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Industry: Industry-agnostic. Specifically tailored for manufacturing rolled items with high fiber content and stiffness. Challenge: During the rolling phase of their production line, a client of USM encountered a significant hurdle. Their product, composed of extruded sheets high in fiber, rendered traditional rollers ineffective in achieving proper rolling and maintaining product integrity. Consequently, they resorted to manual rolling methods, leading to labor dependency. Our Approach: At USM, innovation is ingrained in our culture, motivating us to seek inventive solutions. We conceptualized a unique machine with two hold-down belts positioned at an angle to the conveyor belt, thereby creating a strong rolling effect on the product. This machine performed as desired and had the ability to consistently roll the customer’s product and create a formed product that held its shape. Result: This innovative rolling machine is suitable for use in production lines handling products with high rigidity. By reducing reliance on manual intervention, we improved the uniformity of the final product and mitigated contamination risks.

Industry: Industry agnostic Challenge: In the frozen value added snack industry, MSMEs faced challenges with frying systems available in the market due to issues with machines such as low productivity, improper filtration, and high maintenance costs. Existing solutions hindered efficiency and quality, leading to compromised profitability for these businesses. Our Approach: Understanding the critical need for a solution, we developed a frying system tailored to the needs of MSMEs. Leveraging our expertise in engineering and innovation, we focused on creating a system that is easy for MSMEs to acquire but also comparable in quality to high-end alternatives. Result: MSMEs witnessed a significant increase in productivity, thanks to our streamlined design and efficient filtration system. Our system delivered consistently high-quality results, ensuring that businesses could meet consumer demands without sacrificing profitability. Today, MSMEs across the frozen snack industry are benefitting from our frying system. By offering a solution that is both accessible and high-quality, we have helped these businesses thrive in a competitive market landscape while maintaining their commitment to excellence.

Industry: Nutritional Alternates   Challenge: Amidst the global rise of plant-based meat, scepticism lingered in India regarding the plant-based protein industry. Existing facilities were perceived as too expensive and unable to match the taste profiles of poultry alternatives. High production costs further hindered widespread acceptance. Our Approach: Beyond our expertise in machine line design and manufacturing, we extended support for plant design and recipe development. Collaborating with industry experts in our network, we gained invaluable knowledge and customer feedback. This enabled us to successfully design a facility and machine line capable of producing plant-based meat products at affordable prices. Result: The plant-based protein products we produced matched international standards in taste and quality, yet were competitively priced compared to meat alternatives. By offering comprehensive support from plant design to product recipes, we have supported businesses in their entry into the promising plant-based meat segment. Today, the plant-based protein industry in India is gaining momentum. We stand ready to support food processing companies in realizing their vision of setting up financially viable facilities to produce high-quality products.

Industry: Seafood Challenge: In the seafood sector, impingement freezer offering low freezing time were in higher demand due to better quality of end products. However, existing freezing machines available in the Indian market lacked accurate airflow dynamics, resulting in compromised quality, extended freezing times, and increased operational costs for local MSMEs. Despite their initially attractive price tags, these machines proved economically burdensome over time due to escalating running costs and reduced yields caused by dehydration losses. Our Approach: Harnessing years of experience, we designed the Rapid Impingement Freezer to optimize freezing performance, thereby preserving product quality. Unlike its counterparts, our machine ensured uniform freezing and minimal dehydration losses by incorporating cutting-edge design principles. Result: Our initial deployment in the seafood belt of India yielded promising results. The Rapid impingement freezer not only delivered superior freezing efficiency and productivity but also met international benchmarks – all at a fraction of the cost by leveraging local manufacturing competencies. MSMEs that previously struggled with capacity issues, high running costs, and compromised yields now experienced unprecedented levels of profitability and sustainability. Today, Rapid has been deployed at over six locations across India, spanning multiple sectors. All our customers attest to consistent, long-term benefits, reaffirming our commitment to revolutionizing seafood freezing technology in the region.