Articles/White Papers

One-Stop Resource for Pouch Processing

The Lyco/Sharpe team has been in operation for several years, collaborating on many pouch cook-and-cool projects for food processors. This relationship has enabled both companies to help smaller-volume processors build out their entire pouch process capability, with all machinery and solutions integrated.

Smaller-volume pouch production facilities looking to significantly scale up production from a manual operation to continuous pouch production can now tap into a turnkey, fully-integrated one-stop resource.

Tribe 9 Foods, a premiere alternative pasta maker with an extensive line of fresh and cooked, traditional and gluten-free pastas, recently expanded its gluten-free pasta cooking and cooling line to better service its retail, foodservice and co-manufacturing customers by adding state-of-the-art Clean-Flow^® continuous cook-and-cool technology from Lyco Manufacturing.

Processing up to 8,500 pounds of soaked dry beans per hour, 400,000 pounds per week, RS Hanline’s new fully-automated continuous-process soak-cook-chill-IQF line is equipped with advanced Pressure-Flow® cooking technology from Lyco Manufacturing.

Smaller-volume production facilities looking to significantly scale up production of ready meals from a batch or semi-batch cook-quench-chill operation to continuous production can now economically do so with scaled-down cooking and cooling systems for dry beans, rice, pasta and vegetables.

The preparation of dry beans, lentils and peas for subsequent processing into plant-based meat substitutes in the form of burgers, sausages and crumbles relies on highly-automated continuous-process systems that maintain precise control over time, temperature and moisture during hydration, de-flavoring, cooking, pasteurization and cooling. 

“Plant Based Proteins” have been around for decades but, this market is currently exploding. Plant-based proteins can offer less calcium, less saturated. There are many popular nutrition advantages including reduced saturated fat, calories and cholesterol.

The Sanitary Zero Maintenance Screen is the most automated machine in Lyco’s line of water recovery screens for poultry processors.

In food processing, the reliability of equipment is everything. For example, if a root crop peeler goes down for maintenance, the entire processing line is affected…and that’s lost revenue.

As municipalities and other agencies push for tighter limits on the disposal of wastewater, poultry and beef producers are looking for new ways to meet these wastewater mandates. The Sanitary Zero Maintenance Screen is a perfect solution as it filters wastewater and reclaims it for new uses back in the food processing systems.

Screening and recycling the water stream from Virginia Poultry’s bird washers is reducing its water usage by 170 GPM, an estimated 19 million gallons annually and savings of $160,000 each year in water purchases and treatment. The newly-installed Sanitary, Zero-Maintenance liquid/solids separation screen from Lyco Manufacturing has also provided the turkey processor with the most sanitary rotary-drum screen in North America.

Virginia Poultry recently installed several liquid/solids separation screens for its turkey feather and offal processing. The two new primary and one secondary state-of-the-art rotary-drum screens, provided by Lyco Manufacturing, are a showpiece for optimized throughput and operational efficiency, while reducing water consumption.

Food processors are seeing the benefits of changing from batch to continuous cooking and cooling of pasta. Mixum, AB, the leading producer of cooked pasta in Sweden, recently made the switch from batch to continuous processing with a significant improvement in the quality of its pasta and an 85 percent reduction in its cleanup changeover times.

The most comprehensive lab of its kind in the food processing industry, Lyco manufacturing’s testing and simulation lab is designed for analyzing blanching, cooking, pasteurizing and cooling processes for its clients’ rice, pasta, dry bean, vegetable and pouch products

New generation of food processing coolers utilizes high-velocity, plenum-directed fluid motion capable of reducing cooling cycle times by 80% compared to the most efficient conventional systems. Most pasta, rice, dry beans and vegetables can now be chilled from 200 F to 40 F in 21 seconds with uniform cooling and less than one percent product damage.

With the steady increase in poultry processing rates, there has been a corresponding increase in wastewater pollutant concentrations. Despite mechanical improvements in wastewater treatment, many poultry processors continue to pay unnecessarily high fees for municipal water discharges. Michigan Turkey Producers, $100-million-annual processor, in conjunction with Lyco Manufacturing, has set up a state-of-the-art screening system that is an industry showpiece for poultry wastewater treatment.

Master pasta maker, Perfect Pasta, Inc., supplies airlines with pasta meals, blending traditional pasta making of old world Italy with the latest technology in continuous-flow pasta cooking and cooling from Lyco Manufacturing.

Pepe’s Mexican Restaurants in Chicago maintains critical cook-and-chill temperature levels at its central food production facility, utilizing state-of-the-art continuous pouch cooling technology developed by Lyco Manufacturing.

Lyco Manufacturing’s mobile equipment display provides a convenient, hands-on opportunity for food processors to see the company’s latest production-size cooking and cooling technology in operation, right at their front door.