Industrieanlagen Gb

7/25/2019 Industrieanlagen Gb

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WPBAKERYGROUP

Baking Technology for the Industrial Productionof Durable Baked Goods

INDUSTRIAL PRODUCTION LINES


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The WP BAKERYGROUP with this corporateportfolio, we have brought ourselves comprehen-sively into line with the requirements of bakeriesworldwide. Today, we are in a position to beable to offer complete solutions from projectplanning to fitting out complete bakeries (tradeand industry), as well as supplying used ma-chines.

A central element of our corporate philosophy is a net-worked thinking which spreads across all individual stagesof production. We call it Process Management, the target-ed control of individual production stages and the machin-ery used as fast as possible with the smallest possible lossof materials to achieve the desired result, even with smallproduction volumes, as well as an unrestricted reproducibil-ity 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 formanufacturing a product there are adequate interfacesfor foreign products.


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_ Dough/Mixing. Emil Kemper GmbH, Rietberg

_ Rolls. Emil Kemper GmbH, Rietberg

_ Bread. Werner & Pfleiderer Haton B.V., NL-Panningen

_ Ovens. Werner & Pfleiderer Lebensmitteltechnik GmbH, Dinkelsbhl

_ Instore Baking. Werner & Pfleiderer Sachsen GmbH, Sohland

_ Refrigeration. Werner & Pfleiderer Koeling Benelux B.V., NL-Panningen

_ Laminating. Werner & Pfleiderer Lebensmitteltechnik GmbH, Dinkelsbhl

_ Engineering. Werner & Pfleiderer Industrielle Backtechnik GmbH, Tamm

_ Used Machines. Werner & Pfleiderer Sachsen GmbH, Sohland

_ Bakery Software. BackNet E&S GmbH, Muggensturm

www.wpbakerygroup.com/competencecenter

WP CompetenceCenter


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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 reliabili ty all over the world.


INDUSTRIAL PRODUCTION LINES _ 1


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Werner & Pfleiderer Industrial Bakery Technologies we have been developing, plan-ning, manufacturing, installing and servicing industrial installations for the production ofbaked goods for more than 125 years. We are now one of the leading suppliers of highlyautomated 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 theWP BAKERYGROUP we hold a key position in the industrial solutions sector. Our productportfolio includes machinery concepts for the production of bread and rolls, hard and softbiscuits, pretzels, crisp bread, rusk, cakes, croutons, breadcrumbs etc.

We provide technical solutions that satisfy the highest demands. In co-operation with ourcustomers, we develop concepts which not only meet the requirements of the market, butare also trendsetting for future industrial production.



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www.wpbakerygroup.com/industry

Raw materials handling_Processing_Application_Baking_Cooling_Transferring

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Industrial production lines manufactured by Werner & Pfleiderer Industrial Bakery Technologiesare always designed to meet the individual requirements of the customer. The plant dimensions andequipment vary depending on the products to be manufactured and the scheduled output per hour. Themodules produced by WP BAKERYGROUP are always practice-proven machines or assembly groups thathave been consistently advanced and on which wide experience has been gained. From raw materialshandling through dough processing and dough moulding, the plant configurations include machines forany conceivable type of processing, an immense range of dough processing facilities and oven combina-tions, as well as a wide assortment of conveying, positioning and por tioning systems.The degree of automation in the production lines ranges to fully automated lines with central controland monitoring units, depending on the customers requirements. We always liaise closely with themanufacturers of downstream packaging machines.

Industrial production lines from WPare always supplied complete, ready-for-operations and commis-sioned, and are delivered on schedule production at the customers premises may commence.

INDUSTRIAL PRODUCTION LINESfor the continuous production of baked goods



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www.wpbakerygroup.com/industry

PRODUCTION LINES MODULES

_Hard biscuit/cracker

production linesKneader, continuous dough processing and feedLaminator, gauge rollersCutting machineHybrid oven combinationsConveying, cooling and stacking

_Soft biscuit production lines Kneader, continuous dough processing and feedLaminator/sheeter + gauge rollers

Continuous moulding machineDepositorsSNK tunnel oven and oven combinationConveying, cooling and stacking

_Production lines for pretzels Kneader, continuous dough processing and feedLaminator/sheeter + gauge rollersRotary cutter, moulding machine, extruderLye bath with sprinkler & cutting machineSNK tunnel oven and oven combinationCooling, transfer and packing

_Cake production lines Mixer, continuous dough feed/portioning in tin mouldsOven combinationAutomated demouldingProduct cooling, product injectionConveying and transfer to packing

_Crisp bread production lines Pre-mixersCrisp bread moulding machineFlour duster & dusting flour conditioning

Dockering rolls & dough strand cutting machineTunnel ovenCutting & stacking machineConveying and transfer to packing

_Rusk production lines Kneader, continuous dough processing and feedDough processing, intermediate proofer, long moulderFinal prooferTunnel ovenBread depanning, bread coolingBread cutting and bread slice seating systemToast ovenProduct stacking device

_Breadcrumb production machines Kneader, continuous dough processing and feedPortioningBelt-type proofing channelTunnel ovenBread coolingCrushing, drying, grinding

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Hard biscuit/cracker production linesThe process route for the production of hard biscuits or crackersstarts with the dough-making. This is followed by the dough lamination and gauge rolling. After that, theproducts pass through a rotating cutting machine. The next stage involves an SNK tunnel oven or a suitableoven combination.

The number of oven modules is adapted to the required baking time in relation to the desiredmaximum 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 typewith controls that enable the memory of up to50 recipes. The two Z-shaped kneading arms are optimally suitable for homogeneously kneadinga great variety of dough types.

2 Automatic dough feedunit with dough por tioning, metal detector and feeding conveyor to thedownstream processing machine (laminator, four-roll-sheeter). Four-roll-sheeter in compact constructionfor producing a continuous dough sheet.

3 Laminator for the production of cracker and hard biscuit doughs.4 4.1 Gauge rollers, 4.2 Double cut-out unit, 4.3 Dough net separation and returning5 SNK tunnel ovenin modular design with different heating systems (direct, indirect, convection

and combinations).6 Automatic stacking machinefor 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.

HARD BISCUIT/CRACKER PRODUCTION LINES



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www.wpbakerygroup.com/industry/plants

4.2 4.3 5 6

4.1

Hard biscuits and crackers

Cream crackers, soda crackers, cocktailcrackers, cracker mix, potato crackers

Classical hard biscuits, biscuits for children,zoo-type biscuits, basic biscuits to berefined with chocolate

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Soft biscuit production linesThe 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 stageinvolves an SNK tunnel oven. The number of oven modules is adapted to the required baking time in relation tothe desired maximum capacity.

Finally, the biscuits are conveyed to the packaging machines via a cooling conveyor and stacking unit.

1 Batch-type mixerfor the preparation of soft doughs.2 Rotary moulding machinefor 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 dischargeend.6 Natural coolingand transportto packaging machine.7 Biscuits at the feeding section of staking machine.

SOFT BISCUIT PRODUCTION LINES



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Soft biscuits

Soft biscuits or fine baked goods areproduced on tunnel ovens with wire-meshbelts or solid steel belts.

The doughs are moulded (mouldedarticles), cut (wire-cut articles), extruded(extruded biscuits) or dressed (depositedarticles).

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1 2 3.1 3.2 4.1

Pretzels and lye bath articles production linesThe process route for producing lye bath articles is startedby portioning the filling mass volume and the extrusion process. Cutting groups or biscuit moulding machinecomprise the following step. The final topping of the products is carried out in the lye bath whichincorporates 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 maximumcapacity. The final transport to the packaging machine is carried out by cross and longitudinal belts, thelength of which is dimensioned to correspond to the required cooling time.

1 The SP extruderis used for extrusion and filling mass portioning and intended to provide uniform doughstrands over the entire baking width. Filling masses are homogenised, temperature-controlled, filtered andportioned and then guided to the extrusion head.

2 TheGH biscuit moulding machineis used for the production of a wide range of pretzels or cocktailbiscuits, simply by interchanging the moulding rolls. The machine is of a multipurpose type and suitable foroptimum biscuit moulding.

3.1 Fresh and return dough are sheeted in the cut-out groupand conveyed to the rotary cutting machine forthe production of small and large pretzels via special roll sheeters.

3.2 Synchronised cut-out rollsare 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 ovenprovides 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 beltwith downstream cooling route and transport to

the packaging machine.

PRETZELS AND LYE BATH ARTICLES PRODUCTION LINES



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4.2 5 6

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

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Cake production linesDough making, followed by dough feed and moulding and/or dough portioning in tinmoulds 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 mixerDough portioning in tin moulds with filling equipmentOven loaderTunnel ovenProduct coolingProduct injectionTransport to packaging machinesMould reversing deviceMould cleaning deviceMould greasing facility

CAKE PRODUCTION LINES



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Crisp bread production linesThe 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 nextstage 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 relationto the desired maximum capacity.

Finally, the products are conveyed to the packaging machines after having passed through a coolingconveyor including several cutting and stacking units.

1 Dough processing with pre-mixer, swelling bins, combinator for dough cooling and aeration.2 Flour dusterfor upper and lower flour as well as sprinklers for seeds. The continuous dough sheet

which has been formed in a special dough sheet moulderis inserted in a dusting flour bed.3 Synchronised pair of dockering rollswith cleaning devices for applying the characteristic

crisp bread surface.4 Suction devicefor 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 ovenis 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 its final sizein a cross and longitudinal cutting device.

6 The arranged crisp bread slices are conveyed to the packaging machine via a conveyor belt.

CRISP BREAD PRODUCTION LINES



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Crisp bread

Crisp bread with milk Crisp bread with spelt Crisp bread with sesame Crisp bread with caraway Crisp bread with fibres

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Rusk production lines The process route for producing rusk starts with making the doughs. This is followedby dough feed and moulding steps. The dough is proofed and baked in tin moulds. Once baking has beenconcluded, the bread bars are released from their moulds, cooled and then cut to slices. The slices aretoasted 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 moulderand placing the dough strands in moulds

2 Feeding into final proofer3 Tunnel oven4 Bread depanner5 Bread cooling6 Bread slicingand bread slice feeding system7 Toast ovenand product stackingfor packaging

RUSK PRODUCTION LINES



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Breadcrumb production machinesA 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 proofingprocess, 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 kneader2 Portioning3 Transferfrom belt-type proofing channel to oven4 End of tunnel oven5 Bread coolingand transport to bread crushing mill.

BREADCRUMB PRODUCTION MACHINES



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C

Raw materials handling . Portioning. Kneading Dough processing

Recording the dough qualityand output measurement

Monitoring the height of bulges and the width of the sheetusing speed control



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www.wpbakerygroup.com/industry/automation

Convenience of operation, reproducibility of product qualities at all times as well as a high availability ofthe industrial production lines made by Werner & Pfleidererare in direct proportion to their high de-gree of automation. Measurements and controls all can be dealt with by one central computer, eitherprogram-controlled or with the intervention of the operator of the production line. A great number ofvarious 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, suchas 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 thesettings on the line modules a completely self-regulating system. The whole manufacturing processis documented in every detail and can be traced on product line and host level by persons with therelevant authorisation and adjusted manually, whenever necessary. The entire automation system canbe monitored or serviced remotely by way of internet access.

AUTOMATION

Baking Cooling . Arranging . Feeding

Recording and controlling the humidity in the ovenand the oven temperature

Controlling the moisture content of the product

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www.wpbakerygroup.com/industry/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

CHECK



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_ Inquiry

_ Production analysis

_ Project planning

_ Engineering

_ Production

_ Acceptance I

_ Delivery

_ Installation

_ Integration

_ Operational start-up

_ Training

_ Acceptance II

_ Service

PROCESS

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tammen.de

www.wpbakerygroup.com

Werner & Pfleiderer

Industrielle Backtechnik GmbH

Frankfurter Strae 17

71732 Tamm

Germany

Fon +49 (0) 71 41 - 20 20

Fax +49 (0) 71 41 - 202 - [email protected]

www.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.

0408_0.7

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2008 by WP BAKERYGROUP, Stand 03/08, printed in Germany, = Registered TrademarkAll specifications are non-binding and the right is reserved to make amendments that serve technical advancement.

Industrieanlagen Gb

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