This system is an extension to our existing VACUUM TRANSFER SYSTEM. The VACUUM TRANSFER SYSTEM was designed for Batch Producers who were cooking batches of sauces, chilli and products that have a liquid base.

The sequence is for the product to be cooked in batch kettles and transferred hot into the insulated transfer vessels. The vessels hold approximately 380 litres of product. When the product is ready to be trasferred, a vacuum pump unit is coupled to the holding vessel and the vessel is connected via 75mm pipework to the cooking kettle. The vacuum pump is started and when 30cm of Mercury is attained the valve on the kettle is opened allowing product to be drawn into the holding vessel.

When the vessel is full, pipework and vacuum connections are disconnected and the full vessel is manually transported to the filling line. At the filling line the vessel is connected to the depositor via the bottom outlet and sterile air is applied to the inside of the vessel at a pressure of 1 Bar. The product is then gently pushed into the depositor chamber and filled into trays, cartons, etc.

During this whole operation the product is hot so that the carton, tray, etc has to be blast chilled to take it to 3°C, as required by government guidelines.

Filling into Trays

Product is cooked as before but then manually or by pumps filled into gastronorm trays. These are then manually stacked into racks and wheeled into chillers. After the product has reached the required temperature the racks are wheeled out and operators manually take the tray to the depositor and scrape the product into the depositor hopper. The product is then filled into the cartons, trays, dishes, etc in the standard way. The product trays are then taken to the wash area and cleaned automatically via a tray washer and the racks into the storage area.

The following points were noted for the costing of the ANCHOR COOLING SYSTEM:

	Manual discharge from kettle into trays resulted in many more operators being required = HIGH LABOUR COSTS.
	Danger to operators on hot filling.
	If pumps were used breakdown of delicate products.
	Large numbers of stainless trays and racks required.
	Large chilling area in pre-fill area filled with cooling product.
	Large number of operators required to bring trays from chiller to depositor.
	Operators had to climb steps with trays full of product, in a food environment this is dangerous.
	Some products produce a skin on their surface during cooling resulting in product loss, also there was product residue in the trays again more product loss, in some cases this could be as much as 6% - 7%.
	The operator then has to take the trays to the cleaning area where they are washed by a very expensive tray washer.
	The efficiency of the cold air chiller was not as efficient as the ANCHOR COOLING SYSTEM.
	The Anchor chiller unit is run at night on a cheaper electricity tariff resulting in energy and cost saving.
	Storage and floor space for the racks, trays, washers, chillers meant a larger factory, which in itself, was expensive.

With these points in view D C Norris Engineering developed a system called the ANCHOR COOLING SYSTEM interfacing with their highly successful vacuum transfer system.

The operation of this system is as follows:

	Product is taken from the cooking kettle in the same way as before but transferred into a mobile, jacketed vessel.
	The vessel is wheeled to the cooling booth and located into position.
	Glycol connections are made to the vessel and the Anchor/Agitator is lowered into the product.
	The required temperature is set on the digital controller and the cooling cycle commences.
	After the cooling period has elapsed a warning indicator informs the operator the cycle has finished and allows him to withdraw the agitator unit.
	The product can now be taken to the filling line in the normal way, pressurized and deposited.

The ANCHOR COOLING SYSTEM allows for:

As you can see this system offers many advantages over the existing systems at present on the market.

ANCHOR COOLING SYSTEM

	Features:
	Cooked products transferred into transportable cooling vessel without pumps, reducing product damage.
	End of cooking cycle indication.
	Hot product easily transported to cooling booth eliminating possible contamination.
	Easily cleaned scraped surface agitator.
	Hygienic easily cleaned construction.
	Product temperature monitored and displayed throughout cooling cycle.
	Monitored cooling cycle - can be connected to chart recorder.
	Pre-piped glycol circulation system.
	Direction flow chamber.
	Production Capacity:
	400kgs per vessel.
	85°C to 4°C.
	Dimensions/Weight:
	3000mm high, 1650mm wide, 1450mm deep.
	Approximate shipping weight 400kgs.
	Control Package:
	Temperature monitoring.
	Temperature indication.
	Agitator control.
	PLC control.
	Can be connected to main recording system.
	Cooling medium glycol at -5°C.
	For more information contact the SALES OFFICE at D C NORRIS & CO. (ENG.) LTD. TEL: 01767 677515