cutting fat and doubling cooking capacity in dairy based

Cutting Fat and Doubling Cooking Capacity in Dairy Based Sauces with Steam InfusionLearn why food manufacturers are switching from direct Steam Injection to Steam Infusion

Multi-Award Winning Technology

White Paper • How to Make Healthy, Creamy, Indulgent Dairy Based Sauces Efficently with Steam Infusion •

A Fresh Approach to Cooking Dairy Sauces

Meeting consumers’ demands for convenient, healthy and indulgent food products is a constant challenge for retailers and food manufacturers. With governments from all over the world challenging food manufacturers to decrease levels of fat, salt and sugar in products, new processes present alternatives to reformulation.

The Steam Infusion Vaction™ technology is a disruptive device that sits within a cooking vessel and uses steam as the motive force to uniquely heat and mix food products. The University of Lincoln has researched the patented Vaction™ cooking technology under an Innovate UK funded project to scientifically identify the product development and operational opportunities of the technology.

This White Paper explains how the unique processing environment generated by the Steam Infusion Vaction™ technology can help food manufacturers cook dairy based sauces more effectively and answers the following questions:

From a product perspective:• How can Steam Infusion reduce fat in my product by up to 20%?• Will this impact my product traffic lights?• Can I stop burn-on or Maillard reactions happening?• Will Steam Infusion change my product colour?• How does the process lead to a creamier mouthfeel and more indulgent flavour?

From a cost and operational perspective:• How will Steam Infusion reduce my ingredient costs?• What impact does no burn-on have on cleaning times?• How can Steam Infusion double my sauce capacity?• Is the technology easier for operators and does it reduce downtime?• Why Steam Infusion can reduce energy consumption by up to 18%?• Why manufacturers are switching from Steam Injection to Steam Infusion?


“Steam Infusion has reduced the production time of our soups and sauce by more than 50% as well as

reducing energy whilst still maintaining our exceptional product quality.”

Jan Kusters, Operations Director

“The Steam Infusion Vaction™ technology has made a substantial difference in improving our efficiency of

sauce production. We are typically producing 10 batches in the time it used to take for 5 with significant

labour savings.

Martin Tranmer,Group Engineering Director

Customer Story

“We are very happy with the retrofit of OAL’s Steam Infusion technology to manufacture porridge. We have

been able to quickly master how to maximise the benefits of the Steam Infusion system and we’re confident

that the technology offers the flexibility to cook a wide variety of products to delight our customers.”

“The system is very fast and has reduced our cooking energy consumption by 18%. It’s a quality piece of

equipment that’s definitely “cook proof”. Since the installation, our engineering team hasn’t had to touch the

system.”

Janet Prescott, Manufacturing Manager

Leading UK food manufacturers are now utilising Steam Infusion as a best practice process for cooking dairy based sauces because of its ability to enhance flavours and efficiently manufacture products. The technology can overcome many of the key challenges manufacturers face including burn-on contamination and scaling up concept products.

A 6 tonne an hour Steam Infusion soup

production system.


How Steam Infusion Works

The Vaction™ Unit sits within the cooking vessel flooded with a product as culinary grade steam is introduced via the steam lance. It has no moving parts and uniquely uses steam to simultaneously heat, pump and mix the product. The following is based upon operating at 6 Bar steam pressure; by changing the controlled steam pressure, the processing conditions are changed within the VactionTM Unit to achieve the required product characteristics.

Profiling within the steam chamber accelerates the velocity of the steam to 1,000m/s, faster than the speed of sound.The steam passes into the mixing chamber through an annular nozzle, disrupting the fluid flow to form small droplets, referred to as the vapour phase. The momentum transfer from steam to the product creates a partial vacuum of -0.7 Bar within the unit.

As the steam condenses into the fluid droplets, the pressure rises. This is referred to as the condensation shock-wave and generates a pumping effect. The small droplets within the low-pressure vapour phase offer a significantly increased product surface area for the steam to condense into, typically resulting in a near instantaneous temperature gradient in the order of 10 to 15⁰C.

The very short residence times and partial vacuum within the unit prevent exposure to excessive temperatures. There are no hot contact surface areas/hot spots and therefore the Steam Infusion process stops Maillard reactions and burn-on contamination to products.

An unrestricted Vaction™ Unit pumps at a rate of 55,000 kg/hr on water at 20⁰C and the turbulent mixing conditions in the low-pressure vapour area enhances the transfer of flavours. The Vaction™ Unit has an uninhibited bore of 47mm enabling particulates to freely pass through the unit.

1

2

3

4

5


Enhancing Dairy Sauces

Cooking dairy sauces with a traditional steam jacketed kettle can be challenging for manufacturers. Maintaining an excellent colour and flavour can be difficult because of hot spots on kettles causing burn-on flavour and dark specs in products. The University of Lincoln’s scientific research has identified a number of exciting areas that can greatly enhance the cooking of dairy based with Steam Infusion.

Reduce Fat by up to 20% To offer consumers a luxury, indulgent mouthfeel from dairy sauces, a cream or butter addition is needed giving the final product a high dairy fat content. Industry trials utilising Steam Infusion on high dairy fat content sauces have been able to remove 20% of that fat addition while maintaining the luxurious mouthfeel. The unique processing environment manipulates starch to enhance the creamy mouthfeel, enabling a reduction in overall fat content.

The Science: The University of Lincoln studied the effects on ingredients that passed through the Steam Infusion Vaction™ Unit. Under certain operating conditions, a fat mimetic is formed which simulates the fat properties in sauces. Evidence suggests on bechamel, cheese and hollandaise sauce, a creamier mouth feel was achieved while maintaining the viscosity compared to a traditional steam jacketed cook.

Why it is important to manufacturers?A reduction of up to 20% dairy fat in a recipe can move a product from a red traffic light product to amber. This can drive sales to health conscious consumers who don’t want to forego indulgent flavours.

Homemade FlavoursUniversity of Lincoln GCMS (Gas Chromatography-Gas Spectrometry) testing identified a difference in the flavour profile, whilst the layperson taste panels recognised an improvement in flavour between a conventionally cooked and Steam Infusion sauce sample. Both tests highlighted Steam Infusion cooking preserves delicate “fresh flavours” and prevents “over-processed” notes.

The Science: Shortened cooking times and prevention of burn-on contamination can have a significant impact on the flavour profiles of a product. During testing of a wide range of sauces, GCMS and taste panels clearly identified the retention of volatiles usually boiled off or destroyed in conventional sauce production, thus creating “homemade” flavours.

How can this help food manufacturers?Fresh, homemade flavours appeal to consumers seeking high-quality products. For manufacturers, opportunities are created for ingredient reduction on certain recipes. Recipes are easier to scale up as Steam Infusion offers a more “saucepan” like cook.Steam Infusion cooking offers more consistent,

colourful soups and sauces.


Enhancing Dairy Sauces Continued

Can I stop burn-on or Maillard reactions happening?Burn-on to hot surfaces is a major challenge for food manufacturers when cooking dairy based sauces. Batches are rejected due to dark spots occurring in the sauce and often the colour can be distorted. The Steam Infusion Vaction™ Unit prevents burn-on by preventing exposure to high temperatures. The technology cooks from the centre of the cooking kettle with no exposure to elevated temperatures. A conventional cooking kettle heats from the outside surface with steam at over 100°C, even with an efficient agitator the residence time of the sauce being in contact with the high-temperature sides will cause burn-on, even when the sauce is at a relatively low temperature.

The Science: The University of Lincoln studied the effects on dairy based sauces passed through the Steam Infusion Vaction™ Unit. Evidence suggests the partial vacuum generated within the Vaction™ Unit prevents exposure to high temperatures. Under normal operating conditions all sauces produced with Steam Infusion were lighter and brighter in colour. On emptying the vessel, no burn-on contamination was recorded.

How can this help food manufacturers?The Steam Infusion technology can offer more core consistent and colourful sauces.

Fresher ColourIn addition to preventing burn-on and Maillard discolouration, research identified that dairy sauces appeared cleaner and brighter due to a difference in the diffraction of light through sauces.

The Science: Under certain operating conditions the Vaction™ Unit can have a shearing effect on sauces. The Innovate UK research identified the Vaction™ Unit generated smaller particle droplets that emulsify the fat globules causing the light to diffract differently. The diffraction is particularly noticeable in a high-fat white sauce creating a cleaner whiter colour and brighter sheen.

How can this help food manufacturers?Brighter, cleaner and glossier sauces can be a point of differentiation for consumers because of a higher perceived value and quality.

Cooking dairy based sauces on traditional steam

jacketed vessels burns product on the hot surface.


Delivering Operational Excellence

*Based on data from University of Lincoln, National Centre for Food Manufacturing “Steam Heating of Water” White Paper 2015

Combining experiences of using Steam Infusion in a manufacturing environment with research undertaken by the University of Lincoln, the following are points of differentiation with traditional cooking technologies from an operational perspective:

Double CapacityCooking capacity can be increased dramatically because of the heating speed of the Steam Infusion Vaction™ Units. Work by the University of Lincoln calculated Steam Infusion is up to three times faster than traditional cooking technologies*. Cooking speed is one-half of the puzzle and clean downs are dramatically shortened with no burn-on to the surface of the cooking vessel, any residue can be easily washed away with a water spray.

The Science: The annular design of the Vaction™ Unit allows steam to condense within the unit itself, the heating process does not rely on contact time between the steam and the product and it has the ability to run at comparatively higher steam pressures without compromising on efficiency.

Easy CleaningBy eliminating burn-on, the vessel, cleaning times and use of caustic are dramatically reduced. There are opportunities to run batch after batch of the same product without cleaning.

The Science: Evidence suggests the partial vacuum generated with the Vaction™ Unit prevents exposure to high temperatures preventing burn-on to the cooking vessel. The Vaction™ Unit is fully compliant with 3-A Sanitary Standards and is certificated for In-Place Cleanability in accordance with EHEDG (European Hygiene Engineering and Design Group).

Up to 18% Less Energy ConsumptionUsers of Steam Infusion systems have reported up to 18% reductions in energy consumption over traditional steam jacketed cooking vessels.

The Science: The annular design of the Vaction™ Unit allows steam to condense within the unit itself; the heating process does not rely on contact time between the steam and the product and it can run at comparatively higher steam pressures without compromising on efficiency, thereby minimising losses to the atmosphere.

Reliability & SimplicityThe Vaction™ Unit itself has no moving parts making it inherently easy to clean and reliable. The unit is manufactured from a solid stainless steel billet in the UK.

A standard Steam Infusion lance fitted to a

cooking vessel.

“It’s a quality piece of equipment that’s definitely “cook proof”. Since the installation, our engineering team

hasn’t had to touch the system.”

Janet Prescott, Manufacturing Manager


Why switch from existing cooking methods?

With Steam Infusion, food manufacturers can produce results unachievable on traditional cooking equipment from both a product and operational perspective. Compared to other cooking methods, the Steam Infusion Vaction™ Unit can be; up to three times quicker, gentler on particulates, more controllable, assist with mixing and homogenising and can be integrated to act as a pump. It’s not necessarily a switch either; Steam Infusion can be used in conjunction with traditional technologies to deliver great results.

Steam InjectionSteam injection is often used to speed up a cooking process, but the Infusion technology can cut cooking times further. As highlighted in the Steam Heating White Paper, steam injectors cannot operate at high steam pressures due to significant losses to atmosphere and exposure to elevated temperatures. Steam injection also provides minimal mixing capabilities. Heating 1,000 litres of water from 20°C to 70°C took 26 minutes with steam injectors, whilst a single Steam Infusion Vaction™ Unit heated the water in less than 8 minutes*.

Steam Jacketed VesselSteam Jacketed vessels have a large product contact surface area which is heated above 100°C. When a product comes into contact with the hot surface, it can cause burn-on and start a Maillard reaction compromising the end product’s quality and the ability to make consistent batches. As previously identified, Steam Infusion prevents burn-on and enables rapid heating and mixing. OAL’s standard systems include a steam jacketed vessel to provide flexibility to brat meat and caramelise products if required.

Who can benefit the most?An ideal time to integrate Steam Infusion into a factory is when conducting a range reformulation or new product launch. During product development, you can maximise the benefits of the Steam Infusion technology and create a differentiated product for your customers. In the UK, an ability to create a new, differentiated offering can be a key driver for sales, especially if developments overlap with consumer trends on health and taste.

Reformulation isn’t a prerequisite though; the technology can be used to match existing product ranges before rolling out changes in your own time.

Steam Infusion provides the biggest opportunities to manufacturers of rich and creamy sauces or spicy ethnic sauces. Manufacturers will achieve significant time savings, shorter heating times and a unique processing environment that preserves flavours enabling ingredient reduction.Food industry professionals learn about the

Steam Infusion cooking process. *Based on data from University of Lincoln, National Centre for Food Manufacturing “Steam Heating of Water” White Paper 2015


Operational Benefit

Porridge

Hollandaise Sauce

Cheese Sauce

Béchamel Sauce

Clear Chilli Sauce

Tomato Ketchup

Mushroom Sauce

Processed Cheese

Fruit Spreads

Mustards Ethnic Sauces

BBQ Sauce Maheu

Soups

Rice Pudding

Bolognaise

Vegetable Blanching

Jelly

Custard

Coulis

Fruit Sauce

Sugar Syrups

Pasta

Pectin Based Products

Gum Based ProductsCondensed Milk (from powder)

Pate

Jam

Low Fat Mayonnaise

Stock Concentrate

Mushy Peas

Meat StewFrijoles

Pro

duc

t D

i er

enti

atio

n

Tastier

No Benefit Faster

Sweet Spot

Less

More

More

French Onion Soup

What is Steam Infusion Best For?The matrix below scientifically ranks food products on Steam Infusion’s ability to create a differentiated product (flavour, nutritional, colour etc.) against

the ability to improve the operational efficiency of production (production time, cleaning, energy etc.). The findings are from a £978,246 Innovate UK*

funded “Nutrition for Life” project with the University of Lincoln that scientifically explored the operating envelope of the Steam Infusion Vaction™ Unit.


OAL strive to keep our customers ahead and future proofed by leading multiple R&D projects currently valued at £3.5 million aimed at developing tomorrow’s tried and trusted.

Cryogenic CoolingOAL and the University of Lincoln are committed to discovering new applications and possible health benefits from testing on our Steam Infusion system at the National Centre for Food Manufacturing at the Holbeach Campus. OAL is now leading a second Innovate UK project into Advanced Cooking and Cooling Technology (ACCT). The £969,000 project, partly funded by Innovate UK will last two years and aims to develop an innovative cooking and cryogenic cooling system for ready-meals providing a step change in product quality and healthiness. The project seeks to help tackle the current levels of food waste and increase the speed of production by combining our rapid cooking Steam Infusion Vaction™ technology with a cryogenic cooler. The system is now available for trials.

Robotic Food ProcessingOur team are world leaders in using proven robotic equipment to provide next generation food manufacturing preparation and processing systems. The systems currently support dry weighing, A to B transport, blending and full processing kitchens. The APRIL Robotic Chef Cooking Cell utilises our Steam Infusion technology to offer a step change in productivity, yield, food safety and traceability.

Starch ManagementOAL has worked with Ingredion and the University of Lincoln to optimise the functionality of starches within the system. Compiling a matrix of starch performance and behaviour within the Steam Infusion Vaction™ Unit has led us to be able to predict the best gelling agents for customer applications. The matrix has been extended to cover pectins and gums and is regularly updated as new products come to the marketplace.

Learn More with VideosSeeing is believing and we’re committed to educating food manufacturers on best practice use of Steam Infusion and new food processing technologies. If you’d like to see more, you can visit our YouTube channel.

Tried & Trusted Systems

APRIL OAL’s cutting edge robotic chef.

OAL’s Cryogenic Cooling


Adopting Steam Infusion

1) Run Trials at our UK Test CentreAt the National Centre for Food Manufacturing, OAL has a dedicated 4,000 sq ft food processing hall for food manufacturers to test and learn about our technologies. Food manufacturers can have their ingredients delivered and stored at the centre, before spending a day with our team cooking products on our 500kg Steam Infusion test system. Customers have access to the University’s full suite of analysis equipment including a sensory suite, Mastersizer laser particle size analyser and GC-MS (Gas Chromatography-Mass Spectrometry).

2) Swap for Existing Direct Steam InjectionIf you’re already using direct steam injection, switching to Steam Infusion is easy. As you’re already adding steam to your products there will be minimal recipe changes and we can use your existing steam filtration equipment.

3) Retrofit to New/Existing Cooking VesselBased on extensive knowledge and learnings, OAL can offer process guarantees for certain applications. Customers can then retrofit the technology to existing vessels and perform their own testing safe in the knowledge their application will work.

Service Requirements: • Culinary Grade Steam at 750 [kg/hr] at 6.5 Bar.• Electricity at 24V DC or 110 AC.

With Steam Infusion, seeing is believing so we’ve tried to make it as easy as possible to test the technology. If you’re already using direct steam injection, you’ll find it is a straight swap and our team can work with you to optimise your recipes.

Run trials at the National Centre for Food

Manufacturing.


Join our Steam Infusion Revolution Today

This White Paper explains how the unique processing environment generated by the Steam Infusion Vaction™ technology can help food manufacturers cook dairy based sauces more effectively.

From a product perspective Steam Infusion can:• Reduce fat in certain products by up to 20% with no flavour or texture change.• Prevents Maillard reactions occurring.• Cook brighter, cleaner products.• Lead to a creamier mouthfeel and more indulgent flavours.

From a cost and operational perspective Steam Infusion can:• Reduce ingredient costs.• Shorten cleaning times.• Double cooking capacity.• Reduce downtime and improve consistency.• Reduce energy consumption by up to 18%.

About OALOAL work with food manufacturers to create competitive advantages by reducing the costs (Production, Quality, Environmental) of converting raw ingredients into finished products through the use of our disruptive technologies.

Designing, implementing and automating engineering solutions for over 20 years, we have built a unique team comprising of automation, design, mechanical and product development specialists to deliver state of the art turnkey solutions. We typically work with food manufacturers to eliminate waste, improve product quality, ensure food safety and offer flexibility.

Speak to an expert by calling OAL on: +44 1733 394 700

or by emailing: [email protected]

or visiting: www.oalgroup.com

A1 Parkway, Orton Southgate, Peterborough, PE2 6YN.

cutting fat and doubling cooking capacity in dairy based

Documents