MAUTING chambers for smoking and drying

MAUTING air-conditioned chambers
  • MAUTING chambers provide optimal flow, speed, direction and renewal of circulating air, which enables even distribution of temperature and humidity in a space.
  • They are designed for the second fermentation phase of thermally unprocessed products.
  • They are suitable for enriched fermented products.
  • They are suitable for GDL technology or classic production of salami, sausages, ham, bacon and smoked meat.
  • The central ventilator ensures the optimal and even flow of air through the entire chamber.
  • A control system of side channels for air exhausting ensures the even flow of air throughout the entire chamber.
  • A control system of channels, with recirculated air ensures perfect and uniform drying of products.

Regulation of circulating air with the use of fresh air and enthalpy, and regulation based on absolute humidity, enables a 30% reduction in power consumption.

 

 

Types of air conditioned chambers:

 

Chambers for maturing and cold smoking

are designed for the first phase of thermally unprocessed meat products fermentation.

  • First phase fermentation, the start of fermentation.
  • Smoking with cold smoke.
  • Maturing.
  • Intensive drying.

The work temperature is in the range of 18–30°C at the regulated humidity in the in the range of 65–95%. Standard dehumidifying capacity of the standard unit, amounts to up to 3%/24 h at the chamber temperature of 18°C and relative humidity of 75%. The creation of smoke can be achieved with the help of wood chips or by producing friction, depending on client demands.

 

Curing chambers

are designed for phase two fermentation of thermally unprocessed meat products or the drying of thermally processed products. They can be equipped with smoke generators that produce a smoky aroma in products.

  • Second phase fermentation.
  • Drying.
  • Storing sausages, hams, fats, meat, etc.

 

Working temperature in the range of 15–22°C at the regulated humidity in the in the range of 60–95%. Standard dehumidifying capacity averages from 1 to 1.5%/24 h, depending on the type of product, packaging and production technology, bound to the temperature of 15°C and relative humidity of 70%. The CrossFlow system ensures the dehumidification capacity up to 2.5%/24 h

 

 

 

 

 

 

 

The chambers can be equipped with the following control systems:
  • Temperature based: the controller analyses the external air temperature, the difference between the necessary temperature in the chamber and the external air temperature.
  • External air enthalpy based: external air enthalpy is also measured based on results; the controller calculates the necessary level of heating and cooling in the case of using external air and compares it to the effectiveness, necessary for processing the air in the chamber.
  • Real cost based: The personnel enters actual costs of heating/cooling (if known) and the controller switches the chamber into a mode with minimal processing costs.

By using this system the chamber’s power consumption alternates on the basis of external factors. During the summer, the use of external air is minimised and the regulator operates only with the internal air of the chamber. In spring and autumn, fresh external air is used in limited amounts, so as to lower the power consumption demands. During wintertime the need for cooling is basically non-existent.

The total level of savings amounts up to 60%

 

 

Principle of saving power:

Absolute humidity:

Relative humidity is a value depending on air temperature. With existing amounts of water vapour in air, relative humidity rises with the rise of temperature and reverse. If the chamber is controlled in standard mode, based on relative humidity, the humidity controller reacts to every change in temperature, when relative humidity changes.

 

The control of parameters in Mauting equipment is based on relative humidity. Absolute humidity is a value that does not depend on air temperature.
In this case the controller controls two interactive values – air temperature and humidity. This prevents controller interference, where in comparison to a standard relative humidity control system, we ensure a 10–20% power consumption reduction when heating or cooling, contingent on the running program. Relative humidity, calculated on the basis of temperature and absolute humidity is displayed on the control panel.

 

Utilising the external air supply:

Mauting chambers can be equipped with a system for utilising a supply of external air. The controller makes use of fresh air, without using a cooler or it changes external pressure with the help of a cooler.

In adequate conditions, the controller analyses the interior and exterior of the chamber, to determine if the set parameters should be achieved with the help of external fresh air, or does the chamber have to be reset into a more appropriate mode.

 

Air conditioned chambers are equipped with the following:

  • Stainless steel technology. It can be placed behind or above the chamber;
  • Curing chambers can be placed only inside the chamber.
  • A stainless steel ventilator with continuously variable speed setting.
  • Electricity, warm water or steam heating.
  • Air cooler, working with the help of ammonia, freon or glycol.
  • Stainless water droplets separator, supplying air.
  • Stainless steel pipe system, exhausting the air from the chamber.
  • channels in the air supply system that periodically alternate the amount of air, supplied to the pipes from either left or right.
  • Electric motor powering the channels.
  • Channels are installed in the CrossFlow system, alternating the flow of air vertically or horizontally.
  • The DAF system also has channels installed that alternate the flow of air in the chamber both vertically and horizontally. The air is exhausted from the chamber via a series of pipes located alongside the walls of the chamber.
  • Controlled supply of fresh air.
  • Channels for recirculating air.
  • Temperature and humidity sensor inside the chamber.
  • Sensors that maintain air temperature and humidity.
  • External air temperature sensors that automatically supply fresh air.
  • Foam cleaning system.
  • Control system automatically controlling the entire procedure on the basis of set parameters.

 

 

 

 

 

Defrosting chambers (KMR xxx model)

 

 

  • They are designed for defrosting frozen meat, fish and poultry before further processing.
  • They are designed in a way, similar to maturing chambers.
  • The defrosting process proceeds in accordance to a program regulating temperature, quantity and humidity of recirculated air.
  • The program also prevents the deterioration of raw produce due to the temperature difference between the surface and core of the raw product.

The defrosting process minimises the microbiological contamination of raw products.

 

 

The system enables the alteration of air flow, by changing its course vertically or horizontally, which allows for quicker drying with limited risk of the ring girdling of the product.

  •  DAF (dual air flow) – the air is cyclically sucked from the chamber through the channels situated above trolleys and along the chamber sides. The air quantity from the left and right side varies from 30% to 70% continuously.  DAF1 system – The air is sucked from the chamber through the channels situated above trolleys
  •   Patented CrossFlow system – The recirculated air is cyclically brought in to the chamber from above through the channels situated above trolleys and drawn off through the channels situated along the chamber sides and according to the program, the air flow direction is reversed and air is brought in from below upwards and sucked out through the channels situated above trolleys. The CrossFlow enables the fastest drying on the required water activity with the limited risk of the ring girdling of a product.

The recommended application: KMD Chambers for maturing and drying.

  • For maturing of fermented products with a high level of dehumidification.
  • For drying and maturing thermally processed product with a high level of dehumidification.
  • For products that demand quick and uniform processing.
  • For large KMD units

 

 

 

 

 

 

DAF1 system – The air is sucked from the chamber through the channels situated above trolleys

The recommended application:

  • KMZ cold smoke pre-maturing and curing chambers for first phase fermentation
  • KMD chambers for maturing and drying.
  • For fermented products that need a high level of dehumidification.
  • For products that demand quick and uniform processing.
  • DAF1 system is suitable for KMZ units up to 2 rows and
  • KMD up to 7 rows.

DAF2 system is suitable for KMZ units up to 4 rows

DAF2 system – The air is cyclically sucked from the chamber through the channels situated above trolleys and along the chamber sides.

The recommended application:

  • KMZ cold smoke pre-maturing and curing chambers for first phase fermentation
  • KMD chambers for maturing and drying.
  • For fermented products that need a high level of dehumidification.
  • For products that demand quick and uniform processing.
  • DAF1 system is suitable for KMZ units up to 2 rows and
  • KMD up to 7 rows.
  • DAF2 system is suitable for KMZ units up to 4 rows.

4. EquiFlow system – The recirculated air is brought into the chamber through the channels situated above trolleys and drawn off through 1 or 2 channels situated along the chamber sides.

The recommended application:

  • For complete drying and maturing of standard fermented products.
  • For complete drying of fermented products, the first phase of which had been carried out in the KMZ Classic.

5. Classic system – The recirculated air is brought in to the chamber vertically through the channels situated along the chamber sides and drawn off through the channels situated above trolleys. The air quantity from the left and right side varies from 30 % to 70%

The recommended application:

  • For KMZ units with no more than 2 rows of trolleys and the humidification requirement at the most 3% /24 h.
  • For classic fermented products with the humidification requirement at KMD units up to 1.5%.
  • For KMR defrosting units.
  •  

6. Central system –The recirculated air is distributed with the central three-fold channel situated above trolleys. The central channel serves for air sucking from the chamber; the side channels serve for the horizontal air distribution in to the chamber.

The recommended application:

  • For KMD units for the classic maturing of fermented products and drying of the thermally processed products.
  • For products with the requirement for relatively low dehumidification.
  • Possible application of atypical rooms, shapes, types...
  • For KMR defrosting units.

 

Microprocessor control system

Serves for automatic control of:

KMD smoking chambers
KMD maturing chambers
KMR defrosting chambers

Based on the client’s wishes, the equipment can be delivered
with the following regulators:

  • MIC 2420
  • TP 1011 with a touchscreen
  • PLC programmable automat PP 420 with touchscreen

Control systems MIC 2420, PP 420 and TP 1011:

  • Regulate the chamber temperature and relative humidity.
  • Regulate and operate smoke generators, control automatic chamber cleaning and the fan speed.
  • They monitor the temperature of the chamber, core temperature of products and the smoke generator temperature.
  • They operate additional facilities.

The MIC 2420 display regulator indicates:

  • Actual and required values of chamber temperature, product core and relative humidity
  • Running step time or remaining time till the running step ends.
  • Name of product and program that is running the step.
  • The control unit enables the storage of up to 99 programs, each of them can contain 20 phases.
  • Resistance sensors PT 100 connected to the regulator inputs measuring the chamber temperature and relative humidity,
    monitoring the product core temperature and smoke temperature in the piping behind the smoke generator.
  • The relays numbering from 32–40, according to the type of the regulator, form the regulator outputs. They are used either as regulating elements or for program control of actuating units of the air-conditioned chamber. They are used either as regulating elements or for program control of actuating units of the air-conditioned chamber.

The control unit is usually fitted with a serial interface RS 232 or Ethernet for PC connection, for the sake of processing annually collected data.

VisuNet, MautingNet –software for data collection and diagnostics – the program is designed for collection, loading, identification, retrieval, print and back-up of data and information on the course of the thermal process carried out in the chamber and the control unit program settings.

The program consists of two parts:

  • Data collection program– collects data from the control units of air-conditioned chambers or defrosting chambers and records them into tables running on Windows OS.
  • Diagnostics and configuration change program – enables the performance of diagnostics and service of regulators.