JBT Marel Industrial air frying solution

Market challenge: 

According to market insights, the global low-fat food market is set to double over the next 10 years with North America and Europe driving this growth. This growth will put increasing demand on food manufacturers to invest in low fat processes. With decades of experience in prepared foods processing, JBT Marel helps manufacturers meet these demands with a complete industrial air frying solution.

Our air frying solution:

JBT Marel is the only company that offers a complete industrial air frying solution that combines advanced coating, controlled oil application, high-airflow impingement cooking, spiral freezing, and integrated packaging technologies. 

Highlights:

• Elimination of pre-frying stage means cleaner, healthier and better tasting product
• Controlled oil levels can produce ‘lower fat’ or ‘never been fried’ options
• Up to 50%+ reduction in oil pick-up, offering many benefits that appeal to food producers
• High impingement airflow system enables excellent setting and coloring of coating
• High level of control over the end-product

Coating:

Achieving a successful air-fried product starts with the right coating system. Consistent application of flour, batter, breading, and seasonings is essential to create the desired appearance, texture, and performance throughout the process.

Coating formulations can be optimized with additional proteins, spices, and color-enhancing ingredients to deliver the flavor profile and visual appeal consumers expect. Larger grain, high-protein breadcrumbs can further enhance crispiness and help replicate the characteristics of traditionally fried products.

Oil spraying: control instead of immersion

Unlike conventional frying systems that immerse products in large volumes of hot oil, industrial air frying relies on precisely controlled oil application. Products are sprayed with a carefully measured amount of oil, typically between 4% and 6%, before entering the cooking stage.

This approach provides manufacturers with greater control over final fat content while reducing oil consumption and waste. The recirculating oil spray system requires only small volumes of oil compared to the large volumes of required oil in deep frying.

High-airflow impingement cooking: creating crispiness without pre-frying

Following coating and oil application, products enter the heart of the air frying process: high-intensity impingement cooking. Inside the Double D Revoband, high-velocity hot air is directed onto the product surface from above and below the conveyor. Operating at temperatures up to 280°C, the system rapidly sets the coating, develops an attractive golden color, and creates the crispy texture associated with fried foods.

Because coating fixation and color development are achieved through precisely controlled airflow rather than immersion frying, processors can eliminate the traditional pre-frying stage altogether. The system also provides control over airflow, temperature, humidity, and top-and-bottom cooking conditions, enabling manufacturers to optimize quality across a wide range of products.

Spiral freezing: preserving quality at high throughput

After cooking, products move seamlessly into the freezing stage, where Frigoscandia spiral freezer technology rapidly freezes the product while preserving quality and throughput.

The GYRoCOMPACT spiral freezer range has long been recognized as an industry benchmark and is ideally suited for the high-capacity requirements of industrial air frying lines. By combining cooking and freezing technologies in one integrated solution, processors can maintain product integrity, maximize efficiency, and streamline production flow.

After air frying and freezing, products are transported to our end of line solution.

Check weighing

The M-Weigher Process Check monitors unpacked air-fried products to help ensure they meet target weight specifications. By providing feedback to upstream and downstream equipment, it helps improve weight accuracy, reduce rejects, manage giveaway, and minimize manual rework before products reach the packing stage.

Tray sealing

Our Proseal tray sealing systems carefully package air-fried products, helping maintain seal integrity, product protection, and freshness. Integrated with weighing, loading, and automation systems, these solutions provide reliable, high-performance packaging lines for a wide range of convenience foods.

Weigh price labeling

Our intelligent weigh price labeling systems deliver accurate, high-speed labeling with low running costs. Supporting multiple label formats across a wide range of pack types, the systems can handle up to 160 packs per minute while ensuring precise alignment and consistent label placement. Long-life print heads further support operational efficiency and reduced maintenance costs.

Case packing

Our Proseal Case Packer automates the transfer of packs into cases using high-speed 2D delta robotics. It supports multiple case formats while maintaining product quality and throughput. Quick-release tooling enables fast changeovers, while the ProMotion™ system ensures smooth and continuous operation.

Benefits for the producer

• Be an early adopter in the growing segment of industrial air frying
• Eliminate pre-frying which requires large amounts of oil
• A fully integrated JBT Marel line eliminates reliance on multiple suppliers while enhancing overall equipment integration.
• This industrial air frying solution has been proven in operation and is successfully running at multiple customer sites
• Produce healthier products with low fat content, while maintaining crispiness and succulence

Ready to explore what’s possible?

Whether you are planning your next production line or simply exploring future opportunities, our experts are ready to help. Book a meeting to discuss your goals, ask questions, and discover how a complete JBT Marel air frying line can transform your production.