SMART FLOW BATCH SYSTEM – The intelligent process solution

Standardizing and simplifying process steps is one of the most important goals for all food producers.

Today, there is more and more overlap between individual product groups and their processing. Just a few years ago, for example, completely different production processes were used for the manufacture of sausages and the production of processed cheese. With the emergence and rapidly increasing importance of vegan foods on the market, new technologies and processes have been devised.

Sustainability by all-in-one machine configuration

With its Process Automats, KARL SCHNELL offers an intelligent solution that enables the production of both meat products and meat substitutes in a compact all-in-one machine.

Since all process steps are integrated into one unit and can be implemented flexibly, the user can design his products and formulations in an almost unlimited variety of ways. In the production of meat alternatives, for instance, there are many different parameters have to be set during the mincing and emulsification of the raw materials with regard to the selection and use of the cutting tools

HMMA-based formulations (meat analogs with a high water content) can mostly be treated in a similar way to classic fine  meat emulsions. Here, the focus is on a perfect bite and a good mouthfeel.

In TVP-based (Textured Vegetable Protein) formulations, importance is placed on a pleasant structure. Here, both the pre-mincing and the fine mincing process must be handled very sensitively in order to achieve the desired uniform particle structure in the defined degree of fineness of the end product.

As the pioneer in emulsification technology, KARL SCHNELL can draw on a wealth of experience and offer a variety of process-specific cutting systems. In combination with other features such as temperature control, evacuation, etc., a high-quality, precise and reproducible result is achieved.

Intermediate cleaning of the machine, even during ongoing production, is performed by the CIP (cleaning in place) connection. The result of this self-contained system is the highest standard of hygiene without contamination or cross-contamination, while at the same time minimizing the consumption of water and cleaning agents.

Energy efficiency by smart process technology

In contrast to conventional systems, KS Process Automats require far less motor capacity when manufacturing a comparable product and, system-related, also have shorter process times. In addition, due to KS Smart Control,

only the required amount of energy is applied into the process that the product can actually absorb.