Double D Food Engineering, Baking Ovens, Cookers, Provers, Retarders, Grillers, Smokers, UK

JBT FoodTech develops 'controlled fat' Dry-Fry System

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JBT FoodTech has developed an integrated in-line Dry-Fry System (Patent Pending) designed to process coated products with up to a 50 per cent reduction in oil pick-up.


The system is able to produce coated products which are considerably healthier than traditionally fried products, while retaining an excellent taste and appetising appearance.     


The Dry-Fry System is capable of delivering controlled amounts of oil to the product following the coating or breading stage.  This enables processors to manufacture or market ‘low fat’ or ‘lower fat’ options on a wide range of foods, including chicken and poultry, fish fillets, vegetables and re-formed products, while retaining an appetising appearance and maximum flavour. 


The system integrates three of JBT FoodTech’s equipment brands – the Stein Ultra V™ Breading Line, the Double D Revoband Continuous Protein Oven and the Frigoscandia GYRoCOMPACT® Spiral Freezer. The system also incorporates an oil spray system which delivers controlled amounts of vegetable oil to the product depending on requirements.


The system has a number of key features as Nigel Brunyee, JBT FoodTech’s systems manager, explains.


“What sets this system apart is its ability to provide exactly the required colour and consistency of finished product.  This is due to the impingement technology and high temperature capability of the Revoband Continuous Protein Oven, which is unique in the industry.


“In addition, because there is no pre-frying stage, the oil is much fresher.  This provides a much cleaner taste and better texture.  We also believe that up to a 50 per cent reduction in oil pick-up is the maximum desired, as anything more than this would be detrimental to the taste.

“There are also considerable cost-savings to be made due to the reduction in oil usage, meaning less waste and reduced Health & Safety risks."


The system, says Brunyee, gives processors excellent opportunities to introduce new tastes and exotic flavours by using different types of vegetable oils, such as olive oil, or oils flavoured with herbs or spices.


No special coatings are required for the Dry-Fry System, but the coating must be ‘oven bakeable’ such as Japanese crumb.  The coating is then set by flash cooking in the Revoband Continuous Protein Oven for around 1.5 to 2 minutes, before being marshalled straight to a Frigoscandia GYRoCOMPACT® Spiral Freezer.


“Flash cooking ensures that the coating is efficiently set,” continues Brunyee. “Final product colour can also be carefully controlled.  The Revoband Continuous Protein Oven has a unique high impingement system which provides high temperatures up to 280 degrees Centigrade, so customers can easily achieve their desired colour.


“We’re confident that the new Dry-Fry System is the perfect answer for producing tasty, coated products which respond to consumer demands for healthier choices, while giving processors significant cost savings and massive opportunities for new product development.”