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A new website is in progress, which will “go live” around summer time. This

will be an interactive platform with information on innovations, product

developments, strategic partners and interesting topics. To enhance our look even

more, our drawing office for example present 3D drawings which are not only used for

technical purposes, but also as a marketing tool, see the new layout of our “famous”

potato chips bag. In addition to all our activities, we would also be very pleased to meet

with you during the following exhibitions:

Bring out the best in your process

EditorialWelcome to a new edition of the Kiremko News where we

aim to keep you informed about our recent activities and our

plans for the next few months.

The market for processed potato products continues to

grow and we have seen a great deal of activity in practically

all regions around the world. China is still expanding

rapidly and our office in Beijing is now fully functional

supporting new and existing clients. From the office in

Moscow we learn that the Russian market will very soon

become a significant player in the international market

for processed potatoes of all kinds. Our representative

office in India continues to work hard increasing our

influence in a developing marketplace. At home in

Europe and in the North American market we have seen

large investments by both our corporate clients and

privately owned companies. They all seem to recognise that

Kiremko has the ability along with its strategic partners

to deliver an ever expanding range of products and services

and offer truly seamless turnkey solutions when required.

I hope you enjoy reading the following articles and we

look forward to being of service to you in the near future.

Andy Gowing

News2014 - 04

SummaryPage 2 n High performance batch fryersPage 3n Flexible solutions for Shanghai processorPage 4 and 5n Huge impact with green investmentsPage 6n Coating lines are the new trendPage 7n Intelligent frying technology Page 8n Quick start-up of a complete pellet line

1

Worldwide exposureThe industry is changing as well as how we are presenting

ourselves to the world. In the upcoming year we will not only introduce

new product developments, but also new designs to our look.

China Potato Expo

18th and 19th April, Shandong, China

Interpack

8th to 14th May, Dusseldorf, Germany

Potato Europe

3rd and 4th September, Bockerode, Germany

Gulfood

9th to 11th November, Dubai, UAE

Interpom

23rd to 25th November, Kortrijk, Belgium

Destoning z Washing z Peeling z Cutting z Blanching z Cooking z Drying z Forming z Frying z Cooling z Freezing z Pasteurising z Sorting z Packaging z Product Handling

Another big event last year was the Kiremko Nacht van Woerden. In 2013 we presented

a whole new concept, it became an international event, with presentations by our

strategic partners, a factory tour and in the evening an exciting cycle cross challenge.

The new concept proved to be highly successful and we will continue this for 2014.

Please check our website www.kiremko.com for news and events.

2 3

News

Homemade and rustic style products are very popular at this

moment in the marketplace, to respond to the wishes of the market

Kiremko developed a new generation of high efficiency batch fryers

for potato chips.

High performance batch fryers

When you introduce a new fryer the machine should be

an improvement on existing designs and include all the

latest innovations. Kiremko made an in depth study of existing

designs and identified a number of areas which needed

improvements. Energy usage, environmental issues, oil content

and clean ability were a number of the headlines.

The Kiremko batch fryer contains a number of low volume high

efficient gas burner systems, known as Kireheat. Up to 18

individual burner systems are fitted to each fryer, the number

is determined by the output capacity. The Kireheat burners are

made in series on a robotic production line, so they are easy to

source and the scale of production keeps the cost down. The

burner systems have been tested by an external body which has

determined that they are up to 93% thermally efficient, they

are also low CO2 and low NOx which means in many countries

it is possible that a processor can get governmental financial

assistance due to the high efficiency and low environmental

impact of these units. The low volume of oil in the system

means that oil turn over time can be shortened, in combination

with relatively low skin temperatures in the burner units the oil

quality stays higher for longer, giving impressive savings on oil

consumption and a constant high quality end product.

The whole fryer is controlled by a PLC system. Each burner

unit has its own temperature sensor and each burner is fully

modulating. The oil temperature can be controlled accurately

and consistently over every square metre of the fryer. An efficient

stirring device, accurate oil level control and full control of the

burners means that many different cooking cycles or recipes can

be made depending on the processors wishes. These recipes

can be stored in the PLC to be re-used at a future date.

To keep the oil in optimal condition, oxidation and pollution

must be kept to a minimum, a closed hood is fitted to prevent

oxidation of the oil by air entering the fryer. An integrated oil

filtration system is fitted, oil is continuously drained from the

fryer through a filtration system and injected back into the

fryer, this not only keeps the oil clean but also the injection

system improves heat transfer and increases capacity.

The construction of the fryer is all stainless steel. The smooth

lines and absence of dead spots and difficult to clean places

make the fryer quick and easy to clean, an optional CIP system

can also be offered.

All of these features make that the Kiremko batch fryer offers

users excellent performance in a hygienic, cost effective and

efficient manner.

The traditional potato chips process is well known and fairly well

crystalized over the years. Still, every component of the process

can be improved in essential details. One of the largest snack food

processors in Asia, Liwayway (China) selected Kiremko’s specific

solutions to improve their processes in its Shanghai facility.

Flexible solutions for Shanghai processor

Liwayway Marketing Corporation (LMC) is a Pan-Asian

manufacturer of a large range of snack products under the

Oishi brand, which actually means “delicious” in Japanese.

The LMC group offers over 50 varieties of salty snacks, cereals,

popcorn, cookies, powdered juices and sauces. The main

manufacturing facilities are located in the Philippines, the

motherland of the family owners. However, they now has

manufacturing operations all over Asia, including Indonesia,

Korea, Myanmar, Vietnam and the most important in China

where it embarked in 1993 and now has 12 factories.

Kiremko was requested to come up with a proposal to improve

one of the lines in the Shanghai facility. Finally, it was decided

to replace all the equipment right up to the infeed of the

frying system, including the de-stoner/washer, peeler, slicer

with complete washing system and water saving system and the

Kiremko Hi Flow chips blancher.

Peelers for the potato chips process need to be flexible. Recently harvested potatoes

hardly need peeling, but it is a much harder job for stored potatoes and potatoes

with thicker peel. This is achieved in a 2-stage carborundum peeler. This unique

Kiremko design is simple to operate with its own control panel and can be easily

maintained and cleaned. The peeling drum and bottom can be removed much

faster and replaced than the rollers in the traditional peelers, practically in a

matter of 10 minutes.

The potatoes are then manually inspected, elevated and fed one by one into the slicer

by a Kiremko vibratory singulator to ensure a constant product flow, essential for

good cutting quality. The slicer selected is the latest generation of the FAM PCS-2D

series which consists of a full stainless steel slicing head as standard and double

fixation rings for improved stability. The slicer is fully integrated into Kiremko’s

control system.

A water flume transports the products from the slicers to a grading and dewatering

shaker. Due to the turbulence in this transport flume, the slices are efficiently

washed. The shaker ensures that water and product are separated, including small

slivers and pieces. Part of the recovered process water is led over a set of cyclones

where the free starch resulting from the slicing process is separated. The system

has been designed to ensure a low starch content in the washing water. As a result,

practically no starch sticks to the product, so it cannot be carried to the blancher and

fryer. Thanks to the continuous cleaning of the washing water, consumption of fresh

water for slice washing is kept to a minimum.

To ensure stable product quality also in an environment where potato quality can be

varying from day to day or from batch to batch, blanching is a must. The purpose

of blanching is to partially remove reducing sugars that have a direct effect on the

colour of the fried end product. Some time ago, Kiremko introduced an entirely new

concept for the blanching of chips slices, seeing a strong market demand to replace

traditional drum blanchers. This new design is called the Hi Flow blancher. It ensures

a very short and controlled retention time of the slices, thanks to an integrated screw

conveyor which regulates the product flow. The cross water injection system creates

an intensive contact between the water and every single potato slice for optimum heat

transfer and sugar leaching, which was an issue with traditional systems.

The product is evenly discharged from the blancher with the help of a fast-running,

fine wire mesh belt. A double action water removal system with suction and blowing

facilitates that the product enters the fryer with a minimum of surface water. Also for

this new design, the hygiene aspect has been a priority. It has been equipped with a

hoisting system so that all critical interior parts are reachable for cleaning.

4 5

News

Huge impact with green investmentsFor secluded potato processing factories, smell and vapour emission have never been

given any problems before, but according to the current environmental rules, more

requirements regarding emissions generated by the industry are a reason for potato

processors to reduce visible vapour and invisible smell emission. One such company

looking to reduce their emissions was the Belgian company Ecofrost, where two French

fry production lines and one specialty line are in operation.

Together with Ecofrost we searched for the most effective

way to cover vapour and smell reduction and decided on the

necessary measures. Basic principal; minimal environmental

impact and maximum improvement for the environment of

the manufacturer.

First the emission of the steam peelers is handled. The

blown-off steam of the peelers is transported to a condenser

vessel, where the steam will be condensed. By condensing

this steam, most of the smell is collected and much energy

will be released. This energy is converted into hot water which

will be used as a heating device in the processing lines. The

formerly large visible steam plume is strongly reduced in

volume and is almost invisible.

The dryers and the vapour hoods for the dryers are another

large vapour and smell source. At the dryers, smell occurs

mainly in the first section. Caused by the wet surface of the

potato products (French fries) due to the sticking moisture

of the additive dip system with SAPP and/or dextrose. This

sticking moisture is evaporated in the first section of the

dryers. This does not only emit a lot of smell out of the

extracted air, but also causes much pollution in the dryer

cabinets.

By using a WaterVac® for the infeed of the dryers, the sticking

moisture is removed. The WaterVac® ensures that:

• The vapour hood minimizes vapour because the sticking

moisture is reduced.

• In the dryer the sticking (smelling) moisture no longer

has to be evaporated, only the moisture from the potato,

which causes less smell.

• As the sticking moisture no longer has to be evaporated,

the energy consumption in the dryer will decrease.

• Less pollution will occur in the first dryer section, so it is

possible to use internal heat exchangers underneath the

dryer belt to achieve a more even drying process.

An additional benefit of installing a WaterVac® is that the

removed sticking moisture can be re-used in the additive dip

system. This will decrease the use of SAPP and/or dextrose.

The waste water will contain much less phosphates, a positive

development from an environmental point of view.

The fryers are the third source of smell and emission which

have to be dealt with. These not only provide the largest

possibility of reducing vapour and smell, it is also the largest

source for recovering energy. In a frying vapour condenser

the vapours are transported through a heat exchanger. The

moisture which evaporates out of the French fries, is

condensed. Also during condensing, most of the smell from

the extracted frying vapours, are removed. To clear the

remaining frying vapours of smell, these vapours are passed

through an air centrifuge.

Every hour between 6.000 kg to 9.000 kg steam is condensed

in the frying vapour condensor. The amount depends on the

products Ecofrost produce at that time. The condensed steam

(water) has a relatively high temperature. This water is cooled

down in a heat exchanger before it is transported to the water

treatment. The released energy will be used in the production

process.

In the water treatment, the water coming from the frying

vapours, is filtered from frying oil parts, so that it can be

re-used in the production process. This provides a saving for

Ecofrost and for the environment in the consumption of fresh

water.

The energy which is recovered from the frying vapours and

from the emission of the steam peelers is more than enough

for the complete drying process. By using this available

energy in the dryers, more moisture will be removed from the

French fries during drying. This shortens the frying time in

the fryer, less energy is needed for frying and obviously the

French fries still meet the required product specifications.

The final part of the green investment in the French fry

line is the installation of the Oil Miser®. This machine

removes the sticking oil from the French fries by using

circulating air and transports the oil to the fryer for

re-use. By bringing in the Oil Misers® the amount of frying

oil on a yearly basis will decrease enormously. This is

obviously a saving for Ecofrost and also good for the

environment because less oil, mostly sunflower, is needed. A saving of high-quality vegetable raw materials. In addition it is immediately

visible that less fat will be on the cooling and freezing tunnel belts, also the packaging

is considerably cleaner. Fat on the product acts as an insulator and without this fat

the capacity of the (IQF) freezing tunnel will increase, or, at a constant capacity,

the energy consumption in the cooling process will decrease.

Since less fat remains in the cooling-freezing tunnel and in the packaging, the

cleaning of these units will go considerably faster. Less fat will come into the waste

water, which gives a saving in the load of the water treatment.

To eliminate the emission of vapour and smell which is generated by the specialty

line, the frying vapour discharge of this line will be connected to the frying vapour

condenser on one of the French fry lines. So this last source of vapour and smell

can be handled.

Previous situation

The investments mentioned are all contributing to a reduction

of the visible emission of steam and the invisible, but very

noticeable emission of smell. Also less energy, water and

frying oil is used in the production lines of Ecofrost and all

recovered energy is used optimally.

6 7

NewsCoating lines are the new trendOne of the areas of our business which has been very active recently has been producing lines to make coated

French fries and other cut products like roast potatoes. Many years ago a client told us that if all French fry

factories did not have coating capabilities in the future they would go out of business. Clearly there are still many

factories that still operate without a coating capability but it is obvious that the coated products are high on the

agenda of many processors. You only have to go on to the internet and google coated potato products to see how

many new product launches have taken place recently.

Coating lines come in all shapes and sizes. In the last year we supplied one of our

European clients with a coating line and frying system with a nett width of 2400 mm,

with an output capacity of 16 tonnes per hour. At this present moment in time we

are building a pilot scale coating line for a client in North America with a nett width

of 200 mm and an output capacity of 200 kg per hour.

Coating lines also come in several formats. Lines which are completely dedicated to

coated products, those which typically run coated product but occasionally run non

coated and finally, those lines which typically run non coated product but have the

ability to run coated products when required. We commissioned one of the latter style

lines for a client in New Zealand in January 2014 and in 2013 we installed in Turkey

a line which generally runs coated product. In England we installed a line which only

runs coated products.

All of these lines are designed with the same principles in mind, there is a very high

degree of concentration to detail to ensure that the product is successfully singulated

prior to apply the batter. The coating is applied evenly and efficiently. Sufficient time

is given to allow excess batter to drip off and be hygienically returned to the batter circulation system. The

infeed into the fryer is designed to ensure a smooth and gentle transfer from the coating line into the fryer

so that the coating which has been applied stays on the product and is not washed off as it enters the fryer.

The fryers are designed to have minimal oil content, smooth and steady oil flows with a precise oil level

control to ensure optimal frying conditions. There is always a sophisticated oil management system with

several stages of oil filtration to make sure that the oil quality is maintained and pollution in the fryers is

kept to an absolute minimum. The whole system is designed to ensure that hygiene is maintained at all

times, many of the techniques used come from the dairy industry where hygiene levels have to be kept

at a level much higher than normally seen in the potato industry. The materials of construction, typically

all stainless steel, help to maintain clean ability, but are also necessary to ensure trouble free operation

of machinery, which is actually running in a very aggressive environment. Typically batter coating is very

abrasive meaning that wear on belts and belt supports can be excessive if the right materials are not used.

We take a systems approach to coating lines meaning that we consider all aspects of the line, from batter

preparation through application, into and out of the fryer and also controlling the temperature and

consistency of the batter coating and oil. After the fryer we can offer customised defatting solutions to deal

with the special circumstances of coated product. The Oil Miser® system designed by our partner REYCO

is ideal in this application.

If you are interested in batter coating lines, please do not hesitate to contact us so you can share in our

wealth of experience in this field.

Intelligent frying technologyAs the demands of processors increase, the needs for more intelligent fryer control

systems have become more apparent. The term “Fly by Wire” is well known in the aviation

industry, this is a system where computers adjust many different control surfaces of an

aircraft in an integrated way faster and more accurately than the pilot can achieve alone.

Kiremko introduces the frying equivalent of this system known as “Fry by Wire”.

The Fry by Wire is used by Kiremko on large formed potato product fryers, which

produce products such as patties, croquets and noisettes. These fryers have by nature

critical oil flows and oil levels to achieve even frying and retain stacking patterns on

the fryer belt, small changes in process variables can disturb the balance in a normal

fryer. The fry by wire system controls the oil feed and return by very accurate oil

level control. This constantly adapting system controlled by computer controls the

fryer settings beyond the capability of a human being. Modern accurate radar level

controls and well-designed software are at the heart of the system. Oil is injected

from above and from below the product to ensure even frying. Oil infeed and return

oil are controlled by volumetric variable speed pumps, the combination of flow and

level control with sophisticated control loops leads to an automatically stabilized oil

system in the fryer.

In conventional formed product fryers the product tends to

float, meaning individual patties can stick together forming

clumps which affect the frying quality and disturb the stacking

pattern which can cause inefficiencies in the cooler or freezer.

The Fry by Wire system avoids clusters by maintaining steady

oil flows with no eddy currents and perfect level control, this

means in practicing there is no need for undesirable top hold

down belts which are seen in traditional fryers and cause many

problems for processors.

The Fry by Wire system is fitted with our latest oil injection

system which ensures an even oil flow and spread. Conventional

bottom injection systems are designed for specific oil flows. If

the desired oil flow falls outside the specific design parameters

oil flow is disturbed causing eddy currents. This will have a

negative effect on fry quality and stacking pattern. The Kiremko

bottom injector can handle a wide range of oil flows without

disturbance or eddy currents, flow adjustment distribution

and equalisation is combined into one unit integrated into the

fryer pan. The top injection is designed to give a steady even

flow and to prevent splashing.

The Kiremko Fry by Wire system is being used by numerous

processors around the world with great success. Why not join

them and experience the benefits of Fry by Wire!

ColofonThis Newsletter is a publication of:

Kiremko B.V.

n P.O. Box 5

3417 ZG Montfoort

The Netherlands

Tel: +31 (0)348 - 47 94 00

Fax: +31(0)348 - 47 13 07

E-mail: kiremko@kiremko.com

Internet: www.kiremko.com

Compilation & editing:

n Nicole Peters

With the cooperation of:

n Ecofrost, Mr P. Vervaeke

n Liwayway, Mr A. Chan

n Bettie Benschop

n Jeroen Bos

n Arjan Brouwer

n Linda Charles

n Gerard van Deelen

n Bart van Gent

n Andy Gowing

n Marcel van Huissteden

n Nick Maros

n Ronald van Merkerk

n Eric van Oorschot

n Paul Oosterlaken

n Annuska Tielen

n Arie-Jan Vreeken

April 2014

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Bring out the best in your process8

News

Bring out the best in your process

Quick start-up of a complete pellet lineFor one of our customers in the Eastern part of Europe, we delivered

a 200 kg/h turn-key pellet line, including flavouring system.

In order to have a quick start-up the complete line was built,

pre-cabled and tested at the Kiremko production facility. As

requested by the customer, this was a perfect moment to have a

pre delivery inspection of the equipment.

The key machine in the pellet line is

the Kiremko fryer. The fryer has been

provided with a frying oil circulation

system, to improve the heat transfer

into the pellets and to ensure an even

expansion of the pellets. The pellets

are submerged by an immersion belt,

carrying the product to the fryer outfeed

belt. In order to supply a clean line, the

circulation system has been fitted with

a non-leaking circulation pump. The

pump itself is made entirely of stainless

steel, preferable for the hygienic

production of pellets. All Kiremko pellet

fryers have been designed to produce a

large variation of pellets. This gives the

customer the freedom to operate the

line with many different types of pellets.

For customers who are not equipped with steam or thermal oil in their production

plant, there is an option to supply the Kiremko fryer with electrical heaters. The

production line requires a main power cable to the control cabinet and an air

connection to the pneumatically controlled valves.

In order to reduce the oil usage in the line, the oil recovered at the defatting vibrator

is returned to the fryer by an auxiliary pump. To optimize the seasoning of the pellets,

the flavour is fed by a volumetric dosing auger to a magnetically driven flavour

vibrator. In the flavour drum, the flavour is added to the freshly fried pellets. From

here the customer uses existing packaging equipment to package the product in

small retail bags.

Because the complete installation has been tested at the Kiremko production facility,

the line could be installed quickly. After installation the production line was started

and commissioned within two days. This short installation time ensures a minimum

amount of interference with the existing production facility for the customer.

Destoning z Washing z Peeling z Cutting z Blanching z Cooking z Drying z Forming z Frying z Cooling z Freezing z Pasteurising z Sorting z Packaging z Product Handling