Chicken nuggets are a product that requires numerous processing steps to work together seamlessly. Provisur Technologies and Nothum Food Processing Systems provide technologies for this entire process chain, with solutions precisely coordinated from raw material processing and forming through to breading and frying. As part of the Fortifi Group, the two companies combine extensive expertise and complementary areas of specialization to the design of an integrated production line.
At first glance, chicken nuggets may appear to be a simple convenience product. However, in industrial production, the process is far more complex. Raw materials are minced and blended, before the mixture is formed into products with consistent weight and precise shape, followed by the reliable and even application of the coating before final frying. Success depends not only on the individual processing steps, but also on how effectively the machines involved in each stage work together and how consistently the product is transferred from one step to the next.
In a nugget line configuration featuring equipment from Provisur Technologies and Nothum Food Processing Systems, these process steps are precisely coordinated to work seamlessly together. Through its Weiler and Formax brands, Provisur covers the upstream stages, from size reduction and mixing through to forming. Nothum then provides technologies for predusting, battering, breading, and thermal processing. The two companies bring together an integrated solution that supports efficient, consistent production of chicken nuggets as well as a range of alternative protein applications.
Grinding and Mixing: A Precisely Defined Starting Point for Forming
The configuration begins with Weiler® equipment from the Provisur Technologies portfolio. The Weiler® OmniV® Grinder efficiently processes both fresh and frozen poultry raw materials. Its integrated Dominator® technology optimizes product flow and helps ensure consistent particle definition and product texture. This provides a uniform texture in the raw material for the subsequent mixing and forming stages, which have a significant influence on the consistency of the finished product.
The raw material mixture is then transported in a controlled manner by a Weiler Screw Conveyor. The screw-based conveying system enables the poultry meat to be moved efficiently and continuously between the individual processing stages. Its design is intended to minimize mechanical stress on the raw material while reducing product losses during transfer to the mixer.
The Weiler VM120 Vacuum Mixer combines the minced poultry meat with additional recipe ingredients such as seasonings, additives, and liquids, incorporating them evenly throughout the mixture. “The vacuum function removes air from the mixture during the mixing process. This results in a uniform and reproducible product structure. For nugget production, the mixing process therefore provides the foundation for a consistent mixture with defined product characteristics,” explains Fons Jacobs, Sales Manager at Provisur.
Depending on the process requirements, different mixing tools, such as paddles or ribbons, are available.
The Weiler BPF40 Pump is positioned between the mixer and the forming machine. It feeds the product to the downstream Formax former, such as a machine from the VerTex range. The appropriate pump size depends on the product dimensions and the required throughput. To accommodate different line capacities, the pump is available in various diameters.
Precisely Formed Before Coating
Following product preparation, a Formax forming machine, for example the Formax VerTex 1000, shapes the prepared poultry meat mixture into the desired nugget form. The machine uses rotary forming technology and is designed for high production capacities while maintaining consistent product quality. Its precise forming process enables manufacturers to produce nuggets with a uniform appearance and defined weight.
With a line width of 1,000 mm, the VerTex 1000 can be equipped with different forming tools, providing manufacturers with a high degree of flexibility when it comes to product shapes. A servo-driven feed screw system and an easy-to-clean design also support hygienic and efficient production. The machine therefore supplies consistently formed pieces for the subsequent predusting, battering, breading, and frying stages.
Three Steps to Consistent, Reproducible Breading
Following the forming stage, the process moves into the Nothum section of the line. The formed nuggets are transferred via a conveyor belt to the Nothum predusting machine – the VersaCoat. Here, fine flour or other dry coating ingredients are fully applied evenly to the formed chicken nuggets.
The VersaCoat is a flatbed coating system that utilizes a wide range of coating materials, from fine flour to coarse crumb ingredients. The machine handles these ingredients gently, minimizing breakage and separation during processing with its auger-less system. The result is a uniform product surface and consistent coating coverage.
The predusting step creates a defined surface and supports the subsequent batter/tempura application from the Nothum BatterPro. This all-in-one batter and tempura system can automatically mix and maintain the temperature of the cool blended batter/tempura. A key feature of the system is its ability to automatically control and maintain batter/tempura viscosity, ensuring a uniform batter/tempura coating across the products. This is important for the subsequent breading and frying stages, as the layer contributes to the adhesive of the breading, or provides the perfect “tempura” appearance.
The Nothum SuperFlex performs the final breading stage for the chicken nuggets. The machine enables flexible processing of fine flours, coarse crumbs, and even (baked) panko materials with its auger-less system. Depending on the desired product structure and/or raw material, it can also combine various breading methods and processing techniques. For formed nuggets, Nothum recommends the Flatbed application mode. Whole muscle strips and/or bone-in products will be more suitable to operate in the Drum application mode. In addition, the optional TripleFlip and HandToss modes are available. These four applications in a single machine allow breading particles to be applied to a wide range of products, helping to achieve the desired product characteristics without switching to a different machine.
“Chicken nugget manufacturers are looking for the most consistent coating possible, as variations in coating thickness have a direct impact on appearance, bite, and the subsequent thermal processing,” says Henri Janssen, General Manager of Nothum International BV. The coated products are then transferred via another conveyor belt to the thermal processing stage.
Consistent Frying with Controlled Oil Usage
The Nothum ProTherm performs the final thermal processing step and is designed as a continuous frying system. The nuggets pass continuously through the heated frying oil, where they develop a ‘Golden Brown’ and crispy surface. A key feature of the ProTherm system is its design for low oil content, which enables a higher oil refreshment rate and supports longer production runs. This helps operators maintain consistent frying oil quality throughout production, contributing to consistent product quality and a reproducible product appearance.
The process sequence described above is not limited to poultry products. Products made from alternative proteins can also be formed, coated, and thermally processed according to the same basic principle. The specific recipe, product structure, and process parameters determine the machine settings and line configuration required for each application.
Different Technologies, One Seamlessly Integrated Process Chain
Provisur and Nothum operate as independent specialists, each with distinct areas of technological expertise. As members of the Fortifi Group, the two companies combine their capabilities within the group’s network, including testing opportunities at various locations, technical support, and customer assistance throughout the different project phases.
For customers, this provides a single point of contact for a line configuration that integrates the technologies of both companies. The focus is not on individual machines, but on the entire process chain. This enables nugget production to be covered from raw material preparation through to the finished product. At the same time, the configuration remains flexible, allowing line width and throughput to be adapted to specific production requirements and desired output.
Meet Provisur and Nothum at Gulfood Manufacturing, taking place from 3–5 November 2026, at the Fortifi stand in Hall 4, stand C4-33.
