FENCO vegetables cubes production.pptx

§ Summary
§ Quality
§ Innovation
§ Cleaning-sorting
§ Portioning _______
§ Freezing _________ Twist Freezer
§ Spinach Process..the ‘s portioning solution
- Cleaning & Sorting
1st phase dry-cleaning
2nd phase dry-cleaning
3rd phase wet-cleaning
4th phase wet-sorting
§ Portioning
- Forming - Portioning
“comparison between”
’s portioning solution
VS.
“Traditional” process
§ Freezing
- Advantages
- Main features
- Working priciple
§ Pre-freezing
- Premises
§ Pictures (Details)
§ Innovations
Table of content

Summary
Ø Cooperating with the top Processors in Europe
Ø Major objective: quality of processed product
Ø Innovations in the fields of Dry sorting
Ø Innovations in the field of Wet sorting
Ø Revolution in the field of portioning / packaging
Ø Innovations in the field of Freezing

Quality
The quality of the finished product obtained with its machines:
Ø leaf integrity
Ø reduction of foreign bodies
Ø uniform heat treatments
The quality of its machines:
Ø High reliability
Ø High energetic efficiency
Ø ”made easy” for sanitation operations
Ø “made easy” for maintenance operations
Ø Use of high quality commercial components
The quality of its service to the customer:
Ø Tailor made solution
Ø Fast and efficient After Sales Service
Ø Fast and efficient Spare Parts Delivery
Ø Stock of most common spare parts
Ø Engineering Services
’s portioning solution focused its activity on:

Innovation
’s portioning solution is constantly paying attention to innovative solutions
and machineries and the process of Leafy Vegetables Industry.
’s portioning solution has been developed by working in direct contact with the
leaf processor, and number of “Dedicated Machines” has been developed, like:
o PNEUMATIC SEPARATOR for Dry Cleaning & Sorting
o HYDRO-SORTING for Wet Sorting and Uniform Cooling
o “EASYCUBE” for Portioning
o TWIST FREEZER for efficient Freezing of portions
These machines are setting new standard of quality and / or changing the principles of leaf processing industries.
Obviously ’s portioning solution manufactures Complete Lines
from Product Feeding to Glazing

Spinach Process..the ’s portioning solution
PRODUCT FEEDING
STONE & INSECTS
REMOVAL
SAND SEPARATOR
SEPARATION
of foreign bodies
or stems by
PNEUMATIC SEPARATOR
WASHING
With 2 or 3 washing units
BLANCHER
for Uniform
and constant product
treatment
HYDROSORTING
for the Final Sorting and
Uniform Cooling
Dry-Cleaning
1st Step
Dry-Cleaning &
Sorting
2nd Step
Wet-Cleaning
3rd Step
Wet-Sorting
4th Step

Spinach Process..the ’s portioning solution
PORTIONG
with “EASYCUBE”
From 20 up to 250 g
FREEZING
with
TWIST FREEZER
designed for low energy
GLAZING
To increase yield
and ice protection
on the product
COLD STORING
MULTIHEAD WEIGHER
To optimise
final packaging and costs
gentle &
continuous product
DEWATERING
MIXING
With or other
Ingredients,
to produce portion
with different
mixed products

Process innovation
’s portioning solution includes:
4 stage CLEANING & SORTING that improves the quality of the final product (minimizing the presence of foreign bodies left
in the product)
First area of process innovation is CLEANING & SORTING
* (after Blanching)
CLEANING & SORTING is a four stage process:
1st phase dry-cleaning (through Sand Separator)
2nd phase dry-cleaning (through Pneumatic Separator)
3rd phase wet-cleaning (through Washers)
4th phase *wet-sorting (through Hydro-sorting)

Process innovation
1st phase dry-cleaning
SAND SEPARATOR
q Physical law gravity
Small size and/or heavy foreign body are rejected, or others that thanks to the gravity and mechanical action
are separated from leafs
q Working priciples grading (by mesh)
product distribution
To achieve good results is very important to have a proper product distribution, and keep it in motion
for the required time.
q Technology big size rotating drums
Mesh size determine the quantity and the type of rejects
It’s impossible to use wider mash in order to have better separation because all product will be rejected.
That’s why is necessary to have 2nd phase of DRY CLEANING.
(details)

Process innovation (details)
q Physical law air trust (shape)
gravity (specific weight)
q Working priciples product distribution
product deviation
q Technology air separator
The product is loaded into a rotating drum equipped with gauging wires. The drum provides for gauging and homogeneous feeding of spinach
to the air separation section, which is located immediately below.
The leaves falling from the drum reach a powerful airflow, which can be adjusting according to leaf type and conditions (dry/wet).
The airflow provides to planar-shaped bodies (spinach leaves) a vertical thrust, which is necessary to overcome an obstacle that is located along
their path. Other bodies, provided with different shape, hit the obstacle, notwithstanding their specific weight and are rejected Spinach leaves,
which overcome the obstacle, reach a large chamber equipped with air outlet sections (punched sheet).
Air speed drops and spinach falls down on the outlet conveyor
q Advantages automatic
quite accurate
earth removal (less water consumption during washing)
PNEUMATIC SEPARATOR

To obtain accurate separation a good and uniform product distribution is required:
Working principle: Product distribution
Good Dispersion / distribution assures individual treatment of any single parts
To obtain good dispersion/distribution big size rotating drums are needed
The PNEUMATIC SEPARATOR “grading drum” assures this result.
The drum is equipped with different mesh sizes.

Working principle: Product deviation
Proper product deviation
is the 2nd condition to obtain
a good separation
spinach
+
Foreign bodies
Selection wall
Air gun
a
b
c
Rejected Accepted
a planar
b not-planar
c heavy

Working principle: Product distribution
q a Accepted planar lights bodies
• spinach leaves
• other leaves (autumn harvest)
• insects with open wings
q b Rejected not - planar light bodies
• spinach stems
• spinach roots
• worms
• mice
• frogs
• earth
• other round or cylindrical shaped bodies
q c Rejected large-heavy bodies
• wild animals (like: mouse, frog, etc)
• bricks
• stones
• etc.

HYDRO - SORTING
q Working principles product dispersion in water
thin layer deposit
q technology Water cooler……
The product coming from the blancher falls in a channel where a powerful water stream and bubbling air/water accomplish homogeneous leaf
dispersion. The product dispersion hits a plastic mesh conveyor, which operates as a moving filter.
Spinach leaves are spread in a thin and homogeneous layer on the mesh surface, while filtered water is recycled.
q Advantages
• Sorting of:
 black-brown spinach leaves
 foreign leaves
 foreign herbs
 foreign bodies left
• Homogeneous cooling
4th phase wet-sorting
WET-SORTING “HYDRO-SORTING”

Process innovation
Main advantages of “EASYCUBE” portioning technology:
Ø Separation of DOSING from PACKAGING
Ø Packaging made after freezing, in a later stage (ideal for co-packers)
Ø Reduced production cost (product loss, packaging cost, product over weight, etc)
Ø Weighing made with conventional combination-weighers
Ø Leaf integrity
Ø Easy change of portion dimension
Ø Convenience for final user
Forming - Portioning
’s portioning solution introduced the small portion technology and its “EASYCUBE” machine.
In the last decades this new way of process the leafs vegetables has changed the frozen industryand has constantly gained market share
vs. old process technology “traditional solution”.

 “EASYCUBE” is a portion forming machine specifically designed to process blanched Spinach leaves or other Leaf
vegetables and herbs;
 The product is brought to an in-feed hopper by means of a dewatering belt conveyor;
 The hopper is equipped with a product level control system which starts and stops automatically the “EASYCUBE”;
Machine will follow these sequence:
 Pressing / Shaping: System is handled by brushless motor which allow to determine the power/pressure required in
accordance to the specific product/production and the speed of each phase/cycle.
 Shaping / Moulding: by filling the incaves of the die/mould. Shape dimensions and disposition can be specifically designed.
 Cutting: Through a self adjusting cutting device “knife” which can cut easily the vegetable fibres blanched and/or
unblanched.
 Pressure control system with load cell is controlling the “filling accurancy of the die – mould; thanks to the pre-settled set
point value we can assure an ideal pressing time and pressure in accordance with the products, shape, dimensions,
blanching conditions, etc.
 Product is extracted – ejected by a expulsion device and portions are collected on a modular plastic belt conveyor;
 The length of this mesh conveyor is important to obtain a good dewatering before enter into Twist Freezer
Working Principle
Process innovation Forming - Portioning

Main advantages
LEAF INTEGRITY:
PRESSURE CONTROL:
CUTTING SYSTEM:
AUTOMATIC FEEDING:
No screw compacting system;
Pressure is controlled directly from the brushles motor of the press
and is adjustable in accordance to:
- Type of product
- Blanching cycle
- Relation between solid and liquid required into the final product
No normal blade is used to cut the product, no blade sharpening
required;
No operator required. “EASYCUBE” is equipped with a level of
automatisms which allow automatic start/stop cycles;

’s portioning solution …small portion technology..compared with Traditional one
The comparison is made between “FENCO spa process”.
The factory will produce portioned products, frozen, stored in bulk containers, and these products will be packed in bags
in a later stage when it will be strictly required just before delivering the product to the final customer and/or
distributors or supemarkets, etc.
And the traditional one:

Technical Indicative Data Sheet: (based on 50 g portion weight)
Product: Blanched – Cooled Spinach… …from -2 to 30°C
Portion Weight “Available”: from 15 up to 300 g
Models/Type: 400 500 500S 600 600S 800 800S
Nominal Working Capacity in Kg/h: 2300 2900 4300 3400 5100 4600 6900
N°. of portion each stroke: 32 40 60 48 72 64 96
8x4 10x4 10x6 12x4 12x6 16x4 16x6
Installed power kW: *15 *20 *25 *25 *30 *30 *45
Useful Forming Width mm: 400 500 500 600 600 800 800
Out Feed Conveyor width mm: 450 550 550 650 650 850 850
*Real power absorption in production is much lower.
Outlet Belt Type: Plastic Modular type
Acoustic contamination “Noise level”: <80 decibel
Drive Unit: Each phase of the machine is controlled and driven by electro-mechanical system through brushless electric motors. This allow to determine,
to control and/or adjust the IQF running in very easy way, in accordance to the various nature of the products, and to have always under
control the following parameters:
• pushing power in accordance to the time and the excursion needed;
• pushing pressure required;
• phase cycles between each operations;
Control board: Stainless steel IP55, equipped with
• PLC, “touch Screen” “touch screen”;
• Push buttons.
• Emergency buttons placed to left and right side
Complies with: EEC, American Safety Standards, Ghost
Operator’s manuals available: Italian, French, English; Spanish, German (2 originals on paper plus CD-ROM)
Upon request we can provide copy in: German, Russian, Chinese, Indian,

Typical installation
Portioning - Freezing - Glazing

This comparison has been made thanks to the co-operation of one of the Leading Factory in this sector, which is using both processing schemes.
’s portioning solution Traditional Solution
Type of final product:
SEMI FINISHED PRODUCT
Plant capacity:
FINISHED PRODUCT IN BAG
Time of selection/choice for FINAL PACKAGING:
ANY TIME IN FUTURE UPON THE SALES and/or THE MARKET
and/or DISTRIBUTORS REQUEST (as different BRANDS as well)
FROM THE VERY BEGINNING, BEFORE START THE PRODUCTION
THE FACTORY MUST CHOOSE THE QUALITY, THE BAG SIZE and
THE BRANDS and/or the Type of Packaging to be used
Time of selection/choice for PRODUCT QUALITY:
ANY TIME IN FUTURE JUST BEFORE PACKAGING
Time of selection/choice for PRODUCT QUALITY:
FROM THE VERY BEGINNING, BEFORE START THE PROCESS
SEMI-FINISHED PRODUCT
FINISHED PRODUCT IN BAG
Portion size/weight:
20 g – 50 g – 100 g up to 250 g
Portion size/weight:
½ Kg – 1 Kg – 2,5 Kg
Most common size of final packaging:
½ Kg – 1 Kg – 2,5 Kg
Most common size of final packaging:
½ Kg – 1 Kg – 2,5 Kg
Type of DOSING UNIT needed:
Continuous Dosing – Portioning Unit, i.e. our Mod. “EASYCUBE”
Type of DOSING UNIT needed:
Continuous Dosing Unit assembled in the upper part of a
Continuous Packaging Machine, to pack – Bag the Product In-
Line
Final Shape and Looking of the finished product after bag Opening:
SEVERAL PORTIONED SINGLE PIECES LIKE ANY OTHER
“EASYCUBE” PRODUCTS.
VERY GOOD LOOKING
Final Shape and Looking of the finished product after bag Opening:
1 BLOCK OF ICED/FROZEN SPINACH, WITH SOME PART OF
COLOURED ICED WATER FREEZED INSIDE THE BAGS WITH
PRODUCT.
NOT A VERY GOOD LOOKING

Yield average upon the size:
HIGHER YIELD IN THE BIG SIZE PRODUCTION
Yield average upon the size:
HIGHER YIELD IN THE SMALL SIZE PRODUCTION
Percentage of product processed with this system: 70% Percentage of product processed with this system: 30%
Final Product Handling for the Consumers:
ABSOLUTELY VERY EASY FOR THE FINAL CONSUMER, WHILE IS
GIVING THE CHANCE TO USE THE REQUIRED QUANTITY, AND
STORE IN THE FRIDGE THE EXCESS WITHOUT LOSSES
AND OR WASTAGE
Final Product Handling for the Consumers:
ABSOLUTELY VERY EASY FOR THE FINAL CONSUMER, WHILE IS
GIVING THE CHANCE TO USE THE REQUIRED QUANTITY, AND
STORE IN THE FRIDGE THE EXCESS WITHOUT LOSSES AND OR
WASTAGE
Final consumers of the product:
ALL TYPE OF CUSTOMERS, like:
RESTAURANTS –COMMUNITIES – ALL FAMILIES and SINGLES
Final consumers of the product:
MAINLY – RESTAURANT – COMMUNITIES – BIG FAMILIES
Manpower involved in the processing plant:
FROM RECEIVING UP TO SORTING AFTER BLANCHER IS THE
SAME
SAME
FROM DOSING UP TO FREEZER approx.
10 workers are needed
FROM DOSING UPTO FREEZER approx.
20 workers are needed
ANY TIME IN FUTURE UPON THE SALES and/or THE MARKET
and/or DISTRIBUTORS REQUEST
FROM THE VERY BEGINNING, BEFORE START THE PROCESS THE
QUALITY CONTROL Dept. MUST DECIDE FOR WHO THEY ARE
GOING TO PROCESS THE PRODUCT

Is this system in need to have any further check
weighing system to supervise the final weight
of each bags:
NOT AT ALL.
THE FINAL PACKING OF THE PRODUCT IS MADE USUALLY USING
MULTI-HEAD WEIGHER, WHICH ASSURES THE BEST RESULT.
THIS TYPE OF WEIGHING IS ACCEPTED ON ANY LEGAL POINT OF
VIEW.
Is this system in need to have any further check
weighing system to supervise the final weight
of each bags:
YES AT ALL.
DUE TO THE FACT THAT THIS PRODUCT IS FIRST DOSED USING A
VOLUMETRIC DOSING SYSTEM, AND THEN PACKED THERE ISN’T
ANY ASSURANCE THAT THE WEIGHT IS CORRECT; THAT’S WHY
IMMEDIATELY AFTER THE “BAGGING UNIT” THE PLANT MUST
HAVE CHECK WEIGHER. MOREOVER TO BE PROTECTED ON THE
LEGAL POINT OF VIEW THE PLANT MUST HAVE A SECOND
CHECK WEIGHER EVEN AFTER THE PLATE FREEZER, WHILE THE
BAGS COULD HAVE SOME LEAKAGE DURING THE FREEZING.
IN TOTAL IN THIS TYPE OF PLANT MUST HAVE 2 (TWO) CHECK
WEIGHING UNITS
Hygiene condition of the plant:
SAME
SAME
FROM DOSING UP TO FREEZER IS VERY EASY WHILE ALL THE
MACHINE INVOLVED HAS IT’S OWN WASHING SYSTEM
INCLUDED AND THE OPERATION IS EASILY MANAGED FROM THE
CONTROL PANEL
MUCH MORE DIFFICULT DUE THE MACHINES DESIGN AND PLANT
CONFIGURATION. A LOT MORE MANPOWER IS NEEDED TO
CARRY OUT A PROPER CLEANING OPERATION TO REACH THE
REQUIRED HYGIENE LEVEL CONDITIONS
Cleaning – Washing operation for the DOSING UNIT:
“EASYCUBE” IS VERY EASY TO CLEAN IT AND EASY TO BE
DISASSEMBLED IN CASE OF NEED FOR DEEP CLEANING WASHING
OPERATION
Cleaning – Washing operation for the DOSING UNIT:
DOSING UNITS DUE TO IT’S OWN DESIGN AND DUE TO THE
PLANT CONFIGURATION MAKE THIS OPERATION MORE
DIFFICULT TO BE EXECUTED AND TAKE LONGER TIME AND MORE
MANPOWER

Type of freezer needed:
Continuous Universal – Multipurpose TWIST FREEZER, i.e. our
Mod. Twist Freezer
Type of freezer needed:
Continuous In-Contact PLATE FREEZER with Trays Recycle Circuit
Flexibility of the Freezer for Other Product Utilization:
THIS FREEZER CAN BE UTILIZED OUT OF THE SPINACH SEASON
TO FREEZE OTHER TYPE OF PRODUCT (GRILLED AUBERGINES,
GRILLED PEPPERS, OTHER VALUE ADDED PRODUCTS)
Flexibility of the Freezer for Other Product Utilization:
THE SYSTEM HAS A LOT OF LIMITS FOR OTHER APPLICATION,
WHILE THE PRODUCT MUST BE ALWAYS PREVIOUSLY PACKED,
AND THIS IS CAUSING SOME LIMITATION IN “THE FACTORY
LOGISTICS & PRODUCT HANDLING”
PRODUCT LOSSES during the production due to the
MACHINE – PLANT PERFORMANCES:
ALMOST NOTHING WITH THE EXCEPTION OF SOME PRODUCT
LOSS BETWEEN SOME MACHINE CONNECTION
PRODUCT LOSSES during the production due to the
MACHINE – PLANT PERFORMANCES:
ALMOST NOTHING WITH THE EXCEPTION OF SOME PRODUCT
LOSS BETWEEN SOME MACHINE CONNECTION
PRODUCT LOSSES during the production due to the FREEZER
PERFORMANCES:
ALMOST NOTHING, WHILE THE NAKED PRODUCT IS PLACED
DIRECTLY IN THE BELT CONVEYOR AND THE FREEZING TAKES
PLACE THROUGH AIR CIRCULATION
PRODUCT LOSSES during the production due to the FREEZER
PERFORMANCES:
MUCH HIGHER DUE TO THE FREEZING EFFECT AND DUE TO THE
FACT THAT THE FREEZER IS “CONTACT FREEZEING” SOME BAGS
ARE ICED ON THE PLATES AND DURING TRAYS HANDLING IN THE
FREEZER ARE DAMAGED , this at the end of the Year HAS BIG
INFLUENCE IN THE LOSSES
Maintenance COSTS influence for this Solution:
DEFINITELY MUCH LOWER THEN THE TRADITION SOLUTION
Maintenance COSTS influence for this Solution:
DEFINITELY MUCH HIGHER THEN THE OTHER SOLUTION
SURFACE OCCUPIED for this type of plant in the Factory:
FROM DOSING UP TO FREEZER LOWER SPACE IS NEEDED
SURFACE OCCUPIED for this type of plant in the Factory:
FROM DOSING UPTO FREEZER DEFINITLY BIGGER SPACE IS
NEEDED

Possibility of having a DEEPER GLAZING Treatment:
YES THE SYSTEM ALLOWS TO HAVE THE IN LINE A “SUBMERSION
GLAZING UNIT” JUST BEFORE THE NORMAL GLAZING UNIT, IF
REQUIRED. THERE ARE MARKETS WHERE IT IS REQUIRED A
HIGHER PERCENTAGE OF WATER CONTENT IN THE FINAL
PRODUCT UP TO 20& OR MORE
Possibility of having a DEEPER GLAZING Treatment:
THIS SYSTEM CANNOT ALLOW TO HAVE THIS POSSIBILITY WHILE
THE PRODUCT IS PREVIOUSLY PACKED
Efficiency of the Final Packaging Units and percentage of wasted
Packaging Materials:
THIS SYSTEM DUE TO ITS DESIGN AND CONFIGURATION ASSURE
THE MAX PERFORMANCE DURING THE FURTHER PACKAGING
OPERATION, AND THE WASTAGE OF PACKAGING MATERIAL IS
ALMOST 0%, WITH THE EXCEPTION OF SOME DAMAGE-
BREAKING IN THE REELS – BOBBINS ITSELF.
Efficiency of the Final Packaging Units and percentage of wasted
Packaging Materials:
THIS SYSTEM DUE TO ITS DESIGN AND CONFIGURATION CANNOT
ASSURE TO AVOID THIS TYPE OF INCONVENIENT, WHILE MOST
OF THE TIME SOME WATER DROPS and/or PRODUCT PIECES
REMAIN IN THE WELDING AREA OF THE PACK, AND ONE THE
SEALING BARS ARE SEALING THE BAGS ARE NOT SEALED-
WELDED PROPERLY. UNFORTUNATELY DURING THE
PRODUCTION THIS TYPE OF INCONVENIENT HAPPENS
FREQUENTLY AND AT THE END OF THE YEAR THE LOOSES
CAUSED BY THIS SYSTEM ARE “QUITE BIG”
Level of INVESTMENT TO INSTALL A PLANT LIKE THIS:
THIS TYPE OF PLANT IS USUALLY QUITE EXPENSIVE, BUT IN A
REASONABLE WAY, AND THE REPAYMENT PERIOD IS QUITE
SHORT USUALLY
Level of INVESTMENT TO INSTALL A PLANT LIKE THIS:
THIS TYPE OF PLANT IS USUALLY MUCH MORE EXPENSIVE, AND
OBVIOUSLY THE REPAYMENT PERIOD IS MUCH MORE LONGER

Possibility of PRODUCT DIVERSIFICATION:
THIS SYSTEM MAINLY DUE TO THE “EASYCUBE” ALLOW EASILY
TO DIVERSIFY THE PRODUCTION AND THE PRODUCT JUST
CHANGING THE MOULD AND THE PRODUCT RECIPE, i.e.:
VEGETABLE HAMBURGERS, and/or PORTION with CHEESE with
SPINACH, or SOUR CREAM WITH SPINACH, or others.
Possibility of PRODUCT DIVERSIFICATION:
THIS SYSTEM IT MIGHT BE USED ALSO, BUT AGAIN YOU WILL
HAVE BIG BLOCKS AND THE DIFFICULTIES IN PRODUCTION ARE
THE SAME AS ABOVE MENTIONED IF NOT BIGGER.
Possibility of Identify this Product as Ready Made Food:
YES AT ALL.
Possibility of Identify this Product as Ready Made Food:
NOT AT ALL.
Is the consumer in need to use any ICEBREAKER after BAG
OPENINGS and BEFORE COOKING:
NOT AT ALL.
Is the consumer in need to use any ICEBREAKER after BAG
OPENINGS and BEFORE COOKING:
YES ALWAYS or MOST OF THE TIME.
Handling this product it might be somehow DANGEROUS for the
Final Consumers:
NOT AT ALL.
Handling this product it might be somehow DANGEROUS for the
Final Consumers:
YES WHILE MOST OF THE TIME THE CONSUMERS and/or
COOKERS ARE IN NEED OF THE ICEBREAKER.
Possibility of Identify this Product as “I.Q.F.” Individually Quick
Frozen:
YES AT ALL.
Possibility of Identify this Product as “I.Q.F.” Individually Quick
Frozen:
NOT AT ALL.
Possibility of EARNING SOME NEW AND BIG MARKET SHARE WITH
THIS PRODUCT:
YES, THIS SOLUTION WILL OFFER TO THE PRODUCERS TO BE
“IDENTIFIED AND REMINDED BY THE CONSUMERS AS THE
PRODUCERS OF THIS TYPE OF PRODUCT”.
Possibility of EARNING SOME NEW AND BIG MARKET SHARE WITH
THIS PRODUCT:
NOT AT ALL, WHILE THIS IS A PRODUCT WHICH ALREADY IN THE
MARKET SINCE SEVERAL YEARS, WITHOUT “NEW ATTRACTION
FOR THE CONSUMERS”, THEY SIMPLY GET USED TO HAVE IT.

Possibility of usage of this System for CO PACKERS:
LET SAY THAT THIS SYSTEM IS PARTICULARLY APPRECIATED BY
CO PACKERS, WHILE THEY ARE USUALLY PRODUCE FOR SEVERAL
DIFFERENT “BRANDS – COMPANY” WITH DIFFERENT
SPECIFICATIONS, AND GIVING THE CHANCE TO REDUCE
DRASTICALLY THEIR COST OF PRODUCTION.
Possibility of usage of this System for CO PACKERS:
THIS IS THE SYSTEM COMMONLY USED BY THEM, BUT DUE TO
ALL CONDITIONS and COMBINATIONS WE HAVE LISTED ABOVE,
ONE AFTER THE OTHERS THEY ARE CHANGING THE EXISTING
SYSTEM, IN ORDER TO KEEP THEIR PRESENCE IN THE MARKET.

Process innovation Freezing
’s portioning solution introduced the TWIST FREEZER
Ø Reduced energy and freezing consumption
Ø Reduced production of snow
Ø Longer time between defrost (without snow removal systems)
Ø Simple, reliable and sturdy conveyor system (low tension, low wear)
Ø Standard-high quality commercial components (no custom design spare-parts)
TWIST FREEZER has been specifically studied and designed for small portions of spinach, which is one of the most difficult products.
Main advantages of Twist Freezer technology:

Advantages
• Very high mechanical reliability of TWIST FREEZER belt conveyor;
• Reduced belt wear and elongation thanks to low tension drive system (the belt is pulled by means of dynamic friction on
the total length);
• No belt lubrication and no possibility of product contamination;
• Long work-cycles due to “symmetrical” large fins spacing design, on the air entrance, and over sizing of evaporators;
• Possibility to have bi-directional air flow in the evaporators with the possibility to improve the evaporator “efficiency”;
• Flexibility: TWIST FREEZER can be designed with different air flow types according to product characteristics; standard
ventilation is the VOT “horizontal tangential type” (horizontal double passage up – wards and down wards, vertical
counter-current 3D);
• Low maintenance cost and low spare parts cost due to utilisation of high quality commercial components;
• Belt gear motors positioned outside the insulated cabin avoiding any risks of contaminations due to some oil leakages;

Main features
• Central Drum drive supported by roller bearings;
• Stainless steel flexible belt (plastic belt for special application such as sticky or tender products with low water content
products);
• TWIST FREEZER structures made of stainless steel;
• Low pressure fans to increase air speed and heat exchange;
• Flat fin evaporators with low air pressure drop;
• Self supporting basement allowing easy easily lift able by crane or fork-lift, made in fibreglass and special resins;
• Belt driving gears positioned outside the insulated cabin;
• Fully automatic washing system (optional) with loose water;
• C.I.P. “Cleaning in Place” system with the possibility to use basic – acid – detergent and disinfectant solutions (optional);
• PLC and touch-screen supervision system (optional);
• Ice Extraction Belt “Patented” (option), positioned just on top of the evaporator, which assure a continuous run
minimum of 48 hours between each defrosting cycle, with the possibility to work up to 72 ÷ 120 hours in accordance to
the type of product and the environmental working conditions.

Working principle
The TWIST-FREEZER freezer is basically composed by a TWIST FREEZER conveyor and a freezing system which provides a well distributed air-flow.
In order to obtain a quick freezing process TWIST-FREEZER is designed for the high speed circulation (4 – 10 m/sec) of cold air in contact with the
product, on the whole lenght of the TWIST FREEZER conveyor.
High speed of air increases substantially:
Ø the thermal exchange on the surface of the product,
Ø the speed of cold penetration
Ø the quality of the freezing process.
In order to obtain good freezing results a quick cooling phase is needed, to avoid product stress/degradation of its natural properties.
The air-flow pattern used in this proposal is
“Horizontal Tangential Ventilation”
This pattern (our. Code “VOT”) allows for:
“Easy Clean Design”
This pattern (our. Code “EC”) allows for:
TWIST FREEZER TF … - … - ..- VOT – EC
Ø Hitting the incoming product with the coldest air; the product is therefore immediately “crusted” and snow formation diminished.
Ø The unit doesn’t have any mezzanine floor and or intermediary platform, to avoid any dirtiness accumulation, and making more difficult the
cleaning operations
Ø Drum is without lateral openings to improve the air guidance and to minimize the possibility to accumulate dirtiness, in point where easy
access is not possible
Ø The lateral aprons to guide the airflow on the opposite side of the evaporators are on easy access design like door open able or sliding, but in
any case easy access is granted all around
Ø Possibility to have bi-directional air flow and speed on the product, just adjusting the by-pass and the fans
Ø Snow reduction: the temperature increase of cold air passing through the product is very low. Air cannot therefore increase substantially its
humidity content.
Less Humidity built-up= Less Frost

Process innovation
This solution allow the following:
Diversify the production;
Increase the yield of the portioned product (spinach and similar product);
Possibility to shape and/or port ionize mixed product and giving various shapes, and sizes;
To form portion from minced or pulpy or liquid products
This solution is giving a real flexible solution in the “ready dishes” preparation plant;
Etc;
Pre-freezing – Forming – Final freezing
The main aim of this process is to increased the forming yield from 80% to 100% (pratically no product or water or liquid
loss during forming). The total production yield is therefore increased from 55% (as per traditional process without) up to
70% (with pre-freezing).
i.e. : with this technology a typical line of 4 Tons/h input allow to obtain up to 3 Tons/h of frozen portion, instead of the
traditional 2 Tons/h.
Pre - Freezing

Process innovation Pre - Freezing
“FREEZE CON-BELT”: Ventilation Concept
20 g portions
15 g portions
With béchamel
 The Processing line is designed for production of portions of both:
“whole leaf” spinach and “chopped/grinded” spinach
The chopped/grinded spinach portions can obviously be processed successfully only adopting the 2-stage process.
Otherwise the water loss during forming is huge and the shape and stability of fresh portions is problematic.

Pictures details
...into field - crops
...harvesting solution

Pictures details
...product feeding into the processing line
Feeding Bunker
Dry Cleaning: Sand Separator
Feeding

Pictures details
...product into the processing line
Pneumatic Separator
Washing
Dry Cleaning: Pneumatic Separator

Pictures details
Blanching & Cooling
Washing
Wet sorting: Hydro-Sorting
...product into the processing line

Pictures
Glazing machine
Portioned product
EASYCUBE
Details of

Pictures details
...product into the “EASYCUBE” phase
“EASYCUBE”
with blanched and cooled product
“EASYCUBE”
with pre-frozen product
“EASYCUBE” Spinach

Pictures details
Twist Freezer
Twist
Freezer
Bins - Boxes
Simple Glazing unit
Deep Glazing unit
...product into the “Twist Freezer” & Glazing phase

Spinach Chicory Beet Leaves
Vegetarian burger Spinach burger Spinach with Cheese
Pictures details
...product into the “Deep Glazing” phase & finished product

Portioned products:
-Spinach
-Cicory
-Bieta Erbetta
-Leafs + Sour Cream
-Leafs + Cheese
-Pre-Frozen Products
-Mix of Products and Ice
-Meat Burgher & Vegetable Burgher
-Ecc.

FENCO Food Machinery s.r.l.
Via Monte Sporno 10/A - 43124 (PARMA) - Italy
Tel. +39 0521 303429 - Fax. +39 0521 303428
F o o d P r o c e s s i n g E q u i p m e n t a n d Te c h n o l o g i e s s i n c e 1 9 8 4
E-mail: contact@fenco.it - Web: www.fenco.it

FENCO vegetables cubes production.pptx

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