A comprehensive capability in breakfast cereal production

Transcription

1 Breakfast Cereals

2 A comprehensive capability in breakfast cereal production Baker Perkins combines a portfolio that ranges from unit machines to full modular process lines with the process knowledge and engineering expertise to create solutions for virtually every kind of RTE (Ready To Eat) breakfast cereal product. Our modular approach to process design means that our Cereal Master lines can be adapted or extended with additional units to make the new products required by this established yet still developing market. The greater flexibility that this brings to cereal production quickly maximises return on equipment investment. We offer rotary cooking, extrusion, flaking, shredding, toasting and coating processes for flaked, shredded and expanded breakfast cereals. Baker Perkins is able to fully support newcomers to the market by helping them to create a range of high quality products using either a standard extrusion or rotary-cooking line. The product range can then be expanded or output increased by incorporating additional units into the line. Established businesses work with Baker Perkins to extend product ranges or install additional capacity by taking advantage of new technology and our flexible, modular design philosophy. Cereal Master modular lines provide the ideal platforms for cereal manufacturers to develop their businesses or respond to changes in the market. Along with the expert support and advice on offer from Baker Perkins, plus our promise of Lifetime Support, this makes Baker Perkins the supplier of choice for growing cereal companies worldwide. Breakfast Cereals PAGE 2

3 Product and process innovation Our Innovation Centre is staffed by expert process technologists who help customers turn concepts into commercially viable products. The centre contains a full range of development and test facilities for conducting equipment trials, developing products and producing evaluation samples, with the assurance of complete confidentiality. The centre houses equipment for both traditional and extrusion processes including extrusion, co-extrusion, cooking, flaking, shredding, toasting and coating. Development work can comprise a number of small runs to test a range of different ideas, or longer runs to produce samples for test marketing or other types of assessment. All the equipment faithfully reproduces the processes used in full-size plants so process settings and product characteristics achieved in the lab are easily transferred to a production environment. The Innovation Centre is also the focal point of our development programme. New equipment design is conducted simultaneously with end-product and process development to ensure that our systems perform efficiently and reliably and have the versatility to adapt to new market trends built-in. When it comes to creating new products we are able to offer many different types and variants to use as a starting point. Possibilities are extended further by the option to combine different processes in the same line, either from the outset or later, by adding process modules. With this process flexibility, plus the availability of a wide range of ingredients, fillings and coatings, the opportunity for creative product development is virtually endless. However, there is always room for more and we work with many manufacturers in our Innovation Centre on ideas and concepts which fall outside the normal parameters. For example, products with unusual textures, unconventional ingredients and non-standard weights have all been developed recently with customers in the Innovation Centre. Breakfast Cereals PAGE 3

4 Equipment Overview SBX Master cooker-extruder This range of multi-purpose extruders handles a wide variety of cereal products; it is a versatile production tool with an attractive cost of ownership. As well as flexibility, it combines easy maintenance with enhanced process control. Ingredients are texturised and cooked through a combination of heat, mechanical shear and moisture addition; flavours and colours can be added easily. Clamshell barrel extruders are also available. CoEx Master dies, cream fe Filled pillows are high value breakfast cereals that appeal to both adults and children. They comprise a crispy outer shell with a fruit, cream or FlakeMaster flaking roll State-of-the-art control technology enhances the performance of the latest generation of flaking rolls for high-output, high-quality cereal production. These units provide consistent processing of a wide range of corn and multigrain flakes, from both traditional rotary cookers and cooker-extruders. Thermoglide2 toaster Baker Perkins process knowledge has led to the design of a new generation of toaster specifically created for consistent, even processing of cereals. As well as a Breakfast Cereals PAGE 4

5 ed & pillow crimper chocolate filling and can be made on any new or existing extrusion line simply by adding a co-extrusion die, cream feed and pillow crimper. Rotary cereal cooker Baker Perkins range of cookers is used by leading manufacturers worldwide to meet the market for high-quality, healthy cereals with high consumer appeal. With fully automatic batch operation and a highly effective mixing action, this rotating steam cooker handles milled or whole grain cereal products including wheat, corn and bran. gentle airflow ensuring even toasting with minimal damage, benefits include small machine footprint and a low maintenance requirement. Syrup coating systems Fully automated systems apply frosting and glazing to enhance product flavour and appearance, efficiently and cost-effectively; they enable a product range to be expanded for little additional cost. Emphasis on the health aspect of cereals is achieved via the ability to engineer syrup skids, coating drums and dryers to operate in both sugar and sugar-free modes, with simple interchange between the two. Breakfast Cereals PAGE 5

6 Cereal Master TX the flexible technology The Baker Perkins Cereal Master TX line is the choice of manufacturers needing the assurance of a consistent high-quality end product. Well-proven rotary cereal-cooking technology is at the core of complete lines producing many of the world s leading brands. Cereal Master TX is an expandable process. A standard line making traditional wheat and bran flakes can be progressively extended by incorporating additional units. Multigrain products, cornflakes, and coated flakes are all achievable. A modular approach to process design allows the Cereal Master TX system to grow as the customer s business expands. BASE The Cereal Master base line produce cooker, pellet mill, FlakeMaster flak ADD MODULE 1 ADD MODULE 2 Dryer For Multigrain Flakes Tempering Unit For Traditional Corn Flak Bran & Wheat Flakes Multigrain Flakes Multigrain Process Wheat & Bran Flake Process Corn Flake Process Wheat, Bran & Multigrain Processes CEREAL COOKER PELLET MILL FLAKING ROLL TOASTER DRYER TEMPERING UNIT SYRUP COOKING, COATING & DRYING Breakfast Cereals PAGE 6

7 The key features of Cereal Master TX are: l Gentle steam cooking of cereal grains in the Baker Perkins rotary cereal cooker ensures that the texture, flavour and nutritional benefits of wholegrain ingredients are retained in the final product l Pellet forming is used to achieve the correct size of flake when producing bran flakes, wheat flakes or multigrain flakes l Consistent flake quality is achieved using the Baker Perkins FlakeMaster flaking rolls s wheat and bran flakes and comprises ing rolls and Thermoglide2 toaster. l Controlled toasting and drying of the flakes takes place in the Baker Perkins Thermoglide2 toaster where the fluidised-bed process minimises product damage l Drying and tempering equipment can be added to the line to enable the manufacture of high quality multigrain flakes and cornflakes l The product range can be further extended by adding a Baker Perkins coating system consisting of Autofeed, syrup skid and coating drums The Cereal Master TX base line produces wheat and bran flakes and comprises cooker, pellet mill, FlakeMaster flaking rolls and Thermoglide2 toaster Bran & Wheat Flakes ADD MODULE 3 es Syrup Coating, Coating & Dryer For Frosted / Glazed Flakes Bran & Wheat Flakes Bran & Wheat Flakes Multigrain Flakes Multigrain Flakes Corn Flakes Frosting & Glazing Process Wheat, Bran, Multigrain & Corn Flake Processes Corn Flakes Frosted/ Glazed Flakes Breakfast Cereals PAGE 7

8 Cereal Master EX a base to build on The Cereal Master EX twin-screw cooker-extruder process is a proven, versatile and expandable solution for producing a variety of breakfast cereals. In both emerging and established markets Cereal Master provides the flexibility to broaden and diversify product ranges by expanding the standard lines with additional equipment modules. This can be done at any time and provides manufacturers with the opportunity to develop their business or respond to changes in the market while enhancing the return on their initial investment. The Cereal Master EX line is a cost effective point of entry to the breakfast cereals market. Using Baker Perkins process and product expertise, additional units can be incorporated to build capability. Co-extrusion equipment, flaking rolls, cereal cookers and dryers can be added to form versatile plants suitable for a wide range of high-specification cereals produced in volume. BASE The Cereal Master base line produces cooker extruder, syrup coo ADD MODULE 1 ADD MODULE 2 Co-Extrusion Die, Cream-Feed & Pillow Crimper For Filled Pillows Forming Extruder, Flaking R For Bran, Wheat & Corn Flake Direct Expanded Cereals Filled Process Direct Expanded Process Filled Pillows Bran, Wheat & Corn Flake Process Direct Expanded & Filled Processe COOKER EXTRUDER SYRUP COOKING & COATING FINISHED PRODUCT DRYER CO-EXTRUSION DIE, CREAM FEED & PILLOW CRIMPER FORMING EXTRUDER, FLAKING ROLL & TOASTER CEREAL COOKER & DRYER Breakfast Cereals PAGE 8

9 The key features of Cereal Master EX are: l The Baker Perkins SBX Master range of twin-screw cooker-extruders. Used by customers worldwide to make high-quality direct-expanded and coated breakfast cereals, at outputs between 300 and 1,800 kg/hr l Baker Perkins syrup coating system provides a consistent glaze, or frosting for a high quality finished product l The final dryer is specified to dry the direct expanded and coated products and is also capable of handling coated flakes l Cereal squares can be made with the addition of a free standing cutter, located after the extruder l The plant capability can be extended to include extruded flakes by the addition of a single-screw forming extruder, a FlakeMaster flaking roll and a Thermoglide2 toaster l Cereal cooking and drying equipment can be added to the line to enable the manufacture of high-quality multigrain flakes direct expanded cereals and comprises king, coating and drying. Direct Expanded Cereals ADD MODULE 3 oll & Toaster s Cereal Cooker & Dryer For Multigrain Flakes Direct Expanded Cereals Direct Expanded Cereals Filled Pillows Filled Pillows s Bran, Wheat & Corn Flakes Multigrain Process Direct Expanded, Filled, Bran, Wheat & Corn Flake Processes Bran, Wheat & Corn Flakes Multigrain Flakes Breakfast Cereals PAGE 9

10 Co-extrusion adds value This Baker Perkins innovation extends the capability of the extrusion process to make added-value products with out-of-the-ordinary shapes that catch the eye, complemented by innovative flavours and fillings. A co-extrusion system incorporates fillings with contrasting textures or colours into a cereal outer shell. The essential elements of the system are a die, pillow crimper and cream feed system. The fillings can be of virtually any colour or flavour - creams, fruit pastes or chocolate pralines are typical. Shapes include hexagons, chevrons and waves. The product range is limited only by the imagination. Adding value with a coating system Frosting or glazing creates the opportunity to develop new cereal products with added value and additional consumer appeal through enhanced flavour and appearance. Baker Perkins has extended its range of modular syrup preparation and coating solutions to match individual requirements, by developing process technology for low-sugar and sugar-free coatings. Low sugar/sugar-free coated products enable manufacturers to maintain the taste and consumer appeal of their products while highlighting their nutritional benefits. Baked granola bars and clusters Baker Perkins offers a range of equipment for the production of cereal clusters and baked granola bars. Both products are made by mixing, forming and baking a continuous sheet that is kibbled to form clusters or slit and guillotined for bars. A range of process solutions is available from Baker Perkins for this fastdeveloping product sector. Shredded cereals Baker Perkins can supply the equipment and process knowledge for the manufacture of a range of shredded cereals, including multi-layer shredded wheat, 2-, 3- or 4-layer corn, rice or wheat squares and bran sticks. Shredding is an excellent alternative to flaking and is designed to form cooked cereal into layered, shredded or stranded products. Many shredded products contain a single ingredient (usually wheat) making them very attractive to health-conscious consumers. Their appeal may be widened with inclusions or frosted coatings. Breakfast Cereals PAGE 10

11 Lifetime support for your investment Baker Perkins has a long history of providing high-performance process technology that meets the needs of our customers for efficient and reliable production equipment with low running costs. To achieve the highest end-product quality while maintaining these performance standards our continuous development programme utilises extensive customer feedback and our unique combination of process insight and engineering capabilities. Baker Perkins makes new developments available as retrofit options for existing plant to ensure customers benefit from our latest technology. A popular upgrade is a package producing significant savings for owners of clam-shell extruders. An existing one-piece or segmented clam-shell barrel is replaced with a pair of backing blocks fitted with liner inserts. Further replacement is limited to worn inserts rather than complete liners. Other important developments are available for flaking rolls. Existing flaking units can be upgraded to the latest gap control system. In addition, Baker Perkins offers a full service for maintaining the rolls themselves, including prolonging the life of MkI and MkII rolls by applying a tool steel surface layer. Full process support is provided and includes access to the Innovation Centre, where we offer a complete product and process development service to turn product ideas into successful new products. Breakfast Cereals PAGE 11

12 Baker Perkins Ltd Manor Drive Paston Parkway Peterborough PE4 7AP United Kingdom Baker Perkins Inc 3223 Kraft Ave SE Grand Rapids MI USA T: F: E: I: Baker Perkins 08/12 T: F: E: