BASTRAMATUniversal Cooking

and Smoking Installations

From the very outset, the founders ofour company had the goal of develo-ping need-oriented and value-retentiveproducts for meat- and food-processingcompanies.

An objective that has constantly defi-ned our entrepreneurial thinking andactions right up until this very day, andwill continue to do so.

The rigorous implementation of thisphilosophy has helped put us in theposition we are today as one of thehighest-regarded manufacturers ofsophisticated cooking and smokinginstallations, both at home and abroad.

In excess of 60,000 cooking and smo-king installations sold worldwide for theproduction of meat and sausage goodsas well as for fish and poultry productsare testimony to our competence andwide acceptance in the market.

Innovative technologies have not onlybeen used meaningfully to this end, buthave also been further developed withall our strength and expertise to meetthe specific needs of both the marketand our customers. Numerous deve-lopments protected by patents andregistered designs are evidence of ourinnovation potential.

In order to be able to provide the mar-ket with solutions that meet its specificneeds, we offer our installations with avariety of design, feature and technolo-gy options.

High-quality standards underpin thedevelopment, production and assemblyof our products and installations.

The importance we attach to quality isalso demonstrated by our striving forenvironmental compatibility. The res-ponsible usage of the available rawmaterials and resources is just asimportant to us as is our handling ofthe issue of waste disposal. Seen inconnection with these aspects too, ourtechnologies offer significant benefits. As, after all, we do all we can to ensu-re that high-quality products can beproduced in not only an economicallyviable but also an environmentally fri-endly manner.

Economic viability, i.e. the perfect inter-action between productivity and opera-ting costs, is a key factor wheninvesting in new production installati-ons. Once the requirement profile hasbeen established, we are then able todesign our installations in such an indi-vidual way that they enable a tailor-made solution to be found for the pro-duction and operating processes con-cerned. These customised installationscombined with the appropriate controlunits and accessories thus meet thekey requirements needed to achieveoptimum production results.

In order to be able to fully exploit theproductivity of our installations, thesmooth interaction between ‘man andmachine’ must also be guaranteed. Weattach the utmost importance to thisaspect.

In addition to providing thoroughinstruction in the initial operation pha-se, we also offer our customers theopportunity of further improving and/orupdating their know-how via regularlyheld technical seminars and intensivetraining sessions.

A pronounced customer focus is at theheart of the wide variety of services weoffer. Our teams of advisors – lead byqualified process technicians – provideprofessional, co-operative support inthe individual planning and implemen-tation of cooking and smoking installati-ons and reliable provision of stand-bysupport prior to, during and after pro-duction, installation and initial operati-on.

Foreword

BASTRAMATUniversal Cooking and Smoking Installations

Smoke generation

The BASTRAMAT in action

Cooking · Roasting · Cooling

Climate maturing

Special equipment

Accessories

Contents®

The BASTRAMAT offers more or lessunlimited application options in termsof modern cooking, smoking, coolingand heating technology.

Our programme ranges from the single-truck chamber for small-scaleoperations through to the multi-truckinstallation required for large plants.

Our installations are used throughoutthe world by sausage- and meat-processing companies as well as in therefining of poultry, fish, cheese andbakery products.

The key advantage BASTRAMAT tech-nology offers is based on its capabilityof precise dosage of temperature, moi-sture, smoke density and air flow aswell as on the incorporation of this intoan appropriate control system.

The maxims being – environmentallyfriendly technology combined with optimum efficiency and quality. Thisapplies both to the classic options ofsmoke production via smoulder smokegenerators for sawdust or wood chipsas well as for friction smoke and liquidsmoke.

The wide variety of application areassuch as hot smoking, warm smokingcold smoking, moist smoking, intensivesmoking, fast smoking, reddening, drying, browning, blanching, steaming,simmering, cooking, hot-air simmering,semi-preserving, baking, roasting andthawing guarantee the universal usageof these installations.

The BASTRAMAT system offers youabsolutely optimum perfection, maximum safety and the followingequipment features supplied as standard:

• Fully automatic, electrically drivensmoke- and air-valve operation

• Sensitive, electronic chamber andcore temperature control

• Psychrometric moisture and automa-tic fresh-air control

• Wetting of compressed air for opti-mum moisture saturation for connec-tion to customer’s compressor

• Cleaning of compressed air

• Multi-phase air circulation via speci-ally designed CNS high-performanceventilator fans and the even trans-mission of the smoke via optimisedblow-out sprays.

The ventilator fans are dynamicallybalanced. Vibrations and disruptivenoise development are thus exclu-ded. The dimensioning of the ventila-tor fans provides for an absolutelyeven and strong air circulation withinthe given chamber at low revs.

• Complete piping of additional andauxiliary facilities – cleaning and wetting via corrugated stainless steelhoses. Maintenance-friendly installa-tion of valves on distributionsystems.

• High-quality chrome-nickel steelsmoke and exhaust pipes with speci-al seals.

• Internal area of single- and double-truck chambers in steam-tight weldeddesign with all-round full insulation.The special mineral insulation is cha-racterised by its low conductivity andthus optimum heat insulation. Thisinsulation plays a major role in redu-cing the amount of heating energyconsumed.

• Chambers with a self-supportingdesign and made of high-qualitystainless steel.

• Double-walled door with all-roundsilicon profile seal and heavy sealingelements made of chrome-nickelsteel.

• The installations can be accessed atfloor level for easy loading.

• Heating types:

Model 850/851: electric

Model 1200/1201/1500/1501: electric, gas, oil or LP steam

Model 2000/2001 and multi-truckchambers are available in conjunc-tion with a wide range of heatingtypes. These installations can thusbesupplied as standard with electric,gas, oil or HP or LP steam heating.

BASTRAMAT installations with high-pressure steam heating are equippedwith robust steam registers that arecharacterised by an extremely largeheat-exchange area.

• High-tech microprocessors

These newest-generation programmecontrollers, which have been develo-ped specially for our BASTRAMATsystems, stand out thanks to their easeof handling combined with optimum flexibility and robustness. The digitaltechnology they incorporate guaran-tees maximum precision and the precise compliance with set values. Upto 99 highly varied programmes can becreated and memorised. The automaticprogramme start facility with a preselect option assures round-the-clock operation.

Details of these newest-generationcontrol units can be found in our special ‘MC Controls’ brochure.

BASTRAMAT Universal Cooking and Smoking Installations

®

Blow-out sprays Chrome-nickel steel viewing window High-pressure steam register

Chrome-nickel steel hinge

TS 800 microprocessor control unit

MC 500 microprocessor control unit

VIEW & CONTROL measurement data-logging software

Chrome-nickel steel seals

Wood-chip smoke generation

SMOULDER SMOKE / SAWDUST

UF smoking technology

Sawdust smoke generation with adja-cent smoulder smoke generator.

A part-flow of the smoke/air mix is with-drawn from the chamber and togetherwith fresh air fed back to the smokegenerator. The small quantity of residu-al smoke leaves the chamber via athrottled exhaust valve.

SMOULDER SMOKE / WOOD CHIPS

TF smoking technology

Wood chips’ smoke generation in thedoor. Fresh air is fed into the smoulderzone with the result that the valuable,natural smoke aroma is preserved.

The smoke is sucked in by the BASTRAMAT installation and fed to thegoods to be smoked via the air circula-tion system. The amount of fresh airthat is precisely supplied to the smokegenerator leaves the chamber via athrottled exhaust valve in the form of asmall quantity of residual smoke.

For you, both BASTRA UF and TFsmoking technologies enable you tocarry out your production using anexhaust-reduced, through-flow installa-tion with circulation/fresh air operation.The requirements laid down by therelevant VDI 2595 guidelines for emis-sion reduction are undercut by thissmoking technology.

UF system TF system

®

Smoke generation in a closed system

851 C-GS model

SMOULDER SMOKE / SAWDUST

Sawdust smoke generator built into thedoor.

The BASTRAMAT installation works asa closed system or can be switched toUF-system operation.

As a closed system, the installation canbe fully operated as such during thesmoking phase. Only such oxygen asis located in the installation is used forsmoke development purposes. Theresidual smoke that is in the installationis densified with water vapour duringthe subsequent ‘cooking’ phase orreduced to a small residual quantityduring a later ‘consumption’ phase. Asno notable emissions are producedduring the smoking process, this instal-lation can be operated in compliancewith the currently valid environmentalregulations without an exhaust cleaner.

The UF system offers the operator aprocess whereby a factory-presetquantity of fresh air is constantly fed tothe smoke generator from outside. Theinstallation then works as an ‘exhaust-reduced circulation plant with fresh airadmixture’ during the smoking phase. Itis classed as being environmentally fri-endly thanks to its very low level ofemissions.

This BASTRAMAT unites the proven,traditional, sawdust smoulder smokemethod with the environmental benefitsand low cost operation a closed systemoffers.

Smoke generation using this technolo-gy in a closed system means that cata-lytic after-burning is no longer neces-sary. As certain officially required mea-surements and tests are not needed,this cuts not only operating costs butalso investment expenditure because acatalyser does not have to be purcha-sed.

The installation with a sawdust smokegenerator is only available as a purelyUF system option.

GS system UF system

FRICTION SMOKE

Friction smoke generator built into thedoor or with adjacent friction smokegenerator

The installation works as a closedsystem and therefore produces noemissions during the smoking phase.

Any residual smoke is sprayed withwater and washed away in the smokegenerator after the smoking programme is finished.

A special friction wheel provides forstrong smoke density with low noise.An integrated magazine can store 4beech logs. Other types of wood canalso be used.

Smoke generation in a closed system

1201 C-RR model

Friction smoke production with adjacent smoke generator Friction smoke generator in the door

LIQUID SMOKE

This well-proven environmental friendlymethod offers significant benefits vis-à-vis many conventional smokingmethods and is characterised above allby the non-existence of the known pol-lutants in the smoke, which have alrea-dy been filtered out during the produc-tion of the liquid smoke.

The key advantage of BASTRA liquidsmoke technology is its precise dosagecapability and incorporation into anappropriate control system. BASTRAcurrently offers the most sophisticatedliquid-smoke system in the market and,with this, a technological edge vis-à-visthe competition.

This technology produces ideal resultsthanks to the optimised interaction between state-of-the-art micro-processor control, moisture regulation,even air circulation, temperature andsmoke density. Precise, fine dosageprovides for the stable and dry smokeneeded for smoking.

®

Smoke generation in a closed system

FR 50 liquid smoke generator

Two-component mix spray

FR system

The benefits at a glance

• Emission-free smoking without time- and cost-consuming permissionprocedures

• No costly after-burning

• No costly emission measurements

• Reduction in waste water contamina-tion

• No disposal of tar residue and ash

• Improved hygiene and cleaner workplace

• Safer workplace due to elimination ofrisk of fire and explosion

• Low storage space requirements forsmoking materials

• Maintenance-reduced smoking

• Constant results due to stable smoking colour and aroma

• Improved productivity

• Value-for-money smoking method

The BASTRAMAT in action

®

COOKING AND ROASTING CHAMBERS

For temperatures up to 250° C we canoffer you special high-temperature cooking and roasting chambers thatare characterised by a high heatingcapacity and particularly efficient insu-lation.

These installations are classic, univer-sal plants as they can be used for roa-sting, drying and cooking purposes.

They work in roasting mode with hot airthat is fed past the goods requiring roa-sting at high speed to achieve an even-ly intense simmering effect.

The chambers are operated with eitherhorizontal or vertical air circulation.Your products are thus given gentle treatment with extremely low weightloss.

Electric and LP steam/electric are theavailable heating options.

An adjacent smoke generator enablesthe installations to also be used asBASTRAMATs.

INTENSIVE COOLING INSTALLATIONS

BASTRA intensive cooling installationsare used in the fast cooling of meatand sausage goods produced in theBASTRAMAT or cooking chamber.

Immediately after production, thegoods are cooled in the intensive cooling installation to a preset coretemperature. They are then dried andforwarded for packaging without delay.

Control procedures are carried out viaa microprocessor with all the facilitiesneeded for regulating air circulation,cooling, interval shower, compressed-air wetting, core-temperature measu-ring, automatic fresh-air and exhaustvalves.

The benefits of this installation

Fast cooling Temperature range between +6° C and +8° C Core temperature

Goods are immediately ready for packaging

Extension of shelf-life

The size of the intensive cooling installation can be selected to suit thegiven BASTRAMAT installation

Cooking · Roasting · Cooling

Cooling register

Climate maturing ®

CLIMATE MATURING SMOKEINSTALLATION

The ideal installation for maturing, drying and smoking raw sausage, rawham and long-life products.

The particularly gentle treatment theproducts receive optimises the maturing process and correspondinglyminimises the risk of maturing defects.

The values set on the microprocessorsuch as moisture, temperature andcooling are monitored and correspon-dingly regulated.

This is the only way of achieving ratio-nal and precise climatisation.

Temperature range adjustable between +18° C and +35° C

Moistureadjustable between 65% and 98% relative moisture

Generally speaking, the installationscomprise of multi-truck chambers thatcan be supplied with or without smoketreatment in accordance with the custo-mer’s needs. Climate smoke installati-ons are also available with the all thestandard smoke generation options.

4-truck chamber maturing smoke installation

Machine part and friction smoke generator

• Catalytic exhaust cleaner For installations requiring permits orsubject to other stringent conditions,we offer a tailormade catalyticexhaust cleaner to suit the giveninstallation .

• Cooling facility The targeted interaction betweenheating, exact temperature regulationand air circulation enables you tocarry out any smoking process irre-spective of the given ambient tempe-rature. For connection to the custo-mer’s refrigeration equipment

• 3-phase air circulation

• Built-in cooling shower

• Rotary cooling shower made of stain-less steel with optimum cooling effectand low water consumption, separatewith its own interval shower control

• Control unit and smoke generator inan add-on column

• Automatic sawdust wetting facilitybuilt into smoke generator

• Automatic door opening via compres-sed air cylinder – compressed air tobe supplied by customer

• Doors at front and back

• Horizontal alternating air circulationonly for products that are laid downflat and processed on grills such assides of salmon, roast beef, chickenetc.This type of air circulation enablesthe number of levels per truck to beincreased, thereby significantlyenhancing production capacity.

• Glass door with internal lighting –thus enabling you to view all the pro-cesses in the smoking chamber with‘your own eyes’ and, depending onthe location of the installation, to giveyour customers a ‘live smoking’demonstration.

Special equipment

Horizontal ventilation via perforatedsheet side-walls and 2nd door in rearwall.

BASTRAMAT with glass door

Control unit in an add-on column

A = heat exchanger B = electric heating C = catalyser

A

B C

Outlet Inlet

Rib-pipe cooling evaporator made ofchrome-nickel steel

CHARGING TRUCK

High-quality, stackable charging trucksmade of chrome-nickel steel

With supports for accommodatingsmoking sticks 80, 90 or 100 cm inlength, perforated cooking trays, grillsand fat collection trays. Truck chassis with 6 plastic casters,arranged in such a way as to facilitatesteering and turning.

Each level is fitted with supports toaccommodate smoking sticks, cookingtrays and grills.

• Solid grills made of stainless steel

• Perforated cooking trays made ofaluminium

• Fat collection tray made of chrome-nickel steel

®

Truck for BASTRAMAT 1500/1501 Smoking stick lengths: 90/100 cm Supports: 6 / Support spacing: 25 cm External dimensions: 93/103 x 84 x 169 cm Floor clearance: 32.5 cm

Truck for BASTRAMAT 2000/2001 Smoking stick length 100 cmSupports: 6 / Support spacing: 26.5 cmExternal dimensions: 103 x 100 x 190 cmFloor clearance: 45 cm

Accessories

Truck for BASTRAMAT 850/851 Smoking stick length: 80 cm Supports: 5 / Support spacing: 25 cm External dimensions: 83 x 70 x 136 cm Floor clearance: 28 cm

Truck for BASTRAMAT 1200/1201 Smoking stick length: 90 cm Supports: 5 / Support spacing: 25 cm External dimensions: 98 x 80 x 150 cm Floor clearance: 42.5 cm

Bayha & Strackbein GmbHP.o. Box 12 60 · D-59702 Arnsberg

Kleinbahnstraße 12-16 · D-59759 Arnsberg-Hüsten

Phone: +49 (0)2932/481-0 · Fax: +49 (0)2932/4 8139 Internet: www.bastra.de · E-mail: info@bastra.de

Member of German Association of Cooking and Smoking Installations Sta

tus:

05/

2004

– s

ubje

ct t

o te

chni

cal a

ltera

tions