Innovations in Hydrocutting Technology – By Kiremko
- Innovations in Hydro Cutting in 2023
- Developed in-house at Kiremko
- Best cutting results
- French fries
Cutting potatoes is one of the primary processes in a potato processing line. There has been some significant developments the last couple of years in the way processors cut their raw material. In certain instances, scientific advancements play a crucial role, while in other scenarios, basic intuition prevails. Kiremko leads the way to hydro cutting technology of the future by truly understanding each parameter of the cutting process in relation to product quality and efficiency. It is a clean cut between guessing and knowing.
The longest strips, the highest output
The heart of the hydro cutter is the knife block. The knife block has a tunnel-shaped passage with firmly mounted knives that cut potatoes into strips. This knife block Is mounted into the knife block holder which consists of an alignment tube called a Venturi with a profiled polyurethane lining that inserts the potato lengthways into the knife block. Thanks to the precise aiming capacity of this tube, the tubers are lined up in a way the longest strips can be achieved.
Maximize French Fry Length
The length of the end product is for a large part determined by the way the raw product is cut. To ensure the best possible cut, a solid pre-sorting installation will make the difference to get the longest fries and the least amount of product waste. Processors gain a lot by making sure that especially the smaller potatoes are sorted correctly. By using multiple hydro cutting systems with different sizes of inlets, the potatoes are transported to the matching size hydro cutter for the longest French fries.
Optimize French Fry Production
Hydro cutting systems are installed all over the world by Kiremko. Sometimes up to six stations are set up in a single French fry line to ensure the highest possible yield and the perfect cutting of potatoes into long French fries. Kiremko configures every cutting line to make sure that it is capable of handling different qualities and sizes of raw product.
KnifeGuard identifies knife quality
Kiremko’s hydro cutting innovation includes an RFID tag system to monitor knife usage and prevent cutting mistakes. The KnifeGuard system measures lifespan, sharpness, and alignment, eliminating errors and improving product yield.
Kiremko offers customized alignment tubes and knife blocks for different cutting sizes and shapes. Read more about the KnifeGuard by clicking the link here.
Consistent quality and ease of use
Hydro cutting systems such as Kiremko’s QuadraFlow, feature single or double knife block holders with a switcher. The switcher is a special version of the knife holder system. When an active knife block is blocked, caused by any number of unexpected reasons, or when blade sharpness is no longer sufficient, the second knife block with alignment tube automatically takes over. This prevents downtime of the line.
Because the system will indicate in time when the knives inside the hydro cutters need to be changed, there will be no scenario in which the product is damaged by blunt knifes. That makes the system contribute to an excellent end product and also decreases the amount of operators needed to operate the line.
Smart choice: The Switcher
A second very useful feature of the switcher is the automatic change over, based on knife operation hours. The running hours of a hydro cutter are monitored by the KnifeGuard® system. After a certain time the knife is automatically switched. The blunt knife is taken out and can be sharpened. This is important for a consistent cutting quality.
Easy to clean and maintain
The QuadraFlow is a closed system. That means water consumption is kept to a minimum. Although this can be even further reduced with an extra starch separation system. This way the starch and other solid particles present in the cutting water are continuously filtered out.
Cleaning the durable construction of the QuadraFlow is simple and easy to do. Kiremko has minimized the number of mechanical parts. Only stainless steel pumps are used, designed specifically for this purpose. So maintenance time is reduced, as is the use of water and energy.
Kiremko is able to assist in cutting quality management by highly skilled food scientists and special developed laboratory equipment. Our scientists are able to determine straightness, tapering, roughness and length distribution, indicative for breakage of strips in a scientific, mathematical way, and translate this into objective numbers. This service provides a comparable insight into your cutting process.
Understanding the water flow
In addition to the knife block, the product pump that pumps water through the cutting line that carries the potatoes, is of great importance for an effective cutting process. The stainless steel VPCK single-vane impeller pump has been developed with the aim of designing and building a pump to achieve the lowest degree of product damage possible. The development was carried out with CFD model analysis. Data from this analysis helped to create an ideal flow pattern which has been converted into an optimized pump designs. Tests with different designs of pumps, both former Kiremko style pumps and competition brands, have shown that the damage to products carried through the system is the lowest with the VPCK pump.
Revolutionizing French Fry Production: Advanced Water Flow Optimization
Recently Kiremko extensively researched the water flow in peeling and cutting lines of a French fry line. Together with students from the University of Utrecht and Kiremko’s in house CFD engineer, the groundwork was laid for further enhancements of the cutting line. Foam formation causes products pumps to run more erratically and abates the cutting results. By optimizing the water flow in the cutting system, we are able to lower the air impact on the water, minimizing the formation of foam and the use of antifoam consumption. These studies are all possible due to the increasing possibilities of CFD computable fluid dynamics programs.
QuadraFlow's many benefits range from fantastic results on French fries, wedges, and slices, to easy operation and user-friendliness.
Kiremko KnifeGuard is an innovative knife identification system specifically designed for the QuadraFlow hydro cutter.
With the potato sorter, you will be able to sort peeled potatoes using their diameter.
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