PET Food Processing - September 2021 - 58

EQUIPMENT
Left: Alkar has built
in what the company
calls " handshakes, "
signals sent between
machines to communicate
separation or
other interruptions to
the process.
ALKAR-RapidPak, Inc.
Right: Baker Perkins
has redesigned its
TruBake ovens to incorporate
a " TruClean "
concept, effectively
minimizing the need
for maintenance,
enhancing accessibility,
and significantly reducing
cleaning time.
Baker Perkins Inc.
seeing a reduction of about 75% to 95% in cook times. "
Not only is the TurboChef able to drastically reduce
baking time for these formats, it is also equipped for
more efficient energy usage and a clean-as-you-go approach
to sanitation.
" For example, in a standard convection or microwave
line, the energy is being absorbed at a certain rate, " King
said. " Our energy rate absorption is in the 80th
to 90th
percentile. We've figured out a way to get better absorption
of energy into the cavity, and so we're using less energy
to get that cook result. "
The system is separated into 11-foot, independently
controlled zones, with the three types of energy adjustable
in each zone. Product is run through the system
continuously on a 40- or 60-inch stainless-steel belt,
which is more durable than plastic and easier to clean.
The TurboChef is modular, and the number of necessary
zones is determined for each individual customer
or product. Alkar works directly with companies to test
products, adjusting how much of each type of energy is
needed in each zone to optimize the cook time without
sacrificing key product attributes, like safety and color.
" When we designed this oven, we designed it with five
specific things in mind, " King said. " Reduced footprint,
improved efficiency, consistent performance, measurable
performance, and improved throughput and productivity
based upon the resources being used. "
Ease of access is also built into the TurboChef design.
Alkar actively explored ways to minimize moving parts
inside the oven - the only things that move are the belt,
belt wash and a fan to drive the air in each zone. There
are no ducts, and everything used to power the oven is
located on the sides of the machine. Everything else inside
the baking chamber, King said, " is powered through
physics and science, " making it easier for operators to
get inside the machine when needed.
" The people we worked with to design this didn't
make a living developing ovens - they've made a living
developing medical research, weapons research, deep
space research and controlling energy, " King said. " We
went outside of the standard or the norms of the industry
and went to the smartest people we could find when
it came to applying energy, worked with them, and then
we ran all sorts of simulations to see how to apply that
58 PET FOOD PROCESSING | September 2021 | www.petfoodprocessing.net
energy and control it more effectively and efficiently. "
Sanitation was also a priority, and Alkar figured out a
way to meet sanitation standards in a way that is quick,
effective, minimizes downtime and does not unnecessarily
waste water. A belt wash system is located under the
TurboChef, so as the belt is cycled through the oven, it
then runs under the oven to be washed. There is a cleanin-place
system inside every zone, which happens automatically
and simultaneously after cooking. This speeds
up changeovers and allows processors to run multiple
SKUs on the same machine in the same day. Additionally,
before water is used in the belt wash, it acts as a floor jacket
to eliminate adverse cook-off effects during baking.
" In pet food, we're
seeing a reduction of
about 75% to 95% in
cook times. "
Steve King, ALKAR-RapidPak, Inc.
" By doing that consistently, as well as washing the
belt, we can switch product SKUs in probably 30 to 45
minutes, depending on what they are, " King said. " The
valuable thing for somebody who's processing new
products is, you can run four or five different SKUs on a
TurboChef in a day. "
When describing what this technology means for the future
of the industry, King likes to use a powerful analogy.
" In 1950, you could hop on a plane in Boston and fly
to Los Angeles and it took you 14 hours and you stopped
twice to get refueled, " King said. " That's a great way to
get across country. Now you can hop on a plane and fly
across in five hours. It doesn't mean that what they were
doing before wasn't good, we've just made a significant
leap forward. "
Baking is a traditionally low-and-slow cooking method,
but equipment manufacturers are turning up the heat
to show companies that they can bake faster, smarter and
more efficiently, and deliver products that speak to healthfocused
consumers and planetary pet parents alike.
PFP
http://www.petfoodprocessing.net

PET Food Processing - September 2021

Table of Contents for the Digital Edition of PET Food Processing - September 2021

PET Food Processing - September 2021 - Intro
PET Food Processing - September 2021 - 1
PET Food Processing - September 2021 - 2
PET Food Processing - September 2021 - 3
PET Food Processing - September 2021 - 4
PET Food Processing - September 2021 - 5
PET Food Processing - September 2021 - 6
PET Food Processing - September 2021 - 7
PET Food Processing - September 2021 - 8
PET Food Processing - September 2021 - 9
PET Food Processing - September 2021 - 10
PET Food Processing - September 2021 - 11
PET Food Processing - September 2021 - 12
PET Food Processing - September 2021 - 13
PET Food Processing - September 2021 - 14
PET Food Processing - September 2021 - 15
PET Food Processing - September 2021 - 16
PET Food Processing - September 2021 - 17
PET Food Processing - September 2021 - 18
PET Food Processing - September 2021 - 19
PET Food Processing - September 2021 - 20
PET Food Processing - September 2021 - 21
PET Food Processing - September 2021 - 22
PET Food Processing - September 2021 - 23
PET Food Processing - September 2021 - 24
PET Food Processing - September 2021 - 25
PET Food Processing - September 2021 - 26
PET Food Processing - September 2021 - 27
PET Food Processing - September 2021 - 28
PET Food Processing - September 2021 - 29
PET Food Processing - September 2021 - 30
PET Food Processing - September 2021 - 31
PET Food Processing - September 2021 - 32
PET Food Processing - September 2021 - 33
PET Food Processing - September 2021 - 34
PET Food Processing - September 2021 - 35
PET Food Processing - September 2021 - 36
PET Food Processing - September 2021 - 37
PET Food Processing - September 2021 - 38
PET Food Processing - September 2021 - 39
PET Food Processing - September 2021 - 40
PET Food Processing - September 2021 - 41
PET Food Processing - September 2021 - 42
PET Food Processing - September 2021 - 43
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https://digital.petfoodprocessing.net/sosland/pfp/pet-food-processing-september-2021
https://digital.petfoodprocessing.net/sosland/pfp/pet-food-processing-june-2021
https://digital.petfoodprocessing.net/sosland/pfp/pet-food-processing-march-2021
https://digital.petfoodprocessing.net/sosland/pfp/2020_12_01
https://digital.petfoodprocessing.net/sosland/pfp/2020_10_01
https://digital.petfoodprocessing.net/sosland/pfp/2020_09_01
https://digital.petfoodprocessing.net/sosland/pfp/2020_06_01
https://digital.petfoodprocessing.net/sosland/pfp/2020_03_01
https://digital.petfoodprocessing.net/sosland/pfp/2019_12_01
https://digital.petfoodprocessing.net/sosland/pfp/2019_10_01
https://digital.petfoodprocessing.net/sosland/pfp/2019_09_01
https://digital.petfoodprocessing.net/sosland/pfp/2019_06_01
https://digital.petfoodprocessing.net/sosland/pfp/2019_03_01
https://digital.petfoodprocessing.net/sosland/pfp/2018_12_01
https://digital.petfoodprocessing.net/sosland/pfp/2018_09_01
https://digital.petfoodprocessing.net/sosland/pfp/2018_06_01
https://digital.petfoodprocessing.net/sosland/pfp/2018_03_01
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