If you are one of those people who are thinking of starting a falafel business and you still don’t know the answers to these questions, before reading this article you should read the article from A to Z of Starting a Falafel Business.
And in the next step, give us answers to these questions:
Do you want to open a small falafel shop?
Do you intend to open a small workshop or a large workshop or even establish a ready-made or semi-ready-packaged falafel factory?!
If your answer to the first question is yes, it means that you want to open a profitable small or even relatively large fast food shop, so the full falafel production line is not suitable for you.
You can start your business just by getting a small or medium-sized fully automatic falafel machine or semi-automatic falafel machine , based on your daily sales.
But if you are thinking of starting a wider business and naturally looking for much more profit, reading this article will be very useful for you.
The complete line of falafel or nugget production and similar products can be designed and ordered from small and medium workshop dimensions to very large dimensions and mass production.
At any level of production capacity, the fully automatic production line is in charge of zero to a hundred production of your product, i.e. falafel or nuggets, etc.
This fully mechanized system can be divided into four main parts:
- Preparing ingredients (soaking chickpeas and grinding and mixing falafel ingredients)
- Material production (molding, frying and cooling)
- Packaging
- Storage (it is stored in the refrigerator and freezer according to the use-by date)
Each of these sections includes machines related to that section.
In the rest of this article, you will get to know more details of the machines that are needed in each section.
Materials preparation part
It includes machines for washing materials, transfer trolleys, meat grinder and mixer.
Washing tubs: Chickpeas are washed and soaked in them in two stages.
Transfer trolleys: Used to transfer and move materials between devices.
Fully automatic portable lifter: It is responsible for feeding grinders,mixers and molds.
Grinder and industrial mixer: These are ultra-advanced devices that mix and massage falafel ingredients uniformly and homogeneously, then grind well in several stages. These devices are equipped with a fully automatic lift.
Material production part
It includes industrial molding machines, industrial fryers and pre-cooling tunnels.
Fully automatic industrial mold maker:
At this part, the portable lift and trolleys come to help and put the materials into the mold machine.
This machine molds the prepared materials at a variable speed according to your production capacity in the desired volume and shape.
The molded material is passed through the fryer by a conveyor belt.
Different capacities of these devices can be ordered and supplied (From small one-meter fryers with the capacity to produce 1000 falafel tablets per hour to giant industrial fryers with a production capacity of up to 6 tons per day).
But the majority of food industries that use industrial frying machines are facing problems such as a very large amount of oil that they have to consume, oil burns, oil filter problems, etc.!
Novin Sanat frying machines have solved these problems with their unique design.
The feature that has attracted the attention of the world market is the saving of 70% of oil consumption and the energy consumption of these devices, as well as the fact that they are equipped with an oil filtration system and an automatic oil temperature adjustment system.
Pre-cool:
Pre-cool is made in coordination with the output capacity of the fryer of your production line.
This step includes two types of pre-cooling devices:
_ The first cooling device that reduces the temperature of your patties from 180 degrees immediately after frying to ambient temperature (25-20 degrees).
_ The second cooling device that lowers the temperature again to the extent that the product is ready for packaging or transfer to the cold storage.
How much falafel does the falafel production line produce in a specific period of time?
The productivity of a falafel production line can be vary depending on the specific machine and its settings. For instance, the of the Falafel Machine can produce up to 100 falafels per minute, or 6,000 falafels per hour.
On the other hand, a some of the automatic some falafel machine can produce over 500 falafel balls per hour with just 1-2 workers .
What equipment does the falafel production line include?
A falafel production line can include several types of machines, each playing a specific role in the production process. Here are some examples:
- Falafel Making Machine: This machine is used to form the falafel balls. It usually comes with programmable controls for customizable operation
- Automatic Falafel Machine: This machine automates the falafel making process, allowing a single worker to produce thousands of consistent, high-quality falafel every hour
- Falafel Maker: This machine transforms the intricate process of falafel making into a streamlined operation, producing uniformly sized and consistently delicious falafel with speed and accuracy
- Falafel Frying Machine: This machine is used to fry the falafel balls. It often comes with an automatic temperature control system, automatic conveying system, automatic oil filtering system, automatic slag removal system, and automatic lifting system
- Encrusting and Forming Machine: This machine is designed with a special extruding system suitable for mashed chickpeas and other beans to create falafels with the same weight and consistent appearance
In your case, considering the Novin Sanat’s falafel machine, it’s important to look at the specific features and specifications of the model you’re interested in. This will help you understand its capacity, automation level, and other key aspects that will impact its performance in a production line.
Remember, the choice of equipment will greatly depend on your production goals, budget, and the scale of your operation.
Packaging part
To pack your falafel or nuggets, you don’t need to turn to the general packaging machines available in the market because special packaging machines are designed for these products and are used in these lines.
Falafels that are ready to be packed in these machines are packed in desired capacity and ready to be presented to the market or cold storage.
The last part of the complete falafel production line is transferring the ingredients to the cold storage and keeping the product there and then distributing it to the target market.
The largest fully automatic falafel production line in the world
It is interesting to know that the largest falafel production line in the world with a length of 40 meters and more than 6 tons of production capacity per day has been launched in America by Novin Sanat Company!
Novin Sanat Machinery Industry has a history of more than a decade of specialized activity in the field of engineering design,production and export of all kinds of fully automatic and semi-automatic falafel, cutlet and nugget machines in different capacities and dimensions (more than 50 models) that are suitable for a wide range.
The food industry has been produced from small fast food to large industrial factories, it is known as the mother producer and specialized reference for the production of all kinds of falafel machines in the world.
This company has designed, produced and exported the world’s largest falafel production line exclusively for one of the largest American food manufacturers and exported to America in December 2021.
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