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Ventilex Breadcrumb Production Leaflet
Ventilex Breadcrumb Production Leaflet
PROCESSING EQUIPMENT
Rusk is mainly used as a filler, an ingredient Fluid bed dryer for breadcrumb
for dried stuffing mixes or a binding agent in
hamburgers, sausages, pies, and other com-
pound meat products. It is also a carrier for Imtech Ventilex breadcrumb and rusk-
flavours, colors and seasonings. production equipment
Rusk is important for it's absorption, texture
and color properties. Ventilex is a leading supplier of breadcrumb
and rusk dryer production lines.
We offer a highly developed product line that
Ventilex Breadcrumb processing Benefits: is in use at the leading producers world-
wide.
High quality product with uniform particle
size. The line consists of a bread mill, a fluid bed
dryer/cooler, a gas burner, cyclone, recircu-
Precise controls enable drying, or toasting, lation, exhaust blower, cooling fan with filter,
to achieve precise control of color, shape ductwork and fully automated controls.
and texture to meet your customer’s spec-
ifications. Due to the unique low g-force of the shaking
Processing (milling, drying and cooling) of fluid bed design, Ventilex can offer a fully
integrated fire protection system with fire
pellets, bricks, sheets, extrusions or loaves
detection and water spray nozzles directly in
of bread.
the dryer process space.
Stand alone fire protection system incor-
porated into equipment. The production line can be delivered in seven
sizes ranging from 400 kg/hr ( 900 lbs/hr)
Gentle shaking motion creates fewer fines
to 5000 kg/hr ( 9000 lbs/hr) output (finished
and less maintenance than competition’s
product spec).
high frequency vibration system.
www.ventilex.com
Breadcrumb milling, drying, baking Now the dough is mixed, kneaded, and
and toasting with automated controls. placed into individual baking tins. It is allo-
wed to rise, then baked in the tins.
Breadcrumb comes in many shapes and
sizes based primarily on what the custo- Depending on the choice of the customer
mer wants as opposed to the technical the loaves may be allowed to cool first, or
characteristics of the material. Most food passed straight to the mill.
processing companies have been opera-
ting for many years and have defined spe- Baking process
cific requirements which their end product Bread for breadcrumb is generally made
must meet. with yeast.
The process involves mixing time, proving
Typically breadcrumb is used as a coating time (rising), baking and optionally cooling
for fish, chicken, etc. The crumb is light times.
weight with an airy structure, good for
absorbing allot of oils and water during Cooling / no cooling before milling:
the baking/frying/cooking of the food Cooling helps to fix the structure of the
stuff. bread making it more resilient through the
mill. You get much lighter, less dense
Breadcrumb is assessed based on how it crumb from cooled bread. When cooled the
looks (shape, structure and color), the bread is typically <50°C on the inside and
texture for eating, and the technical pro- mills better.
perties (absorption, initial moisture con- If not cooled, the mill requires a hot air by
tent, etc). pass from the burner to reduce condensa-
Standard breadcrumb is bread made in tion and the effects of smearing inside the
either bricks/sheets using a sheeting line, mill.
or extruded onto the baking belt as indivi-
dual lines or as one large, continuous Milling
layer over the entire baking belt. Milling screens determine the quantity of
large/small particles into the dryer.
These are typically then lightly broken up Typical sizes include Ø 4,6,8,10,12 mm.
as they come off the line and then passed
to the Ventilex mill for fine milling. Drying/cooling
American breadcrumb (also called natural Product inlet moisture 35-40%
breadcrumb) uses actual loaves of bread. dried to 8-14%, product temperature
In the past that has been loaves of bread dryer: 70-80°C, process air temperature:
that were reclaimed from supermarkets. 140-180°C .
Flowsheet
Example of a configuration of a Ventilex Rusk line
2
Rusk production/baking process with forced air, or a room cooling track.
The Ventilex system can also include coo-
Rusk is a bread mix where yeast is not ling (either a belt or a fluid bed) after the
used. This is usually replaced by conditioning screw. Cooling the rusk fixes
a bicarbonate (either sodium or ammoni- the structure before milling in much the
um) to provide some rising during baking same way as it does by breadcrumb.
and to produce the airy structure normal
for bread. Milling
Milling follows a similar principle to that
Because there is no proving time necessa- during breadcrumb.
ry to let the product rise, rusk lines tend
to be have a smaller footprint and higher Drying
throughputs than breadcrumb processing Product inlet moisture 35-40% dried to
lines. 1-3%, product temp dryer: 150-190°C,
A standard baking process using an oven process air temperature: 170-210°C.
is very similar to breadcrumb except wit- Different products/suppliers/customers
hout the proving time required to allow require a different mix of drying and condi-
the bread dough to rise. tioning.
Some use only a high temperature drying,
Fluid Bed pellet oven heating the product up to 200°C in a thick
The dough is extruded into small pellets, bed to get a long residence time and the
Ø ~2-3 cm, that are pneumatically required moisture content.
transported into a fluid bed oven. Ventilex Others use a high temperature drying fol-
has developed a fluid bed pellet oven pro- lowed by a conditioning period
cess that is an intensive baking process (maintaining a constant temperature in the
requiring a significantly smaller footprint product) to get even drier product.
than a typical tunnel oven.
Others use a medium temperature drying
The pellets are heated to ~200°C using (to about 140°C) then conditioning at 130-
process air of about 200-220°C. Due to 140°C to get a dry product with maximum
the speed at which the dough is brought
to temperature, and the small size of the
pellets, there is a relatively large amount
of crust, or denser material in the pro-
duct. Depending on the end user's re-
quirements, significant improvement to
the structure can be achieved by adding a
conditioning time and a cooling time for
the pellets before they are transported to
the mill.
Conditioning / Cooling
The Ventilex system can incorporate a
large diameter screw to hold the product
at a relatively high temperature after the
oven for 15-30 minutes to condition the
pellets.
This helps the interior to form a better
structure by cooking for longer, while allo-
wing the outside denser crust to absorb
the moisture coming from the interior of
the pellet, softening and improving the
structure.
Before milling, standard baking lines may
use a cooling chamber, or a cooling belt Bread crumb production line
3
Breadcrumb processing line options
Milling Drying
Drying
4
3
Ventilex Breadcrumb and rusk processing
lines
Imtech Drygenic
Oude Middenweg 19,
2491 AC Den Haag
Netherlands
T:+31 (0)88 988 3010
E: [email protected]
www.drygenic.com
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