What’s the link between sushi and Scanmaster?

sushi-dosing-viscotec-dispenser

The answer: ViscoTec hygienic dispensers! 

Low in calories, rich in healthy fatty acids, vitamin B and minerals – no wonder sushi has been able to defend its reputation as a trend food for a long time. Cleanliness is an important requirement in the production of the popular rolls. In many variations, raw fish is being processed. However, manufacturers are faced with further challenges, especially when it comes to automated dosing of the various ingredients: Some pastes are highly viscous and cannot be dosed by simple time-pressure systems, for example. Others contain shear-sensitive fillers or are themselves particularly shear-sensitive and must not be squeezed. In addition, flexible switching between different ingredients is often required on a production line. For good results, a pulsation-free, continuous product flow on the production line is required. The choice of the right equipment is absolutely crucial for success in this area.

Gentle processing of the individual ingredients

In an application example of the dosing technology specialist ViscoTec, various ingredients are continuously dosed onto a belt onto which runs an endless web of Nori leaves with rice. For example, salmon with mayonnaise, wasabi, chili sauce or artificial caviar is applied. Wasabi is a highly viscous paste that can be perfectly dosed with ViscoTec’s viscosity-independent dosing systems, which are designed based upon the endless piston principle. The artificial caviar is particularly shear-sensitive – the eggs must not be crushed or ground during the dosing process under any circumstances. The principle built into the ViscoTec pumps is therefore also ideally suited for these ingredients. The solids in their carrier medium are displaced particularly gently through the chambers between the rotor (stainless steel) and stator (elastomer). Form, color and consistency of the solids is not affected.

The amount of material to be applied can be perfectly adjusted to the belt speed by means of a control system. The individual ingredients are dosed continuously and absolutely pulsation-free. An uneven dosing would mean, for example in one roll only half the amount of wasabi, and in another roll double the amount. This would have a negative influence on the taste experience. Anyone who has ever had a little too much of something spicy knows this.

Flexible production

For a product change during production, the VHD Hygienic Dispensers from ViscoTec have a hygienic design which allows for two possibilities: Either a simple disassembly and cleaning can be carried out between product changes or the old material is pushed out with the new material. Since the dispenser is optimized for dead space, this second option can also be easily implemented when changing over. After a short mixing phase, production can continue without having to clean the machine.

Excellent pressure stability

The ViscoTec Hygienic Dispensers are designed according to the EHEDG guidelines. They are easy to disassemble and clean and can also be sterilized or autoclaved. Different dosing needle inserts and dosing speeds allow maximum flexibility in the production process. It is possible to dose very small quantities of the spicy wasabi paste into a sushi roll, but also relatively large quantities as required for example for salmon with mayonnaise. The thin needle during application of the highly viscous Wasabi paste generates a high back pressure – a challenge for the dosing system. The ViscoTec dispensers are predestined for this application due to their excellent pressure stability even at back pressures above 12 bar. The sealed cavities, which span the rotor-stator geometry during filling, allow the dispenser to run against pressure. Due to the overlap at the edge, about 5-6 bar per cavity can be overcome. With several cavities in a row, for example with the 3-stage dosing pump 3VHD12, up to 18 bar back pressure is no problem.

The material is supplied to the dispenser via cartridges with a size of up to 900 ml or directly from a delivery container (i.e. 25 liter bucket) via the ViscoMT-XS emptying system. Overall, the endless piston principle offers a high degree of automation for safe, uninterrupted production.

 

vhd-hygienic-dispenser

Svaret er ViscoTecs hygiejniske doseringspumper!

Kontinuerlig dosering af små og store mængder

Kaloriefattig, rig på sunde fedtsyrer, vitamin B og mineraler – ikke underligt at sushi har været i stand til at forsvare sit ry som en trendmad i lang tid. Renlighed er et vigtigt krav i produktionen af ​​de populære ruller. I mange variationer forarbejdes rå fisk. Producenterne står dog over for yderligere udfordringer, især når det kommer til automatisk dosering af de forskellige ingredienser: Nogle pastaer er meget tyktflydende og kan ikke doseres med enkle tidspressesystemer, for eksempel. Andre indeholder forskydningsfølsomme fyldstoffer eller er i sig selv særligt forskydningsfølsomme og må ikke klemmes. Derudover kræves det ofte et fleksibelt skift mellem forskellige ingredienser på en produktionslinje. For at få gode resultater kræves en pulsationsfri, kontinuerlig produktstrøm på produktionslinjen. Valget af det rigtige udstyr er helt afgørende for succes på dette område.

Skånsom behandling af de enkelte ingredienser

I et anvendelseseksempel med udstyr fra Scanmasters doseringsteknologispecialist, ViscoTec, doseres forskellige ingredienser kontinuerligt på et bælte, på hvilket en endeløs bane af Nori-blade med ris kører. For eksempel påføres laks med mayonnaise, wasabi, chilisauce eller kunstig kaviar. Wasabi er en meget viskøs pasta, der kan doseres perfekt med ViscoTecs viskositetsuafhængige doseringssystemer, som er designet baseret på det uendelige stempelprincip. Den kunstige kaviar er især forskydningsfølsom – ægene må under ingen omstændigheder knuses eller males under doseringsprocessen. Princippet indbygget i ViscoTec-pumperne er derfor også ideelt egnet til disse ingredienser. De faste stoffer i deres bæremedium forskydes især forsigtigt gennem kamrene mellem rotoren (rustfrit stål) og statoren (elastomer). Form, farve og konsistens af faste stoffer påvirkes ikke.

Mængden af ​​materiale, der skal påføres, kan justeres perfekt til bæltehastigheden ved hjælp af et kontrolsystem. De enkelte ingredienser doseres kontinuerligt og er absolut pulserende. En ujævn dosering ville for eksempel betyde, at der i en rulle kun er halvdelen af ​​mængden af ​​wasabi, og i en anden rulle er dobbelt så meget. Dette ville have en negativ indflydelse på smagsoplevelsen. Enhver, der nogensinde har haft lidt for meget af noget krydret, ved det.

Fleksibel produktion

For en produktændring under produktionen har VHD Hygienic Dispensere fra ViscoTec et hygiejnisk design, der giver mulighed for to muligheder: Enten en enkel adskillelse og rengøring kan udføres mellem produktændringer, eller det gamle materiale skubbes ud med det nye materiale. Da dispenseren er optimeret til frivolumen, kan denne anden mulighed også let implementeres, når der skiftes over. Efter en kort blandefase kan produktionen fortsætte, uden det er nødvendigt at skulle rengøre maskinen først.

Fremragende trykstabilitet

ViscoTec hygiejne dispensere er designet i henhold til EHEDG retningslinjer. De er lette at adskille og rengøre og kan også steriliseres eller autoklaveres. Forskellige doseringsnåleindsatser og doseringshastigheder giver maksimal fleksibilitet i produktionsprocessen. Det er muligt at dosere meget små mængder af den spicy wasabipasta i en sushirulle, men også relativt store mængder som kræves for eksempel til laks med mayonnaise. Den tynde nål under påføring af den meget viskøse Wasabi-pasta genererer et højt modtryk – en udfordring for doseringssystemet. ViscoTec-dispensere er forudbestemt til denne anvendelse på grund af deres fremragende trykstabilitet selv ved modtryk over 12 bar. De forseglede hulrum, der spænder over rotorstatorgeometrien under påfyldning, giver dispenseren mulighed for at køre mod tryk. På grund af overlapningen ved kanten kan ca. 5-6 bar pr. hulrum overvindes. Med flere hulrum i træk, for eksempel med 3-trins doseringspumpe 3VHD12, er op til 18 bar modtryk ikke noget problem.

Materialet leveres til dispenseren via patroner med en størrelse på op til 900 ml eller direkte fra en leveringsbeholder (dvs. 25 liters spand) via ViscoMT-XS tømningssystem. Samlet set tilbyder det uendelige stempelprincip en høj grad af automatisering for sikker, uafbrudt produktion.

vhd-dispenser-viscotec
Endless piston princip
5/5

Leave a Reply

Your email address will not be published. Required fields are marked *