OAL sees popularity soar in Africa with Dairy Gold collaboration
OAL is widely specified in Africa following our collaboration with Dairy Gold. Dairy Gold used Steam Infusion to hydrate maize flour to manufacture beverages as part of their efforts to re-launch into the market. Dairy Gold was looking for ways to reduce operating costs for production of their Maheu drink, while improving product quality and were able to achieve their desired results (plus more!) with Steam Infusion.
The figures
Steam Infusion Maize Hydration System
With our patented Steam Infusion technology, we were able to hydrate maize flour up to concentrations of 12% at a rate of 15,000 litres (64.9 US gallon) per hour, using only one 5,000 litre (21.6 US gallon) vessel. The maize slurry was fermented for two hours before two Vaction™ Pumps were used to heat the final product to 90°C (194°F) before filling.
Not only this, but the elimination of burn-on with Steam Infusion meant Dairy Gold’s products were not at risk from dark flecks or discolouration from burnt spots. Steam Infusion does not expose product to excess temperatures because of the partial vacuum generated in the Vaction Pump. At the end of the production schedule, the vessel could be easily washed down with water and time not lost removing burnt patches from the walls.
Varying operating pressure
One of the traditional challenges with grain processing is the ability to quality control the hydration. Traditional cooking methods such as steam-jacketed kettles means the product is at risk from burning on to the side, tarnishing the flavour and look of the product. Furthermore, with Steam Infusion, 95% of the steam energy is transferred to the product, a significant improvement on the steam-jacketed kettle.
With Steam Infusion, the operating pressure and temperature can be varied. The level of shear can be changed as to whether a gritty or smoother texture is required, and this level of control is unique to the Steam Infusion cooking process.
Why not take a look at our video showcasing Maheu manufacturing?
Improving product quality
An additional benefit that can be particularly noted with Steam Infusion and dairy-based products such as Maheu is that you can achieve a glossier, creamier product due to the turbulence of the steam distributing the fats more effectively. This ensures you get a creamier mouthfeel and a fresher taste, without the additional fat. This is because of the unique processing environment of Steam Infusion, which forms a fat mimetic to enhance the mouth-feel.
“When we were seriously considering re-entering the market, we knew that this would entail products and processes that were superior to our competitors. It would have to be cost-effective, as we are operating in a very demanding and competitive market sector.”