Advanced Pet Food Steam Cooker Systems
Project Overview
CHL Systems designed and manufactured multiple steam cooker systems for a leading pet food producer’s roasted meals production lines. The projects spanned several years and facilities, showcasing CHL’s ability to innovate and improve our steam cooker designs over time.
Key Challenges
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- Scaling up production capacity while maintaining product quality
- Enhancing cleanability and maintenance access
- Optimizing steam and heat distribution for consistent cooking
- Integrating systems with existing plant infrastructure
- Meeting evolving food safety standards and regulations
- Accommodating various product types and recipes
CHL Systems’ Solution
CHL Systems designed and built an automated steam cooker system featuring:
- Stainless steel construction with sanitary design for food safety.
- Modular conveyor belts.
- Multiple cooking zones.
- Advanced steam distribution and exhaust systems.
- Automated controls with HMI interfaces.
- Integrated cleaning systems for improved sanitation.
After successful implementation of the initial prototype, CHL Systems replicated the steam cooker system for 8 additional production lines across multiple plants, improving upon the initial design. Design upgrades included:
- Addition of a 16” wide step allowing improved operator access to the upper access openings
- Split access panels to allow inspection from both sides
- Adjustable belt width for greater flexibility in handling a variety of products
- Improved drainage to enhance efficiency and sanitation
- Increased overall length and total cook area to bring cooking process rate up to 12,500 lbs./hour
- Addition of product de-clumper at discharge
- Integration of exit transfer conveyors
Key Benefits and Outcomes
- Increased Production Capacity: The customer achieved a significant increase in production capacity to meet growing market demand and strengthen their competitive position in the pet food market.
- Enhanced Food Safety: The improved sanitary design enhanced compliance with food safety regulations and industry standards.
- Improved Workplace Safety: Designed with safety at the forefront, the system improved operator safety and ease of use.
- Reduced Operational Costs: Design improvements to enhance access openings streamlined the cleaning, inspection and maintenance processes and reduced maintenance downtime.
- Enhanced Flexibility: The solution provided greater flexibility to handle multiple product types.
- Consistent Product Quality: The system improved product consistency and quality across different batches and recipes, enhancing customer satisfaction.
- Greater Sustainability: The system improved energy efficiency and reduced steam consumption.
- Proven Results: After successful implementation of the first steam cooker, CHL provided the customer with additional steam cooker systems across multiple facilities.
- Trusted Partnership: Repeated success with the steam cooker systems
bolstered a long-term partnership between the client and CHL Systems, leading to ongoing improvements and innovations.
Conclusion
The steam cooker projects demonstrated CHL Systems’ expertise in food processing equipment, particularly in thermal processing solutions for the pet food industry. By continually refining our designs based on operational feedback and emerging industry needs, we provided increasingly sophisticated and efficient steam cooking solutions to support our client’s growth and product innovation efforts.