Methods of processing
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Let us describe the procedure of nuts and berries processing in details.
Learn moreMain stages of processing
The industrial processing of nuts is a multistage process that comprises several steps. In general, the technology for processing nuts of various types is similar.
Nuts shelling
It is the most labour-intensive stage of the processing. The industrial-scale processing assumes the use of special equipment for separating kernels from shells.
There are two methods of nut-cracking used on an industrial scale:
- mechanical
- pneumatic
The pneumatic method implies the use of compressed air for cracking the nut. The nuts are placed into a hermetically sealed container. Afterwards the air is pumped with the compressor. Over a given time period the air is promptly drained, which results in a pressure jump that makes the shell crack.
The mechanical method for shelling nuts is known as highly productive, which is crucial for the processing of hard-shelled nuts, such as walnuts and cedar nuts. The machine can process nuts the size of which ranges from 5 to 45 mm.
Nuts shelling comprises several stages:
- 01
First, the nuts are poured into a cone-form hopper for separation.
- 02
Through the hole at the bottom of the hopper the nuts gradually fall onto the steps of the moving conveyor and then are moved along the belt to a sizing scale.
- 03
The nuts are sorted on the sizing scale fitted with pockets of various sizes in compliance with GOST (State Standards). The machine filters out off-grade elements and small waste particles of up to 20 mm in diameter.
- 04
Having been sorted by size, the nuts are moved along the conveyor belt to the distribution grooves of crushing rollers.
- 05
The crushing rollers rotating in opposite directions crack the shell.
The rotation speed of the operating roller and the degree of compression inside the distribution grooves can be adjusted. But even in this case, the metal components of the equipment can split the kernels. thus reducing the quality of the product. Therefore, following the sizing of kernels they are sorted by size once again in compliance with international standards.
Drying and roasting of nuts
The drying of nuts assumes the use of drying chambers, the temperature inside which is maintained stable within 30-60 range. The moisture content of kernels decreases from 40% to 12% for 14-16 hours in the drying chamber.
Upon completion of the drying process the nuts are once again delivered to the nut grader and fan-and-screen separator for sorting. Nuts are considered a natural product, and preserve their biological value in the conditions of high temperature processing. Therefore, primary product is heat-treated in order to prolong its shelf life.
There are two ways for roasting nuts depending on the type of primary product:
- in convection ovens by ascending hot air currents;
- in a tunnel oven by hot air currents.
Both methods of roasting involve electronic control over processing parameters which allows for clean and evenly roasted final products without any scorched particles.
02Salting of the product
In order to enhance the taste of peanuts, pistachios or almonds, the nuts are salted.
Depending on the requirements to the finished product the nuts can be salted in either of the following ways:
- in coating drums made of stainless steel with the use of vegetable oil;
- in water-salt solution without vegetable oil.
Food additives are used for processing nuts having different tastes, i.e. dry mixes containing flavorings as well only natural colors and concentrated ingredients such as spicy greens, vegetable and mushroom or meat and cheese powders along with natural flavorings.
The method of vegetable oil spraying is used to ensure even and durable coating of the processed nuts with powdered formulations. It is also possible to make wet coating using flour and starches as basic ingredients.
03Nuts coating
The coating process is used for applying dark or white chocolate on the surface of peanuts, cashews, hazelnuts and almonds. Special high-tech machinery is used in the process, equipped with tools for emptying, adjusting speed rate as well as with air ducts, the main purpose of which is to air the final products in the end.
The coating technology also comprises several stages:
- 01
The base layer is applied first. It prevents the seeping of nut-oil in chocolate thus preventing the softening of chocolate and eliminating fat bloom.
- 02
The primary layer of white, dark chocolate or chocolate glaze is applied. Due to stable temperature in the equipment, chocolate is quickly crystallized, thus reducing the risk of formation of gummy layers and discolored areas.
- 03
The final layer is applied after that to protect the finished products from fading and to add it a tempting shine. The syrup is applied in small portions on rotating nuts, which allows for smooth top layer. With each portion of syrup, the coating is gradually thickening.
Upon completion of the coating process, the final products are placed on sheet tins for standard time aging at about 18°. During this period, the coating solidifies and becomes covered with a thin glaze.
Specifics of the production and processing of dried fruits
The modern method of freeze drying is used to keep the taste and the value of perishables such as strawberries, cherries and blackberries. Due to water extraction from biological material (through freezing or drying), the duration of storage is basically unlimited.
Fruits and particularly almost all kinds of berries contain two thirds of water. Therefore, the processing of products to freeze-dried state is one of the most affordable and effective ways to preserve them. While retaining the value and taste of the fruit, the drying does not affect its shape.
For the production of freeze-dried berries, the primary product is poured into a special chamber, in which the water is completely removed under vacuum pressure. In order to reduce the destruction of the integrity of cell membranes, it is necessary to convert the intracellular fluid in minuscule crystals. Fast freezing of berries is used thereto.
The technology of coating dried fruits is applied in the process of making confectionery products with natural filling and chocolate coating or yogurt glaze. The production process in this case is similar to the procedure described above. Due to the coating of dried fruits with engrossing syrup and chocolate glaze, the final products look attractive having a tempting round shape and excellent taste.
Depending on the product requirements, the final products are grinded and sized. Small portions of rice flour are applied on the pieces of cut fruits to prevent their clumping.
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