Batch or continuous production
No matter whether you choose batch manufacturing or prefer continuous production, Steam Infusion offers processing and new product development benefits to turbocharge your operations.
Batch processing
If you have a lot of product changeovers, more than likely you favour batch manufacturing. As consumers demand more and more from the products they buy, many manufacturers are turning to batch production to deliver smaller product runs that can tap into niche trends and boost the bottom line.
When Steam Infusion is used in batch processing, it enables you to shorten cycle times and reduce cleaning requirements thanks to the elimination of burn-on. The unique processing conditions within the Vaction Pump also allow manufacturers to reduce processing stages on some products while cutting the heat-up time, halving the processing time. By integrating Steam Infusion into its processes, a Spanish manufacturer was able to run 10 back-to-back batches of a béchamel sauce before carrying out a full CIP, maximising the volumes produced in its facility.
Batch processing with Steam Infusion is ideal for product development during the R&D phase as it’s possible to cook up smaller quantities to test out different variables, enabling you to achieve the perfect product without wasting your resources.
Batch cooking is possible with both the In-Tank and In-Line Steam Infusion Vaction Pumps. The In-Tank unit can be retrofitted into existing vessels to extend their useful life or allow you to double capacity with existing kettles - particularly useful if you have a landlocked facility and have just won a new contract. With the In-Tank Vaction Pump, it can be fitted into vessels between 500L and 3000L (132 and 793 US gallons) depending on the volumes you require.
The In-Line Vaction Pump can also be used in batch production if installed as part of a recirculation loop, which is sometimes preferable if there are any challenges installing the Pump in the tank around existing equipment such as agitators etc. For the ultimate in batch processing, you can also use Steam Infusion in our Robot Chef to revolutionise your operations and discover unimaginable efficiency!
Continuous processing
Continuous processing is often preferable for applications where you’re producing greater volumes of fewer products at higher speeds. Direct steam injection or heat exchangers are traditionally used in this process, but these can be replaced with the Steam Infusion In-Line Vaction Pump to achieve better results both in terms of efficiency and product quality.
To achieve the right processing conditions, we can design a multi-In-Line Steam Infusion system where multiple Steam Infusion In-Line Vaction Pumps are placed in series or parallel depending on the needs or the configuration of the facility. The system can achieve flow rates ranging from 1000kg/hr (2,200lbs/hr) to volumes in excess of 200,000kg/hr (440,925lbs/hr) and beyond to meet your throughput requirements. At the same time, the temperature and shear rate across each Vaction Pump can be adapted to ensure product characteristics and temperature profiles are achieved without the issues of fouling or burn-on seen with traditional methods.
Steam Infusion In-Line systems enable you to scale up concept products developed in the kitchen, better mimicking the results of small scale production at high volumes thanks to the lack of burn-on and textural advantages achieved with Steam Infusion. Continuous production with Steam Infusion can also often be a more cost-effective solution than traditional methods when delivering high volumes without waste or affecting product quality.