Dual-mode RevoBreader

Thanks to RevoBreader's large drum size, changing between flatbed and drum position doesn’t require the removal of any machine parts. It’s very easy to slide the belt out of the drum, allowing the drum to rotate freely. Changeover from one mode to the other takes less than two minutes.

Drum and flatbed

In the drum position, the large drum size ensures optimum control over the level of mechanical impact on home-style products. The drum breading procedure guarantees a high pickup of crumb and optimum home-style coverage all over the product, as well as high retention of crumb to the product during the frying process. This is ideal for coating bone-in products. RevoBreader’s outfeed system in drum mode ensures optimum product distribution over the width of the belt, improving the products’ infeed to downstream in-line processes. In flatbed position, RevoBreader guides product through a bottom bed of crumb, while covering the top layer with crumb, which falls gently on the product. This results in high quality, uniformly coated products.

Minimum crumb breakdown

Once products have been coated, excess crumb is removed in two steps; firstly by a vibrating mechanism and secondly by air knives. Excess crumb is carefully transported back into the machine for reuse. RevoBreader is equipped with a water wheel that gently handles the crumb, guaranteeing minimum crumb breakdown.

700 line

Marel's RevoBreader can be an integral part of a complete 700 convenience line, which would typically feature the following equipment: RevoPortioner, Active Batter Applicator, Active Mixer, Active Tempura Applicator and RevoBreader. Such a 700mm wide convenience line can create a wide variety of tasty added value products. A major asset is its high flexibility, as the line configuration is not fixed. It is easy to have a particular set up for e.g. home-style chicken wing coating (with RevoBreader’s drum option) and change the configuration after one or more production days, giving the RevoBreader another role and another position, e.g. flatbed coating for chicken schnitzels.

Software

New Innova Food Processing Software functionality for the further processing industry benefits RevoBreader too. It includes several useful tools for convenience lines. A real differentiator is that product data, equipment data and process data are gathered for use in a process analysis tool. This helps the operator/manager make smart decisions and prevent products from going out of spec. The Innova QC module automates quality control procedures. This digitalization prevents operators from making mistakes and creates a paperless working environment. The Line Profiler tool is particularly useful for a convenience line, as it guides the operator during changeovers. It configures the required line set-up per master recipe and with the single click of a button can send the programmed settings for this specific configuration to the machines.

Traceability

Innova’s full traceability program provides the customer with an overview of the raw materials' journey through the processing plant. As a part of this, the traceability engine records every process step in the convenience line, including the RevoBreader. Together with the Recipe Manager tool, it is easy to track systematically what has been made, when, where and by whom. Recipe Manager calculates the right amount of ingredients and knows what line set-up is needed to make the desired product, with the same settings as before, resulting in a consistent end product.

QSR Home style example

The Marel RevoBreader is the perfect solution for achieving the typical QSR home style coating. After a predust coating in the Active Flour Applicator, a tempura wet coating is applied in the Active Tempura Applicator to ensure that breading adheres properly. The drum of the RevoBreader completes the coating process, giving product a ‘handmade’ look. The result is a home-style crumb, a breading with a highly attractive appearance, perfectly suited for sale in QSR restaurants.