Dual Purpose Processing Line for Food Ingredients
September 2026
Toasting and Sterilisation Thermal Processing Line, Integrated with Cooling & Bagging
Maze Process Solutions has delivered a fully integrated, dual purpose process line for an established UK food ingredients manufacturer. The system combines Thermal Processing, Cooling and Bagging within a single compact footprint, providing both toasting and sterilisation through controlled infrared thermal processing.
Developed and validated in Maze in house R&D Lab, the solution enables the customer to replace conventional ovens, increase process flexibility, and expand their product range while maintaining required microbial reduction standards.
Developed and Proven in Maze’s In House R&D Lab
The project was engineered through hands on development in the Maze R&D Lab, where we tested the effects of infrared heating with Maze Micronizer on the customer’s own ingredients and food products. This approach ensured:
- Verified thermal performance on real materials
- Confirmed product quality, colour and functionality
- Proven log reduction results aligned with global food safety requirements
- Confidence in the final production ready design
R&D validation allowed the customer to commit to a system tailored precisely to their process, product and throughput needs.
Toasting & Sterilisation Through Infrared Heating
The Micronizing section of the plant delivers controlled infrared heating suitable for:
- Toasting – enhancing flavour, colour and product functionality
- Sterilisation – achieving validated microbial reduction without damaging heat sensitive ingredients
Operational Advantages Over Conventional Ovens
- Lower energy consumption
- Faster processing times
- Improved consistency
- Increased capacity within the existing footprint
Integrated Line: Micronizing - Cooling - Bagging
The installed solution brings three core functions into one continuous line:
- Micronizing – rapid infrared heating for toasting or sterilisation
- Cooling – controlled product temperature reduction prior to packing
- Bagging – integrated packaging within the same footprint
This compact configuration reduces handling steps, improves throughput and simplifies overall plant operation.
Flexible Connection to Existing Urschel Processing
Strategically positioned diverters allow the new line to connect directly into the customer’s existing Urschel particle size reduction system. This integration provides:
- Multi product capability through shared equipment
- Efficient routing of materials between size reduction and thermal processing
- Greater operational flexibility without expanding the production area
The system is designed to work seamlessly within the customer’s established process flow.
Benefits of the Dual Purpose Processing Line
The installed system provides measurable improvements across product capability, process efficiency and plant integration. By combining thermal treatment, cooling and bagging into one continuous line, the customer gains a more flexible, reliable and space efficient operation that supports both current production needs and future product development.
This solution enables the customer to:
- Expand their product range
- Increase market penetration
- Maintain validated log reduction performance
- Reduce reliance on conventional thermal equipment
- Improve process efficiency and flexibility
- Upgrade without enlarging the existing production area
This project demonstrates Maze’s ability to deliver integrated, multi function thermal processing lines that are engineered, tested and proven using real customer materials.
Why Work with Maze
Engineering Focused. Delivery Driven.
Maze Process Solutions provides plant solutions with a strong emphasis on practicality, constructability, and operational performance. We understand that industrial projects must deliver more than design alone — they must work in real site conditions, integrate effectively, and support long-term operation.