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Complete Guidebook on How to Process Eggs Breaking, Separation, Pasteurization, Concentration, Drying, and Boiling

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Complete Guidebook on How to Process Eggs Breaking, Separation, Pasteurization, Concentration, Drying, and Boiling Turning eggs into valuable business 1 Complete Guidebook on How to Process Eggs Breaking, Separation, Pasteurization, Concentration, Drying, and Boiling At SANOVO TECHNOLOGY GROUP we are dedicating our experience and knowledge in egg processing to turn your eggs into a valuable business. This is the only complete handbook on egg processing which serves as a guide for all egg processors around the world. 2 3 Egg Processing One of the most versatile ingredients used in today’s food production is eggs. By breaking and separating the egg, you can turn your consumer eggs into highly valuable pasteurized liquids and/or dried egg products DE-PALLETIZING LOADING WASHING BREAKING ENZYMES TANKS MIXING suitable for an endless number of industrial uses. CIP However, the process of creating valuable industrial egg products requires EGG SHELL highly specialized equipment, skilled production workers, and knowledge of PROCESSING market requirements. TRAY WASHING As a customer at SANOVO TECHNOLOGY GROUP, you are ensured access to the latest technology and know-how no matter whether you are looking FILTRATION PASTEURIZING WAVE for turnkey solutions or optimizing your existing processes. Our concept FERMENTATION PALLET WASHING includes consulting, installation, on-site training, food technology know-how, and maintenance. PALLETIZING OF TRAYS AND PALLETS Your dedicated contact person makes sure that all aspects of your plant are considered and will ensure that you have access to the most dedicated and LIQUID experienced technicians and all of their know-how within egg handling and UF / RO FILLING processing. Whether you are considering to begin processing or need to evaluate your current setup and performance, we encourage you to use this catalog as your reference. As the global leader in the design and development of equipment for EGG WHITE POWDER industrial egg processing, SANOVO TECHNOLOGY GROUP offers a complete EGG YOLK & WHOLE EGG POWDER range of machines with a high degree of flexibility and efficiency. Whether you are looking for high capacity plants or small specialized units, we can supply you with the optimal solution. HOT ROOM PALLETIZING OF FINAL PRODUCTS BOILING, COOLING AND PEELING EGGS LOADING BOILING COOLING PEELING FILLING OF HARD-BOILED EGGS 4 5 The Complete Egg Processing Plant A complete plant for breaking, separation, and processing of the liquids and powder involves many processes. This is an overview showing a 17 typical layout of a complete processing plant. 4 2 6 1 10 5 11 9 12 20 3 13 19 14 8 18 7 16 15 Egg Handling, Loading, Breaking Liquid Egg Processing (Page 20-39) Powder Processing (Page 40-45) Egg Shell Processing (Page 46-59) and Separation (Page 6-19) 1 Fresh Egg Storage 6 Pasteurizing Room 12 Dryer for Egg White 17 Egg Shell Centrifuge and Drying All the eggs are stored at 10-15°C before breaking. The eggs can The raw products are stored in cooling tanks at a temperature The liquid egg white is turned into egg white powder by a spray The eggs shells are conveyed from the breaking machine to a centrifuge be received by trucks (off-line) or in-line directly from the barns. <4.0°C. The products are pasteurized to inactivate all the Pathogens drying process evaporating the water content of the product. where liquid egg white is removed and the volume is reduced. The shells and extend the shelf life. are then dried and inactivated in the Egg Shell Dryer. 2 De-Palletizing and Loading 13 Dryer for Egg Yolk and Whole Egg A robot automatically de-palletizes all the egg trays and loads 7 Product Tanks The liquid yolk and/or whole egg is turned into yolk and whole the eggs on rollers for transfer to the breaking room. The products from the pasteurizer are stored in Ultra-Clean tanks to egg powder by a spray drying process evaporating the water ensure long shelf life of the final products. content of the product. Boiling, Cooling, and Peeling (Page 50-53) 3 Full Automatic Washing of Trays, Pallets and Dividers. 8 Liquid Filling Room 14 Packing Room 4 Storage of Clean Trays, Dividers & Pallets The pasteurized products are filled in various types of packaging. Automatic packing of spray dried products. 18 Boiling, Cooling, Peeling of Eggs and Packing of Eggs 5 Breaking Room 9 Standardization and Enzymes 15 Hot Room All the eggs are gently broken, creating either only whole egg Standardization of egg products before pasteurization and further Dry pasteurization of egg white powder by hot air. 19 Hard-Boiled Egg Storage Room or separated yolk and egg white (with a small amount of whole processing. Stored at 4-6°C. egg). Product from the breaker is collected in small tanks or 16 Powder Storage Room pumped continuously. Any small shell particles are removed Hydrolyzation of egg products before pasteurization, to Powder is stored at room temperatures or in a cold storage. from the product by filtration. The filtered products are cooled improve functional properties, and enable higher pasteurization down to a temperature <4.0° C. temperatures. Plant Automation (Page 54-57) 10 CIP An automatic cleaning and disinfecting system designed to reduce manual operations. 20 Process Automation Control 11 Fermentation Room Complete customized supervision and control system (SCADA) based on PC/ De-sugaring and optionally concentration of the egg white by UF or PLC for the monitoring, process control, logging of all operational parameters. RO technique. 6 7 Egg Handling, Loading, Breaking and Separation Adding Value to Your Eggs Shell eggs are a high-value raw material which, when handled carefully and processed optimally, will form the basis of a profitable business. The first step in every egg processing plant is to obtain as much as possible of the liquids within the eggs, separate the yolk from the white, and discard the shells. This is also the part of the plant that determines the kinds of products and the quality which you will be able to produce. These steps form the basis of any liquid egg processing plant. 8 9 De-Palletizer Full Automatic Unloading of Egg Stacks The De-Palletizer is a fully automatic robotic arm that gently unloads the egg stacks from the pallet to the infeed conveyor. The De-Palletizer handles plastic trays, interlayers, and pallets at a capacity of up to 216,000 eggs/hour (600 cases/hour). The system can be installed upstream of any kind of loader solution from one to two tray stack loading conveyors and from one to two full pallet positions. With the advanced vision system, the De-Palletizer automatically recognizes and compensates for pallet misalignment up to 100 mm. Four tray stacks at a time are picked up and then loaded onto a conveyor. If necessary, the tray stacks are synchronized with the loader inlet conveyor, depending on the loader brand. The full Gently unloads 216,000 eggs/hour (600 cases/hour) pallet accumulation chain conveyor can be customized in order Advanced vision system to reduce the time spent on loading full egg pallets and make Conveyor can be customized the system as self-sufficient as possible. The standard Stainless steel De-Palletizer system has been developed to minimize stops even if it is necessary to extract or insert interlayers or pallets. Washable Power Lift Egg Stack and Tray Lifting Device The Power Lifter is an ergonomic way of loading eggs to a high Handling, Robotic Automation, and Loading capacity processing or grading line. The Power Lifter is designed to handle stacks of 30 egg tray by using an ergonomic balancer that has the capacity for lifting up to 75 kg. It can easily handle Traditionally, eggs delivered to the processing plant are either supplied on pallets (off-line four stacks of six trays each in one movement. production) or delivered directly from the hen houses (in-line production). Productivity and operator health and safety were key areas of focus when designing the Power Lifter, and naturally it Off-line production lines require pallets of eggs to be unpacked and loaded onto the line, while in- complies with EU article 5 of Legislative Decree No. 626/1994 line production, eggs enter directly from the house via a conveyor. regarding manual load handling standards. The fork is placed manually under the tray stack, after which the force balancer In off-line productions it is absolutely vital to have an efficient and stable unpacking and loading of is activated by the push of one button. The arm allows the Lifting up to 75 kg. the eggs as this will determine the overall productivity of the plant. operator to gently lift the trays on to the conveyor system Four stacks of six trays each in one movement where the trays are released by deactivation of force balancing. 626/1994 regarding manual load handling standards Gently lift the trays on to the conveyor system 10 11 FLEXLOADER Optimal Loading under All Conditions FLEXLOADER W/DESTACKER OPTILOADER 6 OPTILOADER PLUS 12 OPTILOADER PLUS 18 39,600 eggs/hour 48,600 eggs/hour 54,000 eggs/hour 144,000 eggs/hour 201,600 eggs/hour Capacity: (110 cases/hour) (135 cases/hour) (150 cases/hour) (400 cases/hour) (560 cases/hour) With the pulp or plastic tray stacks placed on the infeed conveyor, each individual egg must be transferred to the rollers. This is a delicate and vital operation in the processing plant, as this will Feeding with: Single Tray Stacks Stacks Stacks Stacks determine the efficiency of the line. Delivering eggs in: 5 or 6 rows 5 or 6 rows 6 rows 12 rows 18 rows Based on many years of experience, the loaders have been The loaders are easily adapted into any existing production plant Cleaning: Manual Manual CIP CIP CIP designed to operate optimally for all kinds of trays and due to the small footprint.
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