Nuts & Seeds Processing
Nut & Seed Processing Equipment
KOCOTEK is highly specialized in the Log5 nut and seed processing systems with particular emphasis on pasteurization, nut roasting, as well as grinding and refining systems for the production of nut and seed butters and spreads. An additional unique area of expertise are systems that make ultrafine, low fat, high protein peanut (and tree nut!) powders and ‘cold pressed’ nut and seed oils. These ‘prime pressed’ nut powders are rapidly becoming very popular, as they are very soluble, very high in proteins, low in fat and have a spectacular flavor!
Industry Endorsements
Global Ingredients
Bill Morecraft, SVP
“Food safety and high–quality standards are top priorities for Blue Diamond Growers. As a leader in almond innovation, we use Log5 state of the art technology for all of our nut pasteurization needs. Log5 achieves a minimum 4 log Salmonella reduction without compromising almond texture and skin quality. Log5’s advanced technology is effective, environmentally friendly, eliminates the need for chemical treatment, and better preserves the quality of each Blue Diamond almond kernel, delivering a superior ingredient to our global brand and food service partners.”
Sacramento Valley Walnut Growers LLC
Kiran Black, Marketing Manager | Keith Wehri, CEO
“Sacramento Valley Walnut Growers prides itself on being at the forefront of food safety, product quality and technical expertise to serve customers in the retail, manufacturing and food service sectors. After years of testing, Log5’s nut pasteurization system is best suited for walnuts. It achieves the desired kill step while preserving the delicate nature of walnuts by maintaining appearance, taste and texture. The Log5 continuous nut process technology enhances our high-quality product offerings by allowing treatment of all product sizes with an all-natural treatment method.”
CHS Sunflower
Wes Dick, Sales Manager
“We spent about two-and-a-half years researching seed equipment and found only one manufacturer that would give 5-log reduction or more without drastically changing the sunflower itself. Log5 gave us log reduction and its equipment holds the characteristics of the sunflower. We tested the equipment, ordered it and installed it in our Fargo, N.D. facility.”
Sunflower Seeds
Walnuts
Hazelnuts
Pistachios
Peanuts
Almonds
Cashews
Pecans
Nut & Seed Pasteurization
Nuts and seeds are processed in an agricultural environment where infestations are inevitable and cross contamination of pathogenic microorganisms such as Salmonella can put consumers at risk. Pasteurization is necessary (and in certain cases mandatory) to protect the consumer and prevent (nationwide) outbreaks and product recalls. Because nuts and seeds are widely used raw or dry roasted it is important that a defined and validated pasteurization step is incorporated in a production line. Log5 supplies turnkey (non chemical, organic) pasteurization solutions for any nut or seed. The Log5 pasteurization systems comply with the strictest USDA and FDA requirements while maintaining important product qualities such as flavor, nutrition and appearance. The Log5 pasteurization process is so gentle that sunflower seeds still sprout after a validated kill step.
AwCP (water Activity Controlled Pasteurization)
Nut Pasteurization System
Nut Pasteurization System
The Log5 pasteurization system integrates three continuous steps (all at atmospheric pressure) to effectively reduce pathogen levels while preserving the original characteristics of the product, they are: Conditioning (pre-heating), Pasteurization, and Cooling. During conditioning the product is fed into the top of the pasteurizer and is gently transported back down using a series of louvres while warm air flows upward (in counter flow to the product) from the bottom of the system. The pre-heated product is then continuously treated in a separate controlled environment. Since the conditioning step process prevents excessive moisture uptake, only the water activity level near the surface of the nuts increases during treatment. Pathogens can therefore be inactivated with a 5-log reduction at very modest temperatures while maintaining their original organoleptic properties (note that lower and higher log reductions are possible too). After the product has undergone pasteurization, it can either go directly to a nut roaster or is cooled to maintain the original product quality and characteristics. Similar to the condition/pre-heating, the product is cooled with counter-flow technology, as it passes from the top layer to the bottom while cold air is blown in the opposite direction from the bottom of the system.
Capacity – (Range caused by density of the product and if a 4 or 5 log reduction is required)
| Pasteurizer Type | lb / hr |
|---|---|
| AwCP N Pilot Range | 110 - 260 |
| AwCP 10 N | 2,200 - 4,800 |
| AwCP 23 N | 4,800 - 11,000 |
| AwCP 35 N | 11,000 - 16,500 |
Features
No steam in contact with the product, nothing gets wet!
Continuous system, very modest temperatures
Very gentle mixing ensures even treatment of all nuts and seeds
Very energy efficient, no combustion air in contact with the product
Low maintenance, few moving parts
Benefits
Validated & TERP approved for a 5 Log reduction
Maintains original product qualities, such as flavor, nutrition, appearance, crunch
No product drying required, nothing gets wet
No scuffing or skin peal, extremely gentle to the product
Able to handle smaller and larger nuts, also small pieces and combinations of smaller and larger pieces!
'Counterflow' Nut Roasting Equipment
The Log5 ‘Counterflow’ nut roasting technology was originally developed in the late 70’s by German Company, Lehmann. Lehmann was later acquired by the Royal Duyvis Wiener group and today the nut processing technologies fall under their ‘Log5’ brand. The premise of the original Lehmann counterflow nut roaster is quite simple and straightforward: it is a vertical nut roaster where the product is transported from the top to the bottom and the roasting air flows in ‘counter current’ to the product, from the bottom to the top. The Log5 Counterflow nut roaster works exceptionally well on both blanched and red skin peanuts as well as on all tree nuts, including almonds, pistachios, hazelnuts, and others.
Continous Nut Roaster – Type ‘KR’
Vertical Nut Roaster
Vertical Nut Roaster
Vertical Nut Roaster Diagram
The ‘KR’ type Log5 nut roaster from the Royal Duyvis Wiener group can be used for the continuous roasting of peanuts and tree nuts. The unique ‘counter flow’ nut roasting technique ensures that the heating curve is very gentle and even and that the product is gently mixed throughout the nut roasting process. The Log5 nut roaster can be validated for a 5 log reduction as a ‘stand alone’ nut roaster OR can be combined with our Log5 nut pasteurizer so that the nut roaster is independent from the ‘defined kill step’. From peanut roasting to seed roasting, the Log5 nut roaster is the most versatile and efficient roster in the industry.
Every tree nut is unique and has its own specific roasting requirements, as well as, every production line. Our nut roasting equipment is capable of suiting all nut roasting needs, so please contact our team for more information.
Capacity
| Roaster Type | lb / hr |
|---|---|
| KRC - S5 | 1,100 - 2,200 |
| KRC - S7 | 2,200 - 3,000 |
| KRE - S6 | 3,000 - 4,600 |
| KRE - S8 | 4,600 - 6,400 |
| KRE - S12 | 6,400 - 8,800 |
Nut Roaster Features:
Counter flow nut roasting process with very gentle heating (no heat stress!)
Very gentle mixing throughout the nut roast process ensuring an even roast
No 'over roast' ensuring for optimum control over flavor development of nuts & seeds
Automatic product 'hold' if product temperature has not reached required set point (critical if roaster incorporates the validation)
Nut Roaster Benefits
Dramatic reduction of fire risk
No combustion air in contact with the product
No recirculation of the roasting air
Very energy efficient
Extremely low operational and maintenance costs
Space efficient, small foot print
Nut Grinding and Nut Refining
Pre-Grinder (with Optional Ball Mill)
Beater Blade Mill
Beater Blade Mill
Capacity
| Optional Ball Mill Type | kg / hr |
|---|---|
| Nibrotom 600 | 300 - 500 |
| Nibrotom 2000 | 500 - 1,700 |
| Nibrotom 3500 | 1,700 - 3,800 |
Features
Extremely durable high capacity equipment
No use of sharp knives or blades in the grinding and refining process (nothing has to be sharpened!)
Excellent product temperature control - even ability to cool the product during the second and third grinding step
Automatics oil addition available
Small foot print & energy efficient
Benefits
No introduction of 'air bubbles' during grinding, no need for a vacuum/cool step
Excellent temperature control, product can be discharged at modest temperatures
System can product extremely fine butters at 20 microns or less
Tight particle size distribution, excellent for especially creamy nut butters
Nut Protein Powders
The nut pastes is cold pressed for the production of ultra fine, high protein and low fat nut powders.
Nut Paste Press
Nut Paste Press
Powder Mill System
Capacity
| Press Type | Capacities [kg / hr] – low-fat cake | Capacities [kg / hr] – high fat cake |
|---|---|---|
| 4560/7 | 300 - 500 | 500 - 1,200 |
| 4560/18 | 500 - 1,450 | 1,000 - 2,850 |
| 4560/20 | 1,000 - 1,550 | 1,500 - 3,100 |
| 6080/18 | 1,250 - 3,000 | 3,000 - 5,000 |
Features
Hydraulic 'cold' press - no frictional heat during processing
Cake is milled in our unique classifier mill, ensuring ultra fine powders
Very durable, low maintenance equipment
Ability to press any nut and seed, from almonds and hazelnuts to peanuts and sesame seeds
Benefits
Excellent flavor
Ultra fine powder, excellent solubility, free flowing
Consistent & controlled 'rest fat' levels in the powder
Control over color of the powder, from light to 'dark roast' flavor & color
By naturally removing most of the oil the resulting powder is extremely high in protein, very soluble and maintains excellent nut flavor.
Nut Spreads
Nut spreads and butters are produced using Log5’s CHOC system.
CHOC Nut Butter & Nut Spread Systems
CHOC Nut Butter & Nut Spread Systems
CHOC Nut Butter & Nut Spread Systems
Capacity
| CHOC Type | Liquid Mixer Type | Capacities [kg / hr] |
|---|---|---|
| 150 (batch) | Wiecon 50 | 50 - 150 |
| 300 (batch) | MXL-1000 | 100 - 300 |
| 425 (batch) | MXL-1000 | 300 - 425 |
| 600 (batch) | MXL-1000 | 425 - 600 |
| 1250 (continuous) | Wiecomix 350 | 600 - 1,250 |
| 1800 (continuous) | Wiecomix 500 | 1,250 - 1,800 |