Smoke condensates

Equipment.

Modern smoke generators operating on “liquid” smoke (atomizers) and modern smoke condensates (“liquid” smoke) allow achieving high quality in the production of various meat and fish products, as well as cheese products (sausage cheese, “pigtail”, etc.)

 

The atomizer can completely replace the traditional sawdust or friction smoke generator and can be used for any type of smoking – hot, cold, steam.

 

The principle of operation of any atomizer is one and the same – “liquid” smoke is sprayed using compressed air (5-7 atm) through a nozzle, which is installed in the cooking and smoking chamber (Fig. 1) “Liquid” smoke and compressed air are fed into the nozzle through stainless steel tubes or polymeric materials. The supply of “liquid” smoke and compressed air is regulated by the control unit, which is located outside the chamber or in any convenient place (Fig. 2).

 

Currently, there are various models of atomizers:

– from a simple PowrSmoker, which turns on and off manually and is designed for simple cooking chambers (Fig. 3);

– to the fully automated smoke generator Tarber Smoke Master (www.tarber.se), which is installed on modern cooking and smoking chambers and conveyor lines (Fig. 4).

 

The advantages of using an atomizer compared to a traditional smoke generator.

 

Today, spray technology has become more widespread and deservedly recognized throughout the world, especially in the United States and Western Europe.

 

There are several reasons for this, namely:

– Economic feasibility (reducing production costs, increasing equipment productivity),

– Cleanliness and environmental safety of the technology (lack of air emissions, reduction of detergents used),

– Production safety (lack of open flame and heating elements, lack of high voltage, lack of rubbing parts),

– High quality of products (unified smoking process with specified parameters, standard quality from batch to batch, excellent antioxidant and bactericidal properties of smoke condensates),

– The attractiveness of the products to the end user due to the absence or significantly lower content of ash, resins and carcinogens (mainly 3,4-benzopyrene, 1,2-benzanthracene) compared with ordinary smoke.

 

Red Arrow smoke flavors for atomization technology:

 

SmokEz Supreme C – for standard smoking.
SmokEz Enviro 24 – for excellent coloring.
SmokEz LFB Supreme – for steam and cold smoking.
SmokEz Classic 5100 – for a rich smoking aroma.
SmokEz Classic 4065 – for smoking “freshly cut fruit trees”.
SmokEz Supreme Classic – for a rich aroma (low acidity).
SmokEz Applewood 2502 – for smoking “apple wood”.
SmokEz Enviro 24T2 – for a rich aroma and excellent coloring (beech).

The principle of irrigation / dipping technology is to apply a smoke condensate solution (“liquid” smoke) to the surface of the product to be smoked.

Then the product is dried, and the temperature and duration of drying can be different depending on the type of product and the desired end result.

During drying, smoke components (phenols, carbonyls) interact with the product proteins, resulting in the desired smoking effect (color, aroma, taste).

Thus, there is no need to use a traditional smoke generator.

This technology produces different products – meat or fish products, cheeses, hamburgers, snacks, etc.

 

Equipment.

Depending on the technological need, type and volume of products, various irrigation / dipping equipment can be used:

– For small industries (up to 1 t / day) it is economically feasible to manually dip, without using additional equipment. For this purpose, any container made of stainless steel or acid-resistant plastic is suitable;

– For medium-sized productions (3-15 tons / day), PowrDrench tunnel-type equipment is recommended (Fig. 1). Stacked products are loaded on one side of the tunnel. Then the products through a chain conveyor passes through the zone of irrigation with a solution of “liquid” smoke. Products are unloaded from the other side of the tunnel (Fig. 2);

– For large-scale productions (20-50 t / day), chamber-type SpeedSmoke equipment is recommended (Fig. 3);

– For large industries (100-300 t / d), ALKAR conveyor-type equipment is recommended (Fig. 4), but it is advisable to use them only for mass products of the same type (sausages, sausages, poultry or fish products);

– Belt Drench equipment is offered for catering enterprises and manufacturers of semi-finished products (Fig. 5). The products are loaded onto the conveyor belt by the piece and passes through the irrigation or dipping zone. Sometimes such equipment includes a heat treatment unit (drying and / or cooking, frying).

 

Advantages of using irrigation / dipping technology compared to a traditional smoke generator.

Today, irrigation / dipping technology has become more widespread and deservedly recognized throughout the world, especially in the United States and Western Europe.

There are several reasons for this, namely:

– Economic feasibility (reducing production costs, increasing equipment productivity),

– Cleanliness and environmental safety of the technology (lack of air emissions, reduction of detergents used),

– Production safety (lack of open flame and heating elements),

– High quality of products (unified smoking process with specified parameters, standard quality from batch to batch, excellent antioxidant and bactericidal properties of smoke condensates),

– The attractiveness of the products to the end user due to the absence or significantly lower content of ash, resins and carcinogens (mainly 3,4-benzopyrene, 1,2-benzanthracene) compared with ordinary smoke,

– An increase in the yield of finished products by 1.5-3% due to the reduction of drying and smoking times.

 

Red Arrow Smoke Flavors for Irrigation / Dipping Technology:

 

SmokEz Poly C-10 – base smoke condensate,
SmokEz Supreme Poly C – for standard smoking,

SmokEz Enviro 24P – for excellent coloring,
SmokEz Classic 5116 – for a rich smoking aroma.
SmokEz Classic 5105 – for smoking “freshly cut fruit trees” ..
SmokEz Supreme Classic P – for a rich aroma (low acidity)
SmokEz Applewood 2503 – for smoking “apple wood”.
SmokEz Enviro 24 PB – for a rich aroma and excellent coloring (beech).