Nut & Seed Processing Sytems
KOCOTEK is highly specialized in the Log5 nut and seed processing systems with particular emphasis on pasteurization, 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!
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. he 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)
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 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|
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
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 Roasting Technology
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 roaster is quite simple and straightforward: it is a vertical 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 Roaster – Type ‘KR’
The ‘KR’ type roaster from the Royal Duyvis Wiener group can be used for the continuous roasting of peanuts and tree nuts. The unique ‘counter flow’ roasting technique ensures that the heating curve is very gentle and even and that the product is gently mixed throughout the roasting process. The Log5 roaster can be validated for a 5 log reduction as a ‘stand alone’ roaster OR can be combined with our Log5 pasteurizer so that the roaster is independent from the ‘defined kill step’.
|Roaster Type||lb / hr|
|KRC - S5||1,100 - 2,200|
|KRC - S7||2,200 - 3,000|
|KRC - S6||3,000 - 4,600|
|KRC - S8||4,600 - 6,400|
|KRC - S12||6,400 - 8,800|
Counter flow roasting process with very gentle heating (no heat stress!)
Very gentle mixing throughout the roast process ensuring an even roast
No 'over roast' ensuring for optimum control over flavor development
Possible to add alkalizer
Automatic product 'hold' if product temperature has not reached required set point (critical if roaster incorporates the validation)
Very energy efficient
Extremely low operational and maintenance costs
Space efficient, small foot print
No combustion air in contact with the product
No re-circulation of the roasting air
Nut Grinding and Refining
Pre-Grinder (with Optional Ball Mill)
|Optional Ball Mill Type||kg / hr|
|Nibrotom 600||300 - 500|
|Nibrotom 2000||500 - 1,700|
|Nibrotom 3500||1,700 - 3,800|
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
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
|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|
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
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 and butters are produced using Log5’s CHOC system.
CHOC Nut Butter & Nut Spread Systems
|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|