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:

1. High-performance

2. Less maintenance

3. 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.

Material	Stainless Steel
Special Feature	Copper winding motor, 3 Mixing Speeds, 220 Watt, Electric Mixer Machine
Voltage	220 Volts
Wattage	220.00
Item Weight	90 Kilograms

 

Tomato processing plant

 Tomato processing plant

We offer automatic and semi-automatic tomato processing equipment. Tomato ketchup plant , tomato paste, tomato powder, and tomato paste are common forms of tomato processing.

The capacity of the equipment ranges from 500 kg per hour to 20,000 kg per hour of tomatoes.

There is a word that companies often overuse: leader. It comes from the Old English word "lædan" meaning "to go as a guide". When we talk about tomato processing, we are not afraid to say that Wahal Process Technologies is a real leader.

We have offered a wide range of tomato processing machines and complete lines: from production to bottling or canning of tomato products such as tomato paste, puree, sauce, chopped tomato pulp, or peeled tomatoes.

WAHAL ENGINEERS PROCESSING PHASES

Machinery uses for Tomato processing plants as:
High Shear homogenizer
In Tank Homogenizer
Enclosed Shaft Homogenizer
Inline Homogenizer

1. HYDRAULIC UNLOADING AND TRANSPORTATION

In the tomato processing line, the product can be received in crates or containers, and the raw material is unloaded into the transport channel via an automatic dump truck. Alternatively, in case of the arrival of bulk product, unloading is done by flooding the bin using adjustable pipes. The product is separated from the water by an inclined grate or roller conveyors, and the tomato is then collected in a separation tank, filled with cleaner water, and equipped with a chain conveyor for automatic removal of stones, mud, and foreign bodies. At this point, the product is then transported to the processing lines.

2. WASHING AND SORTING

Tomato sorting can be done manually on roller conveyors in two stages: the first, in which the roller conveyor is tilted and where the product is separated from water, foreign bodies, etc., and then washed with a series of sprayers; the other in which the roller conveyor is horizontal and the tomato rotates on its own to allow precise control by operators. Sorting can also be done electronically thanks to optical sorting sensors and/or optical sorters with a digital camera manufactured by our Raytec Vision company.

3. Chopping

Washed and sorted tomatoes need to be mashed in order to optimise the subsequent stages of heat treatment. The BT60 chopper pump, embedded in the Cold-Break and Hot-Break technological cycle, guarantees a perfect, uniform, and fine consistency of the crushed product. In the Hot Break process, in particular, extremely low synergistic values ​​can be achieved using breaking temperatures that are almost 4°C lower than standard values, a factor that also allows significant energy savings.

4A. ENZYME INACTIVATION (HOT BREAK)

Eldorado inactivator, which inactivates pectolytic enzymes, is used to make Hot Break tomato paste to preserve the pectins contained in the juice and obtain excellent values ​​of consistency, colour, and synergy. Thanks to the high recirculation flow and the special geometry of its patented heat exchangers, the Eldorado system can work with maximum efficiency for a long time even in the presence of foreign bodies (such as weeds, leaves, creepers, etc.).

4B. PREHEAT (COLD BREAK)

Tomatoes intended for the production of Cold Break tomato paste are heated in a special tube-type unit to gradually heat the product and preserve the natural flavours and colours of the tomatoes that characterise this type of concentrate. By changing the processing temperature, a final product of different consistencies is obtained.

 

5. JUICE EXTRACTION

The preheated tomato juice is sent to the extraction/refining phase, which is carried out in the Giubileo extractor on the principle of centrifugal separation using adjustable paddles. This operation is able to eliminate unwanted parts of the fruit such as seeds and peel. The high efficiency of the separation process makes it possible to obtain high-quality juice and minimises moisture in the waste.

 

6. PRELIMINARY CONCENTRATION (OPTIONAL)

The refined tomato juice can be sent to the initial concentration stage – from 4.5 to 12° Brix – in the Apollo pre-concentrator, which is a mechanical vapour recompression (MVR) falling film evaporator. MVR technology enables the concentration of tomatoes with up to 98% steam savings thanks to the mechanical recompression of acid vapours. Thanks to the reduced residence time and maximum ΔT of 6 °C between the heating vapours and the product, the organoleptic properties of the outgoing product are of excellent quality.

7. STERILISATION AND COOLING

The SFC Flash Cooler represents the best solution for processing large volumes of products and for long operating cycles. Sterilisation takes place by direct injection of cooking steam into the product and cooling by vacuum expansion (lightning). The SFC system guarantees maximum processing safety, aseptic conditions, and the integrity of the final product.

Alternatively, the tomato puree can be sterilised and cooled in the Olympic TC steriliser. The product is subjected to thermal cycling using indirect concentric tube-type heat exchangers with high production capacity, maximum heat exchange efficiency, and process uniformity.

 

8. ASEPTIC FILLING

The sterilised, cooled product is filled into pre-sterilized flexible bags of various sizes using aseptic filling heads. The high degree of automation of Macropak filling machines and the control system controlled by a microprocessor with continuous monitoring of all working parameters guarantee the sterility of the packaged product. The weight of the packaged product is checked using highly accurate load sensors. The machine uses steam both as the only means of sterilisation and for washing the spout after filling.

 

WAHAL ENGINEER TOMATO PASTE STRENGTH

• Long uninterrupted production cycles

• Maximum yield, minimum production waste

• High quality of the finished product, preservation of colour, and organoleptic properties

• Water recirculation system, minimum consumption

• Considerable versatility in sterilising solutions and aseptic filling

• The possibility of producing multiple products on the same line at the same time

• Less thermal stress on the product due to lower temperatures in the evaporator finisher

• Maximum energy savings thanks to the most modern technologies

• The complete supervisory control system of the line and control of all process steps

• Recording, viewing, and printing of daily production data

TOMATO PASTE PRODUCTION LINE

This plant contains the following machinery:

PREPARATION:

• Dishwasher (for washing tomatoes thoroughly)

• Inspection conveyor (for manual inspection and sorting of tomatoes)

• Elevator (for supply to the hot brake system)

• Hot Break System (crushing and immediate heating of crushed tomatoes to preserve pectin)

• Pulper (to remove seeds and obtain fine pulp as output)

PROCESSING SECTION

• Standardisation tanks (for adding ingredients needed to prepare ketchup/sauce)

• Vacuum evaporators (for concentration in vacuum)

• Pasteurizer (for pasteurising tomato paste/sauce / ketchup)

FILLING AND PACKAGING

• Aseptic bag filling (for filling tomato puree in aseptic bags)

• Automatic can filling (for filling tomato paste or tomato paste in cans)

• Bottle filling (for filling tomato sauce or tomato ketchup in glass or PET bottles)

Product Details:

Minimum Order Quantity	1 Plant
Capacity	500 kgs per hour to 20,000 kgs per hour
Automation Grade	Automatic/Semi-Automatic
Material of Construction	SS 304, SS 316L
End Packaging	Aseptic Drums, Glass bottles, PET bottles, Canned, Pouches
Brand	Wahal Engineers

Colour Coated Granulation Machine

 Colour Coated Granulation Machine Product 

Description:

We are committed to manufacturing and supplying a wide range of granulators to meet the needs of plastic processing in various application areas. These are designed according to international standards and a detailed description is given below. 

Specifications: Palletizer for product pallets. 

The stainless steel cooling tank in which a temperature controller Cylinder heating controls Heating by an energy-saving heater Rugged helical gearbox with built-in thrust housing Cooling system accessories for accurate temperature control The drive from the main AC motor to the auger is rubber It is done via a belt, pulley, and gear unit with Fully nitrated, hard chrome plating.

PLASTIC SCRAP GRINDER MACHINE-16 

Depending on your requirements, we will offer you the most competitive offer of "WAHAL ENGINEER-Heavy Duty Plastic Scrap Grinder Machine".

Feature:

1.  'WAHAL ENGINEER' Heavy Duty Plastic Crusher consists of m.s body & amp. 

2. There is a rotor bar. 

• Engine: -15 HP (standard production) 

• Blades: Two blades are fixed. 

• Blade size is 16 inches (inch) processing capacity: -90 to 100 kg / hr. 

• Power Required 15HP (11.25 kW) 

• Screen Area 3350cm² 

• Floor Area (L&W) (mm) 1200 x 1050 

About Aggregator: 

Aggregate Base

1. The base is made of heavy and heavy channels. Mild Steel plate, top of the base is a heavy-duty plate mount AC induction motor housed in the base Thrust housing

2. Constructed ruggedly of cast iron to hold the base plate vertically With high tension screws Equipped with a heavy flange, it has two camps. 

3. Gaskets are provided to limit the ingress of raw materials into the housing. 

4. All bearings are standard manufacturers. 

• main drive…

• AC motor with V-belt connected... 

• control panel…

• The control panel design is M.S. CRC seat

The plate is powder coated. All switching devices are standard voltmeters with a voltage selector switch for the input voltage. 

Coagulator Specifications 

• MODEL HEAD-30 

• TANK SIZE 760M.M. X 760 mm (ms)

• Blade Material HCHC

• Manufacturing Process Nitride Polishing 

• Special Heat Treatment 120 h \ rH.R.C 65 ~ 68º 

• Blade Size 16m. m. x100mm x215mm 

• Main drive 30 HP-AC MOTOR WITH STARTER ROTATING BLADE FIXED 

• POWER REQUIRED 30 HP (approx) 

• PRODUCTION CAPACITY (KGS PER HOUR) * *(*10%+ - depending on material) 80 TO 100 Suitable for: HM/LD/LLDPE/HD/PP & PVC film.

Expo Paint and Coatings 2022: New Delhi, India

 Expo Paint & Coatings 2022 is a comprehensive Paint & Coatings Exhibition providing platform to the needs of every facade of the coating industry right from raw materials, formulation, application, technology, finishing, quality assurance, recycling and disposal. The Exhibition will feature a wide range display of products, Raw Materials, Application systems, Machines, Tools, current trends, development & innovations shaping future of coating industry

Over the years, paint mixing technologies have faced various challenges. Each challenge leading to a more effective solution. The breaking down of pigments to form agglomeration and dispersing of the solids into a homogenous mixture was achieved with the help of High Shear disperser. The development of the high speed disperser (HSD) blade, paved the way to faster processing of paints and coatings. In spite of its advantages these machines were unable to meet the Industrial requirement of the desired level of size reduction. They were incompetent in terms of production time, as the process demands higher processing time leading to slow production time. In a way affecting its productivity.

Wahal Engineer’s High Shear Mixer & high speed disperser for Paint and Coatings Industries, Paint Manufacturing Process advantages machines.

Emulsified Vaccines

 Emulsified Vaccines: Manufactured with Water-In-Oil (W/O)

Adjuvants are substances that enhance the body's response to antigens used in vaccines. When added to antigens (viruses, bacteria, peptides, etc.), adjuvant - especially oily adjuvant - can improve immune response. An appropriate adjuvant from appropriate are oily products ready for use, each specially formulated for a single type of emulsion (W / O, O / W, W / O / W). The adjuvant and emulsion types depend on the target pathology and types. For pathologies such as Foot and Mouth Disease (cattle, swine), Avian Influenza or Newcastle Disease (chicken), Water-water adjuvants can improve performance policy by introducing a strong and long-lasting drug. Non-infection.

In the case of cancer treatment with immunotherapy, Water-In-Oil adjuvants have been shown to provide an effective immune response and a long-lasting effect on the depot.

Important Points

Vaccine production should be done in an open area to avoid contamination during production or storage. Final sterilisation of emulsified injections is technically impossible, so an aseptic procedure is required.

After construction, the goals should be:

• Barren and Stable - up to 2 years at 39 ° F, no mixing, limited decay and oil release.

• Consistency - from one group to another to ensure uniformity of immune defences due to the repetitive process.

The process

To produce a stable emulsified W / O vaccine with immunosuppressive properties, the production process must reach tiny emulsion droplets (<1 µm) with monomodal dispersion and small particle size. The use of the high shear power provided by the Wahal Engineer rotor/stator mixer is required to achieve this goal.

The process must be improved to reduce droplet size, prevent soil erosion over time, and avoid over-slipping and waterlogging as it may affect the safety and effectiveness of the policy.

The infertility of the vaccine is confirmed by the aseptic process using the first seed material (smoke closure) and auxiliary substances (filtration). Process equipment must meet several requirements, depending on both design and construction:

• Clean construction (UHS or UHLS).

• Requirement-Cleaning-Area (CIP) and Interest-in-Area (SIP).

• The storage areas are as close to zero as possible.

• Specific features of the emulsification process containing appropriate adjuvants

The standard process of W / O emulsions containing appropriate adjuvants involves two steps:

• Pre-emulsion - mixing under low shear movements of the liquid phase and oily adjuvant to form evenly large droplets to improve the droplet size of the homogeneity vaccine. 

• High Shear emulsifying with Wahal Engineer High Shear Mixer - excessive emulsion drops with a high shear head of Wahal Engineer mixer (Collection or In-Line). 

• The production vessel is subject to the shear rotation if necessary for the same purpose.

Solution

High Shear emulsifying with Wahal Engineer Mixer - This step works in a four-phase mixing cycle as follows:

Stage 1

After the pre-emulsion step, large droplets are drawn by rotating high-speed rotor blades in the centre of the work head.

Stage 2

The droplets are driven towards the work surface by centrifugal force when under the action of grinding in a small space between the rotor blades and the inner wall of the stator.

Stage 3

The droplets are then under additional shear strength by being forced at high speed through the stator tubes.

Stage 4

The tiny droplets are dissolved by dispersing the head of the work into an emulsion mass. The mixing cycle continues until the intended droplet size and stability are achieved.

Benefits

Wahal Engineer’s rotor/stator high shear alloys are commonly found in the field to adjust Water-In-Oil targets in various batch sizes. For more than 30 years, An appropriate helped vaccine manufacturers develop processes in their existing Wahal Engineer compounds or provide investment recommendations.

The length of the pre-emulsion process and the high shear step depends on the size of the batch and the adjuvant used.

For specific recommendations on your application, please contact your appropriate sales representative.

High Shear Batch Mixers

• Recommended volumes of less than 1 - 3 US litres

• It can be considered medium volumes

Top High Shear In-Line Mixers

• Recommended for volumes more significant than 13 US gallons

• It can be considered medium volumes

• In-Line mixer with 2.75 "rotors or less:

To use:

• At higher frequencies, there is a standard power supply (70 - 120Hz)

• With Fine Emulsion Screen (FEMSC)

• In-line mixtures with 4.25 "or more rotors:

Can be used:

• At expected frequencies (50 or 60Hz)

• With Standard Emulsion Screen (EMSC)