Meat+Poultry - June 2020 - 63

Equipment manufacturers try to provide
the best solutions possible. How much volume
a processor plans on putting out, as well as
the configuration of the nugget and breading/
battering and cooking parameters, and whether
those variables will change and how much
they will change for the processor's different
customers mean flexibility is at a premium. The
ability to change and be adaptable can save
processors time and money.
"There's some equipment that can switch
over," Garlington said. "Most of your nuggets
are going to go through a flat breader, but a
lot of times you may run something different
on the line. You may run a barrel breaded
tender so that line is not completely filled
with nuggets."
"The Heat and Control batter and breading,
frying, and oven systems all provide for
maximum flexibility and performance when
running poultry or any formed nuggets," said
Doug Kozenski, processing industry manager
for Heat and Control, Hayward, Calif. "The
ability to easily switch from flour- to crumbbased coatings saves time and money when
changing product types."
Consistency of shape and size of nuggets
appeals to processors when considering cost.
Equipment that gives processors the ability
to create uniform nuggets means economic
savings at the bottom line.
"Specifically in forming, it's not only
throughput and quality, but precise control," said
Brian Perkins, executive vice president, further
processing for Chicago, Ill.-based Provisur
Technologies. "You don't want to give away more
than you have to. You want nuggets to be the
same, so they all cook at the same rate."

SHAPE AND SEASONING
Equipment manufacturers and suppliers
must continually strive to provide processors
with the best possible means of producing
high-quality, cost-effective nuggets for the
marketplace. Research and development
departments within companies tackle the
challenges inherent in nugget production from
every angle.
Before processors construct a nugget, the
raw material must be prepared. Regardless
of the size, breaded or battered, cooked or
par cooked, the meat formulation needs to
come together.

"We would have the grinders to do the pregrinding, so whatever trim or muscle came to
us, we would pre-grind that to a uniform size,"
said Lowell Sampson, vice president of project
engineering and food science at Provisur.
"Then that would be incorporated into a mixer,
whether it be vacuum or non-vacuum, with
the ingredients, then chilled to the proper
temperature, whether that'd be with liquid CO2
or liquid nitrogen for the proper time and then
that would be introduced to the former."
Forming technology on the poultry side
started with repurposed slide plate formers
originally used to form hamburger patties in
the late 1970s and early 1980s. Today, rotary
formers are the go-to technology when it
comes to forming nuggets. John Urbanczyk,
product specialist for forming equipment for
Provisur, said rotary forming carries a lower
cost of ownership and handles the product
more gently than slide plate formers.
"They also have the highest output
capacities," Urbanczyk added. "Where slide
plate formers had limitations of strokes per
minute of 120 or so, a rotary former running
just 28 RPM is the equivalent of those slide
plate formers running 250 strokes a minute.
So, the capacity with a rotary former is
considerably higher."
In addition to the various styles of forming
machines, is the various level of pressure used
on the meat matrix during the forming process.
"For more than 20 years, Marel has
been doing intensive research into forming
technology," said Ben Huisinga, product
manager for Marel, Lenexa, Kan. "Because high

Heat and Control's Breaded
Products Fryer provides
a crucial step in creating
a quality nugget.

www.meatpoultry.com | 06.20 | MEAT+ POULTRY

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Meat+Poultry - June 2020

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