Manufacturing News

Impingement Reduces Cook Time by 88 Percent

Growth is a good problem to have. But an increasing demand by customers for a wider product mix can be a tough hurdle to overcome.

Townsend Culinary (Laurel, MD), subsidiary of Townsend Poultry and processor of soups, sauces, vegetable sides and cooked poultry products for restaurant and retail markets, recently found themselves in this predicament. In the past the processor relied on co-packers to fulfill demand for its varied product line. Its own rotary rack ovens cooked too slowly and were only designed to batch-cook a limited range of products.

To leapfrog customer demand levels, Townsend decided to change its batch operation to a continuous system. "We looked for a system that was versatile, could fully cook a variety of foods, brown product surfaces and deliver high yields while maintaining quality," says Faye Feldstein, production manager. "One of our biggest concerns was the portion control grilled chicken pieces. They were taking 35 minutes to cook in the rotary batch ovens."

Townsend researched a number of options and decided on Heat and Control's Airforce impingement oven. "The Airforce oven tests cooked our chicken pot pies in about three minutes with improved quality over our rotary system," said Feldstein. Grilled chicken pieces now only take four minutes in the impingement oven, an 88 percent reduction from the rotary method.

Townsend also compared impingement to multi-purpose ovens (MPO). The impingement oven's footprint is only about 11 ft. long compared to nearly 30 of for an MPO oven, with equal efficiencies, according to Feldstein.

Impingement technology combines high temperature, humidity and air velocity above and below product flow, optimizing heat transfer. Indirect air heating prevents product discoloration caused by combustion gases. Independently adjustable nozzles and airflow baffles allow unique air enveloping conditions and fast, even cooking. "There are no hot or cold spots in the impingement oven," notes Feldstein. "Consistency and uniformity are greatly improved in our products."

The company now has the ability to adjust browning and other process conditions to produce a variety of foods with unique appearance, taste and texture qualities. Touch screen control systems create a programmed recipe list of cooking parameters and allow fast, consistent changeovers. Built-in CIP (clean in place) is computer controlled as well maximizing cleaning efficiency.

Since installing the impingement oven, Town-send has added a second production shift and no longer relies on co-packers.

Heat and Control Inc., 21121 Cabot Blvd., Hayward, CA 94545. Tel.: (800) 227-5980; Fax: (510) 259-0800; Website: www.heatandcontrol.com

Did you enjoy this article? Click here to subscribe to Food Engineering Magazine.

You must login or register in order to post a comment.

Multimedia

Videos

Image Galleries

Plant of the Year 2015

Mars Chocolate was chosen as Food Engineering’s 2015 Plant of the Year. The first new Mars candy plant in North America in 35 years is not only LEED Gold certified, it’s highly automated as well.

Podcasts

Burns & McDonnell project manager RJ Hope and senior project engineer Justin Hamilton discuss the distinctions between Food Safety and Food Defense as well as the implications for food manufacturers of the Food Safety Modernization Act.
More Podcasts

Food Engineering

Food Engineering April 2015 Cover

2015 April

The April 2014 issue of Food Engineering features the Plant of the Year: Mars Chocolate. The first new Mars chocolate candy plant in North America in 35 years is not only LEED Gold certified, it’s highly automated as well.

Table Of Contents Subscribe

Plant Facility/Site Issues

What issue about your current plant facility/site keeps you up the most at night?
View Results Poll Archive

THE FOOD ENGINEERING STORE

Food-Authentication-Flyer-(.gif
Food Authentication Using Bioorganic Molecules

This text provides critical tools and data needed to augment routine food analysis and enhance food safety by aiding in the detection of counterfeit, and potentially deleterious, foods.

More Products

Clear Seas Research

Clear Seas ResearchWith access to over one million professionals and more than 60 industry-specific publications,Clear Seas Research offers relevant insights from those who know your industry best. Let us customize a market research solution that exceeds your marketing goals.

STAY CONNECTED

FE recent tweets

facebook_40.pngtwitter_40px.pngyoutube_40px.png linkedin_40px.pngGoogle +

Food Master

Food Engineering Food Master 2015Food Master 2015 is now available!

Where the buying process begins in the food and beverage manufacturing market. 

Visit www.foodmaster.com to learn more.