Guide to snacks making machine
1. Information for Sev and bhujiya making machine:-
Sev and bhujiya are popular Indian nankeen snacks that are made from gram flour (besan) and various spices. Here’s some information about the machines commonly used for sev and bhujiya making:
•Sev Making Machine:
⇒Sev Extruder: A sev making machine typically includes a sev extruder, which is specifically designed to shape and form the sev strands. It consists of a hopper, a rotating screw, and various sev dies or nozzles with different hole sizes and shapes.
⇒Operation: The besan dough is loaded into the hopper, and the machine’s screw pushes the dough through the selected sev die/nozzle. The dough is forced out in thin strands, which are then cut to the desired length using a cutting mechanism.
•Bhujiya Making Machine:
⇒Bhujiya Extruder:A bhujiya making machine is similar to a sev making machine but specifically designed for thicker strands. It also includes a hopper, a rotating screw, and bhujiya dies or nozzles with larger hole sizes to produce thicker strands.
⇒Operation: The besan dough is fed into the hopper, and the screw pushes the dough through the bhujiya die/nozzle. The dough is extruded as thicker strands, which are cut to the desired length using a cutting mechanism.
•Both sev and bhujiya making machines are often combined with frying systems, where the extruded strands are directly fried in hot oil. The frying system may include a continuous frying conveyor or a fryer with a mesh belt or perforated drum to ensure even frying.
•Some sev and bhujiya making machines may also incorporate seasoning drums or tumblers to coat the fried strands with spices and flavors. These drums help in evenly distributing the seasoning mixture and enhancing the taste of the final product.
•It’s worth noting that sev and bhujiya making machines can vary in terms of capacity, design, and features. Manufacturers may offer different models with various customization options to meet specific production requirements.
∗Gathiya and papdi Making Machine:-
Gathiya and papdi are two popular types of Indian namkeen snacks. Here’s some information about the machines commonly used for gathiya and papdi making:
⇒Gathiya Making Machine:
⇒Dough Kneading Machine: The process of making gathiya begins with kneading the dough. A dough kneading machine is used to mix the besan (gram flour), spices, and water to form a smooth and consistent dough.
⇒Gathiya Maker: Once the dough is ready, it is fed into a gathiya maker machine. This machine consists of a hopper, a rotating screw, and a gathiya die or nozzle.
⇒Operation: The dough is loaded into the hopper, and the screw pushes it through the gathiya die/nozzle. As the dough passes through the die, it forms thin, twisted strands of gathiya. The strands are cut to the desired length using a cutting mechanism.
∗Papdi Making Machine:
⇒Dough Sheeter: To make papdi, a dough sheeter machine is commonly used. This machine is designed to roll out the dough into thin, flat sheets.
⇒Papdi Cutter: The rolled dough sheets are then passed through a papdi cutter machine. The cutter typically consists of rotating blades or rollers that cut the sheets into small, round or square shapes, which are characteristic of papdi.
After the gathiya or papdi shapes are formed, they are usually directly fried in a frying system, which may include a continuous frying conveyor or a fryer with a mesh belt or perforated drum. The frying process gives them a crispy texture and golden color.
Once fried, the gathiya and papdi snacks may be seasoned with spices or served as a base for other nankeen mixtures, such as sev, to create different snack variations.
7.Moongdal and Chanadal Processing Line:-
A moong dal and chana dal processing line involves the processing of moong dal (split mung beans) and chana dal (split chickpeas) to produce fried or processed dal snacks. Here is an overview of the different components commonly found in a moong dal and chana dal processing line:
⇒Cleaning and Sorting: The process begins with cleaning and sorting the moong dal and chana dal to remove any impurities, stones, or foreign matter. This can be done using specific cleaning machines such as air classifiers, sieves, and gravity separators.
⇒Soaking and Dehusking: The dal is soaked in water to soften the outer husk or skin. After soaking, the dal is passed through a dehusking machine that mechanically removes the husk, resulting in split dal.
⇒Drying: The split dal is then dried to reduce moisture content and make it suitable for further processing. Drying can be accomplished using hot air dryers or continuous dryers to ensure the dal is adequately dried and moisture is removed.
⇒Frying System: The dried dal is fried in a dal fryer or frying system. This system usually consists of a fryer with a conveyor belt or frying chamber, where the dal is submerged in hot oil for frying. The fryer may have features like temperature control, oil filtration, and automatic feeding and discharging systems.
⇒Seasoning and Flavoring: After frying, the dal can be seasoned and flavored to enhance its taste. This can be done by adding spices, seasonings, or other flavorings while the dal is still warm. The seasoning can be done using a tumbler or drum that helps evenly coat the fried dal with the desired flavorings.
⇒Cooling and Packaging: Once seasoned, the dal is cooled down to room temperature to retain its crispness. It is then transferred to a packaging machine, where it is automatically weighed, filled, sealed, and labeled into bags or containers suitable for retail sale.
•Automatic moong and chana dal frying lines are designed to handle large-scale production with minimal manual intervention. These lines incorporate efficient frying systems, temperature control mechanisms, seasoning equipment, and automated packaging systems to streamline the production process.
3. Batch type Fryer:-
Batch type fryers are commonly used in food processing to fry a variety of products, including snacks, in small to medium-sized batches. Two examples of batch type fryers are the rectangular fryer with a diesel heat exchanger and the circular fryer with a two-pass wood heat exchanger. Here’s some information about these fryers:
∗Rectangular Fryer with Diesel Heat Exchanger:
⇒Design: This type of fryer typically has a rectangular shape with a deep frying chamber and a heating system powered by a diesel heat exchanger. It may feature a conveyor system or baskets to hold the product during frying.
⇒Operation: The diesel heat exchanger generates heat, which is transferred to the frying chamber, heating the oil. The oil is maintained at a controlled temperature for frying the food product. The rectangular shape allows for efficient use of space and provides a larger frying area.
∗Circular Fryer with Two-Pass Wood Heat Exchanger:
⇒Design: This type of fryer is circular in shape and utilizes a two-pass wood heat exchanger for heating the oil. It typically consists of a frying vessel, a heat exchanger system, and a product loading and unloading mechanism.
⇒Operation: The wood heat exchanger burns wood to generate heat, which is passed through the heat exchanger system to transfer the heat to the frying vessel. The oil inside the frying vessel is heated to the desired temperature for frying. The circular design allows for efficient heat distribution and uniform frying of the product.
•Both types of fryers are designed to provide efficient and controlled frying conditions for the food product. They allow for batch frying, wherein a specific quantity of product is fried at a time, ensuring consistent frying results. The heat exchangers in these fryers help maintain the desired frying temperature while minimizing energy consumption.
∗Heating system:-
Heating systems are an integral part of fryers used in food processing. here’s some information about different heating systems commonly found in fryers, including the direct heating circular fryer, gas heat exchanger, and diesel heat exchanger:
⇒direct heating circular fryer:
⇒Design: the direct heating circular fryer is a type of fryer where the heat is directly applied to the frying oil within a circular frying vessel. it typically consists of a burner located beneath the frying vessel and a system to distribute the heat evenly.
⇒Operation: the burner generates heat, and the flames directly come into contact with the bottom surface of the frying vessel, heating the oil. This direct contact ensures efficient heat transfer and rapid heating of the oil. The circular design allows for uniform heat distribution throughout the frying vessel.
∗Gas heat exchanger:
⇒Design: a gas heat exchanger is a heating system that utilizes gas as the fuel source. it is often used in fryers to heat the frying oil indirectly. the heat exchanger consists of a burner, combustion chamber, and a series of tubes or coils through which the hot gases pass.
⇒Operation: the burner combusts the gas, producing hot gases that flow through the tubes or coils of the heat exchanger. As the hot gases pass through the heat exchanger, the heat is transferred to the oil surrounding the tubes or coils, heating it indirectly. this method provides a controlled and efficient heating process.
∗diesel heat exchanger:
⇒Design: a diesel heat exchanger is another type of indirect heating system commonly used in fryers. it operates similarly to a gas heat exchanger but utilizes diesel fuel instead.
⇒Operation: the diesel fuel is burned in the burner, producing hot gases that flow through the heat exchanger. the heat from the gases is transferred to the oil, indirectly heating it for frying. Diesel heat exchangers are known for their reliability and consistent heat output.
∗Direct heating rectangle fryer:-
1. Design:
Shape: The fryer has a rectangular shape, which provides a larger frying area compared to other shapes.
Construction: It typically consists of a rectangular frying vessel, heating elements, and temperature control mechanisms.
Material: The frying vessel is usually made of stainless steel or another heat-resistant material to withstand high temperatures.
2. Operation:
Heat Source: The fryer uses heating elements, such as electric heating elements, located beneath the frying vessel.
Heat Transfer: The heating elements generate heat, which is directly transmitted to the oil in the frying vessel.
Temperature Control: The fryer is equipped with temperature control mechanisms, such as thermostats or digital controllers, to maintain the desired frying temperature.
Frying Process: The food product is placed in the rectangular frying vessel filled with preheated oil. The heat from the heating elements heats the oil, and the food is fried until it reaches the desired level of crispiness.
•Both gas and diesel heat exchangers offer advantages such as precise temperature control, energy efficiency, and ease of operation. the choice between the two depends on factors such as availability of fuel, cost, and specific production requirements.
•Providing installation services for snacks making machines can be a valuable offering for your customers. Here are some key points to consider when providing installation services for snacks making machines:
⇒Technical Expertise: Ensure that you have a team of skilled technicians who are knowledgeable about the snacks making machines you offer. They should have expertise in the installation process, including understanding the machine’s components, electrical connections, and assembly requirements.
⇒Site Assessment: Before installation, conduct a thorough site assessment to evaluate the space where the machine will be installed. Consider factors such as the availability of utilities (electricity, water, etc.), ventilation requirements, and any necessary structural modifications.
⇒Pre-installation Preparation: Provide guidelines or checklists to your customers to help them prepare the site before the installation team arrives. This may include clearing the area, ensuring proper electrical connections, and preparing any necessary utilities or infrastructure.
⇒Installation Process: Follow the manufacturer’s instructions for the specific machine model being installed. Properly assemble and position the machine, ensuring it is level and stable. Connect the necessary electrical and plumbing components as per the machine’s requirements.
⇒Testing and Calibration: Once the machine is installed, conduct thorough testing and calibration to ensure it is functioning correctly. Test each component, such as the motors, heating elements, controls, and safety features. Make any necessary adjustments to ensure optimal performance.