ELEA SMOOTHCUT™ 10, 100 & 1000 PULSED ELECTRIC FIELD BELT SYSTEM

French fries

French fries

French fries

A Pulsed Electric Field pre-treatment enables structure softening and great cutting improvements for French fries production. Resulting in less feathering, less breakage, much longer fries and an even colour.

French fries

Chicken breast

Chicken breast

Chicken breast

A Pulsed Electric Field pre-treatment of chicken breast brings improvements in the tenderisation processes and a soft mouth-feel. Improved yield and reduced marinating time are great production benefits, too.

Chicken breast

Freeze-dried fruits

Freeze-dried fruits

Freeze-dried fruits

Freeze-drying of fruits assisted by Pulsed Electric Fields enables extraordinary shape, colour and flavour retention. FD PEF fruits are healthy natural snacks, make a perfect ingredient in muesli or covered in chocolate.

Freeze-dried fruits

Potato

Potato

Potato

Structure softening with Pulsed Electric Fields eliminates the need for a pre-heater, allowing for energy and water savings. With the resulting smoother cut and starch retention, more product yield is achievable.

Potato

Carrot

Carrot

Carrot

Both, dried carrot snacks and fried carrot chips benefit from a Pulsed Electric Field pre-treatment in smoother cutting, better processing performance, product optimization and overall higher quality retention.

Carrot

Berry

Berry

Berry

Treating berries with Pulsed Electric Fields for drying purpose will result in gentle water release and excellent shape and quality retention. PEF treatment can also enhance juice extraction for juices or smoothies!

Berry

Osmotic drying

Osmotic drying

Osmotic drying

Pulsed Electric Fields help with osmotic drying, too. Diffusion is enhanced and the dried fruits have a larger volume and better shape. Drying is accelerated with better sensory attributes and retained colour.

Osmotic drying

Sugar beet

Sugar beet

Sugar beet

Sugar beet is a hard tuber and using Pulsed Electric Fields for cell disruption means a low energy sugar extraction method with greatly increased sugar yield.

Sugar beet

Sugar cane

Sugar cane

Sugar cane

Sugar cane consists of very hard fibres and using Pulsed Electric Fields as a cell disruption method opens the structure. This results in increased sugar yield and aims for a low energy sugar extraction.

Sugar cane

Apple

Apple

Apple

Drying apples after a Pulsed Electric Field pre-treatment achieve a product of amazing flavour retention, shape preservation and retained colour.

Apple

Beans

Beans

Beans

Opening the beans cell structure with Pulsed Electric Fields results in accelerated soaking time making the process faster and more energy efficient.

Beans

Onion

Onion

Onion

PEF assisted onion drying brings great benefits to the production process including faster moisture release and drying process optimization. Drying acceleration enabling energy savings and less shrinkage.

Onion

Vegetable chips

Vegetable chips

Vegetable chips

For vegetable chips such as carrot chips, parsnip chips or beetroot chips, a Pulsed Electric Fields treatment of the raw produce results in better cutting, sugar release, less acrylamide and better quality.

Vegetable chips

Asparagus

Asparagus

Asparagus

Pulsed Electric Fields treatment of hard structures such as asparagus means low energy cell disruption for texture modification and enables improved saponins release, too.

Asparagus

Potato chips

Potato chips

Potato chips

In chips manufacturing, a Pulsed Electric Fields pre-treatment results in better cutting, less feathering and enabling more extreme shapes. Frying optimization and less oil uptake result in better chips quality.

Potato chips

Mango

Mango

Mango

PEF dried mango is extra rich in flavour and benefits from a completely retained structure with no shrinkage. A bright colour and drying process optimization results in a premium quality product.

Mango

Beetroot

Beetroot

Beetroot

By applying a Pulsed Electric Field treatment prior to making beetroot chips, the open structure enables better cutting, frying optimization and reduced temperature for great colour retention and taste.

Beetroot

Cassava/Manioc

Cassava/Manioc

Cassava/Manioc

Using Pulsed Electric Fields in Cassava or Manioc production enables structure softening and improves peeling. Outcomes are better cutting with less breakage and huge energy and water savings.

Cassava/Manioc

Sweet Potato

Sweet Potato

Sweet Potato

After a PEF treatment of sweet potatoes, the structure is much more pliable and cutting is improved. Water leakage enables sugar release, resulting in less acrylamide production while frying.

Sweet Potato

Meat

Meat

Meat

Treating meat with Pulsed Electric Fields results in the tenderisation of the meat structure. The opened pores improve brining and a higher yield. A reduction in marinating time enables faster production.

Meat

Tomato

Tomato

Tomato

A Pulsed Electric Fields pre-treatment brings great achievements to tomato processing. The faster moisture release enhances peel removal. No heating step is needed meaning better colour and taste.

Tomato

Broccoli

Broccoli

Broccoli

Pulsed Electric Fields treatment of broccoli opens the structure and makes the extraction of healthy compounds possible without extra heat. That means an energy saving process and improved extract quality.

Broccoli

Grass

Grass

Grass

A treatment with Pulsed Electric Fields can make grass as feed better digestible due to the cell disruption and therefore be more effective for animals.

Grass

Dried vegetables

Dried vegetables

Dried vegetables

A Pulsed Electric Field pre-treatment forces structure opening and a better water release while drying enabling process optimization and energy savings. The result is a retained colour and great shape retention.

Dried vegetables

With over 75 Elea SmoothCut™ systems already installed globally, the food industry is already reaping the benefits of PEF such as greater yield, improved quality and exciting new opportunities for snack products.

The Elea SmoothCut™ belt systems are the most popular treatment solution for our international customers. Ideal for the treatment of tubers, roots, vegetables and fruits, the SmoothCut™ belt system is versatile and comes in four models – one, 10, 100 and 1000.

Our SmoothCut™ system has been used throughout the potato-processing industry since 2010 and our PEF technology pre-treatment has become the standard worldwide due to its dramatic and positive changes to both product and process.

The Elea SmoothCut™ system is an energy-saving low temperature process that replaces the need for blanching potatoes and other produce before cutting. As well as reducing energy and water consumption by up to 90%, the SmoothCut™ system is a volumetric treatment, so you can expect treatment uniformity, no matter the item of fresh produce.

This uniform softening means that a smooth cut can be achieved. French fries and chips achieve longer shapes, become more pliable and experience less breakage, ultimately leading to opportunities for more extreme snack shapes. What’s more, during deep frying 10% less oil is absorbed and browning becomes more even for a brighter, more appetising colour.

Drying processes for the production of dried fruit and vegetables can be enhanced too. The pre-treatment of food with the SmoothCut™ system leads to a greater diffusion coefficient which greatly improves the drying process in both temperature and time. This leads to energy savings and better shape, colour and overall quality of the dried products.

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SMOOTHCUT SYSTEM SPECIFICATION

Elea SmoothCut™ 10, 100, 1000

Pulse Generator
control system
Touch screen, measurement of peak voltage and current, connectors for oscilloscope, safety interlock, emergency off
cooling
Air and water cooled depending on system.
dimensions
Dependent on system, stainless steel cabinet.
Continuous Treatment Belt
capacity
Up to 70 t/h of potato in a potato-water mixture
water management
Automated level control, overflow channel, automated drain valve, water conductivity and temperature measurement.
electrodes
Stainless steel.
dimensions
Dependent on system, belt should be attached to generator.
power supply
Supplied from generator.
Services Required
power supply
400/415 V, 50 Hz, (3Phase/Ground), 100 A. Other options available.
water
Water supply to treatment belt.
compressed air
6 bar.
drain valve
DN150 Flange.

DESIGNED AND BUILT BY ELEA

We manufacture each of our SmoothCut™ systems in Quakenbrück, Germany. They’re designed, engineered and built by experts in PEF to the highest specifications.

24/7 OPERATION

Robust build and solid-state typology ensure that the Elea technology in our SmoothCut™ systems is exceptionally reliable which means 24/7 operation and low maintenance costs.

Our SmoothCut™ systems are manufactured to the highest quality to make sure each one can withstand continuous operation and maximum performance. As part of our range of service contracts, we can supply each customer with around the clock technical support.

FULLY CUSTOMISABLE

To fulfil the needs of our clients, we’ve made sure our SmoothCut™ systems are fully customisable and scalable to specified criteria across design, mechanics and software programming.

Our expert team works in close collaboration with our clients to make sure that the system we delivery meets their requirements, so even if you need something like a split belt, we can make it happen.

TOTAL CONTROL

Our SmoothCut™ systems are designed to be compatible with any standard processing control system and fully accredited and certified for regional installation anywhere in the world.

We work in partnership with our clients to make sure they’re using the full potential of their SmoothCut™ system and getting the most benefits of PEF. We’ll listen to what suits your product and desired application goal and help to achieve that with a tailored treatment parameter.

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FREQUENTLY ASKED QUESTIONS

Do we need a full-time operator for our SmoothCut™ system?

No. There’s no need, we design our SmoothCut™ system to be run without a full-time operator.

What maintenance is required for the SmoothCut™ system?

We recommend that each year your SmoothCut™ system received an annual inspection from the Elea service team. They’ll check the system’s calibration and correct function, along with mechanical checks. There are few parts on a SmoothCut™ system that are likely to experience wear, and we make continual steps to reduce our low maintenance costs even further. We do recommend that customers give their SmoothCut™ system a monthly PPM that takes approximately one hour.

Are all the parts that come into contact with the product food grade?

Yes, each part of the SmoothCut™ system that comes into contact with the product is either stainless steel or CE and FDA listed plastics. All certification is supplied with your system as part of the documentation.

Are the metal parts of the SmoothCut™ system passivated?

Yes. We manufacture all metal parts from Stainless Steel 1.4301 or higher. All metal parts of the SmoothCut™ system are grit polished after welding.

Can I control the SmoothCut™ system remotely and download data?

Yes. We can link to any factory Scada system and allow full access to our PLC and controls as if you were standing next to your SmoothCut™ system. Additionally, if required we can log in from our office to assist with any issues.

Is it difficult to replace any SmoothCut™ system parts if they fail?

No. Our SmoothCut™ system is designed for quick and easy replacement of parts. Any electronic parts are plug and go with no additional set up required.

Are there any special cleaning requirements for the SmoothCut™ system?

No. We ensure that each SmoothCut™ system has easy access for cleaning and have no special requirements regarding cleaning solutions that are typically used in the food industry.

What utilities are needed for the SmoothCut™ system?

Your SmoothCut™ system will require electric, compressed air, water and cooling water for the generator.

Do Elea offer training for SmoothCut™ operators and maintenance personnel?

Yes. During the installation of your SmoothCut™ system, we carry out training for operators and maintenance personnel as standard and can also offer further training at our facility in Quakenbrück, Germany. All training is tailored to your SmoothCut™ system and copies of the training material is provided for all participants.

Can the SmoothCut™ system work with floating products?

Yes, absolutely. We can fit your SmoothCut™ system with an additional top belt (or hold down belt), to keep floating products submerged. If this is something you think you require after initial installation then it can also be retrofitted too.

How many water changes are needed in the SmoothCut™ treatment tank in a 24-hour period?

Typically, your SmoothCut™ system will need between 4 to 6 changes during a 24-hour period – although this will be determined by the product volume and the cleanliness of the product. Your SmoothCut™ system will monitor and control the water conductivity automatically, so can periodically drain small amounts of water from the tank, and replace with clean, fresh water.

Are all the electrical cabinets suitable for placing in wet areas?

Yes. The electrical cabinets found on the SmoothCut™ system are designed for wet areas.

Can I use a closed loop water chiller to supply cooling for the SmoothCut™ generators?

Yes. Some of our customers prefer to use a closed loop cooling circuit for their SmoothCut™ system generators using water or glycol that typically run with a minimum temperature of 15°C.

Will the SmoothCut™ system treat my whole product evenly?

Yes. It is a volumetric method and as a physical process, PEF will be able to treat the products uniformly. For example, all potatoes introduced to PEF in the water tank, or juice in the treatment cell will be affected.

TRAINING, GLOBAL SUPPORT AND INSTALLATION

Our highly skilled technical team provide comprehensive training and a continual support service around the world, including full SmoothCut™ system installation and maintenance.

TRAINING

Investment in training of your SmoothCut™ maintenance engineers and operators will ultimately result in skilled and knowledgeable personnel. This will allow for ideal system operation and performance when it comes to yield, settings, up-time and safety.

Experienced and well-trained staff are essential to your success, so we offer in-house and on-site SmoothCut™ system training that’s tailored to your specific requirements.

SUPPORT OPTIONS

We offer a number of service options that include full support, no matter where our clients are based, and will send a highly skilled technical team to provide full installation and maintenance when needed.

We can also conduct remote monitoring of your SmoothCut™ system and provide customer care around the clock. It’s also possible to connect to your system remotely, to allow diagnostic and support by our Customer Service department.

MAINTENANCE

Our proactive and preventative maintenance programme can be tailored to your SmoothCut™ system, so you can concentrate on creating and developing new ideas.

Production up-time is maximised by conducting inspections alongside a proper maintenance schedule and the replacement of SmoothCut™ parts if necessary.

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ELEA’S CutControl™

Full crop, cutting and quality control with the SmoothCut™ system and Elea CutControl™

OPTIMUM PEF CONTROL

Identify seasonal variations and effects quickly and easily so you can select the optimum PEF treatment conditions.

The Elea CutControl™ measures the cutting force of tubers before and after PEF treatment then displays the results instantly.

CONSISTENT RESULTS

PEF treatment using the SmoothCut™ system gets rid of seasonal variation in raw produce firmness to provide an even and consistent cut throughout the year.

The PEF treatment intensity can be easily monitored with the CutControl™ to identify the ideal parameters for the best possible product yield, quality and flexibility.

PORTABLE AND ROBUST

Elea’s CutControl™ is more cost-effective than a texture analyser and doesn’t need an extra computer to display results. It’s robustness and portability make it the perfect device for SmoothCut™ system process control in industrial production line.

The device comes with a range of cutting grids, sample preparation grid and a handy transport case too.

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Contact us

Prof.-von-Klitzing-Str. 9,
D-49610 Quakenbrück
Germany

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Address
Elea Vertriebs- und Vermarktungsgesellschaft
Prof.-von-Klitzing-Str. 9
D – 49610 Quakenbrück

Telefon: +49 (0) 5431 92629 70
E-Mail: info@elea-technology.com

Managing Director
Stefan Töpfl (Prof. Dr.)
E-Mail: s.toepfl@elea-technology.com

Commercial Register
HRB 206480 Amtsgericht Osnabrück
VAT No.: DE 285 421 329

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Richard, Chant Design Ltd

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