Consumer trends in bread consumption drive many equipment design features of bread systems, but operator efficiency and cost play key factors as well.
A growing trend toward diverse bread varieties as well as the global growth in bread consumption not only results in higher capacity production runs, but frequent changeovers. As such, easy-to-operate, high quality industrial bread lines are needed now more than ever, notes Onno Kuiper, process/bakery technologist, Rademaker BV, Culemborg, The Netherlands. Among the issues bread bakers must be concerned with are consumers' emergent health consciousness and their interest in environmental care, Kuiper adds.
“Although the basics of bread are very healthy, a strong demand from consumers to reduce fat, replace hydrogenated fats with non-hydrogenated fats, reduce flour enhancers, and reduce or replace emulsifiers with enzymes, is very obvious,” Kuiper says. “This leads to adjustments in formulas that results in changes in typical dough characteristics.”
Equipment investment for the future must address consumers' growing interest in healthful products, and consequently the changes in dough handling properties these changes bring, Kuiper adds.
Environmental issues, such as energy scarcity, also impact equipment design. Bread systems that minimize energy use and reduce waste, while delivering higher yields at reduced operating costs, meet bakers' production demands.
Today, bakers need bread systems that provide the flexibility to produce a range of bread and roll products, and at various volumes of production.
HIGH-WATER/SLACK DOUGH
The trend in the world-wide bread market is the use of sheeting lines, such as Rademaker's Crusto® concept for high water dough and/or slack dough products that produce high quality breads with more flavor. Sheeting has tremendous benefits for these doughs even with high capacity outputs. Sheeting lines can be easily equipped to reach capacities like 6000 kg dough per hour. With modules like Rademaker's weighing module® and Rademaker's de-gassing unit®, bakers can obtain a high accuracy and perfect fine structure for sandwich loaves.
Rademaker
330 650 2345
www.rademaker.com
INVERT PANS
The PanVerter™ Automated Pan Turner by Weldon Solutions takes empty bakery pans and inverts them to clean out debris. Pans normally are stored on their bottoms, which can cause damage because of their weight. When pans are stacked upside down, they rest on their band and no weight is on the actual pan. PanVerter also turns pans right side up prior to filling. A conveyor side clamp ensures trouble-free operation. The system offers easy adjustment for a range of bread and roll pans.
Weldon Solutions
717 846 4000
www.weldonsolutions.com
PLC CONTROLS
PLC controls are taking a larger role in today's bakery pan handling and management. Automatic speed settings for multiple pan types picked from menus that are product specific offer greater flexibility. A “dashboard” main screen indicates the product being processed as well as important system parameters. Other screens include maintenance mode, cleaning mode and speed adjustments as well as sensor states. Password protection can be added to any screen for different operator levels of use.
Benda Manufacturing Inc.
708 633 4600
www.bendamanufacturing.com
CHOOSE CUSTOM-MADE MACHINES
The Perfect Score Co. designs, manufactures and integrates pan bread systems; including conveying, indexing, lidding, final proofers, control panel integration, make up and more, depending upon the unique requirements of the particular baking facility. Each system is built to the customer's facility specifications. The goal of The Perfect Score Co. is to provide each customer with lower maintenance costs, higher efficiency in product handling, increased output, reduced labor costs, less downtime and maximized equipment life.
The Perfect Score Co.
440 439 9320
www.theperfectscore.com
FLEXIBILITY IS KEY
Rheon's Flexible Module System, from the basic model to an entire modification, can be completely customized to fit the customers production style. For automatic production of artisan bread lines, customers have the option to add many units for rounded bread, or moulded products such as baguettes. Due to the mobility of the connecting machines, the line can be easily changed to meet all customer needs and expectations. All Rheon equipment is designed with these concepts in mind. Rheon's goal is to continuously improve its equipment design to meet its customers needs and expectations.
Rheon U.S.A.
949 768 1900
www.rheon.com
STACK AND UNSTACK PANS EFFICIENTLY
The Capway Robocap pan system is a completely self-contained robotic storage and retrieval system, which can be used for pans and lids. The advantage of this system is that the pans are stacked (on the bar band and not on the bottom of the pans) and unstacked gently and vertically, thus preventing pan and coating damage. The patented gripper can pick up as many as 30 pans at once, thus reducing the cycle time of the robot. Because the pans are stacked within the enclosed system, carts or shuttles are not needed to remove the pans. The enclosed system allows for stacks up to 94 in. high, reducing floor space. The Robocap is available in a variety of sizes and configurations to fit the required application.
Capway System Inc.
717 843 0003
www.capwayusa.com
FOR USE WITH MULTIPLE PAN SYSTEMS
The Advanced Dough Divider Multi-Metering Pump by AMF is designed for high-speed bread lines with multiple sheeter/moulder/panners. The divider offers reliability and scaling accuracy through advanced extrusion technology. It increases product yield, reduces waste and improves product uniformity. The Multi-Metering Pump features multiple metering pumps that reduce the impeller rpm requirement per pump while maintaining throughput requirements. The result is reduced metering pump dough work at higher throughputs. No divider oil is required with the ADD, which reduces operating and sanitation costs. It offers an efficient design with few moving parts for reduced maintenance costs, and a rotary drive design provides a service life three to four times longer than conventional dividers. The ADD also offers increased productivity, flexibility and improved automation. The operator interface-based formula management system is provided for automated divider setup and downstream equipment setup.
AMF
800 225 3771
www.amfbakery.com
