Egg Breaking & Processing Factory - Advanced Egg Processing Machines in Action [BreakerPro] (2024)

Summary

The video takes viewers on a detailed tour of Pine Valley's modern liquid egg processing plant in the United States, highlighting advanced technology and stringent food safety standards. From washing and inspecting eggs to high-capacity egg breaking with yolk and white separation, the plant ensures optimal yield and quality. Pasteurization, cooling, and storage are carefully controlled to maintain safety and functionality, while self-cleaning systems streamline hygiene. The plant supports large-scale distribution and versatile applications of liquid eggs in food products like mayonnaise, ice cream, and pastries, showcasing Sova Technology Group's innovative solutions for efficient, high-quality egg processing.

Takeaways

• 🥚 Pine Valley houses a modern liquid egg processing plant in the United States, utilizing both inline and offline operations for consistent output.
• 🧼 Eggs are first washed and checked for dirt or defects; dirty eggs are rewashed, and defective eggs are ground and removed from human consumption.
• ⚙️ The plant uses advanced egg breakers: the Senovo Breaker Pro and Opti Breer, each capable of processing over 200,000 eggs per hour.
• 🍳 Egg breakers can separate yolk from egg white, producing three distinct products: egg white, egg yolk, and whole egg.
• 🔍 Photo cells and Senovo Opti Scan technology monitor each egg, ensuring precise separation and quality control.
• 💡 The Breaker Pro features an Egg White Recovery Unit that can increase edible egg white yield by up to 0.5%.
• ❄️ Filtered liquid eggs are cooled below 40°F using plate heat exchangers to inhibit bacterial growth and meet food safety standards.
• 🚛 Processed liquid eggs are stored in stainless steel tanks and can be transported directly to pasteurization or tanker trucks for distribution.
• 🔥 Sova pasteurizers safely heat treat liquid eggs, preserving functional properties while eliminating bacteria and extending shelf life.
• 🧽 The plant employs comprehensive Cleaning-In-Place (CIP) systems, fully automated and controlled by PLCs, to maintain hygiene and safety.
• 🍰 Liquid eggs produced are versatile ingredients used in foods like mayonnaise, dressings, ice cream, pastries, or further processed into egg powder.
• 💼 The facility integrates technology for monitoring, controlling, and optimizing egg processing, maximizing efficiency and product quality.

Q & A

What is the primary function of the Pine Valley processing plant?

The Pine Valley processing plant specializes in modern liquid egg processing, including washing, breaking, separating, cooling, pasteurizing, and storing eggs for further distribution or processing into various food products.

How are dirty or defective eggs handled in the plant?

Dirty eggs are sent back for another wash via a loop conveyor, while defective eggs are dropped into a grinder for further processing and are deemed unsuitable for human consumption.

What are the main types of egg products produced in this facility?

The facility produces three types of liquid egg products: egg whites, egg yolks, and whole eggs, each collected in separate vats and filtered for impurities.

What distinguishes the Senovo Breaker Pro from the Opti Breer model?

The Breaker Pro uses the latest technology, handles a higher volume, delivers the greatest yield, and can feature an egg white recovery unit, while the Opti Breer is a trusted, reliable model with consistent performance for over 18 years.

How does the plant ensure optimal separation of egg white and yolk?

Eggs are broken into specially designed polyethylene cups that are shaken to maximize separation. The Senovo Opti Scan system detects any yolk contamination in the egg white, and cups with ideal separation are collected separately into drain pans.

Why are polyethylene cups used instead of stainless steel for egg breaking?

Polyethylene cups reduce light reflection, improve egg white scanning, and lower power consumption by up to 40% due to their lighter weight.

How is the liquid egg cooled to meet food safety standards?

The filtered liquid egg is cooled using plate heat exchangers to below 40°F, inhibiting bacterial growth and ensuring the product meets safety standards before storage.

What role does the pasteurization process play in liquid egg processing?

Pasteurization safely heat-treats liquid eggs to eliminate bacteria, extend shelf life, and maintain functional properties. Specialized heat regeneration technology prevents cross-contamination and ensures precise temperature control.

How does the plant handle cleaning and hygiene?

Seno's cleaning-in-place (CIP) systems automatically clean pipes, tanks, and equipment using precise detergent concentrations and optimal flow rates, controlled via PLC to ensure food safety.

What are the common end-use applications of liquid eggs produced at Pine Valley?

Liquid eggs are widely used in foods such as mayonnaise, dressings, ice cream, pastries, and can also be further processed into egg powder to extend shelf life and reduce transportation costs.

How does the plant monitor and control egg processing operations?

The facility uses HMIs (Human-Machine Interfaces) on each breaker for easy control, and a fully integrated SCADA system manages operations like storage tank levels, valve clusters, pasteurization, and product flow.

What measures are in place to maximize yield during egg processing?

The plant uses optimal drain times, shaking cups for maximum separation, the egg white recovery unit, and precise scanning to ensure even small amounts of egg white are collected, increasing overall yield.