Efficiently deep frying, optimising quality. Case study: Manufacturer of frozen fish filet in batter.

Transcription

1 Efficiently deep frying, optimising quality Case study: Manufacturer of frozen fish filet in batter

2 The ingredients for your success The following case study illustrates optimisation possibilities provided by the ingredients of Maxfry and accompanying chemometric process optimisation, using the example of a manufacturer of deep-fried frozen fish filet in batter. The products are made in a continuous process deep frying machine with a volume of approx. 1 litres. The machine is heated indirectly and the production temperature is C. A Testo quick test device is used for checking the quality of the deep-frying oil during the ongoing process. This is a secondary measuring process based on the dielectric constants, which calculates mathematical approximate values for the thermal oxidative load condition from the change of this physical parameter and shows this as a % in the unit TPM (Total Polar Material). According to current food legislation, deep-frying oil with a content of % polar compounds is deemed unsuitable for the production of food. In Switzerland the limit is 7% for polar compounds. The reason the company turned to Maxfry was a strongly accelerated deterioration of the deep-frying fat, which the customer traced back to negative influence of the batter. Even the 3 step filtersystem and a continous fresh oil refill with -3kg/h could not achieve satisfying results. The work of Maxfry began with a systematic evaluation of the actual condition of the production process. For this purpose the framework conditions were kept unchanged while oil samples were regularly taken during a complete production cycle. The points in time for taking these samples were after the machine has been filled for the first time, after the heating phase, before and after the partial exchange of the deep-frying oil and at regular intervals of 8 heating hours until the critical value of % polar compounds was reached. The oil samples obtained in this way were analysed by Maxfry using NIR spectroscopy to determine the parameters polar compounds, polymer triglycerides and acid number. The results of these analyzes were consistent with the observations of the customer and confirmed the results of the Testo device used in-house. The lifetime of the deep-frying fat was way too short. As the second part of the test run the production cycle was repeated using the stabilising Maxfry Classic nat. ingredient, type: MFISBFnat 5. Here.5% Maxfry Classic nat. was added to the total volume of oil. A further addition was carried on the automatic level control of the fryining line and periodically directly into the frying. The oil samples taken during the second part of the test run were also subjected to a comparative analysis.

3 Polar compounds Polare compounds Anteile in in % ohne without Maxfry Maxfry Polare compounds Anteile in in %% mit with Maxfry Linear (Polare compounds Anteile in in % ohne without Maxfry) ) Linear (Polare compounds Anteile in % in mit % with Maxfry Maxfry ) ) Polymer triglycerides Polymere triglyceride Triglyceride in in % % without ohne Maxfry Polymere triglycerides Triglyceride in in % with mit Maxfry Linear (Polymere triglycerides Triglyceride in in %% without ohne Maxfry) ) Linear (Polymere triglycerides Triglyceride in in % with mit Maxfry ) )

4 Acid value 5,5 3,5 3,5 1,5 1,5 Acid Säurezahl value without ohne Maxfry Säurezahl Acid value mit with Maxfry Linear (Acid (Säurezahl value ohne without Maxfry) ) Linear (Acid (Säurezahl value with mit Maxfry ) ) TOP (Total Oxidised Products) Total Oxidized Products (TOP) (TOP) in % in without % ohne Maxfry Total Oxidized Products (TOP) in % in with % mit Maxfry Linear (Total Oxidized Products (TOP) (TOP) in % in without % ohne Maxfry) ) Linear (Total Oxidized Products (TOP) (TOP) in % in with % mit Maxfry Maxfry ) )

5 Reduction of the polar compounds by average %. Reduction of the polymer triglycerides by average 36%. Reduction of the acid value by up to 18%. Reduction of the TOP (Total Oxidised Products) by average 6%. The chemical changes of the deep-frying medium were able to be considerably reduced and the production quality was able to be kept consistent. After finished production cycle the quality of the deep-frying oil was good enough to remain in the process for further cycles. Supplementary information on the TOP (Total Oxidised Products): TOP is the mathematical difference between the polar compounds and the polymer triglycerides. The group of polar proportions includes almost all metabolites of the chemical change of the deep-frying oil, whereas the polymer triglycerides exclusively involve the di- and polymer oil constituents. Hence, TOP, as the difference between these two parameters, approximately determines the oxidative metabolites. Consequently a reduction of the TOP value is related to a reduced oxidative change of the oil.