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JBT Dry-Fry: making healthier comfort food without sacrificing taste

Fish and chips

Frying undoubtedly brings advantages for many products in terms of taste, crunch and eating experience, but with consumers taking an ever greater interest in the links between food, health and the environment, a demand for healthier fried food options has also grown. In response, many food processors are actively seeking ways of improving the health characteristics of new and existing food products without sacrificing the taste.

To support producers in this journey, JBT has developed the Dry-Fry System; a unique, innovative and healthier way of frying that keeps the great taste while shedding the unwanted side effects that come with deep frying.

Designed to process a wide range of healthier food options while maintaining a ‘just fried’ taste and appearance, the Dry-Fry uses up to 50% less oil to cook battered and breaded products, as well as meatballs, plant-based and vegetarian foods. Perhaps even more significantly, the Dry-Fry enables the use of a far wider range of frying ingredients, including healthier alternatives such as olive oil, which are not fitting for a deep frying process.

JBT_Dry-Fry_onion-rings_stockphoto

Complete line
The Dry-Fry brings together a complete line process that comprises the Stein Ultra V coating line, a fully controllable oil spray system, the Double D Revoband Continuous Protein Oven, an optional oven for fully cooking the product and the Frigoscandia GYRoCOMPACT Spiral Freezer or Chiller. The system works by eliminating the pre-frying stage while at the same time using controlled, significantly reduced amounts of oil, producing healthier, lower fat products that retain an optimum fried taste and texture.

“The Dry-Fry is a healthier alternative to deep frying, which not only uses less oil, but can also make use of ingredients such as olive oil and margarine that are not suitable for deep frying,” explains Bart Kivits, JBT’s Manager for Coating and Cooking Applications. “You also have the advantage of not having to change the oil every few days, so your overall running costs are lower.”

Olive oil with herbs

Healthier alternative
The system is part of a Healthier Cooking range of solutions from JBT, aimed at helping customers take advantage of growing consumer interest in healthier lifestyles and eating habits, including the burgeoning market for plant-based foods and meat alternatives. “Consumers are becoming more and more educated on food and are much more open to try new things and pay premium price if they believe it is good for them,” adds Kivits.

The range also includes the JBT Formcook Contact Cooker and JBT Formcook Combi Cooker, which make use of innovations from the continuous movement of products on teflon belts to cooking through forced air and steam heat transfer.

LEARN MORE about the JBT Dry-Fry solution

The Xray technology helping achieve the perfect cut

Getting the most value out of a cut of beef steak or pork loin can make a literal, monetary difference to food processors, but up until recently has not always been easy to achieve. By combining XVision Flexscan technology and advanced software with DSI Waterjet Portioning Systems, JBT is now able to add significant value to a cut of meat, while ensuring sensitive products – such as red meat – make minimum contact with water.

Debuted in 2017, the JBT DSI X-ray Guided Waterjet Portioning System marks a major step forward on previous waterjet solutions by enabling an effective analysis of the product interior to take place before the first cut is even taken. However, the 2021 introduction of DSI Value Optimizer software enables product managers to determine a cut pattern that achieves the highest value based on current pricing, allowing companies to maximize both yields and profits.

System innovations
“We have been making a concerted effort working with our software development and mechanical engineering teams on how we can better equip our current machine offering for red meat,” explains JBT DSI New Market Development Engineer, Alec Hewitt. “We’ve put significant effort into a water jet application specifically for the red meat industry.”

Optimizing value: the JBT X-ray Guided Waterjet Portioning System

Hewitt recently hosted a Red Meat webinar as part of the JBTConnect series (register to view), examining how the system can benefit a wide range of products, from beef steaks, sirloins and New York strips to pork ribs, loins and chops.

“We have done a lot more work with pork processors in terms of developing software that is most usable for them,” reveals Hewitt. “We can analyse a rib pack and develop a value-based strategy that can turn a US$6 rib into a US$7 rib and we think that’s of great benefit to the industry.”

When it comes to red meat, one of DSI’s biggest advances has been the development of a system which captures the water stream immediately and directs it away from the meat to minimize any contact with the water. “Our engineers have done an incredible job,” says Hewitt. “Our water stream is only about the width of a human hair, but once it passes through the meat it goes into a water capture or “baffle” that directs it away from the product surface. We have also improved ventilation in the system.”

Optimal cuts
The integration of Flexscan Xray technology means operators can now scan the products and calculate how they want to make the cut before the process begins. “The Xray allows us to individually see every rib in the pack and with that information we can plot a cut pattern, so every cut pattern will be unique,” continues Hewitt. “Our water jet system is on a x/y axis which allows us to make last-minute adjustments of how we are cutting.”

The addition of Value Optimizer software enables product managers to aggregate information on a daily basis and apply the cut strategy to the highest volume based on internal pricing. In fact, the software is connected to futures on the Chicago Mercantile Exchange, so processors can benefit from daily pricing updates.

However, JBT remains very much involved and will work with customers to help develop cut strategies. “For example, a customer might have multiple product SUKs with varying requirements, and we will work with them based on what their specifications are and program that into the equipment so it’s ready to go,” he explains. “Also, if (and when) those specifications change, it’s very straightforward and user-friendly to adjust, so the cut strategies continue to match our customer’s expectations.”

LEARN MORE about the JBT X-ray Guided Waterjet Portioning System

The C.A.T. Transfer Pump: the simple solution to get products moving

Moving labor-intensive protein products down a production line such as trim meat, viscera, skin, hearts, livers or gizzards can be a messy business, but also one where inadvertent product losses can take place. The JBT C.A.T. Transfer Pump is a hygienic, low-maintenance and cost-effectiveway to move soft food products from point A to point B with minimal damage.

Suitable for a wide range of products, from marinated breast meat and tenders through to chicken wings and fish fillets, the Transfer Pump works by moving products suspended in liquid, which removes the risk of product being lost at turns and connection points, helping maximize yield in the process.

Complete control
“The C.A.T. Transfer Pump allows us to easily move a product that would otherwise be on a conveyor, but with the difference being there is less danger or products being lost or dropped, and they are going to sustain little damage during transportation from A to B,” explains Dustan Atkinson, General Manager for Primary Segment products at JBT C.A.T.

The system functions by drawing products from a hopper up a vertical tube. The product will touch a probe near the top of the tube, and once the connection is made the vacuum generator switches to charge mode and the product exits the pump. The Transfer Pump is also available in 4″, 6″, or 8″ diameter pump sizes to better meet the flow rates required by the customer.

Removing risk
According to Atkinson, control of yield is one of the system’s biggest plus points, in addition to precise feeding, both into and out of the pump. “This precision means you can effectively remove trim from waterjet cutting systems, and skin from deskinning machines along with transferring heats, livers and gizzards (GIB packs) from evisceration areas to designated pack out areas,” he says. 

The Transfer Pump requires little to no maintenance, having only two moving parts, while being universally compatible means the system will work within any line, even non-JBT machines. In addition, the solution’s simple, stainless-steel construction enables easier cleaning and maintenance, Atkinson concludes.

Find out more about the JBT C.A.T. Transfer Pump

JBT’s Frigoscandia FLoFREEZE M SD: innovations in Accessibility and Food Safety

With the growth in demand for ready-to-eat fresh foods, so awareness of the importance of achieving optimum hygiene and food safety has increased across the processing industry. JBT’s Frigoscandia FLoFREEZE® M Sequential Defrost (SD) now features new innovations in accessibility and design; all with the goal of the system quicker, simpler and smarter to clean.

An IQF freezer designed to operate up to six days non-stop, the FLoFREEZE M SD utilizes an airflow process that prevents product debris build-up on the freezer’s evaporator, saving hours of cleaning and minimizing the risk for food contamination. Proven and leading JBT IQF (Individual Quick Freezing) technology with true fluidization helps ensure a consistent out-put quality and efficiency for vegetables, soft fruits, fish and other high-value products.

Improved accessibility
But even a sequentially defrosted freezer needs to be defrosted eventually and it is then crucial to have full access to the entire freezer during the defrost turn-around cycle so that any eventual product debris in the freezer can be cleaned out totally and not pose a food safety hazard. The food safety hazards come from that when the freezer is defrosted the temperature in the freezer will reach a level where microbiological growth can occur.

In JBT’s new update of the FLoFREEZE M SD, we have worked hard on improving the accessibility, alongside design improvements focused on making the freezer easier, quicker and smarter to clean and inspect difficult areas after cleaning.

Easy inspection
Hatches and walkways have been added, enabling hard-to-access areas to be inspected following cleaning. As an optional extra, JBT’s automatic Clean-In-Place (CIP) system will be available for the first time with the FLoFREEZE M SD.

According to Stefan Paulsson, JBT’s Director of Value Stream & Global Product Line for Frigoscandia, the FLoFREEZE M SD’s innovations mean accessibility is even more vital to the process as a whole. “Quick and easy access for inspection and cleaning is important with today’s tight operational schedules so that all potential food safety hazards from product debris can be taken care of,” he explains.

For customers aiming to take hygiene and food safety to the next level, JBT also offers the FLoFREEZE M SD with a Fully Welded Enclosure, which enables optimal steam sanitation to ensure all in-freezer contamination risks are removed.

Optimum hygiene
New demands on reaching optimum levels of hygiene in freezers are being driven by changes in consumers’ eating behaviour, according to Paulsson, with the growth in the ready-to-eat category bringing greater awareness across the food industry of the risk posed by bacteria. As a result, companies in the fruit and vegetable processing industry across Europe now have even-higher standards to meet when it comes to hygiene and food safety, which has emphasized the need for further advanced cleaning systems and other hygienic options.

“JBT freezing equipment is hygienic by design down to every detail, with sloping and minimized overlapping surfaces, so that when you flush the freezer during cleaning, you don’t have any hidden surfaces with risk of bacteria growth,” says Paulsson. “We have now further updated the design for even better cleanability and quicker turnaround times. All with the customers and their customers’ best interests at heart.”

LEARN MORE about the JBT Frigoscandia FLoFREEZE M Sequential Defrost

JBT TIPPER TIE to stage high-speed heat-sealing webinar

jbt-tipper-tie-ttsealh-webinar

The ability of the TIPPER TIE TTSealH to increase productivity and lower costs for companies sealing sausage meats and other products with high speed clippers will be the subject of a new JBTConnects Webinar on May 20, with customers able to find out how the system can make a noticeable difference to throughput across a range of industries.

A productivity accessory for the TIPPER TIE TT1815 or TT1512 double clippers, the TTSealH delivers key performance benefits to meat processors, as well as to chemical, confectionary, and dairy manufacturers. The precision-engineered state-of-the-art system for packaging pumpable product improves productivity and lowers packaging costs for processors seeking greater throughput beyond the capabilities of bench clippers or semi-automatic closure machines.

JBT Tipper Tie TTSealH

Key benefits
“The TTSealH is a heat-seal machine which converts flat-stock film into a sealed casing, which can then be stuffed with any pumpable product,” explains TIPPER TIE’s Conrad Faust. “The big advantage here is that instead of using a more expensive pre-shirred casing which has to be changed every 90 seconds when you are running quickly, the flat-stock film heat-seal machine will eliminate those casing changes. Instead of having to change casings every 90 seconds, you only have to change a roll of film every three or four hours, or longer depending on the product. 

“That gives you a lot more productivity and throughput during the course of the day, as well as reducing your cost because the flat-stock films can be cheaper than a pre-shirred casing and a lot less waste.”

CLICK HERE to register for the TIPPER TIE TTSealH Webinar free-of-charge

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