Baked Goods. Flexible Technology for Products You Can Sink Your Teeth Into

Transcription

1 Baked Goods Flexible Technology for Products You Can Sink Your Teeth Into

2 Contents It takes: more than a hundred years of experience and everything that you need for efficient production: Reimelt Philosophy Page - Fresh Baked Goods Page 4-5 Extended Shelf-Life Baked Goods Page - Process Technology Page - Automation Technology Page -

3 Reimelt Philosophy The Right Ingredients for a Integrated Concept. The raw material logistics are of decisive importance for the quality of the end product. Purposeful storage, precise weighing and recipe control and management are the authoritative factors. It is the task of the Reimelt experts to always meet the changing requirements of the market. We develop new solutions for products that interest people and in doing so lay the foundation for success in the market. Properly coordinated raw material handling ensures optimal results in the production process that are also most economical. Reimelt, with its system solutions, has been a reliable partner for the food industry for decades. This is also shown by our extensive international client list. The Complete Solution from a Single Source: Process Technology Systems and Components Automation Thanks to our many years of experience, we at Reimelt know precisely what the customer wants concerning "their" end-product whether it s whole grain bread or cake, cookies or pretzel sticks. Service Performance Spectrum Project Financing Project Management Knowledge of the end product and its requirements such as Raw Materials Process Technology Automation Level is crucial to finding the optimal solutions for production. The Reimelt Principle Flexible System Execution Quality Assurance Optimized Provisioning Strategy Process Technology in the Raw Material Handling Industry Integral Material Flow Supervision Reduction of Production Costs Optimizing the Building Layout

4 Reimelt Philosophy Storage Discharge Conveying Processing Metering Production process - Silo Technology - Big-Bags - Fluidizing - Vibration - Metering - Pneumatic Conveying - Container Transport - Sifting - Mixing - Fermenting - Temperature Regulation - Conditioning - Size Reduction - Weighing Technology - Volumetric and Gravimetric Metering Major Ingredients Minor Ingredients Receiving- Sifting Material Receiving Material Receiving Liquid Metering Processing/Receiving Micro Ingredients System Control Mixing/Blending Fat Processing Systems and Components Key components developed and manufactured in-house Equipment designed for constant operation (4 hours/day, 5 days/year) with a long service-life High processing-quality Patented components Long-term spare-parts availability Sanitary design - easy to clean Competent consultation for system solutions according to ATEX guidelines Process Technology Experience from over,000 built systems Extensive references Own laboratory and central test facility Patented processes Process technology consultation during project Engineering services Technical application trials available by customer order (raw material analysis, conveying, mixing, sifting)

5 Fresh Baked Goods Pioneering Production Technology as Important as Our Daily Bread. The baked goods market of today demands optimized production more than ever and the Reimelt experts keep this always in mind. As a result, engineering leads to system solutions that ensure an optimal process, individually suited to your respective product parameters. Consistent product quality requires the strict adherence of all process capacities. A task that Reimelt systems accomplish on the one hand, through the most modern system and sensor technology and on the other hand, through innovative control concepts. Consistent quality is the key to long lasting product success. Most consumers will immediately recognize the smallest deviations in the recipe. This is why Reimelt systems operate precisely and consistently. Picture : Outdoor silos for the storage of major ingredients The quality of the end product may not be affected by storage. The most important goal is therefore compliance with the high standards of hygiene and a production following the "first in first out"- principle. Reimelt technology constantly monitors all product parameters and controls the corresponding production process. At Reimelt, product oriented production means: all raw materials are checked for their specific requirements with regard to storage and metering so that the optimal process can be implemented. In addition to systems for sourdough and liquid sponge production, Reimelt provides system solutions for the complete spectrum of raw material preparation: from temperature regulating to drying, moisturizing and homogenizing, from sifting, mixing and grinding to recrystallization. Picture : Weighing station above a mixer bowl 4 Your goals: Cost reduction Quality assurance or improvement Compliance with high hygiene standards Consistently high level of production Compensation of varying raw material properties Complete material flow recording, batch tracking Error avoidance through automation Reduction of faulty batches Accurate automated metering of small quantities Increasing system availability The Solutions from Reimelt: Quality control from raw material receiving to finished product delivery Optimized storage Extensive know-how for compliance with hygiene standards Favourable raw material improvement Gentle product handling Improved metering solutions Minimizing the failure rate through reduction of manual processes Customized intermediate storage of end products Security through batch tracking Energy savings

6 Fresh Baked Goods Major dry ingredients Fresh Baked Goods Minor dry ingredients Sourdough preparation Soaked grain Hot soaked grain Yeast system Liquid ingredients Receiving area Recycled bread system Cleaning Mixer Bread Baguette Cinnamon bread Farmers bread Multi-grain bread Pita bread Rye bread Toast bread Tortilla White bread etc. Rolls/Buns Crusty Rolls Dinner rolls Hamburger/ hotdog buns Hot cross buns Sausage rolls Sesame/poppy seed rolls Water rolls etc. Cakes/Pastries Croissants Filled donuts Madeira cake Muffins Scones Sponge cake Yeast cakes and pastries etc. 5

7 Extended Shelf-Life Baked Goods Lasting Quality... It is also valid for extended shelf-life baked goods: to reach a uniform quality, optimized costs and the highest possible level of automation, variations in the raw material properties must be prevented. The quality assurance provided by Reimelt technology begins right at storage, which is performed according to the product parameters. With the integrated raw material preparation and gentle product handling, Reimelt guarantees consistency in quality as well as quantity for the dough production. Reimelt provides systems for both sourdough and liquid sponge production. Picture : Combined manual, bag and Big-Bag dumping station Innovative system solutions guarantee perfect results in every area of raw material preparation. Temperature regulating, drying, humidifying, homogenizing, sifting, mixing, grinding and recrystallization: the system solutions from Reimelt encompass the entire range of raw material processing. Systems for plasticized fat and cream production complete the performance spectrum. Reimelts expertise in processing technology offers you the decisive factors for consistent production processes: pneumatic mixing homogenizes and premixes dry and liquid ingredients. Raw material temperature regulation is achieved in the fluidizing zone. Specially developed components ensure a degradation-free, slow-speed conveying for sensitive raw materials, such as granulated sugar, nuts, fruit or chocolate chips. Picture : Micro ingredient storage with recipe controlled weighing and automated conveying to the processing lines Extended Shelf-Life Baked Goods Almond cookies Biscuits Bread/ Bagel chips Bread crumbs Cheese flavoured Crackers Fruit breads Fruit cakes Gallette Ginger bread Hard baked cookies Honey cakes Pandoro Panettone Pumpernickel bread Pretzel snacks Rice cakes Salted pretzels Seed cakes Shortbread cookies Snack pies Soft baked cookies Wafers Water biscuits etc.

8 Extended Shelf-Life Baked Goods... Requires Extensive Know-how Picture : Storage of liquids in containers with buffer tank. Major dry ingredients Flavourings Sugar grinding Receiving area Minor dry ingredients Mixers 4 Micro dry ingredients Liquid ingredients 5 Central scaling 0 Cleaning

9 Process Technology Innovative Solutions Toast Bread Production Line Picture : Secondary-air conveying for gentle product handling Reimelt systems utilize the most modern sensor technology and control concepts for compliance with all process parameters, and therefore ensure product quality. Here are two examples of how the above is actually carried out. 4 5 Automated toast bread production In the automated production of toast bread, the main ingredients, flour and sugar, are stored in outdoor silos. The production of premixes is advantageous when considering requirements, such as contamination-free production and 0 tracking of raw materials. These mixes are stored in various hoppers, and along with recycled bread mash, water and yeast, weighed according to the recipe. For hygienic reasons, butter and fat are metered directly into the mixer. The process control system monitors the premixing of the raw materials and the dough development during dough production. There are control parameters and indicators, such as time, temperature and energy input are instrumental for a constant dough quality. 4 5 Outdoor silos for sugar, salt and various flours Premix mixer with manually added ingredients Premix storage hopper Pneumatic conveying system Premix scale with pressure vessel Yeast metering system 0 Intermediate flour use bin Liquid fat metering system Butter metering system Recycled bread metering system Premix receiving hopper

10 Process Technology with Exemplary Efficiency. Breadcrumb Production 4 Picture : Dumping station on load cells, directly above the processing 5 0 Continuous breadcrumb production Breadcrumbs are used as a finished product as well as a recipe ingredient in many other food products. Recipes change between countries, dependent on the eating habits of its people and with consideration for further food production applications. 4 5 Color, crumb/granularity and density can be efficiently adjusted at the production lines. Flour, ingredients and premix raw materials are weighed in batches. 4 5 Outdoor silos Scale / Pneumatic mixer Oil metering Premix Minor ingredients 0 Bread crumb dust recycling Grinder Oven Silo for tanker truck filling Metering into the mixer is continuous. Here the raw materials are mixed and kneaded with minimal dough warming and very low energy transfer. The continuous production guarantees a constant and reproducible product quality. Loss-in-weight feeder Water mixing and metering unit Continuous mixer 4 5 Bagging Slow speed conveying Compressor A quality control of the product parameters is carried out right after the dough production. In this way, faulty production is prevented.

11 Process Technology Fermentation Biotechnology... The quality of breads and rolls is largely influenced by the liquid sponge. The use of liquid sponge not only saves yeast during dough Picture : Continuous dry and liquid material metering with vertical mixer for the production of liquid sponge Batch Liquid Sponge Production Continuous Liquid Sponge Production Flour storage Flour metering Water mixing and metering unit Flour use bin Differential metering scale Water mixing and metering unit Yeast tank Cooling unit Fermentation tanks Starter liquid sponge Continuous mixer 0 Continuous liquid sponge systems: The basis for economical production Reimelt continuous liquid sponge systems offer through their innovative construction decisive advantages for baked goods production: Consistent quality Discharge into the production at the desired time Production preparation and post batch production is possible No remaining product in storage tank Flexibility due to short fermentation time Optimal usage of capacity Very small space requirements Future production capacity expansion without problem Reduction of chemical baking agents During the continuous liquid sponge production water, flour and yeast in suspension are metered into the continuous mixer by differential scales and liquid meters and immediately mixed with high shearing forces. After a short time, a finished, homogenized liquid sponge is ready to be pumped from the mixer to the fermentation tanks. Here great emphasis is placed on the "first in first out" principle, so that a consistent quality of the fresh dough is guaranteed.

12 Process Technology... for Better Bread. production, it also has a positive effect on the product properties of the finished baked goods. Picture : Fermentation tanks with a ton usable capacity and down-stream connected buffer tank Continuous Sourdough Production Fermentation tanks Water mixing and metering unit Continuous mixer Flour use bin Differential metering scale Storage tank To production Heat exchanger Fermentation pipe Central cooling and heating unit Starter liquid sponge Sourdough storage tank To production While fermentation tank () is being filled, fermentation tank () is being discharged with the same capacity. When tank () is empty then the "filling/discharging"situation is reversed. In this way the "first in first out" quality principle is fulfilled. When the fresh liquid sponge is being pumped to the storage tank, it passes through a heat exchanger and is cooled. The liquid sponge can be taken from the storage tank to supply the production lines according to requirements. During the sourdough production, mixing is executed in the same manner as the liquid sponge production. After a short time, the finished, homogenized sourdough is pumped from the mixer to the fermentation pipe. On the way through the fermentation pipe the dough is continuously acidified and goes then into the sourdough tank. The continuous mixer constantly recirculates a specific amount of finished sourdough from the tank as a starter liquid sponge. The remaining amount is used for production. During the pause in production, the filled fermentation pipe is cooled to the point that fermentation can continue uninterrupted.

13 Automation Technology Perfect Product Planning for More Reliable Processes. Reimelt has developed the key-components PrismaCE and PrismaWEB for a smooth running process automation. These software applications, together with other components, such as the recipe-metering system Minc form the basis for an optimized production control. This ranges from a simple scaling system to a totally ERP System Corporate Management Level automated production system with Internet technology. Since the single components are retrofittable and expandable, Reimelt configures the system to meet your individual requirements. Here Reimelt know-how comes into play. The Reimelt experts provide a concept that perfectly matches your requirements. It is their task to prepare the system specifications, software, special interfaces, and train your operators in its use. Web-Client Web-Clien PrismaWEB PLC System WLAN Process Management Level Control Level Picture : PrismaWEB Modern technology coupled with comfort of use and operational safety for a transparent production process. Web-Client Minc PrismaWEB/PE (Panel Edition) Visualization Recipe Metering for Small Systems recipes User-friendly structure Degree of protection IP 54 Profibus compatible Metering of liquids Master/slave operation Approved for ATEX zone, CE Optional DAISY-M-system for PC data handling Panel-Based Batch Management Based on panel-pcs Windows XP SQL data base system Up to two web-clients possible Local operation Optional functions: - Integrated visualisation - Data import / export - Remote maintenance System Visualization Based on Modern Web Technology Clear representation of the production process Simple operation Integrated error/fault message system Safe manual operation Trending analysis User access via web browser Integrated maintenance management system optionally available

14 Automation Technology PrismaWEB t Picture : Programming the process automation Picture : Creation of wiring and construction drawings Process Management Level Process Control Level Production Level PrismaWEB Batch Management System of the Future Modern technology coupled with comfort of use and operational safety Web technology, client/server system SQL data base system, OPC compatible Connection to ERP, host systems Access via web browser Operator friendly menu structure Remote maintenance via VPN/Modem MES functions such as batch tracking, warehouse management, etc. Batch Tracking in Food Production Continuous batch tracking in the food industry is becoming increasingly important. It ensures a high production standard that minimizes production waste and maximizes customer satisfaction. Information concerning the production process is the basis for maximum product quality. The process automation from Reimelt takes charge of this important duty to safegaurd the customer s good reputation.

15 back / 00. E Global Presence Reimelt Corporation, Tampa Reimelt (GmbH) UK Ltd., London Reimelt France E.U.R.L., Venissieux / Lyon Reimelt Components, Rödermark Reimelt FoodTechnologie, Rödermark Reimelt Guth Engineering, Landau Reimelt Henschel MischSysteme, Kassel Reimelt Korea Corp., Seoul Reimelt Henschel Asia Ltd., Hong Kong Reimelt Henschel Trading (Shenzhen) Co. Ltd. Reimelt Ltda., São Paulo Reimelt FoodTechnologie Geschäftsbereich der Reimelt Henschel GmbH Messenhäuser Straße -45 Rödermark, Germany Tel Fax info@reimelt.de