POTATO CHIP PLANT
Capacity – 450 kg/hr.
Based on 21% solid content in Potatoes and ideal process conditions.
All the equipments are manufactured on as per know-how from PPM AB, Sweden as per their design, standards and technology.
All process equipments are fabricated in Stainless Steel, except for the, standard parts such as the motors, gear boxes and such components.
All electrical components, motors, modular plastic belts, hot oil pumps etc. are of international brands.
Output - 450kg/hr
Dry matter Reducing sugar Size grade
- 21 % (Min)
- Almost Nil
- 40 to 60 mm
Potato Chips :
- 1.5 % (Max)
- 35 % approximately
Frying Time :
3 to 3.5 minutes
PROCESS SECTION - A:
1. INFEED ELEVATOR
The equipment shall receive the potatoes and feed the same to the De-stoner.
To provide uniform & uninterrupted supply of potatoes to the production line. The feed rate is controlled by variable speed motor, which controls the speed of Elevator to lift the Potatoes to the De-stoner.
For removing stones and elevating the product to the peeler. A high percentage of removal efficiency along with a certain amount of washing is achieved to assist better peeling.
3. CONTINUOUS ABRASIVE PEELER
Used for continuous peeling of potatoes at variable speeds of operation. Adjustable levels of abrasive rolls for optimum peeling results accurately control the degree of peeling. Special roller design results in uniform peeling over the entire surface of potatoes.
Easy replaceable abrasive rollers are driven via timing belts for smooth and silent running and low maintenance. Used rollers can be recoated.
4. INSPECTION CONVEYOR
Peeled potatoes to be inspected on a Inspection conveyor. The equipments also provide for Trim station mounted on either side of table to facilitate trimming and disposal through waste chute.
5. INCLINED ELEVATOR
Inclined Elevator with intermediate buffer hopper for regular and consistent flow of peeled potatoes. The elevator with flighted plastic belt lifts potatoes to the singulator.
6. FEEDER SINGULATOR
Potato singulator ensures regulated one by one feed of potatoes to the slicer. This ensures optimum capacity utilization of slicer and regulated slice feeding.
Mechanical slicer from Urschel, USA, with cutting heads for Plain cut slices and matching with the line capacity, complete with the required stand in SS304 .
Urschel slicers are used all over the world in America or Europe by most well established companies in Potato Chips making, including Pepsico.
8. SLICE WASHER & SHAKER
Specially designed multistage washing on tumbler washer and final washing on vibratory conveyor, which effectively removes surface starch from freshly sliced potatoes and also eliminates small pieces from the finished product.
Exclusive PPM design
Simple operation, Low water & energy consumption, gentle product handling, easy cleaning, separation of small pieces, easy cleaning etc. are some of the features of this system.
Slice washer offers multistage washing of the slices to remove surface starch. Washing starts alongwith slicing, hence no mechanical handling of slices. A vibratory shaking unit ensures elimination of small and broken slices.
Vibratory Conveyor Washing
The final stage of washing takes place on a vibratory conveyor with fresh water. This vibratory conveyor also screens small pieces, which is not desired on the final product.
Provision for re-circulation of water from the last stage washing to the Slicer through a stainless steel pump, tank etc. also included.
Screening of Water & Small pieces
The water from the vibratory shaker is filtered on a screen, to separate small pieces.
9. MULTI TURBO BLANCHER
Exclusive PPM design based on the multi turbulence principle offering uniform heat treatment to individual potato slices.
The multi turbulence effect with cross circulation of water bath, ensure perfect blanching, uniform heat treatment of individual slices, prevents sticking of slices and correct leaching effect of the product. This process ensures uniform color to the finished product.
Belt type Water Blancher with stainless steel transport conveyor for carrying slices. Paddles control the blanching time. Hot water is injected across through multiple inlets along both sides of the pan above the transport belt to create turbulence.
A pump circulates water through heat exchanger into the blanching tub. Surface water from the blanched slices is removed by air knife arrangement fitted at out feed end.
Automatic Temperature Control
The set temperature of the blanching water is automatically controlled by a temperature controller within a range of ± 2°C.
Control of Blanching Process & Time
The hood above the pan is equipped with an open flight conveyor. The flights go down to the transport belt. The speed of the flight conveyor and transport belt is controlled by variable speed drives.
The water in the system is circulated through a stainless steel pump.
The out feed conveyor is integrated with an air knife arrangement, with adjustable air blow, to blow off surface water from the product.
10. DE-WATERING SHAKER FEEDER
Vibratory shaker to remove surface water and individually separate and distributes the product before entering to the fryer.
Imported Ajax drive and AU links are used in this equipment, for gentle handling of the product and smooth working.
11. HIGH SPEED BELT
The slices are fed to the fryer through High Speed Belt, which ensures distribution and separation of individual slices before.
12. MULTI-FLOW FRYING SYSTEM
Designed to produce high quality potato chips. Comprising of Continuous fryer, Hydraulic hood lifting system, Continuous fat filter, Automatic level control, Day tank, CIP etc.
Low cooking oil pickup, less oil in the system, fast oil turn over, better oil quality & management are some of the important features and benefits of PPM Multi-flow Frying System.
The Pan is equipped with multiple inlets multiple and outlets to ensure an even temperature and an even fat flow along the entire pan at the same time. The outlets can be adjusted individually to obtain the optimal fat level in the pan.
S.S Hood & Hood Lift Assembly
Stainless steel hood assembly complete with two belts, telescopic chimney etc. Hood is specially designed with “drip/back” security and evacuation pipe (chimney, height 1Mtr.) of telescopic type. Complete with valve and regulation equipment.
Integrated mechanical lift off system, lifts the complete hood assembly with belts for easy access for cleaning.
Automatic Oil Level Control
For automatic topping of oil level in the fryer. Including valve arrangement, transport pump and internal piping between the components. Stainless steel construction.
Hot Oil Circulation System
Complete with S.S. Pump, stainless steel piping connecting fryer to heat exchanger, fat filter and day tank.
Automatic Temperature Control
The frying temperature is controlled within a range of ± 1°C. The temperature at different places in the pan can also be noted.
Continuous Fat Filter
For continuous separation of fines from the frying oil. The filter is equipped with scrapers, which cleans the belt from particles, to be collected in a tray.
Covered out feed for lifting the finished product from the frying oil. Variable speed drive for adjustment of the belt speed. Made of stainless steel and flanged to the fryer.
The specific construction of our out feed belt gives advantages with regard to the fat
draining during the elevation from fat bath. A warm closed atmosphere during the transport time is obtained. Dripped off fat goes back into the system
Automatic cleaning in place system installed between hood and belt in the fryer.
Tank is Stainless Steel with valves for continuous oil supply to the fryer, sight glass for level indication.
13. INSPECTION CONVEYOR
Inspection conveyor with food grade plastic belt for manual inspection and manual separation of defective pieces from the finished product.
14. SPICE FEEDER
It has an hopper for keeping spices / seasoning material. For dispensing adjustable quantities of dry flavor or salt on the product, it has a dispersing plate to control the outflow of material.
15. SCARF TRAY
For evenly dispersing the seasoning product a in form of a curtain, Scarf Tray is provided with vibratory motor and stand to go into the drum.
16. SEASONING TUMBLER
Stainless steel tumbling drum with built-in wedges for homogenously applying the seasoning material over the product. Complete with adjustable stand.
17. PLC CONTROL PANEL
With PLC from Allen Bradley, USA, it’s a Panel of International standards, for
complete Automation of the Chip-line given by us, with a Coloured Touch Screen.
To be placed suitably in the potato processing area near the frying system to control and interlink equipment. It is in form of a desk having mimic display of process diagram with LED’s and alarms to indicate breakdowns.
Mains Supply – 415V AC; 3 – Ø; 4 wire; 50 Hz. Control Supply – 220V AC; 1 – Ø; 50 Hz.
The panel shall be electrically interlocked for smooth operation and safe operation. An option for manual operation of the complete line shall be incorporated.
The panel shall incorporate alarms for low oil level in fryer and non-operating condition of any motor/system in the line.
18. Thermic Fluid Heating System
Common heating system for heating of edible oil in the Frying System. It will use Diesel Burner for Heating the Thermic Fluid. Its technical details will be advised by us.
19. Heat Exchangers – 2 Nos.
Shell & Tube type Heat Exchangers with Stainless Steel tubes for Blancher to heat water and for
Heating Frying oil to go to the Fryer. Complete alongwith the pipe line, pump etc., connecting to the Fryer & Blancher.
1. All civil and foundation work.
2. Pipeline etc. for Thermic Fluid Heater & Heater Exchangers.
3. All electrical cable from & to Control Panel and individual equipments.
4. All water, steam, air & thermal oil pipe lines to & between the equipment.
5. Air Compressor and its accessories.
6. Any installation pertaining to Thermic Oil Heater, including Chimney.
7. Staircase, Platform, Railings, support structure etc.
8. Labor for loading, unloading, marshalling & positioning of equipments at site.
9. Waste disposal and effluent treatment plant.
10. Anything not specifically mentioned in the offer.
RAW MATERIAL SPECIFICATION
The Potatoes used shall be newly harvested and size graded. Characteristics that are desirable are round shape (not long potatoes), shallow eyes, smooth texture, white flesh color. Besides potatoes, shall be graded to 40 to 60 mm diameter size to effect smooth operation of the plant. Potatoes shall be completely free from diseases, greening, sprouting, loose texture, physical injuries etc.
Shape & Size - Regular Shape and graded to 40mm to 60mm diameter
Eyes - Shallow
Flesh Color - White
Texture - Smooth / waxy
Specific gravity - 1.080 to 1.095
Dry matter - 20.2 to 23.4 % Reducing sugar - Nil
1. Fry test:
This test is conducted during commercial operation of the fryer and the Potato slices fried at 185ºC in edible oil shall have good color and appearance and shall meet finished product quality specification.
2. Edible Oil
Incoming edible oil for frying operation should be checked for purity i.e. color, refractive idex, Free fatty acids, lodine value , Peroxide value etc.
* Potatoes containing reducing Sugar 0.1% and above generally turns brown during frying.
TYPICAL SPECIFICATION – POTATO CHIPS
Golden Yellow to light Golden Brown.
1.0 to 1.4mm
1.5% ( Max 2.0%)
Fat Content :
32 to 38% *
* Fat pick-up Potato Chips vary depending upon solid content in potatoes and the process parameters, standard frying time is 3 to 3.5 minutes.