Nuts & Seeds

It is a highly efficient device for roasting seeds, nuts and other products with direct heating. Heating is carried out by built-in heating elements (the option of heating with steam is possible). The oven is a continuous operation, which implies the constant presence of the product in the drum hopper for its most efficient use.

Purpose

Nuts&Seeds fryer NORMIT drum continuous frying oil oven is designed for uniform frying and drying of such products as:

sunflower seeds,

Pumpkin seeds,

Coffee beans,

Nuts (peanuts, cashews, pistachios, Brazil nuts, walnuts, pine nuts, cashews, almonds, pistachios, hazelnuts)

Cereals: corn, rice, barley, wheat.

Operating principle

The product is poured into the receiving hopper of the drum, from where it is fed into the frying drum. The product inside thanks todrum structure is mixed during the frying process and gradually shifts to the exit. On the output tray, you receiveRoasted product of the highest quality.

The roasting oven maintains the temperature within the range set from the control panel. The rotation speed of the feed auger (optional) and the drum are also adjustable. Adjusting these parameters allows you to fine-tune the drum to provide the required technological regime. The oven can be supplemented with a modular unit for removing oil, drying and cooling the product, as well as a unit for adding salt and various flavors.

Roasting uniformity is achieved by rotating the working drum, which constantly mixes the product, preventing it from burning. The drum is designed in such a way that the product is continuously moving towards the exit, thus ensuring the continuity of the furnace. The electronic thermostat automatically maintains the set temperature inside the drum. In this model heating inertia is kept to a minimum due to the intensive circulation of oil from the heating source (heaters) to the product.

Benefits of deep frying

Deep frying, contrary to popular belief, is the healthiest and most environmentally friendly method of frying. But only if provided oil filtration system. Reaching the required cooking temperature in a short time prevents the product from burning, and the crispy crust protects the product from loss of liquid.

Pressurized Oil Continuous Filtration System

The entire volume of oil in the system is filtered continuously, which eliminates the appearance of small burnt pieces of the fried product in the oil, and hence the deterioration of its consumer properties. Because there are no dead zones, the oil does not overheat, the residues do not burn out, there is a constant filtration, there is no inertia. Depending on the type of product being fried, the oil change ratio can reach very high values, which allows at all stop changing oil.Only pressure filtration can remove particles of the order of 70 microns.

The unloading system from the frying chamber provides high-quality and efficient pouring of finished products. The furnace is operated by one operator.

Advantages of Nuts&Seeds fryer NORMIT drum continuous frying oil oven:

The furnace is completely made of stainless steel.

The continuous oil filtration system allows you to completely refuse to change the oil.

No heating inertia.

No oil spill effect.

No overdrying of the product (juiciness and taste of the product are preserved).

No exfoliation of the product during the work cycle.

The possibility of cyclic frying of a small batch of various types of product.

The design provides for the combination of roasting with the salting process.

Low costs for roasting 1 kg of product.

High reliability and long service life of the plant.

Low operating costs.

Completing materials and units only from leading European manufacturers.

Low background noise and no vibration during oven operation.

The quality of our equipment is at the best world level, which allows our partners to quickly return on investment.

The product completely retains its taste qualities, acquires a special aroma.

Suitable for 24/7 operation.

Performance installation depends on a number of indicators that can be influenced by:

Humidity of raw materials;

raw material temperature;

Humidity and temperature in the working room;

The specified degree of roasting of the finished product;

Supply voltage stability.

Standard equipment:

Rigid base frame

Product mixing mechanism

Frying chamber ventilation system

Block of control and management of the working cycle

Heating jacket

Pump for efficient continuous oil circulation

Product loading bin

Optionally, a version without a pump is offered, without filtration under irrigation. In this version, filtration occurs by supplying unfiltered oil with the help of blades mounted on a drum on a filter mesh (replaceable, made of stainless steel).

Gas heating possible.

The Siemens PLC controller with a touch screen is included as standard, the ability to connect to a PC or an Ethernet network.

The cost of Nuts&Seeds fryer NORMIT with a standard capacity is from 26,200 euros on FCA Malacky terms.

IN Lately especially popular, especially among young people, is such a product as fried sunflower seeds. In addition, a certain (and considerable segment) of the market for this kind of snacks is fried pumpkin and, again, sunflower seeds, but peeled.

Along with its undoubted usefulness, such products have another advantage: high payback and very low cost of equipment for production. This fact is known to few, as start-up entrepreneurs often ignore this fast-growing market segment, embarrassed by the low selling price of products.

It is this fact that makes them refuse to open a business for the production of fried seeds without even studying the issue. In addition, residents of the northern regions of the country often simply do not want to get involved in production based on imported raw materials, fearing inflated prices and supply disruptions.

Thus, the real coverage of needs, i.e. the volume of output does not correspond to the needs of the consumer at all. Therefore, fried sunflower seeds and pumpkin seeds are often imported to regions where these crops do not grow, from afar, and already in the form of finished products, on the price of which the interest of intermediaries is "wound", transport company etc.

All of the above makes the production of roasted sunflower seeds (in original packaging) very profitable business, if, of course, competently dispose of the funds invested in it.

Requirements for production and storage facilities and personnel of the sunflower seed roasting business

Production room for a sunflower seed roasting business, it is no different from any other food production facility - just that it complies with sanitary and building codes and regulations. Depending on the type of equipment - electric oven for frying or gas - fire safety measures must also be adjusted.

By and large, it is believed that an electric furnace is more expensive to operate, but a gas one requires additional investments at the initial stage ( project documentation for gas equipment; installation of an additional fire shield, etc. - in most regions, a separate room is also required for gas equipment).

Ultimately, the choice is made in favor of the type of furnace that corresponds to the equipment of the room - i.e. if the room is not equipped with a gas pipe, it does not make sense to start it on purpose if the volume of production is small.

It is advisable to equip the storage room with additional options against mice and rats - a concrete floor, an iron door that closes tightly, etc., as well as birds that can fly into the windows (if any) or penetrate through a poorly covered roof.

There are also no special requirements for personnel: the presence or absence of a technologist in such a primitive, by and large, production will not affect the quality of the products; ordinary workers will be considered unskilled, respectively, there is no need to talk about high labor costs.

Production and auxiliary equipment for the production of roasted sunflower seeds

The main apparatus will, of course, be the brazier. There are several types of fryers: gas, electric, or microwave ovens (they are also powered, of course, by electricity, but fundamentally differ in the way they are roasted). The latter are quite rare and are made only to order.

Microwave ovens, perhaps the most promising roasting method, are not worth buying just for the production of sunflower seeds - except as an additional equipment when expanding production (see the section on business prospects).

According to the scheme of roasting sunflower seeds, there are periodic loading-unloading ovens (i.e., each roasting cycle is performed manually loading and unloading seeds) and walk-through (automated - on one side of the roasting drum, raw seeds are supplied, on the other - fried seeds are unloaded).

As you might guess, continuous ovens primarily eliminate the notorious human factor and can be built into a fully automatic line for the production of fried and packaged seeds. However, even large manufacturers are more willing to take several dozen impassable braziers.

Of course, the point here is not at all the price of the equipment: with large volumes of production, an automated line is, of course, much more profitable. In this case, the consumer principle applies: "simplicity is a guarantee of reliability."

The fact is that non-passage ovens allow you to control the roasting process manually, at any time you can turn them off and, for example, fix some problem, etc. Of course, also for the start of production, for the moment of opening own business cheap and not requiring qualified personnel non-passage furnaces (especially gas ones) are much more profitable.

The second, both in importance and cost, is packaging equipment. Packaging for sunflower seeds is a polypropylene bag (capacity from 50 to 300-500 g), soldered from a polypropylene tape with two horizontal "Euro-seams" and one vertical overlap.

Polypropylene tapes can be metallized (opaque, with a mirror inner surface) and transparent (such packaging is 2 times cheaper than the first one).

The mini-line for frying and packaging of fried seeds consists of a semi-automatic packaging machine and an electric (or, respectively, gas) oven.

Its cost is € 2,600 (less than 110 thousand rubles), and its productivity is 30 kg per hour. It occupies up to 10 meters of area (including aisles and an area for unloading under boxes or boxes on a pallet).

As you can see, the cost of the line is quite small. Based on the workshop area and financial capabilities, production can be completed with any number of mini-lines.

The installation and list of additional equipment is determined by the type of raw materials that will be used and your ability to expand your business. Regarding raw materials: if you use sunflower heads, you will need a special crusher to extract the seeds (a grain cleaning machine - about 320 thousand rubles or a vibrating pneumatic table - about 180 thousand rubles).

In addition, sometimes sunflower seeds are washed in special baths before frying, and after frying, they are passed through a cooler cleaner, consisting of a rotating sieve with a fine mesh, and simply sifting black dust and ash deposits from roasted seeds. See the extension below.

Further prospects for business development

As mentioned above, the ovens used for roasting sunflower seeds can (after an appropriate one-time reconfiguration) also be used for roasting pumpkin seeds, peanuts , coffee beans etc.

In addition, by purchasing separate equipment for cleaning, peeling and separating sunflower seeds (about 670 thousand rubles), you can sell the sunflower kernel, which also has its own demand.

In general, there are a lot of development options: this is the production of fodder cake, cake, butter, drying oil, margarine, gozinaki, halva and much more, up to biofuel from husks.

Video about the production process of packaged roasted seeds

Let's look at these steps in more detail:
Calibration. This is the process of separating large grains from small ones, as well as cleaning debris. For this purpose, special calibration machines or vibrating screens are used, which perform the function of dividing the product into several fractions.
Washing. What you should pay attention to is, of course, productivity (usually it ranges from 100-150 kg / h). Sinks have a design of a through passage, tunnel type. There are:

• with top irrigation;
• with top and bottom watering (for a more thorough washing of the product);
• with one heater at the outlet;
• with two heaters (for stronger drying of the product, which reduces the frying time later).

Product salting. It is used in the production of salty products (more often nuts, less often seeds). This function is performed by the so-called additive machine (also called a coating drum). Usually such devices are used for high performance.

frying. To date, a very large number of various ovens for drying and frying bulk products are presented on the market.

The most common option is an electric drum oven. Such models, as a rule, are equipped with: a stainless steel drum, agitators located inside the drum, a thermostat, windows for removing moisture, and a sampling blade. Some models are additionally equipped with coolers.

In addition to electric ovens, gas-fired drum ovens are also common. All specifications they save, while allowing significant energy savings. Ordinary gas (propane-butane mixture) is used as fuel for such furnaces, the cylinder is connected using an ordinary gearbox.

The next model, according to customer demand, are models that work on the principle of frying in a stream of hot air. The models are fundamentally different from those described above in their principle of operation, where the seeds are placed in a bunker and roasted "in a fluidized bed". The roasting process takes place in a suspended state due to the operation of a pressure fan at a temperature of 220 ° C. The advantage of this model is a powerful blowing of the product, in which the weight of the carbon particles settle in the exhaust pipe, and do not mix with the product.

Next, it is worth noting models that work on infrared radiation. Models roast (dry) the product using a stream of infrared radiation, which heats the product itself, and not the surrounding air. Typically, such furnaces have a continuous cycle of operation, and allow you to get high productivity (250, 500 or 1000 kg / h). On such ovens it is easy to obtain a clean, evenly fried product without burnt particles. The main characteristic is the heating of the product from the inside, significant energy savings, cleanliness of production, and the purity of the resulting product, due to the absence of heating of the surface of the product and the walls of the furnace, the absence of soot, the absence of heating the air in the room, the absence of soot and burning, easy and precise adjustment of operating modes.

They are ideal for roasting all types of nuts, seeds, vegetables, including potatoes (for the production of dry mashed potatoes).

And the latest model that is gaining more and more popularity is microwave roasting ovens. Such an oven has the advantages of infrared ovens.

Coolers necessary for rapid cooling of the product. The cooling of seeds after roasting occurs rather slowly, while maintaining a high temperature inside the shell for a long time, therefore, coolers are used to prevent overcooking and rapid cooling. There are two types of coolers on the market:

• open round design with agitators and directed air flow;
• conveyor type.

The choice of cooler design depends on the area of ​​​​the room and the principle of operation of the furnace itself.

Polishing. For finer cleaning of the product from debris and carbon deposits, cleaning and polishing machines are used. When using such a machine, the need for pre-washing of raw materials is eliminated, because. this type of equipment copes with the cleaning of seeds better.

The last stage in the production of seeds is, of course, packing and packing.

The demand for products directly depends on “what the product is dressed in”, how colorful and attractive its packaging will be.

Standard packaging is: 3-seam bag "pillow" (seam on top, seam on the bottom, back in the middle "fin"). Such packaging is formed by filling and packaging machines with a volumetric or weight dispenser. A large number of Questions are always raised by the principle of operation of the apparatus.

The product is poured into the storage hopper, after which it is fed into the dispenser, where the required doses are measured and, further, the package is formed.

Features that you should pay attention to are the productivity of the device (number of packs per minute), easy reconfiguration to a different package size, and a different dose of the product - these are the points that will allow the device to be universal.

Profitability and high productivity are achieved in automatic devices.

That's all the main points in the production of roasted sunflower seeds. Whatever equipment you choose, this type of production always remains highly profitable.

Apart from own production it is always possible to provide packaging services using existing equipment, which is also a separate line of business.

The line is easily reoriented to the production of other products, such as frying and packaging of any nuts, packaging of dried fruits, the production of dry mashed potatoes, packaging of spices, food concentrates and much more.

Hello again! My name is Sergey, and some time ago I decided to start a business selling roasted sunflower seeds. I have already shared with Equinet.ru readers. Let me remind you that at that time, in my opinion, the most best idea was the purchase of a furnace for frying in hot air"VORTEX-120A" produced by the company "Russian Meal".

The VORTEX-120A furnace met the price/quality criteria. Time passed, the business developed successfully, one furnace was already not enough. And to ensure the fulfillment of contracts in front of their customers ( retail chains, stores, etc.) I needed to reach a capacity of approximately 500 kg/h. Unfortunately, the VORTEX-120A oven is not very productive, only 90-100 kg/h. I had to buy 4 (four) more similar ovens. With the purchase of furnaces, the cost of electricity has also increased (one furnace consumes about 50 kW per hour, five furnaces - 250 kW), and service staff, because One oven is operated by one person.

As we can see, my electricity costs have increased five times and for maintenance personnel also five times. As a result, the price of finished products. Accordingly, the demand for my seeds fell due to higher prices. I had to come up with something.

I wanted to start frying salted seeds and nuts, but in principle it is impossible to do this on the VORTEX-120A oven, and even on ovens of this type (frying in a stream of hot air). In the process of frying, the salt flies off the seed, and the seed itself cracks, which subsequently leads to its oxidation, and as a result, the shelf life of the product is reduced to one or two months and the seed loses its taste.

After a month of thinking, I carefully "scoured" the Internet, called many companies, including Turkish manufacturers. But the prices for the proposed equipment did not please me. For example, a furnace with a capacity of 500 kg/hour was offered to me for 6,100,000 rubles. It was very expensive.

But, lo and behold, I finally found what I was looking for - a horizontal continuous oven for frying nuts, seeds, dried fruits from the Turkish company OZ STAR. Without thinking twice, I called this company and found out that, it turns out, this company has an official representative office in Russia and the Republic of Belarus, which greatly simplified further communication on equipment.

For the last couple of years, we have been experiencing a boom in sales of packaged sunflower seeds. If even 5 years ago you could buy 200 grams of seeds only from street vendors, now in every supermarket, shop or kiosk you can find a multi-colored bag with the coveted inscription.

Moreover, there are bags of these for different tastes: white, yellow, black, transparent, 100 grams, 200, 500 - choose whatever your heart desires. And what is surprising, despite such a plentiful supply, the demand does not fall: bags disperse with enviable constancy, and in return, like mushrooms after rain, new manufacturers and new packaging appear.

Seeing such a hype, only the lazy did not think about starting the production of packaged roasted seeds on their own. But how to fry it on an industrial scale? In fact, everything is quite simple.

Methods for roasting seeds

The seeds are roasted in special roasting ovens, which are of two types: batch and continuous. Accordingly, there are only two ways to fry seeds. Some still, however, rank among the methods of frying options for heating frying ovens, such as: gas, electric heating elements or microwave ovens. But, in our opinion, these are just heating options that may affect the speed of frying and its economy, but not the method of obtaining the finished product.

Periodic loading of seeds

This method involves frying seeds according to the principle of a frying pan, i.e. fell asleep in the oven, stirred, fried, tried, poured out of the oven. Naturally, this method of frying seeds, as in the situation with a household frying pan, requires maximum human participation. The operator must pour the seeds into the oven, and this, as a rule, is several tens of kilograms or a couple of bags, constantly monitor the process of roasting the seeds, tasting it, and, having reached the right quality, pour the seed out of the oven. If a person relaxes his vigilance, it is possible to spoil the entire loaded batch of the product.

The human factor is a key disadvantage of periodic loading. The advantages include the low cost of the frying oven, due to the simplicity of its design. Actually, due to their low cost, intermittent frying ovens retain their popularity - the consumer principle works: “simple, cheap, reliable”.

Passage method of frying seeds

The second method of roasting seeds minimizes human participation in the roasting process. The seeds are roasted in a special drum, on one side of which the original product is fed, and on the other side, the finished product is poured out. The seed, in fact, "passes" through the drum, roasting along the way, which is why the oven and the method are called walk-through.

Used in equipment:

Furnace frying electric walk-through PZHP-70
. Automated line for frying and packaging of seeds ALZHUS-70

In this case, the operator is only required to set the operation parameters once (product feed rate and frying temperature) and in the future, the oven can independently continue roasting the seeds. The human factor does not play such an important role as in periodic loading - the quality of frying is guaranteed not by the care of the operator, but by the immutability of the process.

But such obvious advantages are offset by the price: continuous-type furnaces are much more expensive than batch furnaces.

Our choice

After a long weighing of all the "pros" and "cons", in the end, we opted for the pass-through method - and for about 5 years we have been producing exclusively electric pass-through frying ovens. We also recommend our customers, despite the price, to give preference to continuous-type furnaces. What is the reason for such a decision?

1. Seed roasting speed. In batch ovens, the average seed frying speed is about 20-25 minutes, while in continuous-type ovens it is only 10. In addition to banal productivity, an increased seed frying speed has a number of advantages. Firstly, 20 minutes in the oven is no longer frying, but rather drying. Drying out, the seed, like any other product, loses its taste. This does not happen in continuous ovens and the seeds are really roasted, while maintaining the optimal taste. Secondly, 20 minutes of being in a hot environment leads to charring of the outer cover of the seed and the formation of ash, which then, when the seed is poured out, stains everything it touches: hands, clothes, packaging. And it gets dirty so that getting rid of black spots, sometimes, is quite difficult. In a continuous oven, the seed does not have time to char.
2. Quality stability. The notorious human factor in batch ovens leads to the fact that simple inattention, fatigue or poor health of the operator entails damage to a significant amount of the product. Everything that was loaded into the oven can either be undercooked or overcooked. Therefore, the operator is forced to constantly taste the product and monitor its mixing and even roasting. In through-type ovens, the influence of the human factor is minimized - the seed passes through the drum at a given speed. It is enough for the operator to set the necessary parameters once in order to constantly receive the same fried product, without the risk of spoilage.
3. cooling problem. Everyone who has ever fried seeds in a frying pan at home knows perfectly well that this product has the property of “reaching”. Those. continue to fry even when removed from the pan. To stop this process, the seed is cooled, as a rule, spreading it in a thin layer on a flat surface (table), where air circulation extinguishes the roasting process. If you neglect this moment and simply pour the seed into a pile, you can definitely get a burnt product. Now imagine that you are roasting a few bags of seeds in a batch oven. When all this mass is ready, it must be poured out and cooled. And cool everything at once, avoiding staying in the total mass. And at this time, you still need to pour a new portion into the oven (after all, the oven is working) and control its frying. In continuous ovens, the situation is simpler: the seed does not spill out in large volumes, but goes in a small constant stream, so to speak, in a “thin stream”, and therefore it is not difficult to cool it.
4. Versatility. Passage ovens, due to the ability to independently support the frying process, seeds are easily integrated into automated lines for frying and packing seeds. These lines are capable, in the absence of direct human intervention, to provide a full cycle of packaging of roasted seeds: from the receipt of raw materials (calibrated seeds) to the issuance of portions packed in a separate package. For batch furnaces, the issue of inclusion in the line is not even raised: a significant share manual labor makes it just pointless. Thus, through-type frying ovens are more versatile than batch ovens, and are able to function both independently and as part of production lines.

Used in equipment:

The above factors, in our opinion, are significant enough to justify the price of continuous furnaces and give preference to them. Moreover, having created our first line for roasting sunflower seeds in 2006, we decided that the design of continuous ovens was not quite optimal and worked on its modernization for several years.

Our innovations

Realizing that the only way to compete with cheap batch furnaces is by clearly superior quality and performance, we have tried hard, and are still trying, to improve the efficiency of the continuous furnace. As of the current moment, we can record the following achievements in this field as our asset.

1. The design of the frying drum and heating elements has been changed, as a result of which the frying time has decreased (less than 10 minutes) and the efficiency has increased. This made it possible not only to increase productivity up to 70 kg per hour, but also to obtain the most optimal taste of roasted seeds. We can say that we have found the only case when, with an increase in productivity, the quality does not fall, but rather tends to perfection.
2. Organized effective thermal insulation of the inner space of the drum, which reduced heat loss and reduced energy costs. In other words, we are gradually moving towards a highly efficient yet economical product.
3. An uninterruptible power supply (UPS) has been introduced into the standard equipment of the frying oven, the task of which is not only to equalize the “jumping” voltage of the mains, but also to prevent the seed from burning out when the power is cut off. Those. in the event of a power outage, the UPS ensures the operation of the electric drive of the drum and allows the seeds poured into the drum to be roasted due to the residual heat and spill out of it.
4. A frequency controller has been added to the design, allowing the operator to adjust the speed of rotation of the drum and, accordingly, the time of frying the seeds. This moment is important in the case of using raw materials of different moisture content or changing the product to be fried: for more humid (dense) products, you can increase the frying time, and for less humid ones, reduce it. Thus, we, in fact, made the oven even more versatile.
5. Created Feedback according to the voltage of the vibrating feeder, which feeds the seed into the drum, because of which it maintains a stable vibration amplitude during any "jumps" in voltage. The seed will always be fed in the same and uniform flow. In our opinion, this is especially true for manufacturers located outside the big cities.

But, probably, the most important thing is that when modernizing the furnace, we are constantly working on simplifying its design, eliminating unnecessary elements and optimizing the manufacture of parts. Thanks to this, we can afford to keep the prices of the furnace at least one third lower than those of competitors. And this despite the fact that the benefits listed above are included as standard, while competitors, at best, some of them are installed for a fee.

And finally, in the production of roasting ovens, we are faced with another important point- the more expedient it is to heat the furnace.

Electricity or gas?

As mentioned at the beginning of this material, there are at least three ways to heat a fryer: gas, electric heating and microwave. The first two are the most common, the third refers more to the exotic than to reality (although some consider it quite promising). Accordingly, there are two energy carriers suitable for heating the furnace: gas and electricity. Which one to choose and which one will be optimal?

In the race to increase demand, many manufacturers complete their furnaces with gas heating, motivating such a decision by the consumer's familiarity with this type of energy carrier, its availability and low cost. However, in our opinion, this is not entirely true and an attempt to get a cheap stove can have negative consequences.

Firstly, the availability of gas is a relative thing. OK, when production shops are already equipped with a gas main and the only question is to connect a separate installation, but if there is no gas supply to the room where the stove is located, or gas is supplied for domestic needs, the economy loses all meaning. After all, the cost of the furnace is in no way comparable with the cost of the project and the physical connection of the industrial gas pipeline.

Secondly, the gas price is a variable value and very much depends on various conditions: on the political situation, quotations on world markets, limit overruns, etc. In this connection, its sharp and little predictable jumps are possible.

AND, third, sunflower seeds - a product prone to absorption. The seed, although not strongly, absorbs the products of gas combustion, which leads to a change in its taste characteristics and, perhaps, is not entirely beneficial for the end consumer. Absorption can be avoided by using a heat exchanger in the design of the furnace, but in this case the cost of the furnace increases greatly and the main advantage is lost - low cost.

Therefore, our ovens are exclusively electric. We do not strive for mythical cheapness and do not incline our customers to it, it is much more important for us to make a product of high quality and justified in price. Electricity is connected to almost every building, and if not, the connection cost is much lower than that of gas. The price of electricity consumption is more or less stable, and the combustion process, as such, is absent in principle - the seed simply has nothing to absorb.