ContinuTherm

The ContinuTherm thermal screw is a flexible continuous thermal processing system configurable for a broad range of products; from meat, poultry and fish to fruits and vegetables to pasta, rice and other grains. Continuous thermal screws are as simple to operate and maintain, as they are versatile. Processors benefit by switching a batch process over to continuous operation where streamlined product handling reduces labor requirements and improves consistency of product quality. Blentech specializes in turn-key ContinuTherm systems including raw material metering upstream and downstream separation, handling and cooling/chilling equipment.

In addition to designing ContinuTherms for customary cooking modes such as direct steam and water or oil immersion, Blentech has developed several unique processing solutions by adapting proprietary technologies to this “tried-and-true” continuous cooking system for high value added applications such as sautéed onions, bacon bits and stir-fried rice.

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DIRECT STEAM

Steam blanching or steam cooking in the ContinuTherm improves yields for products like potatoes that tend to lose soluble solids when cooked in water. Conversely, products like pulped fruit or vegetables for baby food, for which moisture addition and particulate degradation are not an issue, can be rapidly heated with direct steam injection. The proprietary steam diffusers mounted along the bottom of the ContinuTherm trough disperse steam evenly throughout the product for uniform heating.

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WATER IMMERSION

Water immersion cooking suits products such as pasta and rice that require additional moisture to hydrate while cooking. Other items like diced meat or shrimp benefit from being cooked in water, which provides good heat conductivity and the lubricity to keep individual pieces from cooking together into a larger mass.

Heating is normally via direct steam injection, though indirect heating by steam jacket and/or external heat exchanger is possible if required by the application. The cook water is separated from the product at discharge and re-circulated to conserve residual heat potential. Application specific methods are employed to keep concentrations of starch, rendered fat and other process by-products at acceptable levels during production.

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OIL IMMERSION

Cooking in hot oil develops desirable browning color and flavor notes to products in a way that water immersion cannot duplicate. The oil is indirectly heated to 212°F (100°C) by a high pressure steam jacket and an external heat exchanger in the oil recirculation line. In this “low temperature” deep frying configuration, the ContinuTherm is ideal for cooking pizza toppings, meatballs, chicken and beef cubes or fajita strips. Increasing the residence time or raising the cook oil temperature [up to 275°F (135°C)] produces a crispier texture and richer, brown finish. Results on pizza toppings indicate this process improves yields versus continuous ovens.

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SAUTE/ STIR-FRY

Blentech has incorporated features of our VersaWok batch stir-fry cooker to devise a ContinuTherm system capable of continuous sautéing or stir-frying diced meats, poultry and seafood, onions, peppers and other vegetables as well as fried rice.

A high-pressure steam heated jacket provides sufficient temperature for most sauté applications. For stir-fry applications, the jacket is heated with thermal oil to temperatures approaching 300°C (600°F). A PLC controlled forward-reverse agitation action mimics the distinctive mixing and tossing action of the VersaWok for authentic sautéed and stir-fried products. Blentech's patented scraper system is essential to inhibit burn-on allowing shift-long run times.

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HOLLOW SCREW AND JACKET

The heat exchange area of a steam jacketed ContinuTherm is dramatically increased by the addition of a hollow screw. The expanded heat transfer capacity makes possible the rapid heating of products where direct steam injection or water or oil immersion is not practicable. It enables a ContinuTherm to meet the enormous peak heat load requirements necessary to evaporate moisture from products, making continuous frying of bacon bits in the ContinuTherm a reality.

High pressure steam or thermal oil - as well as glycol coolant - can be circulated through the hollow screw and jacketed trough.

Hot Water with Direct Steam Injection

Steam Jacket and Hollow Flights

Hot Oil with Jacket and Heat Exchanger

Range of Products & Applications:

The ContinuTherm is an extremely versatile machine that can be designed to fit a whole host of continuous thermal processing applications.

Products Blanched or Cooked with Steam
Diced Potatoes, Carrots and other Fruits and Vegetables, Pulped Fruit and Vegetable Slurries, Scrambled Egg, Pet Foods.

Products Blanched or Cooked in Water
Rice, Pasta, Pizza Topping, Diced Meat or Poultry, Shrimp, Fruits and Vegetables, Pet Foods.

Products Cooked in Oil
Pizza Topping, Ground Beef Crumbles, Bacon Bits, Cubes or Strips of Meat, Poultry or Fish, Garlic, Onion, Peppers and other Vegetables.

Stir-Fried & Sautéed Products
Cubes or Strips of Meat, Poultry or Fish, Diced Mixed Vegetables, Egg-Fried Rice, Sautéed Onions and Garlic.

Proven Modes of Operation:

WORKING CAPACITIES:

Each ContinuTherm continuous cooking system is custom-sized to a specific process and desired production rate. Blentech has designed units with capacities of 100-lb/hr to 10,000 lb/hr (45-kg/hr to 4,500-kg/hr) or more, depending on the application.