A batter coating preparation system (Batterline) is an intelligently designed, fully automated system for the industrial preparation of liquid batter.
This liquid coating is applied using an applicator as a thin, even layer on the product, prior to baking or frying. The Batterline is specifically engineered for industrial applications where a continuous supply of high-quality batter is essential such as in the potato processing industry.
Thanks to its continuous operation and smart, robust system design, the batter coating preparation system is perfectly suited for high-capacity industrial environments where efficiency, reliability, and consistency are critical. The Batterline enables producers to maintain a stable and uninterrupted batter supply, even at high production speeds, minimizing downtime and reducing product waste. Its advanced control features ensure precise mixing ratios and uniform batter quality, resulting in a consistent coating thickness and optimal adhesion to the product.
Do you have any questions about the Batterline?
What is coating batter?
Batter coating is the process of applying a liquid batter layer to food products, usually before frying or baking. This technique not only enhances flavor, color, and texture but also offers functional benefits such as moisture retention and improved crispiness.
The Batterline ensures that this process is efficient, hygienic, and consistently reproducible. By maintaining stable mixing conditions and continuous operation, it helps deliver a uniform batter quality throughout the entire production cycle. This reduces variability in coating thickness and minimizes product loss or rework. Ideal for large-scale producers who refuse to compromise on quality, the system also supports high production speeds while maintaining strict hygiene standards and process control.
Applications of the batterline – Flexible coating principles
The Batterline is a versatile batter coating preparation system available in multiple models and configurations. The system can be easily adapted to different recipes, powders, viscosities, and coating specifications. Feel free to inquire about the possibilities. The batter coating preparation system is suitable for line capacities ranging from 3 to 60 tons per hour and coating capacities from 500 to 21,000 kg per hour. This makes the system fully scalable, suitable for both smaller production lines and large-scale processing facilities. The system effortlessly processes various types of coatings, from transparent batter layers to rich herb and spice blends with viscosities exceeding 55%. This ensures each product achieves the desired crispiness, color, and flavor.
Hygienic batter coatings
Thanks to advanced mixing and dosing technology, the system prevents quality loss and improves process efficiency. Its closed system design minimizes waste and prevents product contamination. In addition, sensors continuously monitor the viscosity and composition of the batter. The batter coating preparation system is CIP-cleanable and easy to maintain, reducing downtime and ensuring a hygienic production environment—essential in the food processing industry.
Inline Mixer |
High Speed 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 Heavy Batters Herb Batters | Clearcoats Heavy Batters Herb Batters |
| Type of Products | French Fries | French Fries Wedges Specialties | French Fries Wedges Specialties |
- Cold water unit
- Falling film cooler
- Screw powder transport system
- Vacuum transport system
- Automation
- Manual bag unloading
- CIP cleaning system
- Big Bag unloading stations
- Shell & tube or scraped surface heat exchanger (Kelstream)
From batter-coated French fries to batter coatings for fish
Whether it concerns fries, wedges, or other specialties (for example fish or meat), the right combination of mixing technology, viscosity, and process capacity ultimately determines the quality of the coating. Gpi develops complete process installations for batter coating preparation, fully tailored to the required capacity, product composition, and type of batter.
Within potato processing, a Batterline is used to prepare a coating that is then applied to the product before baking or frying. This includes clear coats, heavy batters, and seasoned batters. The batter is continuously mixed and supplied to the coating machine, ensuring a consistent structure and uniform coating thickness across all products.
Food process equipment of batter coating
A Batterline is a fully integrated system for the continuous preparation, handling, and circulation of batter in industrial food processing. The process is designed to ensure consistent quality, high efficiency, and strict hygiene standards throughout every stage of production. From powder handling and batter preparation to application and return flow, each step is carefully controlled and automated to maintain a stable and homogeneous batter at all times.
Powder handling system
The first phase of the process begins with the supply of dry powder.
This can be done using Big Bags or smaller packaging. The powder is discharged via a Big Bag unloading system and then transported to the powder hopper using a screw conveyor or vacuum transport. With vacuum transport, it is possible to keep the dry and wet sections of the line strictly separated, which promotes hygiene and ease of maintenance.
Batter preparation – inline high shear mixer system
In this phase, the batter coating preparation system mixes the powder with water in a precisely calibrated mixing system. A volumetric dosing unit ensures the exact ratio between powder and liquid. The mixing process is fully automated and continuously monitored to guarantee a homogeneous batter.
The batter is then stored in buffer tanks, where it can rest until it is ready for use. By utilizing multiple tanks, a continuous supply of fresh batter to the production process is ensured without interruptions. Once the batter is set, it is pumped to the working tank.
Battersystem return unit
From the working tank, the batter is pumped to the applicator, where it is applied to the product. Before reaching the applicator, the batter passes through one or more heat exchangers to achieve the desired processing temperature.
Excess batter that does not remain on the product is returned to the working tank. During this return flow, the batter is filtered to remove residual particles such as product fragments. This ensures consistent batter quality and minimizes food safety risks.
View our other process installations products
FAQ
What viscosity can the Batterline handle?
How does the Batterline mix powders and liquids?
What is batter?
Batter is a liquid coating used to apply a thin or thicker layer to potato products. This coating can consist of water, starch, flour, spices, and other dry ingredients. The mixture helps products achieve, for example, a crispy texture or improved color during frying, and can also help the product retain heat for a longer period.
