Organic pioneer Rapunzel relies on FoodSafety-IRD, brand KREYENBORG
Food safety and processing that is as close to nature as possible and meets consumer expectations for high-quality products are focal points on the agenda of organic companies. The organic food manufacturer Rapunzel has installed a new system based on infrared light for its nut segment: for safe sterility, gentle roasting and a balanced taste experience.
"We have been in contact with Kreyenborg for several years and have already carried out basic tests," says Alexander Karst, Head of Production at Rapunzel. The company's nut range: almonds, peanuts, macadamias, pistachios and more, has now been refined using Kreyenborg's infrared light technology since mid-2021. This has also enabled the company to expand its roasting capacities at its Bavarian site in Legau.
Constant roasting for a full aroma
With the help of the thermal process, the product to be treated is heated from the inside out in a targeted manner and in a short time, so that the whole nut is roasted evenly. The patented FoodSafety-IRD regulates the intensity of the infrared light, the process temperature and the product temperature. This prevents the treated products from overheating, allows the aroma to develop slowly and produces the most balanced roasting result possible.
"During roasting, the substances that give the nuts their special aroma are released," explains Karst. A recognizable taste is achieved through uniform treatment with a constant degree of roasting - and this is exactly what Kreyenborg's system offers.
In the new installation in Legau, the nuts are transferred from big bags to the conveyor belts via an emptying station, cleaned, collected in the storage silo and then dosed into the FoodSafety IRD. After roasting, a cooler brings the products back to room temperature to prevent mold growth. Once weighed, the nuts are transported to interim storage and are now ready for further processing in the various production areas.
Focus on food safety
In addition to the pasteurization, drying and roasting of nuts, the family-run company Kreyenborg from the municipality of Senden in North Rhine-Westphalia specializes primarily in the storage protection of foodstuffs. Seeds, spices, herbs, tea, cereals and other dried products can be freed from germs, insects, larvae and eggs using the heat of light. Unlike steam-based processes, there is no visual or sensory damage to the products. The plant proteins remain intact. Gentle heating should also guarantee a longer shelf life.
The goal of self-sufficient energy operation
The FoodSafety-IRD is powered 100 percent by electrical energy. Rapunzel's goal is to generate all the electricity required for the roaster itself in order to keep the ecological footprint as small as possible. Many conventional technologies were based on the combustion of gas or other fossil fuels, which consequently led to a significantly higher CO2 consumption.
One challenge was to configure the infrared roasting system as a whole in a user-friendly way and in accordance with the operational specifications and to integrate it into the existing space. The emission limits specified by the authorities had to be taken into account, as did the lowest possible noise level out of consideration for the neighborhood.
Alexander Karst is satisfied with the innovation. "The Kreyenborg system works both efficiently and gently and ensures a high level of operational safety," says the production manager. In the food technical center at the company's site in Senden, Kreyenborg's customers can experience the processing of their products.
To the press compartment of KREYENBORG GmbH & Co. KG
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