INDUSTRIAL PRODUCTION LINES. Baking Technology for the Industrial Production of Durable Baked Goods WP BAKERYGROUP

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1 INDUSTRIAL PRODUCTION LINES Baking Technology for the Industrial Production of Durable Baked Goods WP BAKERYGROUP

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3 The WP BAKERYGROUP with this corporate portfolio, we have brought ourselves comprehensively into line with the requirements of bakeries worldwide. Today, we are in a position to be able to offer complete solutions from project planning to fitting out complete bakeries (trade and industry), as well as supplying used machines. A central element of our corporate philosophy is a networked thinking which spreads across all individual stages of production. We call it Process Management, the targeted control of individual production stages and the machinery used as fast as possible with the smallest possible loss of materials to achieve the desired result, even with small production volumes, as well as an unrestricted reproducibility of results that have been achieved. And all that with an extremely high output. Any unit can be docked on at any time if required for manufacturing a product there are adequate interfaces for foreign products.

4 WP CompetenceCenter _ Dough/Mixing. Emil Kemper GmbH, Rietberg _ Rolls. _ Bread. _ Ovens. _ Instore Baking. _ Refrigeration. _ Laminating. _ Engineering. _ Used Machines. _ Bakery Software. Emil Kemper GmbH, Rietberg Werner & Pfleiderer Haton B.V., NL-Panningen Werner & Pfleiderer Lebensmitteltechnik GmbH, Dinkelsbühl Werner & Pfleiderer Sachsen GmbH, Sohland Werner & Pfleiderer Koeling Benelux B.V., NL-Panningen Werner & Pfleiderer Lebensmitteltechnik GmbH, Dinkelsbühl Werner & Pfleiderer Industrielle Backtechnik GmbH, Tamm Werner & Pfleiderer Sachsen GmbH, Sohland BackNet E&S GmbH, Muggensturm

5 INDUSTRIAL PRODUCTION LINES _ 1 INDUSTRIAL PRODUCTION LINES The professional development, manufacture, installation and servicing of industrial machines for the production of bakery goods calls for a comprehensive know-how and decades of experience. Multi-shift operation at full capacity, accomplishing optimum, reproducible product qualities, control systems in state-of-the-art technology, hygienic standards that comply with highest demands as well as short cleaning and maintenance times are essential requirements faced by modern system concepts. Requirements that are satisfied at a high level by the individual companies belonging to WP BAKERYGROUP. Based on these demands, we supply individually equipped industrial production lines which are renowned for their reliability all over the world.

6 INDUSTRIAL PRODUCTION LINES Werner & Pfleiderer Industrial Bakery Technologies we have been developing, planning, manufacturing, installing and servicing industrial installations for the production of baked goods for more than 125 years. We are now one of the leading suppliers of highly automated inline concepts for the continuous production of an extensive variety of goods ranging from raw materials handling to the transfer to automatic packaging machines. In the WP BAKERYGROUP we hold a key position in the industrial solutions sector. Our product portfolio includes machinery concepts for the production of bread and rolls, hard and soft biscuits, pretzels, crisp bread, rusk, cakes, croutons, breadcrumbs etc. We provide technical solutions that satisfy the highest demands. In co-operation with our customers, we develop concepts which not only meet the requirements of the market, but are also trendsetting for future industrial production.

7 2 _ 3 Raw materials handling_processing_application_baking_cooling_transferring

8 INDUSTRIAL PRODUCTION LINES INDUSTRIAL PRODUCTION LINES for the continuous production of baked goods Industrial production lines manufactured by Werner & Pfleiderer Industrial Bakery Technologies are always designed to meet the individual requirements of the customer. The plant dimensions and equipment vary depending on the products to be manufactured and the scheduled output per hour. The modules produced by WP BAKERYGROUP are always practice-proven machines or assembly groups that have been consistently advanced and on which wide experience has been gained. From raw materials handling through dough processing and dough moulding, the plant configurations include machines for any conceivable type of processing, an immense range of dough processing facilities and oven combinations, as well as a wide assortment of conveying, positioning and portioning systems. The degree of automation in the production lines ranges to fully automated lines with central control and monitoring units, depending on the customer s requirements. We always liaise closely with the manufacturers of downstream packaging machines. Industrial production lines from WP are always supplied complete, ready-for-operations and commissioned, and are delivered on schedule production at the customer s premises may commence.

9 4 _ 5 PRODUCTION LINES MODULES _ Hard biscuit/cracker production lines Kneader, continuous dough processing and feed Laminator, gauge rollers Cutting machine Hybrid oven combinations Conveying, cooling and stacking _ Soft biscuit production lines Kneader, continuous dough processing and feed Laminator/sheeter + gauge rollers Continuous moulding machine Depositors SNK tunnel oven and oven combination Conveying, cooling and stacking _ Production lines for pretzels Kneader, continuous dough processing and feed Laminator/sheeter + gauge rollers Rotary cutter, moulding machine, extruder Lye bath with sprinkler & cutting machine SNK tunnel oven and oven combination Cooling, transfer and packing _ Cake production lines Mixer, continuous dough feed/portioning in tin moulds Oven combination Automated demoulding Product cooling, product injection Conveying and transfer to packing _ Crisp bread production lines Pre-mixers Crisp bread moulding machine Flour duster & dusting flour conditioning Dockering rolls & dough strand cutting machine Tunnel oven Cutting & stacking machine Conveying and transfer to packing _ Rusk production lines Kneader, continuous dough processing and feed Dough processing, intermediate proofer, long moulder Final proofer Tunnel oven Bread depanning, bread cooling Bread cutting and bread slice seating system Toast oven Product stacking device _ Breadcrumb production machines Kneader, continuous dough processing and feed Portioning Belt-type proofing channel Tunnel oven Bread cooling Crushing, drying, grinding

10 INDUSTRIAL PRODUCTION LINES HARD BISCUIT/CRACKER PRODUCTION LINES Hard biscuit/cracker production lines The process route for the production of hard biscuits or crackers starts with the dough-making. This is followed by the dough lamination and gauge rolling. After that, the products pass through a rotating cutting machine. The next stage involves an SNK tunnel oven or a suitable oven combination. The number of oven modules is adapted to the required baking time in relation to the desired maximum capacity. Finally, the products are conveyed to the packaging machines via a cooling conveyor and stacking unit. 1 Twin-shaft high-capacity mixer of the ZK type with controls that enable the memory of up to 50 recipes. The two Z-shaped kneading arms are optimally suitable for homogeneously kneading a great variety of dough types. 2 Automatic dough feed unit with dough portioning, metal detector and feeding conveyor to the downstream processing machine (laminator, four-roll-sheeter). Four-roll-sheeter in compact construction for producing a continuous dough sheet. 3 Laminator for the production of cracker and hard biscuit doughs Gauge rollers, 4.2 Double cut-out unit, 4.3 Dough net separation and returning 5 SNK tunnel oven in modular design with different heating systems (direct, indirect, convection and combinations). 6 Automatic stacking machine for piling up biscuits. A follower aligning device ensures that the biscuits are stacked in precise lines. Depending on the product type, penny stackers may be employed

11 6 _ Hard biscuits and crackers Cream crackers, soda crackers, cocktail crackers, cracker mix, potato crackers Classical hard biscuits, biscuits for children, zoo-type biscuits, basic biscuits to be refined with chocolate

12 INDUSTRIAL PRODUCTION LINES SOFT BISCUIT PRODUCTION LINES Soft biscuit production lines The process route for producing soft biscuits starts with making the doughs. This is followed by dough feeding, dough moulding and placing the dough strip on a steel belt. The next stage involves an SNK tunnel oven. The number of oven modules is adapted to the required baking time in relation to the desired maximum capacity. Finally, the biscuits are conveyed to the packaging machines via a cooling conveyor and stacking unit. 1 Batch-type mixer for the preparation of soft doughs. 2 Rotary moulding machine for the scrapless moulding of biscuits and cookies. 3 Extruded products, cut at the transfer point to the baking belt. 4 SNK tunnel oven, ideally suited for the production of soft biscuits and fine baked goods. 5 Biscuits at the oven discharge end. 6 Natural cooling and transport to packaging machine. 7 Biscuits at the feeding section of staking machine

13 8 _ 9 3 Soft biscuits Soft biscuits or fine baked goods are produced on tunnel ovens with wire-mesh belts or solid steel belts. The doughs are moulded (moulded articles), cut (wire-cut articles), extruded (extruded biscuits) or dressed (deposited articles)

14 INDUSTRIAL PRODUCTION LINES PRETZELS AND LYE BATH ARTICLES PRODUCTION LINES Pretzels and lye bath articles production lines The process route for producing lye bath articles is started by portioning the filling mass volume and the extrusion process. Cutting groups or biscuit moulding machine comprise the following step. The final topping of the products is carried out in the lye bath which incorporates a salt applicator and a cutting machine. The next stage is an SNK tunnel oven. The number of oven modules is adapted to the required baking time in relation to the desired maximum capacity. The final transport to the packaging machine is carried out by cross and longitudinal belts, the length of which is dimensioned to correspond to the required cooling time. 1 T h e SP extruder is used for extrusion and filling mass portioning and intended to provide uniform dough strands over the entire baking width. Filling masses are homogenised, temperature-controlled, filtered and portioned and then guided to the extrusion head. 2 T h e GH biscuit moulding machine is used for the production of a wide range of pretzels or cocktail biscuits, simply by interchanging the moulding rolls. The machine is of a multipurpose type and suitable for optimum biscuit moulding. 3.1 Fresh and return dough are sheeted in the cut-out group and conveyed to the rotary cutting machine for the production of small and large pretzels via special roll sheeters. 3.2 Synchronised cut-out rolls are equipped with a special return-dough system. 4.1 The moulded, cut or extruded dough pieces are passed through the temperature-controlled lye bath. After this, the desired topping is applied. 4.2 The dough strands are cut to length or grooved by a special guillotine. The transfer to the oven is carried out on the basis of defined parameters and results in optimised loading of the baking belt. 5 The SNK tunnel oven provides for an excellent development of the articles to be baked. Convection and radiation can be ideally combined to obtain an optimum baking process. 6 Transfer of baked sticks onto the cross conveyor belt with downstream cooling route and transport to the packaging machine

15 10 _ 11 Pretzels and lye pastries Moulded or cut-out pretzels Extruded or cut-out sticks Co-extruded sticks, filled with spicy mixtures Sticks as sweet biscuit, co-extruded and filled with sweet mixtures Toppings with salt, sesame, cheese or spice mixes

16 INDUSTRIAL PRODUCTION LINES CAKE PRODUCTION LINES Cake production lines Dough making, followed by dough feed and moulding and/or dough portioning in tin moulds are the beginning of the process route for the production of cakes. Once baking has been concluded, the cakes are released from their moulds, cooled and then transferred to the packaging machines. The size/length of the ovens is adapted to the required baking time in relation to the desired maximum capacity. Dough processing with vertical batch-type mixer Dough portioning in tin moulds with filling equipment Oven loader Tunnel oven Product cooling Product injection Transport to packaging machines Mould reversing device Mould cleaning device Mould greasing facility

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18 INDUSTRIAL PRODUCTION LINES CRISP BREAD PRODUCTION LINES Crisp bread production lines The process route for producing crisp bread starts with dough making. Dough aeration, dough cooling and dough application and several flour dusting steps then follow. The next stage involves a special tunnel oven with very high baking temperatures. The number of heating zones or the length of the oven is adapted to the required baking time in relation to the desired maximum capacity. Finally, the products are conveyed to the packaging machines after having passed through a cooling conveyor including several cutting and stacking units. 1 Dough processing with pre-mixer, swelling bins, combinator for dough cooling and aeration. 2 Flour duster for upper and lower flour as well as sprinklers for seeds. The continuous dough sheet which has been formed in a special dough sheet moulder is inserted in a dusting flour bed. 3 Synchronised pair of dockering rolls with cleaning devices for applying the characteristic crisp bread surface. 4 Suction device for removing the dusting flour from the dough surface. The removed dusting flour is processed and returned to the process circuit. 5 The special high-temperature crisp bread oven is equipped with two gas burners each for top heat and bottom heat. Once the baking process has been finished, the dough sheet is cut to it s final size in a cross and longitudinal cutting device. 6 The arranged crisp bread slices are conveyed to the packaging machine via a conveyor belt

19 14 _ 15 2 Crisp bread Crisp bread with milk Crisp bread with spelt Crisp bread with sesame Crisp bread with caraway Crisp bread with fibres

20 INDUSTRIAL PRODUCTION LINES RUSK PRODUCTION LINES Rusk production lines The process route for producing rusk starts with making the doughs. This is followed by dough feed and moulding steps. The dough is proofed and baked in tin moulds. Once baking has been concluded, the bread bars are released from their moulds, cooled and then cut to slices. The slices are toasted in a second baking process and conveyed to the packaging machines. The size/length of the ovens is adapted to the required baking time in relation to the desired maximum capacity. 1 Dough processing using a spiral-type kneader; dough dividing and moulding machine, conical round moulder, intermediate proofer, long moulder and placing the dough strands in moulds 2 Feeding into final proofer 3 Tunnel oven 4 Bread depanner 5 Bread cooling 6 Bread slicing and bread slice feeding system 7 Toast oven and product stacking for packaging 1 2 3

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22 INDUSTRIAL PRODUCTION LINES BREADCRUMB PRODUCTION MACHINES Breadcrumb production machines A continuous mixer usually is at the beginning of the process route. This is followed by dough feed and moulding steps. A belt-type proofing channel is used for the proofing process, the next stage involves a tunnel oven. In the course of the process shown, individual breads are produced which, once baking has been concluded, pass through a cooling route. Afterwards they are reduced to smaller pieces which are then dried and milled. The size/length of the oven is adapted to the required baking time in relation to the desired maximum capacity. 1 Continuously dough processing using the ZPM kneader 2 Portioning 3 Transfer from belt-type proofing channel to oven 4 End of tunnel oven 5 Bread cooling and transport to bread crushing mill

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24 INDUSTRIAL PRODUCTION LINES Raw materials handling. Portioning. Kneading Dough processing C Recording the dough quality and output measurement Monitoring the height of bulges and the width of the sheet using speed control

25 20 _ 21 AUTOMATION Convenience of operation, reproducibility of product qualities at all times as well as a high availability of the industrial production lines made by Werner & Pfleiderer are in direct proportion to their high degree of automation. Measurements and controls all can be dealt with by one central computer, either program-controlled or with the intervention of the operator of the production line. A great number of various sensors are installed in pairs for safety reasons. Their operability is checked by the system itself. The sensors consistently monitor the parameters affecting the quality of manufacturing process, such as for instance dough quality and output, height of bulges, sheet width and speeds, oven humidity and temperature, product moisture content and temperature. Their measuring results directly influence the settings on the line modules a completely self-regulating system. The whole manufacturing process is documented in every detail and can be traced on product line and host level by persons with the relevant authorisation and adjusted manually, whenever necessary. The entire automation system can be monitored or serviced remotely by way of internet access. Baking Cooling. Arranging. Feeding C Recording and controlling the humidity in the oven and the oven temperature Controlling the moisture content of the product

26 INDUSTRIAL PRODUCTION LINES CHECK Pos I Consultancy Planning. Design. Equipment. References Pos II Equipment Materials. Component groups. Electronic components. Mechanical components Pos III Modularity Workflow. Space requirement Pos IV Capacity Number of pieces/h. Weights Pos V Quality TA. Dough qualities Pos VI Cost Investment. Current cost Pos VII Workflow Interfaces. System Workflow Pos VIII System responsibility Complete system integration. Set-up of individual sequences Pos IX Service Service presence. Self-Service. Remote maintenance Pos X Group know-how Process thinking. Interface know-how. Solutions from one source

27 22 _ 23 PROCESS _ Inquiry _ Production analysis _ Project planning _ Engineering _ Production _ Acceptance I _ Delivery _ Installation _ Integration _ Operational start-up _ Training _ Acceptance II _ Service

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30 tammen.de Werner & Pfleiderer Industrielle Backtechnik GmbH Frankfurter Straße Tamm Germany Fon +49 (0) Fax +49 (0) info@wpib.de The WP BAKERYGROUP possesses subsidiaries in France, Italy, Belgium, Russia and the USA. Agencies with Service Departments can also be found in all regions of the world _0.75_ by WP BAKERYGROUP, Stand 03/08, printed in Germany, = Registered Trademark All specifications are non-binding and the right is reserved to make amendments that serve technical advancement. WP BAKERYGROUP