Consumer demand for healthy foods has been a boon for meat and bone broth products. Here’s how to convert broth production from batch to continuous processing – improving product quality and profitability.
Broth production is often a batch process. But there’s a better way. Continuous pressure cooking improves product quality and consistency, cuts production costs, and improves the sustainability of the cooking process. Produce either liquid broth or leverage Bepex drying technologies to create instant mixing powders for bouillon or for use as ingredients for products like instant ramen.
Improve Product Quality
Batch processing increases the potential for variation between batches – leading to inconsistent product quality, flavor, and consistency. Continuous operation provides a more consistent end product.
Lower Production Costs
Continuous production is more efficient. It reduces touchpoints and labor costs, lowers overall processing time to increase production capacity, and requires less energy and utilities. In addition to our patented thermal processing options, Bepex offers equipment to grind and reduce blocks of meat, tissue, and bone into a consistent feed stream ahead of cooking – further increasing production efficiency.
Increased production efficiency means less energy and utility usage. And, since broth is often produced from scraps and waste from other production processes, increasing broth production capacity also increases the overall sustainability of your operations.
An End-to-End Solution for Better Broth Production
Bepex provides more than 100 years of experience in designing full-process heating and cooling systems. Our Continuator allows food processors to convert common batch processing applications into continuous operations. A patented feeding system allows for continuous operation in a pressure vessel. The Continuator’s indirect heating technology and gentle agitation ensures consistent heat transfer and provides more efficient cooking.
Bepex produces the industry’s broadest array of size reduction equipment. Our RP Disintegrator grinds meat, bone, and tissue to a uniform feed size, improving product consistency. Built and supported in the USA, Bepex coarse grinding systems are backed by a century of experience and proven performance.
Bale and Block Grinding
Reducing large, bulky meat blocks ahead of downstream cooking often is the first step in many broth production processes. Our block grinder’s compact high-torque, low-speed design delivers maximum power with minimum heat generation. Plus our rugged construction and easy-to-maintain designs ensure continuous, dependable operation.
After releasing and capturing nutrients, the remaining boney matter can be milled and compacted to form granules for fertilizer and other value-added products. The Bepex Roll Compactor transforms process “waste” into dust-free granules with consistent density and dispersibility characteristics.
All new inquiries begin with a feasibility study. These studies aim to provide preliminary insights into the viability of a commercial process. Using as little as 100 grams of material, we can begin early process design, develop plans for pilot-testing and/or confirmation, and begin providing early economic estimates. Our experience across our wide range of technologies gives us a unique ability to provide quick feedback on the feasibility of your process.
From our learnings, we’ll begin the process development work. The primary work in this phase takes place in the form of pilot-scale testing in our Process Development Center. Our pilot tests look a bit different than what you may have experienced in the past. Each test is designed to measure the system performance and feasibility rather than that of any single machine.
Each system is custom assembled for each test. Our goal is to provide as much of a pilot-scale simulation as possible while gathering scale-up data to deliver on commercial capacities. When a certain technology proves ineffective, we’ll draw from our range of options to determine if there is a better fit. The Process Development Center is our sandbox to build, test, and revise to ensure we get every detail right.
With a successful pilot simulation completed, we now have everything we need to scale up and provide proposals for capital equipment with included performance guarantees.
System Design And Build
After receipt of the purchase order, we begin with both equipment and system engineering. Each proprietary technology we sell is custom-designed and built per application. We do not have any off-the-shelf units. At this stage, your exact system begins to take shape, including auxiliary equipment, process flow diagrams, process and instrumentation diagrams, safety provisions, and more.
After delivery and installation of your new system, Bepex will provide a mechanical check to ensure everything is placed according to plan. This is followed shortly thereafter by system commissioning. This is where our pilot-scale simulations become invaluable, as our team of application engineers, controls technicians, and sales engineers begin working with your team to successfully bring your system online.
At this point, you’re up and running at rate, producing a quality product, but our work doesn’t stop there.
Following commissioning, Bepex remains a reliable partner, providing quality OEM parts, immediate field service, process optimization, training, system troubleshooting, and more. We have consistently had high customer retention rates, and we believe it is due in large part to our comprehensive approach to serving our customers long after the original sale.