Confectionary High-Speed Reclamation
Confectionery must be returned or reworked for a variety of reasons. For example, when a high-speed production line fails due to downstream issues such as Coating machine error or packaging line failure. Another source of waste is when candy is deformed or rejected as being off-spec. Stopping production can be difficult and costly, so continuously produced raw materials are often dumped in the trash until the line is restarted. Confectionery waste can be difficult to collect and, in the past, was simply discarded. However, the high cost of raw materials such as sugar and cocoa makes it increasingly important to recycle "off-spec" products.
Processes
Post-treatment processes vary greatly depending on the type and geometry of the material being processed. This can range from a raw material or mixture of ingredients to a “finished product”.
• Clumps or large solids must first be crushed or crushed before being treated in a similar manner.
• Hard, brittle solids and insoluble materials may need to be crushed or ground to a manageable particle size.
• At the operating temperatures required to melt or dissolve solids, volatile components, especially fragrances, can be lost by evaporation, so closed containers are often necessary.
Chocolate confections have additional requirements:
• Adding even a small amount of water to melted chocolate can cause it to "harden" quickly.
• Chocolate can also make you nervous.
•The temperature must be carefully controlled so that the product does not burn or caramelize.
Problems
Using a conventional agitator to collect confectionery can lead to several problems.
• Large clumps or agglomerates in the mixture can seriously damage the agitator
• Incomplete solubilization may result in poor product consistency.
• Storing products at high temperatures for long periods of time can affect flavor and quality.
• The structure of gelatin-based confectionery collapses at temperatures above
160 ̊F (70 ̊C), so more gelatin must be added after transformation to regain the gel structure.
Solution
Wahal Engineer has developed a completely new system specifically for the recovery of larger solids and agglomerated confectionery. The system consists of a jacketed vessel with a high-shear bottom entry mixer and an in-line mixer with a recirculation system. The device is rack-mounted and has an integrated control panel. The operation is explained below. Small solids can be collected with Wahal Engineer Duplex
Wahal Disintegrator/Dissolver unit.
In a typical workflow, the vessel is first filled with a base liquid (usually water). This is heated to the required operating temperature before starting the bottom entry mixer and the recovery product is added. Larger solids can be added without prior grinding. The mixer exerts a powerful suction force that draws the material into the working head, where it quickly breaks it down into fine granules.
Once the particle size is small enough, the in-line mixer can be started. The material is drawn into a recirculation line and passed through the working head of an in-line mixer. A self-pumping unit pumps the product back into the container while sucking in fresh ingredients.
A combination of heat, vigorous agitation and intense high-shear forces accelerates the solubilization process, rapidly reducing the entire container contents to a homogeneous mixture without significantly reducing product quality or flavor. The Inline Mixer can also be used to return processed rework to the production line, possibly without the aid of a positive pump.
When processing chocolate confections, one of the ingredients of the final product, such as cocoa butter, or part of the original product is added to the container to provide enough liquid to cover the working head. Once solid chocolate is placed in a jar, it can be fitted with an integrated scraper unit that provides gentle movement and even heating until the product melts. To speed up this part of the process, you can also operate a bottom entry mixer to grind up large solids once the liquid level covers the working head.
Benefits
• Significantly reduced processing time.
• Improved product uniformity and consistency.
• Sanitary construction.
• Strong agitation in the tank with the bottom entry unit eliminates the need to agitate the shaving surface in the tank.
• Can be custom manufactured to meet individual process requirements.
• A CIP spray ball can be incorporated into the tank design.
• Vessel jackets and (if necessary) in-line mixers can be used for temperature control to prevent product damage from overheating when processing gelatin-based confectionery.
• Various levels of automation and instrumentation can be integrated at the design stage. This device can also be connected to additional devices or process computers as needed.
Wahal Duplex Disintegrator/Dissolver (HSD) When Processing solids smaller than, the Duplex Disintegrator/Dissolver can be used in place of a conventional in-tank agitator.
Wahal Sigma mixer
We also manufacture, supply, and export a wide range of Sigma mixers suitable for the above task. In accordance with international quality standards, these mixers are designed and developed using premium materials and modern technological methods. These mixers are widely demanded in various industries for their smooth performance, easier operation, less maintenance, and longer life.
Function:
High-performance
Less maintenance
Well-analyzed
Wahal Planetary mixer
Planetary mixers have one motor and a stationary bowl. They come in smaller countertop versions and larger freestanding models and are among the most popular faucets for commercial kitchens. As the name suggests, planetary mixers are equipped with an agitator that moves around the bowl like a planet.
