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GEA Coating Guide

engineering for a better world

Contents

ABOUT GEA 3

AN INTRODUCTION TO COATING 4

THE SIX FACTORS OF COATING 5

SUBSTRATE CONSIDERATIONS 6

COATING SYSTEMS 7

PRE-DUST 8

ADHESION BATTERS 9

BREADERS 11

MARINATIONS, WET SAUCES AND GLAZES 15

COATING PICK-UP (YIELD) 16

APPLICATIONS 17

RECONSTITUTION 20

GEA COATING EQUIPMENT 23

GEA MULTIDRUM (DRY COATING) 24

GEA BULKLOADER P 25

GEA OPTIFLOUR (DRY COATING) & GEA OPTIAIR

®
26

GEA CRUMBMASTER (DRY COATING)

®
27

GEA OPTICOATER (WET COATING) 28

GEA WETCOATER (WET COATING) 29

GEA OPTIDIPPER (WET COATING) 30

GEA TEMPUDIPPER (WET COATING) 31

GEA TEMPUMIXER II (TEMPURA MIXING) 32

GEA BATTERMIXER (BATTER MIXING) 33

A-TO-Z OF COATING TERMINOLOGY 34

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ABOUT GEA

GEA takes you forward with performance-focused solutions for the food industry, from
single machines to complete production lines for the preparation, marination, processing,
slicing and packaging of primarily meat, poultry, fish, seafood and cheese-based products.
Our equipment helps you meet today’s operational challenges such as product variety,
process flexibility, reducing the cost per kilogram and per pack, food safety and the
environment.

GEA has a particularly long and rich history in processing equipment, with over 50 years’ experience
in forming, coating and cooking. In 1961 Koppens was one of the pioneers in these fields, introducing
revolutionary machines for forming hot dogs and cooking tunnels among others. Throughout the
years, the range grew to include fryers and cookers. Koppens became part of CFS in 1997, and this
proud heritage now forms the basis for the processing expertise in GEA. The company is a leader in
many fields, with highlights including the GEA CookStar spiral oven, the GEA EasyFry XL fryer, the
GEA MaxiFormer high-capacity forming machine and the GEA MultiDrum drum coating machine.

PROCESSING EQUIPMENT FROM PREPARATION TO PACKAGING

Today’s processing product range includes In addition to the processing equipment, GEA
machines for: also supplies:

• Forming and portioning • Preparation equipment (mixers, grinders,

• Dry- and wet coating bowl cutters, emulsifiers, fat analyzers)
• Frying and oil treatment • Marination equipment (injectors, tumblers,
• Spiral and in-line cooking massagers, tenderizers, defrosters)
• Grilling, roasting and pasteurizing • Slicing equipment (slicers, loaders)
• Packaging equipment (thermoformers,
vertical form, fill and seal baggers)
• Loading and handling equipment

This guide book presents an introduction to coating.

3
AN INTRODUCTION TO COATING

The coating process was commercially introduced with seasoned breading in the late
1930's, primarily for sea foods. Today, many more food types are coated, and commercial
coatings are formulated from a vast array of flours, seasonings, batters and breaders that
enhance product appearance and texture, as well as lock in flavor and moisture. GEA
coating equipment handles most types of coating for a huge variety of products, from
fragile fish to formed snacks.

Battering and breadcrumbing are traditional food preparation methods which have been
industrialized over the last few decades. Coating adds value to the product and creates an interest for
the consumer. Despite public concern about unhealthy diets and trends for low carb and low fat
products, the coated food market remains healthy and generates billions of euros/dollars each year.
There are regional variations in the type of coatings used.

WHY APPLY A COATING?

Coatings add value to a product. They offer the They also have the following business- and/or
following product-related benefits: process related benefits:

• Improve the visual appearance and • Increase yield to increase product value
uniqueness of the product • Reduce the product cost (/ kilogram)
• Enhance the taste by adding flavor • Allow utilization of trim/waste products
• Change the texture, mouth feel or ‘bite’ • Protect the product during freezing
• Modify the nutritional value (addition of • Enable more reconstitution methods
vitamins or calories) • Create interest for the consumer

4
THE SIX FACTORS OF COATING

Food coating is not a ‘hard’ science such as more predictable processes like drying or
cooling. It is a ‘soft’ knowledge derived from know-how and experience. One reason is the
product to be coated and the ingredients used in coatings typically have complex
characteristics and variations, and interact with each other.

There are six factors that influence how successfully a coating can be applied to specific products.
These are:

1. Substrates
the product to be coated can be fresh, frozen, formed or whole muscle, and its moisture content
and surface texture can vary
2. Processes
coating systems that apply the coating, such as wet, dry, single-, double-, triple- and even 5
pass
3. Coating composition/formulation
ingredients, flow characteristics, combination of wet and dry layers, single- or multi-layer
4. Line integration
how the machines interact with each other, line set up, yield, control possibilities, belt speed,
compatibility, optimizing set-up
5. Oil quality/Oil Management
this important subject will not be covered in this guide. Please refer to the GEA Oil Management
guide
6. Reconstitution
how the consumer re-heats and prepares the product for eating, such as conventional oven,
deep-fat fryer, pan fryer, microwave, steamer

5
SUBSTRATE CONSIDERATIONS

The substrates (products to be coated) can be fresh, frozen, formed or whole pieces such as
whole muscles or poultry parts.

FROZEN PRODUCTS
To effectively coat frozen products, such as Individually Quick Frozen (IQF) fish or seafood, it is first
desirable to defrost or de-glaze the surface. This is done using a steam tunnel. A pre-dust is
recommended, so a 3-step dry - wet - dry (also known as 1½ pass) coating system should be applied.

FORMED PRODUCTS
The preparation and ingredients of formed products can have an impact on adhesion - and therefore
affect the coating quality, but generally this type of product is easy to coat if the right guidelines are
followed. The simplest approach is a 2-step wet - dry coating system (also known as single pass), but
the batter (the wet coating) may not adhere properly to the substrate.

A better approach is to apply a pre-dust prior to the batter in a 3-step dry - wet - dry process (also
known as 1½ pass). The pre-dust acts as a key for the batter, ensuring an even coat without voids.
Intermediate wet and a dry coating steps can be added to increase the pick-up (5-step process; pre-
dust - wet - dry - wet - dry).

FRESH WHOLE MUSCLE PRODUCTS

Fresh skinless whole muscle products are generally easy to coat, and a pre-dust is recommended.
Skin-on products, such as poultry parts can present adhesion problems. This is related to the de-
feathering process used prior to the coating. In soft -scald de-feathering, the poultry is immersed in a
hot bath before the feathers are knocked off using rubber fingers. This leaves a waxy cuticle
(membrane) on the skin which looks more appetizing for non-coated products. However, the cuticle
layer is hard to coat, even when a pre-dust is applied.

The solution is to de-feather using a hard scald, which uses a hot bath at a temperature a few degrees
higher than the soft scald as this also removes the cuticle. A hard scald can leave brown patches
(known as ‘barking’) on the skin, but this is not an issue for coated skin-on poultry.

6
COATING SYSTEMS

A coating system sequentially coats the product in a number of steps that are usually
referred to as ‘passes’. A pass combines a dry and wet stage, and passes are often repeated.
This may be done to increase the total pick-up or give the end-product a particular taste,
look or mouth feel. The table below summarizes the definitions often applied for typical
coating systems.

A typical coating system comprises various process stages:

• Pre-dust: a dry coating

• Adhesion batter: a wet coating, applied over the pre-dust to glue the breader or crumb
• Breading: a dry (particulate) coating containing components ranging from flour to bread crumb
and coarse cornflakes

MACHINE APPLICATION STEP

Note that definitions may vary in coating technology. Although a ‘single pass’ is considered to be the
combination of a wet and a dry coating (e.g. batter then breading), it is sometimes referred to as a
double pass since the product goes through two different machines. For clarity in this guide, each
time a product passes under or through a coating machine (for example, for a pre-dust, a wet or a dry
coating), it will be referred to as a ‘machine application step’. For example, a 1 ½ pass is a 3-step
process, a triple pass is a 6-step process and so on.

7
PRE-DUST

A pre-dust is the base component of a coating system, and comprises a blend of finely
ground grain-based breaders, or dry batter. It is usually applied as the first layer in a coating
system as it prepares the surface of the substrate to allow the remainder of the coating
system to be ‘built’ on top of it. Pre-dusts may be off-the-shelf commodity items or tailor-
made for a particular product or process. They are usually flour based but may contain
additional agents to help coatings bind better to the substrate.

WHY PRE-DUST?
Typically, a pre-dusted product will have a more uniform coating, improved appearance and texture.
The pre-dust has the following functions:

• Provide adhesion in the form of a good binding surface to which batter can attach
• Boost yield by increasing the total coating pickup and reduce coating blow-off during frying
• Act as flavor carrier as it is protected by subsequet coating layers during the frying process (many
flavor volatiles degrade at high temperatures)
• Act as a moisture/fat barrier that controls water and fat migration during later heat treatment

These functions are achieved by blending components such as wheat flour, native and/or modified
starches, proteins (e.g. whey concentrate, gluten and egg albumen), and gums.

PRE-DUST PICK-UP
The quantity of pre-dust pick-up can be closely controlled with process adjustments. A substrate with
a wet surface will naturally pick up more pre-dust. Excess pre-dust can be removed using air blowers.

Insufficient pre-dust may lead to: Excess pre-dust may lead to:

• Batter or breading voids • Batter or breading voids

• Poor adhesion • Soft doughy underlayer
• Tingeing (discoloration of coating) • Overweight product
• Underweight product

8
ADHESION BATTERS

Adhesion batter is a liquid coating which acts as a ‘glue’ to stick the top coat of dry
components to the substrate. This means the stickiness of the batter is important and its
viscosity must be strictly controlled as it must enable a sufficiently thick layer of dry
ingredients to stick to it in order to achieve the desired product characteristics.

WHY USE A BATTER?

Batters are usually wheat flour based and adhesive agents are sometimes added to coat products with
a slick or dense surface. Flavors and colors may also be added to modify taste and appearance.

The following characteristics of adhesion batters are important:

• Viscosity - set by using different starch blends and gums, and is influenced by the degree of starch
damage during heat treatment. Changes in the water: powder ratio are also used to manage batter
viscosity.
• Moisture/fat barrier - to control water and fat migration during later heat treatment stages (where
applicable
• Seasoning - may contain spices to add flavor to the final product
• Color - may contain spice extracts for vibrant color or sugars for accelerated Maillard browning

These attributes are achieved by blending common batter components including wheat flour, rice
flour, maize flour, native and/or modified starches, proteins (e.g. whey concentrate, gluten, egg
albumen), gums, spice extracts (e.g. paprika , turmeric for color), reducing sugars (e.g. dextrose),
seasoning (e.g. herbs, spices and salt) and raising agents for light crisper bite.

BATTER PICK-UP
Although viscosity is key to obtaining the desired coating pickup, adhesiveness and texture, the batter
temperature is also important for the desired coating qualities. It is desirable to keep the batter
between 5° and 10°C during application. The liquid batter coagulates (hardens) during later heat
treatment stages (where applicable) to form a continuous structure incorporating all layers of coating
and firmly adhered to the substrate. Batter pick up can be controlled through viscosity adjustment and
the use of air blowers to remove excess.

Insufficient batter may lead to: Excess batter may lead to:

• Batter or breading voids • Skirting at the edge of the product

• Poor adhesion • Soft doughy underlayer
• Tingeing (discoloration of coating) • Overweight product
• Underweight product

9
TEMPURA
Tempura is an alternative final coating, and is prepared and blended like other batters, although
leavening (raising) agents are added to form gas in the mixture. These agents release CO2 gas when
they are heated in the frying process and during the gelling stage of the starches and proteins. This
results in the crispy open texture associated with tempura coatings. As with other batters, control of
viscosity and temperature is critical for maintaining peak performance. To prevent dissipation of the
gas, the GEA TempuMixer mixing system for tempura batters is designed to minimize pumping and
shearing of the batter.

Tempura is applied as a wet batter immediately prior to frying. It is made from wheat flour, rice flour,
maize flour, native and/or modified starches, proteins (whey concentrate, gluten, egg albumen),
gums, spice extracts (e.g. paprika and turmeric for color), reducing sugars (e.g. dextrose), seasoning
(herbs / spices / salt) and raising agents (for light crisp bite and open texture).

WASH BATTER
Wash batter is a combination of water, eggs, starches, adhesion agents, color agents, and flavor
agents. It adds a unique surface texture to fried products like French fries, egg rolls, seafood products,
and many specialty foods. A gum-based clear gel batter can be used to prevent products dehydrating
during freezing. Again, viscosity and temperature play an important role in managing the coating
adhesion, the integrity of the shell or casing, and the finished surface texture.

10
BREADERS

Breaders form the top layer of the coating and are used to add further weight, volume and
organoleptic characteristics. Each breader has a characteristic flavor, size, texture and color.
They can be anything from a simple flour to complex structured breadcrumbs or blends.
There is a large variety of breadcrumbs ranging from small hard crumb to large, extremely
fragile crumbs. They can be made by extrusion or traditional bread baking methods. Adding
spices, nuts and other natural and artificial flavorings, as well as different flours, starches
and crumbs, augment taste and appearance.

WHY USE A BREADER?

Breaders add both weight and value to a product. The composition of the breader can adjusted to
impart a wide variety of finished product characteristics - including flavor, appearance and texture
(both visual and mouth feel).

The following characteristics of breaders are important:

• Quality of flour (and or heat treatment) can effect oil pick up, color and texture of crumb based
breaders
• Grist (particle) size can have an impact on oil-pick up, color and texture of flour based breaders
• Seasoning, may contain herbs and spices to yield flavor to the finished product
• Color – may contain spice extracts for vibrant color or sugars for accelerated Maillard browning
• Frying temperature: Lower frying temperatures will yield a higher oil-pick up but generate less color
and may result in a soggy, oily mouth feel. Higher temperatures will generally result in a crisper
darker product, but at the expense of reduced yield and more rapid oil deterioration.

Organoleptic characteristics can be influenced by blending different flours and breadcrumb types
along with flavor and coloring components. The production of breaders is a highly specialized
process. Ingredient suppliers can adjust this process and the recipe to generate a huge variety finished
product characteristics.

Pick-up at this stage is largely influenced by the batter viscosity. A heavier batter will generally yield a
heavier breader pick-up. Higher pick-ups can also be achieved by using a pressure roller. Excess
breader not fully adhered to the product should be removed using blowers to prevent carry-over into
the frying process.

Insufficient breading may lead to: Excess breading may lead to:

• Breading voids • Overweight product

• Tingeing (discoloration of coating) • Soft doughy coating
• Underweight product • Flour carry-over into frying oil

11
FLOUR
Flour is the most widely used coating, and flour breaders are a mixture of various types of flour, mostly
wheat. It is good at carrying flavors and colors, so various spices, starches and other ingredients are
often mixed with it. It has excellent flexibility and tolerance to frying. Blended with seasonings and
colorings provides a simple Southern Fried or Southern Style coating. It may be applied in such a way
as to give a ruffled appearance known as homestyle. Pick-up with flour based breaders is generally
low, so multiple steps of the batter- breader stage are applied to increase product pick-up. Typical
components of flour based breaders include wheat flour, maize flour, rice flour, seasoning (herbs,
spices and salt), breadcrumb for texture, spice extracts (e.g. paprika or turmeric for color), reducing
sugars (e.g. dextrose) and milk proteins.

CRACKER MEAL
Cracker meal is a versatile, low-cost breader. It is a hard dense crumb with a gritty, crunchy texture.
The dough consists of flour and water, which is thin sheeted and baked. After baking, the cracker is
dried and ground to specific granulation sizes (mostly fine). Mid-range pick-up levels can be achieved.
It is a durable coater, often used in long fry applications because of its low oil absorption. It can be
applied over many different types of batters, and due to its relatively low cost, it can be used to extend
more expensive breaders. Blending cracker meal with other breaders can also help achieve certain
absorption qualities and frying characteristics. Cracker meal is frequently used on such products as
fish sticks, and is often colored.

12
EXTRUDED CRUMB
Extruded crumb is another low-cost coating option. It can be manufactured from a range of different
cereals as well as high-starch ingredients like potato. The material is cooked continuously under
pressure, and at the end of the process, the sudden release of pressure causes the moisture to expand
quickly. This creates the extrusion. The inexpensive process allows high volumes of crumbs that have
light- to medium density to be produced with various different shaped particles. Low- to high pick-up
levels can be achieved depending on the particle size. Without adequate filtration, lightweight
crumbs will float in the oil and burn, creating black specks on product and rapid oil degradation.
Extended storage can cause a loss of crispness as substrate moisture is absorbed by the crumb.

AMERICAN CRUMB
American crumb (also known as traditional crumb) has a hard texture and is largely used to coat
products like croquettes and fish. It is baked as a continuous bread loaf, but contains less water in the
dough and has a dark and hardened crust after baking. The presence of crust particles is a typical
feature of this type of crumb, giving rise to a two-tone appearance to the end product due to particles
coming from the crust of the loaf (darker) and the centre. Coloring agents such as paprika and
turmeric can be added to develop a rich brown appearance during frying.
Traditional breadcrumbs are similar in appearance to homemade breadcrumbs with a distinctive crust
which highlights during frying. Particle size distribution can be controlled at the milling stage and can
vary from fine to quite large (10 mm) pieces. Mid- to high pick-up levels can be achieved.

13
JAPANESE CRUMB
The texture, lightness and crunchy bite of Japanese crumb are unlike any other breading. It is
manufactured with yeast using an electrical induction process, which contributes its open and porous
structure. Compared with other breaders, the coating surface is remarkably free of oil when
reconstituted. When handling this fragile breader, care must be taken to maintain the integrity of the
particle shape and size for as long as possible.

Japanese breadcrumbs have a long pointed 'sliver' shape. The texture is open an porous and can be
produced in a range of sizes and colors. Mid- to hgh pick-up levels can be achieved.

FRESH CRUMB
Fresh crumb is not dried like other breaders, and needs to be refrigerated for extended storage
periods. When fried, fresh crumb gives the coated product a crispy texture and delicate appearance.

14
MARINATIONS, WET SAUCES AND GLAZES

Marination and glazes are combinations of flavorings, seasonings, water and juices that are
used to enhance a food's taste, mouth-feel and appearance.

MARINADES
Marinades are liquids that are either injected into the product or poured onto its surface to increase
flavor, moisture and tenderness. Depending on the desired result, the food is left to become saturated
from a few minutes to several hours.

GLAZES, SEASONING AND DRY RUB

Glazes can be either dry or liquid, and are applied only to the product surface. A dry glaze draws
moisture from the product to create the desired surface result. A medium viscosity liquid glaze can be
applied by a batter applicator. Seasoning and dry rubs are a mix of herbs and spices, for example, to
make products appealing in the barbeque season.

15
COATING PICK-UP (YIELD)

GEA works with major coating suppliers to produce optimal mixes for the desired coating
system and type of product. The extensive processing and coating facilities at the GEA
Technology Center in Bakel (the Netherlands) are available to test recipes and coatings, and
to fine tune new products.

Note regarding pick-up percentages - conventions vary as to how pick-up percentages are
presented. There are two ways used in the processing industry. As a percentage of the weight of the
uncoated product or as a percentage of the weight of the coated product

> calculated 100 % uncoated meat > calculated 100 % coated meat

• formed meat weight (A) 100 g • formed meat weight (A) 100g
• coating system (B) 40 g • coating system (B) 40g
• Finished Weight (C) 140g • Finished Weight (C) 140g
• Pick-up calculation%(B/A)*100=40% • Pick-up calculation%(B/C)*100=28.6%

As can be seen, although both methods are describing exactly the same composition they report very
different values. It is therefore important to ensure that all parties understand which method is being
used when reporting coating pick-ups.

16
APPLICATIONS

There are many variations of applications for coating. The coating stage may comprise one
or more steps depending on the substrate type, required pick-up percentage and quality
demands. Each pass typically comprises a wet and a dry step. A pre-dust is often used prior
to the wet batter coating.

17
TRADITIONAL BREADCRUMBS

• Coated products giving crisp bite

• High pick-up / high added value
• Simplest coating process
• Very high line outputs achievable

TEMPURA

• Coated products giving crisp bite

• High pick-up / high added value
• Highly attractive products
• Unique textural properties of Tempura
• Recognized coating throughout the world through association with fast food outlets

18
SOUTHERN FRIED / HOMESTYLE

• Recognized coating throughout the world through association with fast food outlets
• Coated products with softer bite (can be crispier with homestyle coatings)
• High pick-up / high added value
• Signature spicy flavour profiles within flour breading
• Lower oil pick-ups than crumb coated

NON-FRY APPLICATION FOR NICHE 'FAT-FREE' CRISPY COATED PRODUCTS

• Coated products containing less fat

• Fat free production process - cooking instead of frying
• 40 to 60% less fat than traditional processed coated products
• 25 to 30% reduction in energy consumption
• Less environmental stress - reduction in CO2 and fat emission
• Process efficiency and cost reduction by taking out the frying step
• Maximum exposure and shelf life

19
RECONSTITUTION

Reconstitution is the heating or cooking technique the consumer uses to prepare the coated
product for consumption.

Different coating systems will be used for ready-to-heat and ready-to-eat products:

• Raw or par fried products have not been cooked during processing, and will have to be fully cooked
by the consumer. The coating may have been par-fried or flash-fried to set the coating, but this will
not have taken place in a high-care environment (to ensure the product is pathogen free). The
substrate is essentially still raw. Moisture in the product may affect the coating.

• Ready to heat products may have been heat treated (to eliminate Salmonella / Listeria spp. or simply
to extend shelf life) but have been packed in a low risk environment. They should be reheated by
the final customer prior to consumption.

• Ready-to-eat products will have been fully cooked (usually flash-fried to harden and seal the
coating and then cooked in an in-line or spiral oven) during processing. The heat treatment and
subsequent packing operation will all have taken place in a high-care environment. The product is
safe to eat without any further heat treatment by the final consumer.

The coating recipe, pick-up percentages and dwell times in the coating machines, fryers and cookers
need to be set according to the intended reconstitution technique. Many coated products can be
reconstituted by two or more of the techniques, but the convention of the packaging is to give the
best reconstitution technique first in the list.

The four techniques are:

1. Shallow fry (also known as pan fry)

2. Deep fry
3. Oven bake
4. Microwave oven

20
SHALLOW FRY (ALSO KNOWN AS PAN FRY)
The product is not immersed in oil or fat, but heated in a frying pan with a thin layer of oil to prevent
the product sticking. Products need to be turned in the pan frequently.

Benefits Pitfalls

• The product is crispy • Black (burnt) spots may arise if the

• Not too much oil absorbtion (healthier) product is not evenly heated
• Fast; no waiting for oil to heat up • Product can become dry

DEEP FRY
The product is immersed in a container of oil or fat, and heated evenly. Some of the coating may fall
off the product into the oil, gradually contaminating it with residue that eventually burns and
blackens.

Benefits Pitfalls

• Even heating of the product • Oil degradation can become an issue

• Traditional flavor and bite • Fat content increases

21
OVEN BAKE
The product, for example breaded chicken wings, is heated for a given time and temperature in a
conventional oven.

Benefits

• Evenly heated, crispy product

• No absorption of additional oil (healthy)

MICROWAVE OVEN
The product is re-heated in a microwave oven. With this type of reconstitution, the moisture from
within the substrate distributes the thermal energy to heat the product as there is no dry hot air in a
microwave oven. Coatings for microwave reconstituted products need special recipes and
ingredients.

Benefits Pitfalls

• Very fast • Moisture from the substrate can soften

• No additional fat is absorbed the coating, causing it to lose its bite

22
GEA COATING EQUIPMENT

GEA’s pre-dusting, battering and breading machines give you the capability to cost-
effectively produce an appetizing variety of products. You can precisely balance quality,
yield and costs with innovative machines and configurations of wet and dry coatings.

DRY COATING
• GEA MultiDrum (+ GEA OptiAir) - Innovative drum coating machine for home style products
• GEA OptiFlour (+ GEA OptiAir) - finely adjustable pre-dust, flour or breading pick-up in a dust-free
processing environment
• GEA CrumbMaster - coats fine and coarse crumbs with excellent consistency and quality, easy to
clean, simple to operate and causes minimal crumb breakdown/damage

WET COATING
• GEA WetCoater - for efficient, even coverage of batter
• GEA TempuDipper - for efficient, even coverage tempura
• GEA OptiCoater - for versatile, even product coverage with batter, extra options to meet high
product demands, hygienic, recipe controllable
• GEA OptiDipper - For even product coverage with batter or tempura

MIXING
• GEA TempuMixer - fully automatic tempura mixer that sets the industry standards in product
quality, crispiness and consistency of tempura mix ingredients
• GEA BatterMixer - versatile batter mixer, suitable for milk wash, adhesion batters and high viscosity
batters

23
GEA MULTIDRUM (DRY COATING)

• Produces crispy and attractive home-style coated products

• Overcomes the typical drawbacks of using a conventional drum breader
• One-to-three in-feed technology reduces the need for manual labor
• Three parallel drums maximize coating consistency
• Very small footprint
• Dust-free work environment (in combination with GEA OptiAir)
• Available in 600mm and 1000mm belt widths

Home style products are characterized by a To create a dust-free work environment and
coarse, crispy coating. Typical examples include keep the machine clean, the GEA MultiDrum can
natural boneless and bone-in poultry. To get the be completely closed with covers and used in
look, bite and coverage, pick-up of the coarse combination with the patented GEA OptiAir
flour may be up to 45%, which means that system. Much attention has also been paid to the
almost half of the end-product is coating. Flat- cleanability of the machine.
bed breaders struggle to achieve this level of
coverage whilst still maintaining the desired YOUR PERFORMANCE BENEFITS
“Coral Reef” appearance. • Saves valuable factory space
• Fewer operators required
The GEA MultiDrum uses an innovative • Huge potential savings in flour usage
technique to separate a single stream of
• Cleaner and safer working environment
products into three streams to ensure products
are fed into the three parallel drums evenly and
therefore maximize the consistency of the
coating. It is no longer necessary to use manual
operators to do this. The machine is also very
space efficient, requiring less factory space.
Optional a quick-link coupling minimizes the risk
of belt damage.

24
GEA BULKLOADER P

• Bulk loader with hopper capacities of 1000 resp. 1300 liters

• Capacity up to 7400 kilograms per hour resp.12300 kilograms per hour
• Available in 600 mm and 1000 mm belt widths
• Strong and stable construction with modular, frequency-driven conveyor belt

Optimized for raw meat processing applications, and there is a drain in the bottom of the hopper.
the GEA BulkLoader P is particularly suited for The robust, stable frame features height
uniform loading of bone-in and boneless poultry adjustable legs with braked castors, and the
products via a transport conveyor into the GEA operator panel can be mounted on the right
MultiDrum. The belt speed is adjustable and the (standard) or left (option). It is available in two
need for manual handling is significantly widths: 600 mm and 1000 mm.
reduced. It is also designed for line integration
with other pieces of GEA meat processing YOUR PERFORMANCE BENEFITS
equipment. The outfeed height of the hopper is • Reduced manual handling and uniform
the same as the discharge height of the GEA loading
Transport Conveyor. • Hygienic design and easy cleaning
• One operator can run a 1000 mm line
Depending on the application, the maximum
capacity of the GEA BulkLoader P 600 is
approximately 7,400 kilograms per hour,
whereas the GEA BulkLoader P 1000 has a
maximum capacity of 12300 kilograms per hour.

The GEA BulkLoader is made of stainless steel

with an easy to clean glass-bead-peened finish.
Special attention is paid to hygienic design and
easy cleaning. For example, the belt can be
hydraulically lifted for cleaning and there is a
spray bar for cleaning the bottom of the modular
belt. The closed design prevents drip on floor,

25
GEA OPTIFLOUR® (DRY COATING) & GEA OPTIAIR

• For fine pre-dust up to seeded flour types and light- to medium crumbs
• Patented flour divider for accurate pick-up control
• Lump removal system to remove lumps and other contaminants
• Designed for performance in high-volume production lines
• Dust-free work environment (in combination with the GEA OptiAir)
• Available in 400mm, 600mm and 1000mm belt widths

The GEA OptiFlour® applies coatings ranging YOUR PERFORMANCE BENEFITS

from a fine pre-dust to seeded flour types and • Huge potential savings in flour usage
light- to medium crumbs. It is optimized for high • Cleaner and safer working environment
output and longer production runs, and is simple
to operate, flexible and easy to clean. In
combination with the GEA OptiAir, it contributes
to a dust-free work environment. GEA OptiAir
extracts air from the GEA OptiFlour, creating
under-pressure within the machine. The dust
taken with the air is separated and can be re-
used in the GEA OptiFlour® without interrupting
production. This puts an end to inconveniences
associated with flour - such as:

• Health and Safety issues associated with a

dusty environment
• Increased cleaning costs cleaning a dusty
room after production
• Increased flour usage due to airborne losses

Optional a quick-link coupling minimizes the risk

of belt damage.

26
GEA CRUMBMASTER® (DRY COATING)

• Applies a wide range of fine and coarse crumbs up to J-crumbs

• Lowest crumb break down in the industry
• Easy to clean and operate
• Available with 400, 600 and 1000 mm belt widths

The GEA CrumbMaster® breading machine system minimises dust escape. The machine is
applies a wide range of both fine and coarse designed with a minimum of loose parts and a
breadcrumbs. Its unique crumb circulation hinged cover around the vertical auger, which
system virtually eliminates crumb damage. The speeds up cleaning cycles and ensures easy
integrated design simplifies cleaning and keeps access to the machine interior. The machine is
the machine easy to operate. Thickness of the self-draining, and all drive shafts are welded and
top and bottom coating layers can be without wedges. Optional a quick-link coupling
independently adjusted from the outside of the minimizes the risk of belt damage.
machine.
YOUR PERFORMANCE BENEFITS
A conveyor belt carries the products through a • Optimum coating adhesion
bottom layer of breading, while the top coating • Top and bottom coating layers can be
is applied from a hopper above. An extra-long independently adjusted
breading bed with adjustable pressure roller • Integrated design keeps cleaning simple
ensures optimum coating adhesion. Excess
• Push buttons process control
breading is blown off and returned to the
circulation system by the built-in blower with
closed air circulation

27
GEA OPTICOATER (WET COATING)

• A four-layer curtain ensures full coverage

• Designed according to hygienic standard ISO 14159
• Available in 600 and 1000 mm belt widths
• Easy to operate and to clean
• Extremely short changeover times
• Excellent for high quality products and extended production runs
• Optional cooling jacket to control batter temperature

The GEA OptiCoater is a wet coater for The machine conforms to the latest hygiene
producing high-quality products during standards (ISO 14159), and is easy and safe to
extended production runs. It guarantees total operate. Push button control is standard, while a
coverage of the top of the product thanks to a PLC controlled for automatic execution is
conveyor belt that passes under a four-layer available as an option.
curtain. The bottom is covered while passing a
small dip construction, although an optional YOUR PERFORMANCE BENEFITS
bottom flow box is available for irregular shaped • Guaranteed even batter pick-up
products. A hygienic blower blows off excess • Increasing production uptime to the
batter on the top side, while excess batter can be maximum
removed with an (optional) bottom blower pipe. • Short cleaning time and extremely high
Options include a cooling jacket to control batter hygiene standards
temperature and a quick-link coupling to
minimize the risk of belt damage.

Extremely short changeover times are possible

thanks to a self-emptying drain underneath the
machine. The blower is easily opened without
additional tools for inspection and cleaning,
quick-release pipes between the pump and
curtain (instead of hoses) gives better access and
leaves no loose parts.

28
GEA WETCOATER (WET COATING)

• Flexible battering machine for thin batters

• Ensures even coverage of products in a variety of shapes
• Four-layer batter curtain for top coverage and V-shaped under-bath for bottom coverage
• Also suitable for marinating pork tenderloin and spareribs
• Available in 400, 600 and 1000 mm widths
• Compact design and small footprint simplifies positioning the machine in line
• Optional cooling jacket to control batter temperature

The GEA WetCoater delivers smooth and Options include a cooling jacket to control batter
efficient batter coverage using an under-bath temperature, heavy-duty pump and blower for
and a four-layer batter curtain. By changing the thicker batter applications, a 500 mm long
position of the batter curtain, the process can be infeed belt for manual loading and avoiding
fine-tuned to suit the application and provide excess flour dripping from the previous machine
adhesion for breading. By controlling the batter in the line, and a quick-link coupling to minimize
flow, the layer thickness can be adjusted. Air the risk of belt damage.
supply and air distribution to the top and bottom
is also adjustable, and by changing the position YOUR PERFORMANCE BENEFITS
and angle of the blower, even coverage is • High reliability, due to proven, simple design
guaranteed. The small return rollers ensure • User-friendly operation, cleaning and
excellent product transfer. When the products maintenance
leave the machine, excess batter is blown off and • Even coverage and efficient batter usage
returned for re-use. The GEA WetCoater works • Robust, stainless steel construction for ease of
effectively with a minimum quantity of batter in cleaning
the machine, meaning little batter is required to
start the machine up or while changing to a
different batter.

29
GEA OPTIDIPPER (WET COATING)

• Easy and safe to operate

• Shorter cleaning time and less waste water
• Extremely short changeover times
• Excellent control over quality even with small products
• For use with thin and thick batters (with recirculation pump)
• Available with 650* and 1050* mm belt widths. *(Netto beltwidth is 600 and 1000 mm)
• Optional cooling jacket to control the temperature of batter (and tempura)

The GEA OptiDipper batter machine for wet A frequency converter adjusts the conveyor belt
coating is easy and safe to operate. There are no speed. An adjustable bottom layer former
loose parts, which simplifies cleaning and optimizes bottom coverage with difficult and
maintenance (cleaning time is up to 50% shorter hollow products. A hygienic blower blows off
and it produces less waste water). The excess tempura or batter on upper side, and
changeover times are also extremely short excess on the bottom is removed with a scraper
thanks to a self-emptying drain underneath the or an additional bottom blower pipe.
machine, and the machine can remain in line. It
provides excellent control over product quality YOUR PERFORMANCE BENEFITS
even with small products, and is suitable for thin • Up to 100% improved lifetime of your batter
and thick batters. Applications include formed and tempura
and coated cheese, poultry, seafood, beef and • Guaranteed total product coverage
pork. • Reduced product waste
• 50% savings on cleaning and labor
A conveyor belt in combination with an
adjustable top conveyor ensure products are
completely submerged. The design ensures that
no product transfers take place inside the
machine to give maximum flexibility and reduce
damage of products to the minimum. Optional a
quick-link coupling minimizes the risk of belt
damage.

30
GEA TEMPUDIPPER (WET COATING)

• Low-cost tempura applicator

• Proven and simple design with good accessibility for cleaning
• Suitable for a wide range of product types and sizes
• Even coverage and efficient tempura usage
• Available in 400, 600 and 1000 mm widths
• Optional cooling jacket to control the temperature of tempura

The GEA TempuDipper is a cost efficient tempura The interior of the machine is easily accessible for
applicator, with a proven and simple design. It cleaning. An electrical control box with push
handles a wide range of product types and sizes, buttons enables adjustment from the outside of
and applications include formed and coated the machine. Optional a quick-link coupling
cheese, poultry, seafood, beef and pork. It minimizes the risk of belt damage.
ensures even coverage and efficient tempura
usage, and facilitates direct transfer of product YOUR PERFORMANCE BENEFITS
into the fryer. • Direct transfer of product into the fryer
• Even coverage and efficient tempura usage
A conveyor belt submerges the products using • Handles a wide range of product types and
an adjustable top conveyor to ensure they are sizes
completely dipped in tempura or batter. The
conveyor belt speed and correct quantity of
tempura or batter for the under layer are both
manually adjusted. A standard blower blows off
excess tempura or batter on upper product side.

31
GEA TEMPUMIXER II (TEMPURA MIXING)

• Highly automated tempura mixer with consistent mix viscosity and pick-up
• Fast recipe changes and very low overall waste
• Easy and safe to operate - up to 50% labor savings
• Gentle vortex mixing action with low mechanical impact
• In-line measurement and automatic viscosity adjustment
• Cooling jacket to control the temperature of tempura

The GEA TempuMixer II is an automated mixer YOUR PERFORMANCE BENEFITS

that delivers consistent viscosity, composition • Consistent quality results
and temperature. It automatically controls the • Time (and cost) savings thanks to batch
mixing and dosing quantities of the flour and correction and automation
water and features in-line viscosity measurement • Less giveaway due to accurate control of the
and temperature control. Consistent tempura fully automated mixing process
viscosity is essential for optimizing pick-up and to
• Consistent tempura quality results in fewer B-
get as close as possible to the specified minimum
grade products
weight of the coated product - therefore
eliminating unnecessary give-away.

The gentle vortex mixing technique with low

mechanical impact optimizes blending and
dilution of the ingredients into water, and helps
preserve the tempura’s crunchiness after frying.
Aggressive mixing with rotating blades in a tank
can reduce the quality and appearance of the
end product.

An integrated CIP system simplifies and speeds

up cleaning to the highest food safety level.

32
GEA BATTERMIXER (BATTER MIXING)

• Simple to operate and easy to clean

• Manual supply of flour and water (automatic option)
• Available with capacities of 70 or 200 liters
• Equipped with wheels for ease of movement
• Self-draining design
• Stainless steel construction
• Optional cooling jacket to control the batter temperature

The versatile GEA BatterMixer is suitable for milk Options include a pump that automatically fills
wash, adhesion batters and high viscosity batters the battering machine, automatic batter level
types (except tempura batters - refer to GEA control and a cooling jacket to control the batter
TempuMixer). It contains a tank and a rotary temperature.
mixing system. The mixing time is adjustable and
includes an intermittent remix cycle to avoid YOUR PERFORMANCE BENEFITS
batter and water separation. It is fitted with a • Controlled batter quality
gate valve for manual supply to the batter
applicator.

33
A-TO-Z OF COATING TERMINOLOGY

A-B

Absorption - the capabilities of a batter or bread coating to absorb water. A higher absorption
ensures uniform pickup, better adhesion to the product, better oil retention, and products tend to dry
faster.
Adhesion - the capability of a batter (or combination batter and breader) to bind to a substrate. It is
influenced by ingredients, absorption rate, and compression.
Air Knife - a technique used to remove excess coating from the product using an air blow-off
manifold above the product.
American Crumb - a coating made from bread that is dried and ground to a specified granulation,
also known as traditional crumb.
Auger - the helix-shaped device that conveys coating materials through a breading machine (also
known as “screw” or “worm” drive).

Ballooning Effect - when the food shrinks within the coating layers as result of improper coating
formula, improper heat treatment, or a weak substrate formula. Also known as ‘the football effect'.
Barking - brown patches arising from hard scald de-feathering of poultry.
Batter - a coating applied as a liquid made from a blend of water, flour, eggs, leavening, starch, and
seasoning. It can be used as a topcoat on products (e.g. tempura) or as an undercoating to provide
adhesion for a breader material.
Batter mixer - a machine used to add and mix correct amounts of water and dry batter ingredients.
Sometimes with automatic viscosity measuring and temperature control.
Bed - the layer of breading on the bottom belt of the breading machine. Also known as bottom bed.
Binder - a blend of ingredients within the substrate which absorbs free moisture, enabling the
product to hold together through batter, breading, and frying.
Bite - a subjective way of describing the crunchiness and mouth feel of a product.
Blended breaders - a customized coating application for specific products using a blend of two or
more breaders such as cracker meal, flour, spices, or Japanese crumb in varying amounts.
Blow-off - the excess coating removed from a product by the air knife prior to exiting a batter or
breading applicator. Coating material dislodged during the frying process is also sometimes known as
blow-off.
Bottom bed - the layer of breading on the bottom belt of the breading machine. Also known as bed.
Bread crumbs - a granulated mix derived from baked, dried, and ground leavened dough products
and seasonings.
Breader - a dough of flour, water, and other ingredients baked and ground to a specific granular size.
The ingredients determine the product's flavor, fry characteristics, raw and unfinished color, and
texture.
Breader ball - aggregates of batter and breader or water and breader. Can be desirable in
“Homestyle” products.
Bulk density - the breading mass measured in terms of weight/volume.

34
C-G

Coarse bread crumb - a large particle bread crumb that can be fragile.
Coating - general term for a coating system consisting of both batter and breader.
Coverage - the uniformity of the coating material on the product.
Cracker meal - a coating to extend products or to act as a binder made from a dough mixture of flour
and water that is sheeted, baked, and ground. Salt is sometimes added to the dough or added after
grinding.
Curtain - the layer of falling batter or breading applied onto the top and sides of a food product being
conveyed underneath it.

Dehydration - loss of moisture.

Dipper (batter and tempura) applicator - a type of batter applicator where the product is
submerged into a pool of batter by a top wire mesh conveyor. (Such as the GEA OptiDipper and GEA
TempuDipper). Sometimes also referred to as “Drag and Dip” or “Submerge” enrobers.
Double pass - a process where products are coated with a batter and/or breader twice that is used
when the required coating pickup is more than 35% (for example coated shrimp).
Drum breader - a rotating cylinder or barrel used to apply breading, associated with 'Homestyle'
coating.
Dry batter - the batter ingredients before being mixed with water.
Dwell time - the time spent in a particular process or machine (e.g. batter immersion time, fryer, oven
etc). Also known as 'residence time'

Encapsulation - a coating that completely covers a product. Also can have specific meanings with
regards to control of raising agents in leavened batters and heavily spiced ingredients.
Extruded bread crumb - a breader produced through a high pressure process which simultaneously
cooks and “puffs” the particles.

Flavor profile - the overall taste characteristics of a product. Can be objectively evaluated using star
charts etc.
Flip - turning the product over as it is being processed in a breading applicator to remove excess
coating from the top surface, or to achieve successful transfer between processing steps.
Flow cup - a simple portable stainless steel device used to measure viscosity.
Football effect - see balloon effect
Former - equipment used to shape food materials. (Such as the GEA MultiFormer.)
Free-flowing breader - breading material that does not adhere to itself when compressed, or bridge
when dispensed into a breading applicator.

Granulation - the particle size of a ground breader. Granulation size affects coating pickup, oil
pickup, color highlights, and texture.
Grinder - a food product size reduction machine. (Such as the GEA SuperGrind.)

35
H-N

Hard scald - de-feathering process for poultry using a hot bath that also removes the waxy skin
cuticle that inhibits coating adhesion. See also soft scalding.
Highlights - the color of darker top particles against the basic background color of coating. Large
particles brown faster. When highlights are desired, a blend of coarse particles and fine particles is
normally used in the final breader.
High-care environment - a heat treatment environment where special precautions are required to
ensure the cooked product does not come into contact with raw products and are therefore “Ready
to eat” (Rte).

Injection - the process of introducing a liquid mixture of flavor, yield, and binding enhancers directly
into muscle meat products by injection on a machine. (Such as the GEA YieldJector or GEA
AccuJector.) Also known as stitching.
Interface - the point at which the coating joins the food portion.

Japanese style bread crumb - particles of baked, yeast-leavened, proofed dough. This crumb
generally has a large particle size and provides a very crunchy bite. It is very fragile and requires gentle
handling, Japanese crumb is often the final coating on extruded products where the product itself has
very little firmness for good bite. GEA CrumbMaster has been shown to be best in class for handling
this type of fragile product.

Leavened batter - a batter, such as Tempura, which contains leavening agents.

Leavening agent - an ingredient which rapidly produces CO2 to aerate the batter during the frying
process. This gives the finished product a light, crispy bite.
Lumps- aggregates of batter and breader or water and breader. Can be desirable in “Homestyle”
products.

Machinability - the ease with which a product or coating can be handled through a machine.
Marinade - a liquid mixture of flavor, yield, and binding enhancers introduced directly into muscle
meat products. Marinating is usually done under vacuum in a tumbler (such as the GEA ScanMidi) or
through injection (such as in the GEA AccuJector or GEA YieldJector).
Marinated Raw Breaded (MRB) - a raw food product that is coated and immediately frozen.
Marriage - when two or more product pieces bind together. Also known as “Twins” or “Doubles”
Milk wash - Low viscosity batter, frequently used as a first stage batter in tempura coated products.
Mix ratio - the percentage of water and percentage of solids in a given batter mix, which determines
the batter thickness and viscosity.
Modified food starch - starch that has been chemically or physically altered.
Moisture - available water content.
Mouth-feel - the overall textural quality of a food.

Non free-flowing breader - breading material that will not flow from the hand or through the
fingers after making a fist. Will bridge if used in the wrong machine.
Non-leavened batter - a batter that has no leavening agents in it. Also known as conventional or
adhesion batter.

36
O-So

Oil pick-up - the amount of oil absorbed by a fried product.

Oil turnover rate - the description of how many hours it takes to completely replenish all of the oil in
the frying system as a result of product oil pickup.
Ovenable coating - batter and breader coating systems that are designed specifically for products
that are to be reconstituted in an oven (convection, impingement or microwave).
Over-mixing - excessive agitation of a mixture (can refer to batter, tempura or meat dough etc).

Pick-up - the percentage of batter and breading adhering to the product. This can be expressed as a
percentage of start weight (“green” or “addition”) or final weight (“inclusion”).
Pre-dust - a fine flour breader or dry batter material applied to a product prior to a batter and
breading coat to improve coating adhesion and add to total coating pickup.
Pre-duster - a standard breading applicator. (Such as the GEA OptiFlour.)
Pressure roll - a roller that presses the breading material onto the product, and is useful in controlling
the overall coating pickup.

Raising agent - ingredients that aerate the coating during the frying process, causing the coating to
puff up or change. See Leavening Agent.
Ready-to-eat - products that have been fully cooked during processing and subsequently packing in
a high care environment, and are safe for the consumer to eat directly from the package.
Ready-to-heat - products that have been heat treated during production processes (in order to
eliminate specific micro-organisms such as Salmonell/Listeria) but have not been processed/packed
under “High Care” conditions. The product should undergo a further cooking process by the
consumer before being eaten.
Reconstitution - the cooking process used by the consumer to heat a frozen product to prepare it for
eating. Also known as rethermalization.
Rethermalization - see Reconstitution.

Shallow fry - reconstitution of a coated product by the consumer in a frying pan. Also known as pan
fry.
Screw - see Auger
Shear - mechanical deterioration, particularly relating to starch molecules of flour, the batter
viscosity, and batter functionality.
Shortening - animal or vegetable fat used in bread products to achieve light, tender, or flaky
characteristics.
Single-pass line - a process where the coating is applied only once. Typically, a pre-dust, batter and
breader, or just batter and breader. Single-pass is typically used when required total pick-up is low.
Skirting – excessive coating around the edges of a product. Usually caused by excess batter.
Slivers - the elongated shapes of Japanese style bread crumbs.
Soft scald - de-feathering process for poultry using a hot bath that does not remove the waxy skin
cuticle that inhibits coating adhesion. See also hard scalding.
Solids - any particulate matter suspended in a batter mixture.

37
St-Z

Standard yield - the average amount of product produced during several hours of production.
Normally many tests over several hours are taken and then averaged to obtain a standard yield. This
average yield is usually the key yield test for most processors to compensate for slight deviations
during processing.
Stitching - see Injection
Substrate - the food inside a coating system.

Tailing - a flange or lip formed on the trailing edge of a food item during processing.
Tempura batter - a batter that is highly leavened for rapid expansion during frying. Produces a
coating with a very crisp and light texture.
Top curtain - batter or breading which is deposited on the top of the product being coated.
Top submerger conveyor - a conveyor on top of the product that pushes it under the surface of a
process liquid. Helps maintain product orientation and reduce marriages. Can apply to batter
applicators or fryers.
Transfer point - the location where a product moves from one conveyor belt to another on coating
equipment.
Twins - see Marriage.

Vacuum blender - a machine where size-reduced or ground products, seasoning and chilled gas are
blended or mixed into a homogeneous mixture for shaping in a former. (Such as the GEA
MultiFormer.) (The GEA UniMix is an example of a vacuum blender.)
Vacuum tumbler - a batch process machine to massage marinade into whole muscle food products
while tumbling the product under vacuum. (Such as the GEA ScanMidi.)
Viscosity - the thickness and flowability of a fully mixed batter, determined by the ingredients
mixture, the amount of water at hydration, and the temperature of the mix.
Viscosity control unit - a chamber and control system where batter resistance, or flow, is measured.
Can be part of a batter mixing unit. Dry batter and/or water are fed into a mixing tank on demand
from a controller measuring the mixed batter's viscosity. (The GEA TempuMixer includes a Viscosity
control unit.)
Voids - bare spots in the coating where either the batter or breading has not fully encapsulated the
product.

Wash batter - a batter used to add a unique surface texture to fried products, or to prevent
dehydration during freezing.

Yield - the amount of product produced expressed as a percentage of the weight of the initial raw
materials. Can also be defined as the finished weight of a product divided by the raw weight of the
product.

Zone - separately controlled area of processing equipment.

38
Επίσημος Αντιπρόσωπος:
Επίσημος Αντιπρόσωπος:

CFS Industrial
CFS Industrial
Λευκάδος 22,
Λευκάδος 22, Γλυκά
Γλυκά Νερά,
Νερά, 15354,
15354, Αττική
Αττική
www.cfs-industrial.gr
www.cfs-industrial.gr
[email protected], [email protected]
[email protected], [email protected]
τ. 210
τ. 210 6655240,
6655240, φ.
φ. 2106655230
2106655230

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