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CARAMEL PROCESSING EQUIPMENT

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Caramel processing equipment

By specialising in design andconstruction Hosokawa Ter Braak areable to supply the most comprehensiverange of processing equipment forthe production of all types of caramel. Simultaneously, the technicaldepartment has built up an internationalreputation for the practical supportprovided in the field.

Hosokawa Ter Braak can supplyequipment for all types of caramelapplications, whether to meet therequirements of the small specialistconfectioner, or a major product

manufactured by an internationalorganisation. A feature of constructionis that most individual units can besubsequently integrated into acomplete line as capacity requirementsgrow. Usually production starts with aweighing, mixing and pre-heatingsystem type Caramix, which canbe used to deliver the correctformulations of prepared ingredients toany style of cooker, whether batch,continuous batch, or truly continuous.

The continuous caramel productionlines can be controlled by either a

conventional control system or a PLCsystem. Varying degrees of automationare available as standard, or canbe designed to meet customerrequests. Supervisory, control and dataacquisition (SCADA) can optimise thesystem and provide the requiredmanagement information.

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The Caramix is a weighing and mixingplant in electronic execution withmicro processor. The jacketedweighing vessel is mounted in a frameon a 3 point load cell assembly.The lower holding vessel is also

jacketed to keep the premix at thecorrect temperature. The Caramix isavailable in a sophisticated versionwith PLC control system andoperating screen or a dedicated batchweighing controller (economyexecution).

CaramixWeighing, Mixing and Feeding

Specifications Caramix 200 500

Working capacity max. kg/h 1.600 3.000Power consumption kVA 11 11Air consumption nl/h 500 500Valve for water 1 2 x 1Valve for glucose 2 2 x 2Valve for milk 1 1Valve for fat 1 1Capacity of weighing vessel l 200 500Capacity of lower reservoir l 500 1.000

Length mm 1.850 2.375Width mm 1.070 1.750Height mm 2.875 3.700Net weight kg 1.400 2.200

All data are approximate and subject to specific process parameters and quality/type of raw materials.

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The TBT is a multi-task steam heatedbatch cooker designed for theproduction of soft confectioneryarticles such as caramel and toffee,

jellies (based on pectin, gelatine, agar-agar or Gum Arabic), fruit fillings and

jams. Because of its scraped surface,even products with high protein levelscan be made. The machine is designedto accommodate batches of 100 kgfinal product.Vacuum systems can be added in orderto cool down the cooked mass beforeadding heat sensitive ingredients, suchas fondant (fudge production) andgelatine solution (chewy caramel, jellyand gummy production). The cookeris equipped with a heavy-duty, 2-speed anchor type stirrer with Teflonscrapers. Upon request breaker armscan be fitted to achieve a higher

turbulence and to assist breaking uplumps or to melt down fondant blocksor pieces. The cooker can also beconstructed for air-assisted discharge.All TBT cookers are fully executed instainless steel.

TBTBatch Cooker

Specifications TBT 100 TBT 200

Working capacity kg/h 300 450Batch capacity kg/batch 80-130 180-210Steam working pressure bar max. 10 10Steam consumption kg/h 100 150Power consumption kVA 7,5 7,5Air consumption (compressed air discharge) nl/h 1.800 2.500Water consumption vacuum exec. (max. 18C) l/h 1.200 1.200

Length mm 1.140 1.700Width mm 1.450 1.720Height mm 2.350 2.720Net weight kg 700 950

All data are approximate and subject to specific process parameters and quality/type of raw materials.

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TBFUniversal open cooking pan

Dissolving and cooking pan in copperor stainless steel execution, not onlysuitable for the production of caramelbut also for the preparation of fondantmasses and all kinds of syrups. Thepan is available in 200 or 500 litres.

The outer jacket of the pan issuitable for steam heating. The cookeris equipped with a heavy-duty, 2-speedanchor type stirrer with Teflon scrapers.Upon request breaker arms can be

fitted to achieve a higher turbulenceand to assist breaking up lumps or tomelt down fondant blocks or pieces.The above picture shows the TBF (atthe right) mounted on load cells in acontinuous application for the

production of sesame snacks.

Specifications TBF 200 TBF 500

Working capacity kg/batch 200 500Power consumption kVA 8,4 8,4Steam consumption kg/h 120 300Air consumption nl/h 500 500Length mm 1.000 1.550Width mm 1.025 1.050Height mm 2.400 2.400

Net weight kg 700 800 All data are approximate and subject to specific process parameters and quality/type of raw materials .

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HotmixFeeding, mixing and cooking plant

The Hotmix is a highly flexibleand accurate cooker for various typesof confectionery, especially themanufacture of caramel or toffee. It isa combined machine based on theCoolmix weighing system and cookertype TBT 100. The Hotmix isavailable in standard single executionwith one cooker and in twin with twocookers. Further multiple executionsor combinations are available uponrequest. The photograph showsan example of a Twin Hotmix, whichis a weighing and high capacitycooking system for the simultaneouspreparation of different recipes. Thecooker is executed witha loss-in-weight auger feeder fordosing of dry ingredients after thecooking cycle.

Vacuum systems can be added in orderto cool down the cooked mass beforeadding heat sensitive ingredients(fondant/ fudge/gelatine solution). TheHotmix can be supplied with standarddedicated batch weighing controllerand electronic thermostats, or witha small PLC with HMI (HumanMachine Interface). Through the HMIthe operator can select, edit, save anddownload recipes and monitor theactual status of the installation.

Specifications single twin

Working capacity kg/h 350 700Batch capacity kg/batch 80-130 80-130Steam working pressure bar max. 10 10Steam consumption kg/h 150 300Power consumption (vacuum execution) kVA 15 26Air consumption nl/h 500 500Air consumption (compressed air discharge) nl/h 1.800 3.100Water consumption (vacuum execution) l/h 1.200 1.200

Length mm 2.100 2.350Width mm 1.100 2.800Height mm 3.500 3.500Net weight kg 1.750 2.500

All data are approximate and subject to specific process parameters and quality/type of raw materials .

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The Contimix is a continuous mixersuitable for mixing caramel, toffee oraerated masses with other ingredientsor inclusions such as nuts, coconut,almonds, fruit pieces, raisins, sesameseed, icing sugar, milk powder, cocoapowder, fondant and similar materialswith minimum loss of density andvirtually no degradation or breakageof the inclusions.

To ensure even distribution into a

hopper of forming equipment, theContimix can be supplied in oscillatingexecutions . The system is also availablein easy clean execution with optimalaccessibility of the screws.

ContimixContinuous Mixer

Specifications 700 1200 2450

Working capacity l/h 700 1.200 2.450Power consumption kVA 3,3 3,3 3,3Length of total machine mm 2.000 2.500 2.800Length of mixing chamber mm 820 1.600 1.700Net weight kg 200 250 325

All data are approximate and subject to specific process parameters and quality/type of raw materials.

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CandyflexFlexible continuous caramel cooker

The multipurpose Candyflex (patented)has been designed for maximumproduct diversification in candyprocessing. Ter Braak developed thissystem for cooking under pressure orvacuum (depending upon application),which permits caramelisation within avery short time as compared toambient caramelising systems.Alternatively, this system can also beused to produce white milky chewwithout browning effect.

The Candyflex cooking system iscapable of producing products asdiverse as:

from white to dark caramelscontaining high percentage of milk solids and whey powders

plain hard candy masses white milk hard candy butterscotch chewy masses with or without milk

sugar free candies

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The Candyflex is designed as acontinuous cooking system andcomprises the following threeprocessing stages.

1 Pre-dissolving and caramelising,under pressure.

2 Film cooking/evaporating stage eitherunder atmospheric or vacuumconditions.

3 Open take-off with simple surgevessel and pump (plain caramel) or

4 Vacuumizing, whereby the vacuumchamber is used either as a buffervessel or to operate under vacuum.

Specifications single standard single super twin super twin mega

Working capacity kg/h 300 600 1.200 2.000Steam working pressure bar max. 10 10 10 10Steam consumption kg/h 135 275 550 1.000Power consumption kVA 42 50 90 110Air consumption nl/h 500 500 1.000 1.000Vacuum pump power kW 5,5 7,5 7,5 15Water consumption of vacuum pump(open system) at 15C max. l/h 1.200 1.200 1.200 1.500Chilled water flow rate in closed loop

(ecovac system) at 10C max., T=6 m3/h 8 11 15 27Length mm 3.000 3.400 3.400 5.000Width mm 1.200 1.600 1.800 2.200Height mm 3.700 4.000 4.300 4.500Net weight kg 2.600 3.500 4.500 8.000

All data are approximate and subject to specific process parameters and quality/type of raw materials.

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Cooling drumContinuous Cooling

This is a continuous cooling unit forcaramel and chewy masses. The unitcomprises a specially designed hopperto receive the product from the cookerand spread it evenly on the surface of the drum. The drum is available with adiameter of 1000 mm and of 1500 mm.Capacities up to 1000 kg/hr. The drumis cooled through cooling liquidcirculation in the jacket of the drumssurface; the latter is lubricatedcontinuously to prevent the productfrom sticking to it. The cooling liquiddistribution in the cooling jacket isdesigned to use as little chilling energyas possible against the best possiblecooling result, resulting inconsiderable savings in water andenergy.The picture alongside shows anenlarged custom made cooling drum

with a diameter of 2350 mm.

Specifications 1000 x 600 mm 1500 x 700 mm

Cooling capacitysoft caramel 110 -> 40C kg/h 300 600Steam consumption kg/start up 10 10Power consumption kVA 1,7 2,3Water consumption at 18C* l/h 3.500 5.000Length mm 1.200 1.800Width mm 1.070 1.700Height mm 1.850 2.800Net weight kg 1.200 1.500

* Closed loop cooling water system possible. Specification of temperatures andrequired energy of water chilling unit upon request.

All data are approximate and subject to specific process parameters and quality/type of raw materials.

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The cooling conveyor is a continuouscooling/tempering unit equipped witha stainless steel belt built into astainless steel frame in sections of 2.5or 5 metres. The cooling conveyors canbe supplied in varying lengths and/orwidths for various capacities.Each section is equipped with awatertempering system allowing theadjustment of various temperaturesthroughout the cooling conveyor. Thisprovides the possibility to graduallyand smoothly cool down/temper thecooked mass to its ideal plasticity forsubsequent forming in the batch roller/extruder/cut and wrap machine.Ploughs and water cooled egalisingrollers take care of the kneading actionin the belt. Release agent is appliedcontinuously to avoid sticking of themass to the belt.

Cooling conveyorContinuous Cooling

Specifications 10 m x 600 mm 15 m x 600 mm

Cooling capacitysoft caramel 110 -> 40C kg/h 500 1.000Steam consumption kg/start up 25 25Power consumption kVA 7,5 9Water consumption at 18 C* l/h 2.500 4.000Length mm 11.000 16.000Width mm 1.300 1.300Height mm 1.600 1.600Net weight kg 4.000 5.500

* Closed loop cooling water system possible. Specification of temperatures andrequired energy of water chilling unit upon request.

All data are approximate and subject to specific process parameters and quality/type of raw materials.

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Flow diagrams

TBT-VTBF

TWIN HOTMIX COOLING DRUM

CARAMIX CANDYFLEX

CONTIMIX

COOLING CONVEYOR

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Hosokawa Ter Braak pays muchattention to future development of themachines. The well-equipped pilotplant offers the facilities to carry outthe most diversified tests, in order todetermine whether and how specificproducts can be made on ourmachines. It also helps to design anddevelop adapted versions of ourequipment to meet specialrequirements.

The small scale equipment offers thefollowing advantages: Time is saved by running short trials,

also ingredient usage is held at aminimum.

The results on all laboratorymachines can be scaled up for fullsized production units.

Specialised technical staff: candy

technologists and experiencedmachine operators.

Test centre

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HOSOKAWA TER BRAAK B.V.Subsidiary of Hosokawa Bepex GmbH

Thurledeweg 101-1053044 ER Rotterdam / The NetherlandsTel.: +31-10-2081 888Fax: +31-10-2081 800

confectionery@terbraak.hosokawa.comwww.TerBraakHosokawa.com

HOSOKAWA BEPEX GmbHHeadquartersSales Department

Daimlerstrae 8D-74211 Leingarten / GermanyTel.: +49 (0)7131 / 907 - 0Fax: +49 (0)7131 / 907 - 301

confectionery@bepex.hosokawa.comwww.BepexHosokawa.com

HOSOKAWA BEPEX GmbHProduction Plant Hamburg

Essener Strae 104 - 108D-22419 Hamburg / GermanyTel.: +49-(0)40-527209-0Fax: +49-(0)40-527209-99

confectionery@bepex.hosokawa.comwww.BepexHosokawa.com

C 2 11/07 Printed in the Netherlands