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01. July 2022

Natural food producer Rapunzel (Germany) has installed a new infrared light-based system for its nut segment

Organic pioneer Rapunzel relies on FoodSafety-IRD for safe sterility, gentle roasting and a balanced taste experience

"With KREYENBORG, we have been in contact for several years and have already conducted trials," says Alexander Karst, Head of Production at Rapunzel. The company's nut range - almonds, peanuts, macadamia nuts, pistachios, and more - has been refined using KREYENBORG's infrared light technology since mid-2021. This has also allowed the company to expand its roasting capacities at its Bavarian site in Legau.

Consistent roasting for full flavor

Using the thermal process, the product to be treated is precisely and quickly heated from the inside out, ensuring uniform roasting of the entire nut. The patented FoodSafety-IRD (short for Infrared Rotary Drum) regulates the intensity of the infrared light, as well as the process and product temperature. This prevents overheating of the treated goods, allowing the aroma to develop slowly and achieving a balanced roasting result.

"Roasting releases the substances that give nuts their unique flavor," explains Karst. A recognizable taste is achieved through consistent treatment with a uniform degree of roasting—and this is precisely what KREYENBORG's system offers.

Through a discharge station, the nuts are fed from large bags into the conveyor belts in the new installation in Legau, cleaned, collected in a storage silo, and then precisely dosed into the FoodSafety-IRD. After roasting, a cooler brings the goods back to room temperature to prevent mold growth. The nuts are then re-weighed, transported to intermediate storage, and prepared for further processing in various production areas.

Focus on food safety

In addition to pasteurizing, drying, and roasting nuts, the family-run company KREYENBORG, based in Senden, North Rhine-Westphalia, Germany, specializes in the protection of food stocks. Seeds, spices, herbs, tea, cereals, and other dry products can be freed from microbial contamination, insects, larvae, and eggs through infrared light heat. Unlike steam-based processes, there is no optical or sensory damage to the products. Plant-based proteins remain intact, and gentle heating is said to ensure longer shelf life.

Goal of energy self-sufficiency

The FoodSafety-IRD operates entirely on electric energy. Rapunzel aims to generate all the electricity required for the roaster itself to minimize its ecological footprint. Many conventional technologies rely on the combustion of gas or other fossil fuels, which result in significantly higher CO2 emissions.

One challenge was to configure the infrared roasting system to be user-friendly, fully compliant with operational requirements, and integrated into the available space. Regulatory emission limits had to be met, as well as ensuring minimal noise levels out of consideration for neighbors.

Alexander Karst is pleased with the innovation. "KREYENBORG's system works both efficiently and gently, ensuring high operational reliability," says the production manager. At the Food Trial Center at the company's headquarters in Senden, customers can witness the processing of their products firsthand.

 

Source: BioPress

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