Keeping convenience food safe and healthy

Everyone wants their convenience products to be healthy and safe. Due to flaws or mistakes in the production process, products can taste bitter, they can suffer from unwanted burnt residue and black spots. Such products can even be a health risk. This should be avoided at all times, by keeping frying oil in top condition.

Full Flow Filter

Processors can achieve and maintain the best oil quality by creating a stable climate in the frying system with particular emphasis on oil temperature and filtration. Concerning filtration, Marel has developed the Full Flow Filter, a two-stage process consisting of a Vertical Particle Separator (a kind of enclosed centrifuge) and a belt filter. The entire oil volume passes through the first stage, and particles that compromise the oil quality are pushed to the side wall of the centrifuge. The clean oil goes back to the fryer, the concentrated dirt goes to the second phase of the filter system, the Belt Filter. All this happens at a rapid pace, up to fifteen times each hour. Capacity of the Full Flow Filter is up to 55 cubic meters per hour [55,000 liters/h].

High speed with less aggressive heating

Maintaining a stable frying climate also depends on the correct oil temperature. In most frying systems, thermal heating elements reach 280-300°C [536-572°F] to ensure that frying oil is heated to the correct temperature. GoldFryer, Marel’s high-end frying solution, has the highest speed of frying oil circulation in the industry. Its large heating elements, through which thermal oil is also circulated rapidly, can operate at the lower temperature of 260°C [500°F]. Frying oil spends less time in direct contact with the heating elements. It heats up more evenly without becoming too hot. The result is lower energy use and slower deterioration of the frying oil.

Maintaining oil quality

Because of the higher circulation speed of the frying oil, its pressure also increases, propelling the oil forwards in straight lines, similar to lanes in a swimming pool. Plenty of turbulence is also created. Both are essential for capturing the largest amount of particle debris. The aim is to remove all particles as quickly as possible, so that they do not burn. The longer these stay in the oil, the darker they become and the greater negative effect they have on the chemical quality of the frying oil. Such chemical deterioration not only impacts the product quality but also poses health risks. Once a given value has been exceeded, there is a real risk that the oil becomes carcinogenic. This must definitely be prevented, a task for Full Flow Filter that keeps the oil in optimum condition.

Delaying oil deterioration

An official laboratory study has confirmed that Marel’s Full Flow Filter system effectively delays chemical deterioration. Frying oil remained in good condition over an extended period, even during long production runs. Marel frying and filtration technology can fry products to the highest standards, cost-effectively and sustainably. According to laboratory tests, GoldFryer and the Full Flow Filter system already achieve a ‘future-proof’ oil quality score.

The broader context

For the frying process, the preceding coating process is particularly crucial. The better the coating system, the less crumb will fall off the product due to poor adhesion. The result will be less contamination in the frying oil. A customer confirms, “Since we put in a Marel coating line, we’ve seen a reduction of some 60% in contamination in the fryer, resulting in extended oil life. The better the product entering the fryer, the better the outcome.” This is the advantage of having a full-line supplier and a true technology partner like Marel. Marel considers each step in a broader context, ensuring well-founded and well thought-out decisions.