India, Feb. 10 -- In the world of food processing, the demand for efficient, space-saving, and energy-efficient technologies is ever-growing. One of the most innovative solutions to address these needs is spiral technology, which has made significant strides in both food and non-food sectors. To better understand the technology's impact and Neologic Engineers' role in its evolution, we spoke with Mr Shrikrishna Ozarkar, Business Head for Fruits and Vegetables, Prepared Food, and Spiral Solutions at Neologic Engineers. Mr Ozarkar offered insights into the workings, advantages, and applications of spiral technology, along with how Neologic Engineers stands apart in the industry.

What is Spiral Technology?

Mr Shrikrishna Ozarkar began by elaborating on the core concept of spiral technology, originally designed as a conditioning system for secondary food processing tasks such as cooling, heating, and freezing. He elaborated, "Conditioning involves processing foods after their primary preparation is complete. For example, bread needs to be cooled after baking, ketchup must be cooled after hot filling, and ice cream requires freezing to preserve its texture and taste."

"Traditional linear tunnels were the go-to solutions for these processes. However, they consumed significant horizontal space and required substantial energy and manpower. With the rising cost of land and labor, as well as energy constraints, the industry began exploring vertical solutions," explained Mr Ozarkar. By utilizing the third dimension-height-rather than just relying on length and width, spirals make it possible to achieve the same cooling, freezing, or heating functions within a fraction of the space.

Why Spiral Technology stands out?

Spiral systems offer several compelling advantages over traditional linear tunnel systems. Mr Ozarkar highlighted the following:

Space efficiency: A spiral system can reduce the required floor space by 10 to 20 times compared to a linear tunnel for processing the same amount of product.

Energy efficiency: With innovative drive systems, such as overdrive, side drive, and direct drive, spirals consume far less energy. The direct drive system, in particular, reduces frictional losses and ensures that the belt operates efficiently without intermediary mechanisms.

Low operational costs: Spiral systems are designed to reduce operational expenditure (OpEx). They require significantly less energy, space, and manpower to operate, which translates into a faster return on investment (ROI).

Reduced maintenance: Unlike traditional systems, spirals require minimal maintenance, making them more cost-effective in the long run.

Versatility: Spiral systems can handle both solid and liquid products. Whether it's bakery items like bread and biscuits or dairy products like cheese and ice cream, spirals can accommodate a wide range of food processing needs.

Applications in the food industry

Spiral technology is used for multiple applications in the food industry, from cooling and freezing to pasteurizing. Mr Ozarkar provided several examples of how the technology is utilized:

Dairy Products: In dairy applications, products like cheese, paneer, and ice cream require cooling or freezing post-production to maintain their desired quality. For instance, after being filled at high temperatures, cheese must be quickly cooled to preserve its texture and taste, a process that spiral systems efficiently manage.

Ready-to-Eat Meals: Ready-to-eat items like curries, gravies, Sauces, Ketchups are typically hot-filled at temperatures ranging from 80-90 degC and need to be cooled rapidly to avoid overcooking or flavour degradation. Similarly, Samosa, Naan, Paratha all need to be cooled in time to retain taste, texture, crispiness etc. Spiral systems ensure that these products are cooled efficiently to retain flavour and texture.

Frozen Foods: Products like samosas and parathas often undergo baking or roasting before cooling and freezing. Spiral systems are well-suited for this process, ensuring that products are cooled down before being frozen at optimal temperatures.

Interestingly, spiral technology is not limited to food products. Mr Ozarkar also pointed out that industries like cosmetics and soap production benefit from spiral technology. Soaps, for instance, need to be cooled to achieve their final form, and spiral systems offer an effective solution for this purpose.

Neologic Engineers: A step ahead

What sets Neologic Engineers apart is their expertise in both primary and secondary food processing. Mr Ozarkar noted, "We are not just spiral manufacturers; we are solution providers with deep knowledge in prepared foods, sauces, dairy, and fruit processing." This comprehensive approach ensures their systems meet the highest hygiene and safety standards essential for food processing.

Neologic Engineers' spiral systems are also designed with sustainability in mind. By reducing energy and media consumption, such as hot water or steam, they minimize operational costs and environmental impact. The company also prioritizes after-sales support, including routine preventive maintenance to ensure long-term system efficiency. "One of our systems supplied 14 years ago for Namkeen (fried snacks) is still running efficiently and non-stop with just routine preventive maintenance," Mr Ozarkar shared.

Customization and efficiency

Neologic Engineers offer customized solutions based on specific product requirements. Mr Ozarkar explained, "Spiral systems are not one-size-fits-all; they are highly customizable based on the specific needs of the food processor. For instance, stainless steel belts are used for high-temperature processes like cooling fried snacks, while modular plastic belts suit delicate, low-temperature items like batter."

He further added, "Neologic Engineers provides specialized systems tailored to the customer's production layout. Since spirals work in a circular manner, the inlet and outlet can be adjusted to suit the available space, offering far more flexibility than traditional linear systems."

Direct Drive Technology: A game changer

One of the most exciting innovations from Neologic Engineers is the Direct Drive Technology, a patented system developed in collaboration with the US-based company Interlocks. "Globally, only a handful of licensed manufacturers use this technology, and we are proud to be one of them," says Mr Ozarkar. This technology offers several key advantages:

Elimination of vibrations: Traditional spiral systems can experience vibrations during product movement. Direct Drive system used by Neologic Engineers eliminates these issues by using a dual motor setup that automatically adjusts the belt tension, thus preventing potential damage and ensuring smoother operation.

Improved efficiency: The Direct Drive system also reduces belt tension, which is often a source of problems in traditional systems. This leads to lower risk of belt wear and tear, ensuring that the system runs efficiently and with fewer disruptions.

Meeting industry demands

Spiral systems designed by Neologic Engineers cater to both hot and cold processes. Depending on the application, they use ambient air, cold air, hot water, or chilled water to achieve desired temperature differences within specified time limits. For pasteurizing applications, they deploy air or water systems to heat and cool products efficiently.

According to Mr Ozarkar, Neologic Engineers' spiral technology is trusted by leading brands across the globe. In India, ID Fresh leverages this advanced technology for a variety of its products. Hindustan Unilever employs Neologic Engineers' spiral systems at multiple locations to process ketchup, sauces, gravies, and ready-to-eat meals. Global giant Mars utilizes this technology at their Pune facility for several of their products, while Heinz has adopted Neologic Engineers' spiral systems worldwide for processing various food items. Other notable clients, including PepsiCo, Nestle, Kraft Foods, have also embraced this innovative solution, showcasing its widespread application and reliability.

Neologic Engineers' Technical Partnership with FENCO Food Machinery & Intralox Direct Drive Partnership brings unique advantages of latest European & American technology at competitive pricing.

A bright future for spiral technology

Spiral technology is not just a processing system; it is a testament to how innovation can address industry challenges and create opportunities for growth and efficiency.

Mr Ozarkar emphasized the growing importance of embracing advanced technology in food processing. He stated, "While some food processors remain hesitant to adopt spiral systems due to initial costs, the long-term operational savings and improved product quality make the investment worthwhile. The technology not only saves on energy and space but also ensures products are processed faster, retaining their flavour, texture, and colour."

"Spiral systems can also seamlessly integrate into automated production lines, offering food processors an opportunity to upgrade their operations without significant disruptions. Our goal is to provide efficient, cost-effective, and maintenance-free systems that deliver value to our customers across industries," Mr Ozarkar concludes.

Neologic Engineers' expertise in both process design and spiral systems positions them as a leader in this space, helping food manufacturers across the globe reduce costs and enhance product quality. For those in the food processing industry, the message is clear: embrace the future with spiral technology, and experience faster returns, improved efficiency, and superior product quality!

Published by HT Digital Content Services with permission from FoodTechBiz.