DCN has recently launched their new Jet Process System which is ideal for the manufacture of wet pet food.
The system can cook, entrain (mixes and hydrates hydrocolloids) and sterilise in a single pass. A recent installation required a footprint of only 120 sqm. and can produce 18,000Kgs of wet pet food per hour, using only one operator. With Jet Process manufacturers can reduce the amount of processing vessels used, save energy and improve their products.
Traditional wet pet food processing consists of multiple jacketed or pressure vessels, emulsifiers, heat exchangers and/or retorts all to achieve high temperature sterilisation. These typically take up a large footprint and the equipment requires regular maintenance and yearly pressure testing. The multiple processing stages use huge amounts or energy along with large volumes of water and caustic to clean and remove burn-on. A considerable amount of labour may also be required depending on throughput.
We use our high speed Jet Entrainment for powders such as gums, gels, vitamins and hydrocolloids. This entrains, heats, mixes and hydrates the powders to their required temperature in single figure minutes. It then automatically transfers them to a unjacketed processing vessel, where ingredients such as meat, vegetables, water and rice are added .
Our patented Jet Cook™ In-tank units heat and emulsifies the pet food to 50°C, then high shear mixing heads are used to create the final texture before the product is automatically diverted via Jet In-line units. It is then heated again from 50°C to 150°C in a single pass in less than 2 metres, with zero burn-on or fouling. As product goes through the units, the process flow undergoes a double phase change and a very rapid transition of pressure and velocity.
Any powders, fats or liquids contained in the flow become thoroughly homogenised, along with even heat distribution from steam condensation, giving a 99.8% usage of the steam energy. The cooling process is completed using the same line, bringing it back down to 70°C before diverting to the filler holding vessels.
Finally, the mains water that has cooled the product after sterilisation is recovered back into the first process vessel, saving huge amounts of energy and ensuring the system is highly efficient.
DCN also installed a recovery system that utilises energy and water from one part of the process and recycles it for use in another, thus further saving energy and lowering water usage making the system even more efficient.
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Product Technology Manager
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