While superior grinding and blending of ground beef play a big role in the creation of burger taste and texture, it is high quality forming equipment that helps processors create the handcrafted look and premium mouth-feel that today’s consumers are willing to pay premium prices to enjoy.
Processors of every size can better understand and master the forming process of producing better burgers by distinguishing the different fill systems and learning which method will best achieve their customers’ product goals. In general, the three primary fill systems to produce premium burgers can be categorized as Standard Fill, Verti-Form, and Tender-Form. All three filling systems are designed to deliver a distinctive texture in the formed portion, as well as processing flexibility, consistent portion weight and other features that add value and produce a home-style product appearance.
Standard Fill
The Standard Fill System is the most common fill system for forming ground beef patties. With Standard Fill, the mold plate cavity is filled through a narrow opening, or slot. The patty is filled from the rear toward the front, causing the product fibers to be aligned in that direction. This fill system delivers the mouth feel that most consumers recognize as having a regular or expected burger bite.
Verti-Form Fill
This forming system is usually reserved for whole muscle type applications, but some of the design features of Verti-Form technology can help produce a unique burger. Its fill opening is much larger than other fill methods, which helps minimize fill restrictions. This larger opening is perfect for the production of patties or chubs with inclusions, such as peppers, onions or cheese. These ingredients are able to pass through the opening intact, so they can be easily identified in the finished portion.
Tender-Form Fill
The Tender-Form fill system is used almost exclusively with higher-end burgers. The mold plate cavity fills through a series of holes, similar to a grinder plate. This unique design causes the product fibers to stand up through the thickness of the mold plate, allowing for a more effective heat transfer, faster cooking, reduced shrinkage and faster freezing times. This technology also produces the tenderest bite while enhancing the juiciness of the burger – strong qualities processors desire in a premium patty.
How mold plates achieve maximum yield for patties
Whether it’s Standard Fill, Verti-Form fill, or the Tender-Form fill system, mold plates must be kept in excellent condition to minimize giveaway. Mold plates help with yield through weight control, so if they diminish, they experience leakage, which occurs when the product seeps from the front of the machine during the forming process.
Mold plates may also be customized for processors’ products, ensuring maximum yield. Provisur’s Formax equipment customizes mold plates to meet the specific requirements of its customers. Virtually any size and shape of the opening can be designed to match exacting expectations. Formax mold plates deliver weight control within +/- 0.5 percent. That’s important to note because as little as one gram of giveaway per patty can result in loss of potential annual revenue of $125,000 or more per forming line.
Visit our microsite to learn how Provisur leads the way in burger processing innovations.
Provisur’s Ingenuity Center can help
For processors looking for guidance on which fill system to use, Provisur’s Ingenuity Center was built for the sole purpose of helping customers develop their products. Those looking to custom design their burger patties may work with the unique tooling department, which is composed of a group of engineers. In the tooling design process, engineers can provide full three-dimensional control over the portion sizes and shapes. They can also assist processors in designing a distinctive patty that customers will recognize as their brand and product. There’s also a food science group to help customers understand their meat matrix and demonstrate what an end product would look and taste like.
Explore our offerings at our Ingenuity Center or schedule a visit.