Batch cookers and what I term as “Batch Cooking Engineering” is nearly a lost art form. In the 1950’s and 1960’s there were many rendering engineers who knew this product line inside and out and were well-versed on how the cookers were supposed to be run. Although it is a simple product in terms of construction and operation there are many formulas and calculations that can be performed to make sure the cooker runs efficiently. Today, most rendering suppliers are focused on newer, bigger continuous cookers and product lines. Alloy has also evolved into the newer technologies, and we know the rendering engineering used to make sure the bigger plants are properly run and designed.
When Alloy really began to get heavily involved in continuous cookers and newer technologies, our management group decided that we were going to continue to service the smaller batch rendering renderers in addition to the larger plants.
I feel fortunate that Duane Dahnert and Bill Aulik, two great men in Alloy’s history, passed along this rendering engineering knowledge to me prior to their passing. I, in turn, have taught the same formulas and engineering methodology to our Application Engineers and Alloy has retained that obscure knowledge that most companies have long since forgotten.
Alloy understands the evaporation rates and steam demands on all batch cookers. So if you have an Alloy, Dupps, Anco, French, Boss, or Globe batch cooker, we know what that cooker is capable of and how to size steam and condensate lines, boiler horse power required, evaporation rates, and we know if your cooker is operating at peak performance.
Condensing of the vapor off of the cooker is critically important, because if the vapor is not properly removed then back pressure is encountered and millions of BTU’s are wasted and long cook times result. Do you know what velocity the vapors need to move at in order to properly evacuate the cooker yet not pull product, fat and particulate from the cooker? We do. Alloy has this obscure cooking knowledge.
What happens if you have reduced steam pressure? How do you calculate the result of that reduced pressure on a batch cooker? Alloy remembers the old ways and we have the answers.
Does paddle clearance play a role in efficiency? What about RPM of the cooker for different products? Is speed of the cooker different for meat versus feathers? What are the differences between square and round shafts, is one better than the other? What temperature should I cook my product to? Is cook temperature different on beef, chicken and pork? How long should my cook times be? What do I need to do to hydrolyze safely? How do I size a bucket trap? What size condenser do I need? The answer to these and many more questions Alloy has retained. So if you know a batch renderer who is struggling or want to know how to answer these questions just give Alloy application engineers a call.
