El arte detrás de los alimentos deshidratados de calidad superior

Creating exceptional dehydrated products isn’t just about the drying process – it’s about mastering what happens before. While EnWave’s REV™ technology is revolutionizing food dehydration, the magic often begins with precise preparation. Let’s explore how the right pre-processing techniques can transform good ingredients into extraordinary products.

The importance of pre-processing in food dehydration

Pre-processing plays a pivotal role in determining the final quality of dehydrated foods. These initial steps can significantly impact texture, flavor retention, and overall product appeal. Understanding and optimizing these techniques is essential for product differentiation and market success.

Cutting

The way a product is cut can dramatically influence its final texture and consumer appeal. At REVworx, our state-of-the-art facility offers versatile cutting options to suit various product needs:

• Slices: Typically 5-10mm, ideal for chips and snacks
• Cubes/Chunks: 10-20mm, perfect for ingredients or standalone snacks
• Fry Shapes: Tailored for products like carrot, beet, and sweet potato

Each cutting method imparts a unique texture and mouthfeel, allowing for product customization to meet specific market demands.

Blanching

Blanching is a crucial step in preserving the visual appeal and texture of many fruits and vegetables:

• Chemical Blanching: Utilizing solutions like sulfites or citric acid to maintain color during drying. For instance, apple slices are often blanched in a citric acid and salt solution to prevent browning.
• Water/Steam Blanching: This method partially cooks the product, locking in color and improving texture post-REV drying. It’s particularly beneficial for vegetables that require cooking to achieve optimal texture after dehydration.

Air Drying

Air drying is a critical preliminary step for most fruits and vegetables:

• Reduces moisture content to <60%, enhancing commercial viability
• Efficiently removes initial moisture, with up to 70% weight reduction when drying from 85% to 50% moisture content
• Allows for product customization:
  • Drying to 50% moisture before REV processing yields a fresher flavor and airier texture
  • Drying to 10% moisture results in a crunchier texture with a more concentrated flavor profile

Freezing

For certain products, freezing before REV drying is essential:

• Preserves shape and structure, particularly beneficial for high-moisture items
• Enhances texture: For example, carrots dried from frozen maintain their shape and develop a pleasant, light crunch
• Typically reserved for premium products due to additional processing costs

Flash Frying

Flash frying is an innovative technique used primarily for vegetables:

• Applied to air-dried vegetables at around 50% moisture content
• Involves brief (10-second) immersion in very hot oil to rigidify the product surface
• Excess oil is removed via centrifugation
• The remaining oil contributes to the final texture without imparting an oily taste
• Post-REV drying, products achieve a crisp, easy-to-eat texture superior to vacuum-fried alternatives

Pulsed Electric Field (PEF) Treatment

PEF technology represents the forefront of food processing innovation:

• Utilizes high voltage to create an electric field, forming pores in food cell membranes
• Combined with light air drying, freezing, and REV drying for optimal results
• Produces end products comparable or superior to freeze-dried items in terms of rehydration, color, texture, and appearance
• Currently cost-prohibitive for high-moisture products due to extended REV drying times

Your partner in advanced food processing

At REVworx, we understand the complexities of bringing innovative food products to market. Our SQF Level II certified facility is equipped with cutting-edge technology to support your product development journey:

• Temperature-Controlled Environments: Walk-in refrigeration and freezer units for optimal product handling
• Advanced Drying Technology: Large-scale air dryer and both 60kW and 10kW REV dryers for versatile processing options
• Comprehensive Processing Capabilities: From pre-drying to post-dry seasoning, formulation, and recipe batching using industrial mixers
• Quality Assurance: Metal detection systems ensure product safety
• Packaging Solutions: Bulk N2 flush packaging and palletization capabilities
• Retail-Ready Options: Consumer retail packaging services available

The REV™ advantage

EnWave’s REV™ technology stands at the forefront of food dehydration innovation. By combining vacuum and microwave energy, REV™ achieves rapid, low-temperature drying that preserves the integrity of food products. This unique approach addresses many of the shortcomings associated with conventional drying techniques:

• Rapid Processing: Most products are dried within 30-60 minutes, compared to hours or days required by traditional methods
• Nutrient Retention: Low-temperature processing preserves heat-sensitive compounds and nutritional value
• Flavor and Color Preservation: The gentle drying process maintains the product’s original flavor profile and vibrant colors
• Texture Customization: Precise control over the drying process allows for the creation of various textures, from crispy to chewy
• Energy Efficiency: REV™ technology achieves 85-90% energy efficiency, surpassing traditional drying methods

From concept to market

For entrepreneurs and established manufacturers alike, navigating the path from product concept to market launch can be daunting. REVworx offers a comprehensive solution to streamline this process:

Packaging and Distribution

Take advantage of our packaging capabilities and distribution network to bring your product to market efficiently

Desarrollo de productos

Leverage our expertise to refine your product concept and optimize pre-processing techniques

Pilot Production

Utilize our state-of-the-art facility for small-scale production runs to test market viability

Scale-Up Support

Benefit from our experience in scaling production to meet growing demand

Quality Assurance

Our SQF Level II certification ensures adherence to the highest food safety standards

Partnering for Success in Food Innovation

The journey from concept to market-ready product is complex, but with the right partner, it becomes an exciting opportunity for innovation and growth. REVworx, powered by EnWave’s revolutionary REV™ technology, offers a comprehensive solution for food manufacturers looking to stay ahead of the curve.

By combining cutting-edge pre-processing techniques with the unparalleled advantages of REV™ dehydration, we empower our partners to create products that not only meet but exceed consumer expectations for quality, nutrition, and sustainability. Contact EnWave today to schedule a consultation and explore the possibilities of advanced food processing for your business.