Minimal Labor in Jam and Jelly Production

June 25, 2015

2 Min Read
Minimal Labor in Jam and Jelly Production
Terlet Process Systems engineered and installed a turnkey production line with a capacity of 18,000 lb/hr that is operated by only three people.

A global manufacturer of marmalade, jam, and jelly wanted a turnkey process system that would provide a lower labor cost per ton and speed up product change over times. Terlet Process Systems engineered and installed a turnkey production line with a capacity of 18,000 lb/hr that is operated by only three people.

Terlet had the full responsibility of designing and installing the system that would deliver an hourly capacity of 18,000 lb/hr. This hourly capacity needed to include product change over time. Within a nine-month period the line was designed, prefab manufactured, and installed onsite. Due to the size of the system, the complete installation was lifted through the roof and put in place within three days. The complete installation was installed in a 39 x 33 x 23-ft room. After a short installation and test phase the first production took place within two weeks.

The vertical design uses gravity to transport product eliminating the use of product pumps. This in combination with the extremely fast Terlet Process Systems specially designed donut cookers improved the taste, color, and particle integrity of the end product.

The process line consists of four premix tanks, two vacuum cookers, and fully automated sugar dosing. Small ingredients like citric acid, calcium chloride, and pectin are pre-dissolved in a separate unit. The complete line was designed around fruit particle integrity. IQF fruit is lifted up using a bin hoist and product moves down by gravity through each step of the process. The premix vessels have special dynamic agitators and baffles to gently mix and minimize shear. The vacuum cookers don’t have agitators and rely on natural convection. The final product is transferred into a horizontal buffer. The horizontal agitator keeps the fruit particles in suspension assuring that each jar is filled with the same consistency.

To save energy, the CIP system reuses 165°F warm water from the condenser system. The warm water is stored and used as pre-rinse water and for cleaning the fruit wagons. The line can be CIP cleaned in different stages, and there are multiple cleaning levels from a simple rinse to a full CIP cycle. Each step is automated and a full CIP cleaning cycle of the entire line takes approximately 90 minutes.

Due to the efficient design it takes only two operators to prepare the necessary raw materials (IQF or aseptic fruit concentrates) and one operator in the control room. The vertical design without pumps and the low number of agitators keeps the necessary maintenance to a minimum as well.

Terlet USA, Swedesboro, NJ 856-241-9970

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