process that produces dry sediment. In most processes, the products also pass through a two-zone GEA CookStar spiral over that efficiently cooks in the first zone to seal in moisture and boost yield and provide a crispy coating in the second zone.GEA also offers a complete range of spiral freezers, horizontal thermoformer packaging machines and vertical baggers to enable the complete line solution to be specified with integrated control software for optimum automation.
The secret is GEA’s advanced technology
To re-create the authentic homestyle coating in an automated industrial environment, GEA’s integrated line solution gives the true homestyle look, feel and taste in a highly cost-effective way.
GEA MultiJector 2mm
The new GEA MultiJector brine injection system with 2 mm OptiFlex needles features unrivaled injection accuracy with a low standard deviation for excellent product quality and maximum profitability; flexible needles that will not break or distort, and maximum Time-in-Meat technique. Injecting can turn ordinary or cheap cuts of poultry, meat or fish into a succulent basis for a delicious meal as well cost-effectively prepare traditional products like high-quality chicken tenders on an industrial scale.
When injection is followed by a short tumbling or massaging step in the GEA ScanMidi, protein activation is stimulated. This optimizes product quality and the consistency of the marination process. Besides, marinades and spices can be added. The net result is increased yield, enhanced appearance and an improvement in processing efficiency.
The right coating adds value to the end-product. The GEA MultiDrum provides opportunities to re-create authentic homestyle coating in a highly cost-effective way. With total control over the quantity of coating material used, optimizing the degree of pick-up, so that food manufacturers can precisely balance quality, yield and costs. GEA MultiDrum is first in the industry to work dust-free and re-create homestyle appearance.
It is an acknowledged problem with poultry tenders that they tend to fold, disorient and they can roll over at transfer points on the belt and therefore fall between belts and remain trapped. To avoid using intensive manual labor to correct this, GEA has introduced the TenderAligner. Poultry tenders are automatically aligned so that they pass over transfer points. This results in better process yield, up to 50 % higher throughput and more consistent product appearance.
GEA PowerPak PLUS
GEA PowerPak PLUS is state of the art modular thermoforming equipment, integrating GEA latest technology and promoting easy and reliable operational management, excellent package quality and high food hygiene. Suitable for packaging of all kinds of food products in array of pack types such as skin, shrink, zipper, topforming or modified atmosphere packaging (MAP).
The GEA PowerPak PLUS offers highest package quality in combination with high output and low Total Cost of Ownership. Which makes this the optimal solution to pack your homestyle coated products.