In order to maintain the quality of the broilers, turkeys and other poultry products during processing cooling is needed in various parts of the process. Some of these requirements can be satisfied with chilled water or glycol; others require ice – Vogt Ice can supplier both needs.
Processing needs: Reducing the temperature of birds as quickly as possible through initial processing retards microbial growth and slows deterioration. Both increase the shelf life and freshness of the product. This goal can be met with chilled water and ice.
Immersion chilling in the slaughter line is the most effective way to reduce the carcass temperature quickly and create the desired quality and longevity. Typically the temperatures are 100° F for the bird after evisceration and the target temperature range by USDA is 40° in the breast area and 34 -35° F outside the body cavity. This is normally accomplished by using re-chilled processing water (via a red water chiller) distributed to a tumble or drag through bird chiller where the birds come in contact with the low temperature water. USDA requirements stipulate that a certain amount of water must be removed from the chiller for each bird processed. These water needs range from 1/2 gallon for each broiler to 1 gallon for each turkey processed. The make up water is needed at the lowest temperature achievable. TURBO® chillers can deliver 33ºF water directly to the process or a plate frame hat exchanger.
Turbo® HTD falling film plate water chillers are normally used to provide the low temperature make up water need for the bird chiller processing lines. Although not as common, ice can be used in the bird chiller to accomplish the chilling and make up water needs by mixing ice with the water in the drag tanks. Chilled 33º F water can be supplied by HTD and HF type Turbo Falling Film chillers using R-22 or ammonia. The cleanable nature of the chiller and stainless steel construction make it the preferred way to supply clean cold water to the immersion chilling lines. This equipment is USDA approved and has been used in USDA inspected facilities for over 40 years.
Water is cooled from temperatures as high as 85 to 90ºF down to 33ºF in a single pass. The water enters the chiller at the higher temperature and leaves at the lower temperatures and can be delivered directly to the process or to a storage tank for later use. TURBO chillers can deliver water to within one (1) degree of the freezing point.
Chiller products can deliver several hundred gallons per minute of chilled water to the chilling process typically with a single chiller.
Chilled water benefits:
- Chilled water generator has sanitary, accessible construction
- Energy efficient production of low temperature water (33° F)
- Several different storage capacities (sump sizes)
- Chiller versatile with temperature differences and flow rates.
VOGT has a large line of chiller sizes and frames to meet large and small chilled water needs.
VOGT offers a number of icemakers suitable for poultry applications using both R-404a and ammonia refrigerants.
- C-Line Modular series icemakers producing a fragmented ice on plate icemakers. The C-Line series uses a water defrost system to provide a dry sub-cooled ice. Capacities are in 13 tons tons of ice per day per module with either R-404a or ammonia.
- The MHG Modular series icemakers providing a fragmented ice on plate icemakers. The MHG series use a hot gas defrost and produce higher capacity than the C-Line series in the same foot print. Capacities IN 26 tons per day per module.
- Simple user friendly controls can be used to adjust the ice thickness to meet the customer’s needs.
- Ice can be produced continuously to meet the ice requirements as it is needed or during non-production period and stored for later use.
If the ice requirements are met using icemakers to produce the ice as it is required, a larger icemaker is typically required. The icemaker capacity depends on the hours of processing and the amount of ice required. This method eliminates the need to store ice – ice is delivered directly to the mixing process. Smaller icemakers can be used with the addition of ice storage and production of ice during non-production hours.
Ice Storage and Delivery Systems:
TURBO ice rake systems are designed for storage of tube, or fragmented ice produced by the VOGT line of icemakers. Storage bins are available in two different series:
- CB Rakes: Available in three rake assembly sizes and 12 different capacities. Completely automatic loading and unloading of the ice through the use of a programmable logic controller to monitor all aspects of the rake system operation ensuring reliable operation. CB rakes range in capacities from 20 to 87 tons of ice.
- Automatic Rakes: A larger higher capacity version of the CB series available in a number of standard sizes. Capacities rang from 100 to 400 tons of storage.
- Both versions are completely automatic – unload and load operation require the operator to turn on the “Delivery” switch.
- Fabrication of all TURBO ice rake meet FDA and USDA requirements for sanitation and operation. Constructed of hot-dipped galvanized and stainless steel components to ensure the ice is always in contact with sanitary surfaces. All stainless steel materials of construction are also available as an option.
Ice Delivery to Ice Storage and Mixing System:
Ice can be delivered to the ice storage and mixing process by two methods:
- Galvanized or stainless steel screw conveyors (augers) can be used to deliver ice from the icemaker to the ice storage bin (rake system) and form the ice rake to the process – all automatically. Simple user friendly controls allow adjustments to the ice loading and unloading process to match the customer’s requirements. The speed of the screw conveyor(s) are selected to meet the delivery volume and rate required for the process loading.
- Pneumatic delivery systems consisting of a blower, diverter valve (for delivery to more than one mixer), rotary valve, after-cooler, cyclone to decelerate ice delivery to mixer and release the air transporting the ice, piping, and control systems. Pneumatic systems are typically used for long transport distances or in application where space is limited in the process area. Ice is transported in small aluminum piping system to deliver the ice to one or more icing points in a minimum of space.
Delivery rates of 15 to 40 tons per hour are typical and easily accomplished with the complete line of delivery system components.
Fragmented Ice Benefits
Fragmented ice produced on TURBO icemakers has many advantages:
- Large amount of ice fragment surface area for quick cooling of product.
- Does not "shrink" from product in a box; stays in contact with product continuously cooling the product as it melts without creating voids around the carcass.
- Easy to handle and store due to fragmented shape, density and temperature of the ice produced.
- Has an average density higher than other types of ice- more BTU's, same space
- Ice thickness is easily adjusted to meet individual customer requirements.
- Large capacity in small foot print – up to 180 tons per day in a single icemaker; larger capacities with multiple icemakers
- Smaller capacity models available in self-contained models up to 100 tons per day – icemaker and high side completely packaged on a common skid; larger capacities available with complete high side in both R-22 and ammonia.
Packaging needs: Ice is needed for fresh product being sent to market or to further processing facilities. Fresh poultry that is packaged for shipment and not frozen requires a cooling medium that is long lasting and low in temperature to ensure the quality and freshness are maintained during transport to the end-user. Ice is typically used to top ice the product even in refrigerated truck and rail cars. The ice maintains contact with the product and maintains the desired temperature. At delivery the presence of the ice ensures the end user that the product temperature was maintained through the entire shipping process and is still fresh.
Ice is normally manufactured at a central point and distributed via a pneumatic blowing system or screw conveyor system to loading docks or box icing stations in the final processing points.
VOGT can supply the complete chilled water systems, and complete ice making, storage and distribution systems. Advantages include:
- Complete line products – chillers, icemakers, ice delivery systems, and accessory equipment.
- Single source responsibility for the system.
- Proven experience in solving customer problems with reliable solutions.
- Used in hundred of USDA inspected plants for over 40 years.