FOOD & BEVERAGE
The trolley specified by AVE UK consists of a tilting flat-bottomed tray featuring perforated sheet-metal grids, which enable the whey to successfully drain away, leaving the curd intact. To create the elasticity for which mozzarella
is renowned, the curd must then be stretched. Replicating the traditional manual process, the system supplied by AVE UK comprises mechanical arms that continuously move the curd and heat it via hot water injection, turning it into mozzarella. The cheese is then transferred to a moulding
machine, where it is shaped into the famous mozzarella balls, before being left to harden in a salting cheese vat. Essentially an automated ice bath containing a brine solution, the Priamo cheese vat is vital to the success of the finished product as it is the sudden change in temperature that causes the mozzarella to harden.
RETAINING INTEGRITY Fratelli Amodio were also keen to retain a level of traditional, artisanal cheesemaking in their production process. AVE UK’s solution successfully combines the efficiency, reliability, and hygiene demands of today’s market while facilitating the hands-on approach that makes authentic Italian mozzarella so unique. “AVE UK’s solution supports our production
of authentic Italian cheese while delivering the productivity and sustainability benefits expected with modern manufacturing,”
says Cesco. “Exclusively hand-making the mozzarella would bring the potential for human error, causing wastage which goes against our ethos of being a sustainable brand. Equally, switching to mass production would dilute the authenticity of our product. With this solution, we get the best of both worlds – consistent, reliable cheesemaking with a good yield of product per hour, combined with the hands-on artisanal approach that our customers expect.” This view is echoed by Steve Bradley: “We
designed our system to dovetail traditional cheesemaking skills with cutting-edge processing techniques. Although the equipment is automated, it is the operator who sets the parameters, such as the temperate and cutting speed. It is also up to the cheesemaker to determine when the mozzarella has reached the perfect level of elasticity, ensuring the artisanal qualities of the finished product are retained.”
ADDITIONAL REVENUE STREAM AVE UK’s solution also enables Fratelli Amodio to create an additional product from the processing residues. The whey that is separated from the curd at the start of the process is often retained in Italy and used to make ricotta. Remaining faithful to this traditional approach, the system comprises a cradle vat dedicated to ricotta production. Containing an automated heat injection system featuring a steam jacket, it keeps
the product at the desired temperature and ensures even heat distribution, avoiding the risk of hot spots.
COMBINING PAST AND PRESENT Due to be installed in early 2022, the new processing line will not only enable Fratelli Amodio to avoid the import taxes imposed on EU suppliers since Brexit but will also maximise their productivity rates, thanks to precision temperature and cutting control, automated production capabilities and consistency of quality. Also helping to minimise wastage during production, thereby further boosting profitability, it successfully combines the best of today’s processing expertise with heritage cheesemaking traditions. “Innovation doesn’t have to mean creating
a new technique,” says Steve Bradley. “For this project, it was essential that our solution respects and reproduces the traditional methods of mozzarella-making to replicate the true flavours of Italy right here in the UK, while also incorporating the hygiene, efficiency, sustainability, and reliability benefits requested by today’s market. It’s about cutting cost and waste, not taste and quality.”
AVE UK
https://www.aveuk.net/en/home
FACTORY&HANDLINGSOLUTIONS | APRIL 2022 15
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