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“We All Scream for Ice Cream” – Pfannenberg’s Thermal Management plays a key role in a favorite summer treat!

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From the Farm to the Factory

When the trucks arrive at the factory, the milk and cream are pumped into storage silos and kept cool at 36°F until they are ready to begin the process.

Making the Ice Cream Mixture

The process begins by mixing ingredients and various flavors into a 1000-gallon stainless steel blender.  Heavy cream, liquid sugar cane, and condensed skim milk are the first foundational ingredients. After that, sometimes egg yolks and cocoa powder are incorporated depending on the desired flavoring. A natural stabilizer is mixed in to prevent various ice crystal formation or heat shock.  Blended for a total of about 6-8 minutes, it is then ready to be transferred and strained into a large tank.  This tank will store the mixture until it is ready to begin the pasteurization process.

Pasteurization & the Homogenizer

Pasteurization heats up the mix to kill harmful bacteria. The mixture flows through various plates. Hot water flows on one side of the plate and cold water (cold mix) flows on the other side of the plate. The heat from the hot water is transferred to the ice cream mix, heating this mix up to 180°F.

Right from there, the mixture enters the homogenizer.  Here the mix is exposed to high amounts of pressure so that the fat particles from the cream do not separate from the rest of the mix.  Then the heat from the ice cream mix is transferred to the cold water, cooling the ice cream mix down to 36°F.

The mix is then moved to a tank room.  This room is cooled down to 36°F degrees, where the mix will be stored for 4-8 hours which allows the ingredients to really form.  Next more flavorings are mixed in (such as vanilla, peppermint, purees, and other extracts).  Once the appropriate flavors are added it is then transported into the freezer.  The temperature has to be below freezing, most plants keep it at -40°F.

Freezing & Packaging

To further the process in making hard ice cream, it travels to the packaging area of the factory.  Here the soft serve ice cream is dispensed into various packaging containers and then delivered into the storing freezer before shipment. At this point the temperature of the mixture is around 22°F. For the mixture to reach a colder state it has to enter a spiral freezer where it travels around in a -60°F maintained temperature part of the plant.  When the ice cream leaves the spiral freezer it should be around -10°F. From there the ice cream cartons are stored into various freezing warehouses until they are shipped.

So what role does Pfannenberg play in this desired product?

Automation plays a critical role in the manufacturing of ice cream. Numerous electrical enclosures contain the critical electronics (VFDs and control components) to operate the machinery ranging from mixing to the final packaging. Even though these enclosures are found within a relatively cool environment, the temperature inside the cabinets needs to be maintained. Without proper enclosure cooling these electronics may overheat, bringing operations to a halt. Pfannenberg’s PWS Air to Water Heat Exchangers are ideal for cooling electrical components found in food and beverage processing facilities. The units can utilize existing cooled liquid while saving energy costs vs, traditional compressor based AC cooling units. Our cooling solutions make this cool summer treat possible.

Be sure to visit us at IBIE 2016 in Las Vegas, NV — October 8th-11th at Booth #9247 to learn more about our closed loop liquid cooling solutions.

Be sure to follow our NEW Food and Beverage LinkedIn Showcase Page!

Topics: Air Water Heat Exchangers, Thermal Management, Food & Beverage

Marine Vienney

Pfannenberg Products Assist in Making an American Staple Summer Treat

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Hot dogs – a staple summer treat that brings back memories of family cookouts and baseball games. It is an American favorite summertime food! Hot dogs go through a series of complex processes that combine the ingredients into their delicious final form and Pfannenberg’s PWS Air to Water Heat Exchangers are perfect to keep things running.

Meat Processing

The first step into creating one of the most loved foods is the preparation of the meat.  The meat is cut into small pieces and is placed into a large mixer.  These mixers have chopping blades to further cut the meat into smaller sizes. Here the raw ingredients and flavorings are added.  All are mixed until the mixture is a smooth paste consistency. Processes like this can require large control panels to operate the system and Pfannenberg’s PWS Air To Water Heat Exchangers are ideal for cooling your electrical components. Pfannenberg’s Air/Water Heat Exchangers utilizes chilled water, that is readily available, and an internal fan to provide cool air to prevent critical electronics from overheating.

Linking

The paste is always going through inspections throughout the entire process. After inspection from the mixer – the mix is moved into a stuffer.  This machine will push the paste into tube casings.  The casings are twisted at measured sections to make equally sized hot dogs. There are various casings – natural or artificial. The shaping of the hot dogs we all know is now complete.

Smoking

After the stuffing and linking, the hot dogs are then moved to a smokehouse to cook under controlled conditions.  Manufacturers can control the temperature and the difference flavors that the smoking has on the hot dog by using difference smoke sources.  Average time it takes in this step is an hour.

Final Processing

Once the smoking is completed, the link casings are removed by an automatic peeler.  During this time, the hot dogs are sprayed with water to help bring down their temperature.  Then the hot dogs are then transported to be packaged. Before going into the final packaging, the hot dogs are inspected to make sure there are no foreign ingredients in the product.

Pfannenberg has experience with inspection and x-ray equipment. Pfannenberg was able to combine a Chiller and PWS Air  To Water Heat Exchanger to cool the x-ray tubes as well as the electrical enclosure as one example.

The packaging machines can process thousands of hot dogs in an hour.  They are operating at very fast speeds and require proper thermal management cooling to keep their machines up-and-running. Once packaged, hot dogs are inspected again, freshness dates are added, and they are all boxed up to be transferred to the warehouse for refrigeration until they are shipped. The entire process from start to finish, only takes a few hours.

Click Here to read “Chillers for X-Ray Machines – A Food & Beverage Success Story”.

Be sure to follow our NEW Food and Beverage LinkedIn Showcase Page!

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Chillers for X-Ray Machines – A Food & Beverage Success Story

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With the next round of Food Safety Modernization Act (FSMA) updated regulations taking into effect September, food processing companies are scurrying to make sure their facilities are up to code. The newest set of updates will support efforts into the quick responses to food/beverage related emergencies (contamination, expired products, recalls, and foreign materials). The new amendments also require that the FDA inspect the food production facility every two years to make sure that the facility and products adhere to all regulations.

A simple first step into maintaining food processing safety is x-ray/inspection equipment for product safety and making sure the machines operate properly.  In making sure these machines operate properly, one has to make sure that they have the proper thermal management equipment; something in which Pfannenberg has extensive experience in.

Success Story

Pfannenberg worked directly with a food and beverage inspection OEM to provide complete engineering solutions for the cooling of x-ray tubes and the internal cavity of their inspection machines. These machines would end up in various food & beverage and pharmaceutical end use facilities.  Before meeting with Pfannenberg our customer used several different competing thermal management products; conventional cabinet air conditioners to cool the machine cavity, two small internal fans to move the air around and a small chiller. It was costly, cumbersome while leading to additional maintenance costs and condensate issues.

The Pfanneberg team came up with a solution to utilize a CC Chiller in conjunction with a small PWS Air to Water Heat Exchanger to cool the x-ray tubes and internal cavity.  By combining products and eliminating an air conditioning unit, the Pfannenberg option required less maintenance and was more cost effective eliminating dependencies on different competing products.

Click Here To read, “The Technology of Cooling Part 4: Closed Loop Liquid Cooling Solutions”.

Have a question regarding which equipment is best for your application? Ask Us Here.

Click here to learn more about Pfannenberg’s CC series chillers.

Topics: Air Water Heat Exchangers, Packaged Chillers, Food & Beverage, Chillers

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Closed Loop Liquid Cooling Reduces Downtime, Maintenance & Repair Costs for Commercial Bakeries

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Pfannenberg’s Cooling Solutions Help Keep Equipment Running for One of the Fastest Growing Independent Wholesale Bakers in America.

Flour is one of the paramount enemies of electrical enclosures and enclosure air conditioners, particularly in the make-up area of a commercial bakery. Keeping the electronics cool which power the machines, is essential to the entire operation of the Schwebel Baking Company. Without the electrical enclosures staying cool, the machines fail and require replacement or downtime for repair.

Pfannenberg’s PWS Series Air To Water Heat Exchangers were an ideal solution for the Schwebel Baking Company, these Air/Water Heat Exchangers utilize glycol or a cool water source that is already available in the factory, to cool their electrical units. Pfannenberg’s Air To Water Heat Exchanger has no filters, which means there is no down time trying to change filters or having them becoming clogged.

By installing Pfannenberg’s Air To Water Heat Exchangers, Schwebel’s was able to see a significant difference in the cleanliness of their electrical cabinets as well as in the efficiency of the cooled air.

 

Pfannenberg’s PWS Series Air To Water Heat Exchangers were the precise solution for Schwebel’s manufacturing process. Incorporating closed loop cooling with Air To Water Heat Exchangers improved performance, reduced maintenance, was energy efficient, and prevented unplanned repairs.

Click Here to Download the Case Study in PDF

 

Marine Vienney

Selecting the Proper Equipment for Food and Beverage Applications

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Proper thermal management is key for saving resources and keeping electronics (and equipment) up and running on a consistent basis. It is important to understand the various types of cooling methods available and how the ambient conditions may effect the product chosen.  Choosing the wrong method may lead to a solution that is undersized or oversized, or fails prematurely due to being specified for incompatible ambient conditions.

Selection of the preferred thermal management method, based on various environmental conditions:

Click here to view our thermal management selection guide.

With products that include fans, heaters, packaged air conditioners, air to water heat exchangers, packaged process chillers, and signaling devices, Pfannenberg offers a full range of thermal management solutions for the food and beverage industry. Standard options such as stainless steel materials, NEMA 4/4X enclosures, and washdown duty construction allow these time-tested products to be seamlessly incorporated into even the most demanding food and beverage processing applications.

Have a question regarding which equipment is best for your application? Ask Us Here.

Be sure to follow our NEW Food and Beverage LinkedIn Showcase Page!

Topics: Air Water Heat Exchangers, Filterfans, Cooling Units, Thermal Management, Heaters, Food & Beverage, Chillers, Air Air Heat Exchangers

Marine Vienney

Ammonia Gas Detection in Food & Beverage Facilities

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Alarm and Warning Devices to Notify Personnel Regarding Dangerous Gas Leaks

Ammonia leaks are pretty uncommon, but when one does occur – the results could be lethal.  Ammonia gas is very toxic and flammable.  Typically ammonia can be detected by smell (a strong and pungent odor), but it is a colorless gas.

The human nose can detect an ammonia leak with exposure between 5-20 ppm. With exposure 25 – 1,000 ppm, employees with have teary eyes, difficulty breathing, and the instinct to flee the area. The time exposed and the amount of ammonia the employee(s) are exposed to, determines various effects on the human body – ranging from a slight smell to teary eyes and unable to breathe, possibly death.

There are both, caustic and hazardous versions of the chemical.  In most large scale food and beverage facilities one would find the caustic version of the chemical used to aid in refrigeration.  The chemical can also be mixed with water (ammonia hydroxide) to create a multipurpose cleaning agent. 

Majority of these leaks occur in the mechanical room containing the refrigeration compressors of the facility.  Most ammonia used within a plant is used for refrigeration.  Why do so many food and beverage manufacturers use ammonia refrigeration in their facilities when it is potentially dangerous?  Ammonia refrigeration is one of the most energy efficient and cost effective ways of storing and processing food and beverage product.

Food and beverage ammonia refrigeration applications include:

  • Cooling of beverages, beer, wine
  • Freezing of process foods
  • Freezing of ice cream
  • Cooling of dairy products
  • Freezing and refrigeration of meats

Unlike fire evacuations and being told to exit to the closest door… with ammonia leaks, employees are asked to wait for specific instructions in where to exit. Sometimes the closest exit may not always be in the right direction, away from the gas leak.  Ammonia evacuation signals must be different from fire alarms to avoid confusions.  All employees must be trained on the difference in the alarms.

Pfannenberg has had experience in protecting personnel from gas and vapor leaks.  Our robust and multi-toned flashing sounders, offer 80 different tones – perfect for alerting and protecting personnel. Due to the large signaling coverage provided by each alarm, the amount of signaling devices required is significantly reduced. This supports an application that is economical while ensuring industrial safety.

Generally speaking, a blue light/strobe is a warning color used for toxic gas leaks, and red is used as a warning color for combustible gas leaks – but users can use any color unless directed by a local code or law. Blue tends to be the favorable color used in Ammonia gas leak alarms.

Common refrigeration alarms alert people about high concentrations in a room where they should not go.  Our signaling will extend this warning to other operating employees in the facility who can be immediately alerted to a problem so corrective action can be immediately undertaken.


Pfannenberg industrial alarms with visual and audible notifications come with a standard 10-Year Warranty, guaranteed in protecting man, machine, and the environment.

Click here to learn more about Signaling Technology and Solutions!

Topics: Industrial Safety & Signaling Solutions, Food & Beverage

Marine Vienney

Using Chillers to Help Make Pasta

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Pasta – A staple in Italian cuisine that can be found in almost every household. It is a food that carries memories and conveys emotions.

Pasta is a noodle that is made from water and flour (eggs and other ingredients can be added for various flavors) – it has a simple composition, but the process requires a lot of love and patience. Pasta is classified under two broad categories: dried and fresh – from there it is classified by various shapes, sizes, flavors and ingredients.

In the United States, there has been an increase in buying trends for ready-made meals and easy to prepare foods. Dried pasta falls under both categories, but also has a strong nutritional composition – containing various vitamins and nutrients. Pasta takes many different shapes and sizes. Making dried pasta is a delicate process, it can easily tear and get ruined.  Ingredients are first mixed, extruded and dried, then taken to be packaged and shipped – all important steps into delivering a sought-after product.

Variety of types and shapes of dry pasta

An important manufacturing step in the dried pasta making process is the use of an extruder.Pfannenbergs’ packaged chillers are an ideal solution for the temperature regulation in this process. At the extrusion phase the pasta is given it’s distinct shape and size. This is the step in the process that classifies the pasta style, from angel hair and bow tie to lasagna and spaghetti.  Depending on the type of pasta that is desired, the dough is either pushed through dies or rolled out and cut.  Many types of dried pasta are commercially reproduced through this extrusion process.

The extrusion machine can mass produce large amounts of pasta to be dried. As the pasta enters the extruder it is approximately 95 °F (35 °C). As the pasta is pressed through the extruder there is an increase in the product temperature due to the friction of the pasta being forced out. A chiller is used to cool the water jacket built within the extruder to maintain an ideal exit temperature of 115 °F (45 °C). Anything warmer than this leads to a different consistency and risk of damage to the product.

Our Pfannenberg CC chiller series are used for this extrusion process globally. It’s compact design, ease of use and durability allows for integration within the OEM equipment.

We would all love to make our own fresh pasta at home, but with today’s busy lifestyle having a box of dried pasta in your cupboard is a staple for a quick meal.  Next time you cook your pasta in a pot of hot boiling water, remember its the cooling needed in the process to help make this delicious meal possible.

Click here to learn more about Pfannenberg’s CC series chillers.

Be sure to follow our NEW Food and Beverage LinkedIn Showcase Page!

 

Topics: Packaged Chillers, Food & Beverage, Chillers

Marine Vienney

Indication, Warning & Alarm Solutions for Food & Beverage Applications

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Robust, field-proven, visual and audible devices for alarm, warning, and indication

Signaling confusion throughout many manufacturing facilities is a big problem. At the plant level, many OEM machines have the proper alarms, but they only emit a couple of tones and optional visual alerts, making it difficult to determine which machine had an event or why the alarm was triggered.

Pfannenberg’s visual and acoustic signaling devices can easily be installed on existing systems. Satisfying numerous alarm, warning, and indication requirements, including: machinery operating status, process monitoring, system startup, and building or area evacuation due to fire, toxic gas leak, spills, or intruder alert. With robust construction, up to 80 tones and the ability to withstand severe environments these devices are ideal for the state and federal safety requirements that companies need to obey.

Pfannenberg’s Signaling Technology: Protecting Man, Machine, and the Environment.

Typical Applications:

  • Machinery Startup Indicator
  • Heavy Equipment Movement Alarm
  • Machinery Malfunction Alarm
  • Process Upset
  • Evacuation Sounder
  • Gas Leak
  • Industrial Fire Alarms

Warn operators and employees anywhere of danger, accidents or technical faults – increase facility safety and reduce risks.  Process interruption indication lights alert personnel of machine/line status, minimizing costly downtime. Combination of audible/visual signals provide warning on noisy or busy production lines.

Pfannenberg industrial alarms with visual and audible notifications come with a standard 10-Year Warranty, guaranteed to protect man, machine and the environment.

Click here to learn more about Signaling Technology and Solutions!

Click Here To Learn More About Signaling Confusion

Topics: North America, Industrial Safety & Signaling Solutions, Food & Beverage

Marine Vienney

Control Enclosure Temperatures in a Food & Beverage Manufacturing Plant

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Controlling enclosure temperature is crucial in the food and beverage industry.  If the temperature is too warm or too cold, condensation and higher risks of contamination arises. 

Pfannenberg’s Heaters, Thermostats & Hygrostats detect and keep ambient conditions above dew point to avoid the harmful effects of condensation on your electronics and products. They can be used as standalone or in partnership with our other Thermal Management solutions specifically our Filterfan® and Cooling Unit product lines.

  • Thermostats are used for alarming, fan control and heater control
  • Hygrostats can control humidity levels within enclosure when used with small heaters
  • Heaters are available for cabinets in cold storage areas as well as for condensate management

For over 60 years, Pfannenberg has been helping to cool and maintain temperatures for your electronics.

 

Topics: Thermal Management, North America, Hygrostats, Thermostats, Heaters, Food & Beverage

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Pfannenberg’s Process Chillers Meet the Most Demanding Food & Beverage Applications

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Pfannenberg Liquid Solutions – Now That’s Cool™

Designed for today’s food-processing environment, EB Series  and CC Series Chillers feature stainless steel pumps and evaporators, non-ferrous water circuits, and a polyester-epoxy blend powder-coat finish.  Stainless steel or aluminum casing panels are available.  Our outdoor-rated construction provides flexibility for remote installation requirements.

EB Series:

  • In recirculated cooling loop applications, our unique combination of thermal storage and refrigerant gas bypass technologies allows operational flexibility.
  • Refrigerant capacity control reduces thermal storage volume resulting in a smaller footprint, lower operating weight, and lower coolant costs.
  • Supply water temperature stability is easily achievable for close tolerance applications and higher energy efficiency.
  • Once-through configurations are also available for cooling water, liquid ingredients or products prior to packaging. This arrangement features FDA recommended liquid contact surface materials and optional CIP connections for easy maintenance.
  • NEMA 4, UL-listed control panels and state-of-the-art microprocessor based controllers are standard equipment providing safety, ease of use and service.
  • Options include remote control and communication systems, casters for portability, and status signal lighting.

CC Series:

  • Hermetic compressor with R-134a refrigerant.
  • Peripheral pump with a wide flow & pressure range.
  • Stainless steel brazed plate evaporator.
  • Non-ferrous coolant circuit.
  • Hinged front panel allows full access to interior for service.
  • Microprocessor-based electronic controller.
  • UL & CE approvals.

Generous evaporator and condenser heat transfer surfaces maximizes efficiency and tolerance to fouling to provide low operating costs and trouble-free operation – even in the most demanding food and beverage environments.

Topics: Cooling Units, North America, Packaged Chillers, Food & Beverage