GEA-CMT

CONTINUOUS STEAM STRETCHING MACHINES SERIES

DISCOVERY PLUS
 SOME MODELS CMT PATENTED ARE AVAILABLE FOR PRODUCTION 500 - 6000kg/h:

DISCOVERY PLUS N 600 AC1

DISCOVERY PLUS N 800 AM1
DISCOVERY PLUS N 1000 SM1C
DISCOVERY PLUS N 1200 SL1C
DISCOVERY PLUS N 1500 SM2C
DISCOVERY PLUS N 2000 SL2C
DISCOVERY PLUS N 3000 SL3E
DISCOVERY PLUS OVER N 4000 OM*2C
DISCOVERY PLUS OVER N 5000 OL*2C
DISCOVERY PLUS OVER N 6000 BL*3C

Discovery Plus engineering for a better world

 Dipping arms mixing
chambers Pre-stretching tunnel
Curd loader
and cutter
Pasta filata extruder

MODULAR STRETCHING MACHINES

Discovery Plus engineering for a better world

 MODULAR STRETCHING MACHINES

Discovery Plus engineering for a better world

 The series Discovery Plus (models for small, medium and big productions)
offers some important advantages that can be summarized as follow:

PRODUCTION FLEXIBILITY

possibility to process both fresh and commercial curds of any origin or

mixture of both the curds

these machines can work only with steam or only with water, or both with
water and steam, with or without recirculation of fat water

they are suitable for production of fresh mozzarella (bocconcino), braids,

loaves for pizzerias, scamorza, kashkaval

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 INCREASED PRODUCTION YIELD FROM +0,5% TO +1%
(compared to traditional technology with water)

very high yield (according to the moisture of the curd and the wished
final moisture)

starting from commercial curds with dry matter not lower than 57-58%
(moisture 42-43%) these machines together with the exclusive applied
technology allow obtaining a high moisture mozzarella (62-65%) with
production yield that can be stated between 38 and 42% or pizza-cheese
(48-52%) with yields of 13-15%

dipping arms allow obtaining a structured product with a longer fiber,

higher absorption and retention of water with a consequent increase in the
yield and longer shelf-life

in case of production of pizza-cheese the long fiber structure allows

shredding the cheese in-line with a higher moisture compared with other
technologies

Discovery Plus engineering for a better world

 HOMOGENEITY OF STRETCHING TEXTURE

stretching process with dipping arms without compression of the fibres

the pasta filata obtained has the same structure as per the traditional
stretched products i.e. fibrous, elastic, with clear structure; it allows to
obtain the best quality concerning moisture and taste
dipping arms allow a perfect and homogeneous mixture between fresh
and commercial curds, even if pH are different, avoiding in this way
colour striations the in the final product
along the whole length of the machine there are many steam injection
points; the pasta flows continuously and in the same direction along the
whole stretching machine; in this way it undergoes to a gradual increase
of temperature and there are no brusque concentrations of steam.
Finally the product is less stressed and is more white

Discovery Plus engineering for a better world

 HOMOGENEITY OF STRETCHING TEXTURE

heating of the curd is not done for "impact" as in the case of the
traditional stretching, but it is the result of condensation of steam. In the
first case a compact mass of water at 85C is poured on the curd
creating melted" zones on the surface while the inside is not reached
by the heat yet; consequently the stretching is not homogeneous. The
steam, consisting of particles very mutually spaced, even at
temperatures above 100C, has a less "aggressive" effect on the curd
that is gradually heated by condensation of the particles. A more
homogeneous and regular stretching is therefore obtained
the hot water (necessary in some productions) is produced directly in
the vat placed under the machine; therefore it is not necessary to
arrange an external hot water heater
inside the mixing chambers the pasta is kept at the temperature of ~
62C for ~ 1015 minutes
Discovery Plus engineering for a better world
 SALT DOSAGE
salt can be added in the mixing chambers. During production process with
steam water the whole quantity of added salt is absorbed by the final
product

ENERGY SAVING 30%

there are no by-products such as fat milk or stretching water. In fact the
whole added steam is merged in the final product; expenses for recovery,
skimming, cooling and tailings removal are saved

VULCAN TREATMENT ON SURFACES IN CONTACT WITH

THE PRODUCT

all surfaces in contact with the product are not teflonized anymore but
treated with the new non-stick treatment Vulcan, patented by CMT - this
treatment, unlike the Teflon to be restored to deadlines determined by the
conditions of use, will have virtually unlimited life, being it not a covering
but a mechanical and chemical action on the surface

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 GENERAL CALCULATION OF
THE PRODUCTION YIELD

Mi = initial mass of curd to be processed (kg)

DMi = dry matter of the initial curd (%)
DMf = dry matter of the final product to be obtained (%)
Mf = final mass of the obtained stretched product (kg)

Mi DMi
Mf
DMf
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 Starting from 100kg of
commercial curd with dry
matter 55% YIELD CALCULATION:
(moisture 45%) PIZZA-CHEESE

To obtain pizza-cheese
with dry matter 48%
(moisture 52%)

It absorbs 14,58kg of
steam condensate +
Mi DMi
water
Mf
DMf
Quantity of final product:
114,58kg pizza-cheese

Discovery Plus engineering for a better world

 YIELD CALCULATION:
PIZZA-CHEESE

CURD
WITH DRY MATTER 54-55% PIZZA CHEESE WITH DRY MATTER 48-52%
(MOISTURE 46-45%) (MOISTURE 52-48%)

8kg STEAM FOR EACH 100kg OF CURD

(considering steam pressure at 2,5 bar)

Discovery Plus engineering for a better world

 Starting from 100kg of
commercial curd with dry YIELD CALCULATION:
matter 55%
(moisture 45%) FRESH MOZZARELLA

To obtain fresh mozzarella

with dry matter 40%
(moisture 60%)

It absorbs 37,5kg of steam

condensate + water
Mi DMi
Mf
DMf
Quantity of final product:
137,5kg fresh mozzarella

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 YIELD CALCULATION:
FRESH MOZZARELLA

CURD
WITH DRY MATTER 54-55% FRESH MOZZARELLA WITH DRY MATTER 38-60%
(MOISTURE 46-45%) (MOISTURE 62-60%)

8kg STEAM FOR EACH 100kg OF CURD

(considering steam pressure at 2,5 bar)

Discovery Plus engineering for a better world

 CALCULATION OF AVERAGE YIELD GAIN COMPARED TO
TRADITIONAL STRETCHING WITH WATER

The calculation is done considering the global coefficient of retention of fat and proteins that occurs in the process of turning milk into finishing
product; not all the fat and not all the milk proteins will remain in the cheese. Part of the fat is lost in the sweet whey after the cutting phase in cheese
vat and part remains in the buttermilk as a result of the stretching process; part of the proteins, at least 20%, remain in sweet whey (albumin) and
other are lost in the process of stretching.

A) Considering the transformation of milk in cheese using traditional stretching with water these global retention coefficients amounted on average to:
- 0,8 for fat (this means that in the cheese will remain 80% of the total fat content into the milk)
- 0,7 for proteins (this means that in the cheese will remain 70% of the total proteins content into the milk)

B) Considering the transformation of milk in cheese using steam stretching these global retention coefficients amounted on average to:
- 0,88 for fat (this means that in the cheese will remain 88% of the total fat content into the milk)
- 0,75 for proteins (this means that in the cheese will remain 75% of the total proteins content into the milk)

The difference between the coefficients of retention is attributable to the fact that in the traditional stretching with water there is always, even in the
recycling process, whey water which partially or completely is eliminated from the machine, causing a loss of fat and proteins; in continuous steam
stretching technology the coefficients are higher because there is no elimination of whey water, the condensation of the steam and the water added
remain completely incorporated in the stretched product.

Discovery Plus engineering for a better world

 CALCULATION OF AVERAGE YIELD GAIN COMPARED TO
TRADITIONAL STRETCHING WITH WATER

Having said this, here below there is a sample of yields calculation using traditional stretching with water and continuous stretching with steam. For
the sample consider a pasta filata product with final moisture of 50%.

Input data - traditional stretching with water

Fm = % fat in the milk 3%
Pm = % protein in the milk 3,3%
Fp = % fat in the final product 22%
Pp = % protein in the final product 24%
Cft = fat retention coefficient 0,8
Cpt = protein retention coefficient 0,7

Input data - continuous steam stretching

Fm = % fat in the milk 3%
Pm = % protein in the milk 3,3%
Fp = % fat in the final product 22%
Pp = % protein in the final product 24%
Cfs = fat retention coefficient 0,88
Cps = protein retention coefficient 0,75

The difference is just in the coefficients of retention of fat and proteins while other parameters are equal.
Discovery Plus engineering for a better world
 CALCULATION OF AVERAGE YIELD GAIN COMPARED TO
TRADITIONAL STRETCHING WITH WATER
Calculation is done considering the fat and proteins yields using traditional and steam stretching
according to the following calculations:

Yield in fat - traditional stretching with water

% yield in fat Rf is given by the following formula:

Fm Cft 3 0,8
Rf Rf 100 10,91%
Fp 22

Yield in protein - traditional stretching with water

% yield in protein Rp is given by the following formula:

Pm Cpt 3,3 0,7

Rp Rp 100 9,62%
Pp 24

The theoretical average Rmt in traditional stretching with water be given by the average of the yield of
fat and yield in protein.

Rf Rp 10,91 9,62
Rmt Rmt 10,26%
2 2

Discovery Plus engineering for a better world

Yield in fat - continuous steam stretching
% yield in fat Rf is given by the following formula: CALCULATION OF AVERAGE YIELD GAIN COMPARED TO
TRADITIONAL STRETCHING WITH WATER
Fm Cfs 3 0,88
Rf Rf 100 12%
Fp 22

Yield in protein - continuous steam stretching

% yield in protein Rp is given by the following formula:

Pm Cps 3,3 0,75

Rp Rp 100 10,31%
Pp 24

The theoretical average Rmp in continuous steam stretching will be given by the average value between
yield of fat and yield in protein.

Rf Rp 12 10,31
Rmp Rmp 11,15%
2 2

Therefore the average yield of 10,26% with traditional stretching will become an average yield of
11,15% with continuous steam stretching, with an increase of 0,89%.

You have about 9kg more of cheese for each ton of transformed milk.
Discovery Plus engineering for a better world
 TECHNICAL DATA
N
COOKING
DIMENSIONS PRODUCTIO CUTTER MIXING PASTA
MODEL AUGERS
[m] N [kg/h] TYPE CHAMBER CONVEYOR
LENGHT [m]
S
3,35 x 1,25 x H
DP N 600 AC1 400-600 TRA-A 1,9 1 NO
2,75
DP N 800 3,85 x 1,25 x H
500-800 TRA-A 2,3 1 NO
AM1 2,75
DP N 1000 5,95 x 1,25 x H
500-1000 TRA-SP 2,3 1 SI
SM1C 2,75
DP N 1200 7,15 x 1,25 x H
700-1200 TRA-SP 3,5 1 SI
SL1C 2,75
DP N 1500 6,60 x 1,25 x H
800-1500 TRA-SP 2,3 2 SI
SM2C 2,75
DP N 2000 7,75 x 1,25 x H
1300-2000 TRA-SP 3,5 2 SI
SL2C 2,75
DP N 3000 8,70 x 1,25 x H
1800-2500 TRA-SP 3,5 3 SI
SL3C 2,75
DP OVER N
9 x 1,6 x H 2,75 4000 TRA-OM 4,3 2 SI
4000 OM*2C
DP OVER N 10 x 1,6 x H
5000 TRA-OM 5,3 2 SI
5000 OL*2C 2,75
DP OVER N 11 x 1,6 x H
6000 TRA-OM 5,3 3 SI
6000 BL*3C 2,75

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 DISCOVERY PLUS N 800 AM1 DISCOVERY PLUS N 1000 OM1

DISCOVERY PLUS N 600 SC1C DISCOVERY PLUS N 1000 SM1C

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 DISCOVERY PLUS N 1500 SM2C DISCOVERY PLUS N 2000 SL2C

DISCOVERY PLUS N 2000 SL2C DISCOVERY PLUS N 3000 SL3E

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DISCOVERY PLUS N 3000 OL3E

DISCOVERY PLUS OVER N 6000 BL*3C

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 VULCAN Anti-Stick SURFACE TREATMENT

Anti-Stick treatment.
CMT has recently developed a new Anti-stick treatment
for surfaces of the machines that come into contact with
stretched product.
All machine surfaces that get into contact with the sticky VULCAN SURFACE
Pasta filata have been coated with Teflon for many
years.
SANDBLASTED SURFACE
This has resulted in the anti-adhesive at the same time
has taken a disadvantage because the manufacturers
never know exactly if a piece of Teflon in the cheese falls P atent
l
off. nat iona
ter
Ts In
CM
Discovery Plus engineering for a better world
 VULCAN Anti-Stick SURFACE TREATMENT
This is a real alternative to the traditional teflon-coating.
This is a completely new technology for the treatment of metal surfaces; it consists of multiple steps of
mechanical polishing, with different pressures and angles of incidence of the "treating product. In what they call
Anti-stick, metal no longer needs a coating in Pasta filata production.
While the teflon must be re-done from time to time depending on the use conditions, the CMT Vulcan treatment
will have a nearly unlimited life since it is not a coating but a mechanical-chemical action on the surface.
High resistance to CIP cycles.
Such a treatment has been incorporated very recently in two production lines and the concept has a great future.
The CMT Vulcan anti-adherent treatment is used now on the machine bodies of the CMT stretching machines
series FB, COMBI and DISCOVERY and on the moulding machines (both drum and carrousel moulding
machines). Customers request for such a treatment is increasing more and more.

P atent
l
nat iona
ter
Ts In
CM

Discovery Plus engineering for a better world

Discovery Plus engineering for a better world
SALES DEPARTMENT CONTACTS

Paolo Tomatis (Sales Director): paolo.tomatis@gea.com

Elena Giordanengo (Sales Management Assistant): elena.giordanengo@gea.com
Paola Adamo (After Sales Business Dev. ): paola.adamo@gea.com

Visit us at:
www.gea.com
www.cmt-spa.com
info@cmt-spa.com
Phone: +39.0171.339456

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