Additiveline

Mixing and dosing of additives for potato flakes

  • The perfect solution for dosing additives for making potato flakes
  • Mixing and dosing of emulsifier, SAPP, dextrose, phosphate, colorants and more
  • Single of multi tank systems
  • Optional fully automated for consistent results

Additives mixing and dosing

The Additiveline is a system used in the potato industry for mixing and dosing additives in the potato flakes production line. 

Since both french fries- as flakes processing lines are becoming bigger and bigger, the demand of automated systems increases. 

Potatoes are cooked and mashed, then crushed by rollers on the surface of a drum. The mashed potato is fast-dried until its humidity reaches the desired level, then the layer of dried, mashed potato is scraped from the drum. This sheet is broken up by a mill sifter, and the resulting flakes are then packed.

To give the flakes the desired characteristics in terms of flavour, colour end other specifications, additives are dosed in the mashed potatoes. 

Batter Coating Preparation System
  • CIP Cleaning system
  • Cold and/or water unit
  • Screw powder transport system
  • Vacuum transport system
  • Big Bag Unloading
  • Manual Bag Unloading
  • Various mixing principles
  • Dextrose
  • Phosphate
  • Emulsifier
  • Sulfite
  • Citric acid
  • Pyrophosphate
  • GMS
  • SAPP
  • Starch

How it works

Batter Coating Preparation System - powder handling render

Powder handling

The first part of the Additiveline is the powder handling part. The dry additives can be brought to the line in big bags by a big bag unloading station or in smaller bags through a powder filling cabinet. Of course, a combination of both is also possible.

From that point, the powder can be transported to the tanks by vacuum, screw conveyor or directly dosed in the tanks. Working with vacuum transport allows you to keep the dry part of the line separated from the wet parts.

Mixing

In the second part of the Additiveline, the additives are mixed with water. A volumetric feeder doses the correct amount of additives in the water.

The solids percentage of additives and the characteristics of it, will determine the agitator needed. This can be a simple propeller agitator, a disperser, a high shear mixer or even an inline mixer.

Several setups can be used, a single tank setup, where all additives are dosed into the same tank or a multiple tank setup, where certain additives will have a dedicated mixing tank. The big advantage of the second option is, that the additives can be dosed separately into the potato mash, which increase the flexibility of the system and the quality of the end product.

Batter Coating Preparation System - batter preparation system render

Dosing

Once the additives are mixed with water, it will be dosed in either the ricer or the cooker. In the ricer only liquid additives can be dosed into the ricer, where in the cooker it’s also possible to add dry additives.

Throughout the year, the potatoes used for making flakes will vary in quality and characteristics. By having the ability to change the dosing percentages, a nice and even quality can be produced whole year round.

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Projects

Complete installations

  • Prefabricated and assembled inhouse
  • Design, manufacturing and installation
  • Short installation time
  • Guaranteed operation
Batter Coating Preparation System

Projects and installations

Next to separate tanks and process equipment, Gpi designs and produces also integrated our solutions as an installation which is prefabricated inhouse, to make sure all parts fit before shipment. 

Because Gpi designs the entire installation, you are assured that the technology supplied works seamlessly together and delivers the highest possible product and process quality.

If needed, we can have a full FAT at our facilities, so you’ll be sure that the installation will work on site as well. 

Pick the right configuration

We understand that every application is different. That is why we design our installations specifically to your specifications, so that we can be sure that the skid best suits your product and process.

Do you prefer certain brands in terms of component choice? Fine. Do you want us to choose the best components for you? No problem.

Gpi has good relationships with various component suppliers such as pumps, valves and instruments.

Project Management

Realizing a project is not only about welding and fabricating. It is about process design, making P&IDs, time management and communciation as well. 

Gpi has its own department of project management which take care of realizing project on time and within budget. Having one point of contact makes it easy to communicate and results in the best quality throughout the whole project. 

Gpi vacature

Gallery

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Skids

Your process compactly composed

  • Seamless solution for your product and process
  • Compact and plug-and-play solution
  • Short installation time
  • Guaranteed operation

Stainless Steel Skid

Next to separate tanks and process equipment, Gpi designs and produces also integrated solutions on a frame, better known as skids. You can think of a preparation vessel in combination with a  surface heat exhanger, control panel, the right valve train and piping.

Because Gpi designs the entire skid, you are assured that the technology supplied works seamlessly together and delivers the highest possible product and process quality.

The skid is supplied plug-and-play, so that you are hindered as little as possible in your production environment during installation.

Stainless Steel Skid - mobile

Options and applications

Each application requires different requirements for the skid. That is why our skids are designed and manufactured in close cooperation between all our departments so that they perfectly match your product and process and meet all desired requirements.

  • Integrated control panel
  • Agitators
  • Heated or cooled (Dimple, Halfpipe)
  • Loadcells
  • Level Switches
  • Cleaning connections
  • Warm- and cold water units
  • Various finishing levels 
  • Various SS types possible (304, 316L)
  • Pumps
  • Piping and valves
Soups and sauces
 
Fruit
 
Food

Tomato sauces

 

Fruitfilling

 

Mashed potato

Sauces

 

Piefilling

 

Mechanically Deboned Meat

Dressings

 

Fruitpuree

 

Ready-to-eat fillings

Salsa

 

Jam

 

Egg

Hummus

 

Marmelade

 

Jelly

Soup

 

Fruitsauce

 

Peanut Butter

Starch slurry

 

Applepulp

 
Pharma

Spreads

 
Dairy
 

Lotions

Confectionary
 

Milkconcentrate

 

Creams

Fat cream

 

Cheese sauce

 

Wax

Chocolate

 

Yoghurt

 

Toothpaste

Caramel

Stainless Steel Skid

Pick the right configuration

We understand that every application is different. That is why we design our skids specifically to your specifications, so that we can be sure that the skid best suits your product and process.

Do you prefer certain brands in terms of component choice? Fine. Do you want us to choose the best components for you? No problem.

Gpi has good relationships with various component suppliers such as pumps, valves and instruments.

Finishing levels

Gpi uses a high level of quality as standard. We always design our skids with the highest possible level of hygiene.

We take into account the drain possibility, we avoid blind spots and our frames can be built in a so-called diamond frame, whereby the tubes are tilted. In this way, as little dirt as possible remains on your skid frame.

Stainless Steel Buffer Tank - upperside

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Batterline

A continuous batter preparation system

  • Continuous high capacity batter production
  • Fully automated for consistent results
  • Low and high viscosity options
  • Hygienic design
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Batter Coating Preparation System

The Batterline is a system for high volume, continuous preparation of batter, as typically seen in the potato- meat and fi sh processing industries. The liquid batter is applied via an applicator, where product is covered in a thin layer before they are baked in the oven. This ‘battering’ or ‘coating’ is done to give the product certain additional properties, such as ‘bite’ (crispness), color or taste.

Batter Coating Preparation System

Options and applications

The Batterline has several options and standard applications.
Please contact us for more detailed information on all available layouts.

 

Inline Mixer

High Shear Mixer

In Tank Mixer

Line Capacity Fryer

Up to 25.000kg/hr

Up to 25.000kg/hr

Up to 25.000kg/hr

Capacity Coating System

Up to 5.000kg/hr

Up to 7.500kg/hr

Up to 7.000kg/hr

Capacity Dry Matter

75kg/min

140kg/min

100kg/min

Dry Matter %

Up to 37-40%

Up to 48%

Up to 48%

Viscosity

500cP

5.500cP

5.500cP

Type of Batters

Clearcoats

Clearcoats

Clearcoats

Heavy Batters

Heavy Batters

Type of Products

French Fries

French Fries

French Fries

Wedges

Wedges

  • CIP Cleaning system
  • Cold water unit
  • Falling film cooler
  • Screw powder transport system
  • Vacuum transport system
  • Big Bag Unloading
  • Manual Bag Unloading
  • Potato industry
  • Frozen vegetables
  • Fish industry
  • Meat industry

How it works

Batter Coating Preparation System - powder handling render

Powder handling

The first part of the Batterline is the powder handling part. The dry powder can be brought to the line in big bags or smaller bags. The powder is unloaded by a big bag station.

From that point, the powder can be transported by a transport screw or by vacuum. Working with vacuum transport allows you to keep the dry part of the line separated from the wet parts.

The powder is transported to a powder hopper, where the second part of the line starts.

Batter preparation system

In the second part of the Batterline, the powder is mixed with the water. A volumetric feeder doses the correct amount of powder into the mixing system, where it will meet the correct water supply.

The batter is automatically mixed into the right ratio. The mixed batter goes to one of the buffer tanks where it can settle till ready. The batter mix will alternately goes into one of the buffer tanks, which gives you a continuous flow of mixed batter.

Once the batter is settled, it will be pumped to the working tank, part three.

Batter Coating Preparation System - batter preparation system render
Batter Coating Preparation System - batter return unit render

Batter return unit

The batter in the working tank, is pumped to the applicator. It passes one or more shell-and-tube heat exchangers to get the optimal temperature. The batter not picked up by the end-product is returned to the working tank, after passing a particle filter. All waste coming with the returned batter, like pieces of French Fries, will be filtered out and disposed.

Gallery

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