Macadams International -World Major Bakery Equipment Manufacturer- A Profile

Macadams  International  is  a  major  bakery  equipment manufacturer  from South Africa .It has strong presence in African continent and has establsihed  a prominent place in  other countries for retail bakery equipment segment .

Established in  1904   Macadams  have  been  manufacturing  bakery equipments , packing machines  and bake ware. Macadams International  is wholly owned subsdiary of Universal Industries . It  is based at Capetown , Blackheath , South Africa .

Here  are range of equipment  manufactured  by them

Baking Systems
        Rack Ovens
        Deck Ovens
        Convection Ovens
        Provers
        Kneaders,Mixers,Bowl Hoists and Bulk Hoppers
        Moulders
        Dividers
        Bread/Cake Slices
        Pastry Sheeters
        Industrial Frying Pan
        Doughnut Fryer
        Biscuit Machines
        Water Chillers
        Specialised Solutions

    Food Service Solutions
        Combi Oven
        Chicken Grillers
        Slicers
        Foodwaste Disposers
        Meal Merchandisers
        Ice Cubers and Flakers
        Fryers
        Fridges,Freezers and Blast Chillers
        Packaging
        Dishwashers & Utensil Washers
        Ovens
        Premier Ranges
        Oil Filtration Systems

    Packaging Solutions
        Macadams MacPak Automatic Packaging Machine
        Macadams MacPak Horizontal Packaging Machine
        Macadams MacPak Multiple Packaging Machine

 

HQ &  Address

Head Office & Exports
Macadams Business Park
School Street
Blackheath
Cape Town
75811
Phone: +27 (0) 21 907-1000
Fax: +27 (0) 21 907-1111
Email: info@macadams.co.za

Website : www.macadams.co.za

Automation In Bread Plant

Indian bread  plants  in majority  are labour  dependent with most of the process done manually  its high time that  manufacturers think of   automating  the whole proces or  in parts to eliminate

dependence on labour
eliminate waste
have consistent quality
to eliminate human errors
increase productivity
safety 



In ingredient section automatic feeding  to mixer  with help  of  bulk handling , load cell based weigh hoppers  and pneumatic or screw conveyors ( flour , fat, chemicals  and sugar )

Auto greasing of moulds 

Direct feeding   of dough sticks  from  moulder to moulds

Auto  stamping of  dough sticks .

Auto  Lidding  and  De lidding  for  prover  and  baking  oven

Auto  loading  and unloading  of  moulds  into prover  and oven

Auto depanning of   breads from  moulds

Direct feeding to  slicers   from  spiral conveyors

Control  cooling 

Automatic  packing  with  direct feeding  to packing machine

Automatic  twist n tie  or wrapping  in packing

Automatic  loading of packed bread in  plastic  trays .

Direct loading to  containers  with conveyors

Grinding  for  sliced  bread waste to recycle

List Of Popular Industrial Baking Ovens

Various  types   of  Commercial /Industrial  baking  ovens are  available  to manufacturers  for  their  specific  requirements .

Selection of  ovens are done  on the basis  of  following
     product
     space
     fuel
     volumes/capacities
     heating


Following are different type of  commercial /industrial baking oven


    Pretzel-baking ovens
    Steam ovens
    Continuous-feed ovens
    Electric ovens
    Multiple-deck ovens
    Gas ovens
    Wood-fired ovens
    Infrared high-frequency ovens
    Swing tray ovens
    Contray  ovens
    Confectioner ovens
    Shop ovens
    Thermo-oil oven
    Pizza ovens
    Rotary Rack ovens
    Tunnel ovens

 Also  visit : types of  oven 

Energy Audits In Bakery

With  ever increasing cost of energy  bakeries  need  to  get their plant audited once in every 3-5 year period for modification and changes in their energy management and technology  to reduce energy cost . Energy  aud
its  can be done  by  experienced  auditors  or through  institution s .

Energy Audit Methodology:

Energy Audit Study is divided into following four steps

a. Historical Data Analysis:

The historical data analysis involves establishment of energyconsumption pattern to establish base line data on
energy consumption and its variation with change in production volumes.

b. Actual measurement and data analysis:

This step involves actual site measurement and field trials using various portable measurement instruments. It
also involves input tooutput analysis to establish actual operating equipment efficiency and finding out losses in
the system.

c. Identification and evaluation of Energy Conservation Opportunities:

This step involves evaluation of energy conservation opportunities identified during the energy audit. It gives potential of energy saving and investment required to implement the proposed modifications with payback period. All recommendations for reducing losses in the system are backed with its cost benefit analysis.


d. Monitoring and Control:

With increasing energy prices, many organizations have incorporated sub-metering systems in their
plants. It is required to identify and monitor parameters for energy consumption per unit of production
or services i.e. Specific Energy Consumption (SEC).SEC monitoring is an important tool for monitoring and
proving of energy conservation measures especially to see the effect of implementation of projects directed towards energy conservation.


Major Area's  for Energy Audits

Baking Oven
Lighting in Plant
Air Compressors
Air conditioning and Refrigeration unit
Packaging Unit
High  rating Motors
Electrical s system including Transformers
Mixers , Grinders , Blenders  and conveyors 


Energy Audits  has been made mandatory  by several countries . Incentives  for  better power factors  in electrical energy usage  are provided through lower bills .Few  easy  to implement plans  are suggested through these energy  audits  and the cost of  conducting such  audits  are insignificant in comparison to the savings generated   through the   suggestions and modification .

Wiesheu Dibas 64 Oven Wins Prestigious International Forum Design Award 2011

International  design forum ( IF  ) conducted by IF GmbH has  given Weisheu  Dibas 64 convection for  best design in product design category  for year 2011. IF  awards  are given to best design in product categories  for engineering , architecture and  other categories .

Wiesheu  ovens  are  popular ovens  in European market mainly in smaller bakery  category . Its German design and features makes it s  leading oven for bakeries . Unique  features of Dibas 64 that  it is the only baking oven in the world with the door disappearing into the oven casing at the side and furthermore convinces with its elegant, clear and timeless design unique in the industry.

With features like   double glass doors , removable racks ,halogen bulbs and complete S.S constructions  with  compact modular design makes it perfect for smaller bakeries .

 

The baking oven Dibas 64 in all its three sizes is a visual highlight in every store and perfectly emphasises the surrounding store concept and baking competence ( source : www.worldbakers.com)

for more on Wiesheu  Ovens  

visit  www.weisheuovens.com

Food Handling Gloves In Bakeries

Food handlers or operators in bakeries  more often comes into manual contact to perform activity in  pre mixing ( addition of ingredients & chemicals) ,mixing ( check dough consistency) , baking ( remove defectives ) , stacking ( packing) .Manufacturers provide workers with protective gloves to prevent cross contamination ,microbes and bacteria from handlers hand .Wearing gloves is not mandatory in most countries but still as per good manufacturing practices manufacturers provide their workers  with food handling gloves


Conventional method which most of the bakeries still use is  to provide wash basins  near to working areas  with potassium permanganate solution  to wash their hands in frequent intervals .


PVC  thin clear transparent disposable  gloves

These gloves are preferred gloves for  food handlers as its cheap in comparison to latex or vinyl gloves .Even while wearing these gloves workers should be trained to switch over to new pairs in case of damage or high perspiration in hands .One has to wash his hands and use dryer  before putting up new gloves  . These types of gloves are mostly used  where glove changing is frequently required .


Latex  disposable gloves

These gloves are required for handling of hot objects  such hot cookies while at baking section or removing defective biscuits from oven or depaning  operations , oven loading or unloading  in bakery manufacturing process.Its also used in area where workers have to handle chemicals .Latex gloves are costlier than PVC poly gloves  hence it is used only where you cannot  replace it withpvc poly gloves.These have to be washed and sanitised for multiple use .These gloves could sometimes results in rashes and itching.

Guidelines for Gloves
 

•      Wash hands properly before and after wearing or changing to a new pair of gloves
•      Use gloves that fit properly and that are designed for the task at hand
•      Change gloves whenever tasks change or whenever an employee leaves his/her workstation
•     Sneezing, coughing or touching one's hair or face with a gloved hand all require hand washing and a   new  pair of gloves
•     Because perspiration and bacteria buildup under gloves, wash hands and switch to a fresh pair periodically

Few experts  are  of the view that  gloves  are as harmful as manual contact . These gloves develops  pinholes when damaged which may not be visible by naked eyes , this may then results in bacterial contamination of hands.Workers never remove these gloves as often as required.Expert still believes the  conventional method of hand washing  to gloves

Provers In Bread Manufacturing

Proofing

Bread, Bun , Pie and Rusk  manufacturing  have unique ingredient yeast which is responsible for texture requires either time or conditions ( humid and  hot ) to act  and release gases which are trapped into dough ( leavening)  or fermentation . Various type of provers are available as per plant layout such as Box type , L type or Type , Gas  or  steam could be used for humidity and heating arrangement .It includes  gas burners , steam heaters or steam injection system .Rack type or Traveling tray type provers  are available for proving/proofing  process.Proofers are thermally insulated enclosures and. vary in size from a small box with shelving to a room. With  space  for  many  portable  bread  racks. Proofer  is  heated  by  steam  coils  or  electric  heating. Elements located inside the enclosure.



Intermediate  Prover
Intermediate provers are provided in bread manufacturing process to allow bread to relieve and recuperate from stress- strain to mechanical action on dough by  dividers and rounder . It also  gives dough to ferment during  this time and make dough soften up for  Final prover  after moulding .Its  also called relaxation prover  where it travels for few minutes in trays .



Final Prover

Dough  are  converted into elongated  cylindrical dough pieces  which are twisted  and re placed into moulds  which are greased  with emulsion or oil  for depanning . Final prover have arrangement for steam  which spread out  uniformly in  the final prover . Temperatures in Final prover  is about 38 deg c - 45 deg c. Humidity level and temperature maintained in such manner  that  yeast activity is maximum  in the final prover . Precautions need to be taken  so as to prevent  dough to rise above moulds . box or inversely the dough is left without rising . Speed of moulds travel in the prover  is either controlled through timers or through manual start and stop . Speed of travel of moulds are  to monitored with respect to rate of  dough yeast activity . Tray movement could be horizontal ( swing tray )  or  vertical ( Contray Oven ) . Approximately time for proving is  60- 75 min as per conditions . Final prover are mostly fabricated at site for large bread manufacturing  with drives and sprockets  to which racks are attached on which mould s are kept .With completion of  cycle in prover  the dough which is risen to 3/4 th mould is  then  transferred to oven for  baking .   Other popular type of prover are retarder prover . Capacities are matched with that of  Oven .

Chocolate Muffins Home Recipe

Holiday  seasons  are here again .Most would  have been trying  different recipes and bakery products  to celebrate this seasons . My favorite has been  chocolate muffins . Try  out your self


List of Ingredients  required for  chocolate muffins



Chocolate Muffins:


1/2 cup (113 grams) unsalted butter, melted and cooled


2 large eggs


1 cup (240 ml) buttermilk


2 teaspoons pure vanilla extract


1 3/4 cups (230 grams) all-purpose flour


2/3 cup (60 grams) unsweetened cocoa powder


1 1/4 cups (265 grams) light brown sugar


1 teaspoon baking powder


1 teaspoon baking soda


1/2 teaspoon salt


1 cup (170 grams) milk or semisweet chocolate chips


Process


Preheat oven to 375 degrees F (190 degrees C). Position rack in center of oven. Butter, or line with paper liners, 12 - 2 3/4 x 1 1/2 inch muffin cups.


In a large measuring cup or bowl whisk together the eggs, buttermilk, and vanilla extract.


In another large bowl whisk together the flour, cocoa powder, sugar, baking powder, baking soda, and salt. Stir in the chocolate chips. With a rubber spatula fold the wet ingredients, along with the melted butter, into the dry ingredients and stir only until the ingredients are combined. Do not over mix the batter or tough muffins will result.


Evenly fill the muffin cups with the batter (the muffin cups will be full), using two spoons or an ice cream scoop. Place in the oven and bake until a toothpick inserted in the center of a muffin comes out clean, about 20 minutes. Transfer to a wire rack and let cool for about 5 minutes before removing from pan.




Chocolate Frosting: Melt the chocolate in a heatproof bowl placed over a saucepan of simmering water. Remove from heat and let cool to room temperature.


In the bowl of your electric mixer, or with a hand mixer, beat the butter until smooth and creamy (about 1 minute). Add the sugar and beat until it is light and fluffy (about 2 minutes). Beat in the vanilla extract. Add the chocolate and beat on low speed until incorporated. Increase the speed to medium-high and beat until frosting is smooth and glossy (about 2 -3 minutes). Spread a little frosting on each muffin with a knife or offset spatula.


Makes 12 - 14 regular sized muffins.




Source

www.joyofbaking.com

Rotary Ovens For Bakery

Rotary oven are suitable for uniform and perfect baking of various products like bread, buns, cakes and cookie. Widely popular among small to medium bakery businesses and is best suited for bakeries producing  number of varieties .
Rotary oven are with turntable and has stainless steel, body and baking chamber for easy maintenance. It has one-piece door with heat reflecting glass, specially designed gasket that gives complete sealing of doors. It has large steel heat exchanger that ensures lower fuel, consumption and fully indirect heating, from cold to 250°c in 20mts. It has pictorial indicating plate with electronic digital display. The machine also has steam generators on feed wall for better steaming. It has an excellent air distribution system for optimum baking performance. Illuminating elements outside main heating chamber with off facility to reduce electricity bills.
Rotary oven are designed to be easy and safe to use. The thick, overlaping insulation keeps the heat where it should be,inside the oven ,and forbid to transfer heat to the working environment;.  It can be heated by electricity ,oil,gas or coal. the control panel can be used for either by hook or rotating plantform. the large window in the door incorporating heat-reflecting double glazed glass and the effective internal light permits close observation of the baking process inside the oven. ,toast,biscuit,cake,etc.

Rotary  Ovens  have  anti  explosion safety installed for  any explosion inside  the chamber . Trolleys as per the dimensions of the products are provided or could be fabricated by the bakery manufacturers  . Trolley once loaded with  dough is placed onto  the rotating platform on which this trolley is stationed .Rotary  oven  thus gives uniform heating  to  the product .Main components are  Burners , Extracting Fan , Controls and Rotating base

Specification for  Rotary  Oven

Capacity : Varies from 50kg -200kg
Type :  Convection  Oven / Turbo Oven
Fuel :  Electric /Gas/Diesel
Trolleys : Single or Double
Tray :32trays/trolley or 64trays/trolley
Power : 2.0-5.0 kw
Controls : Manual /Automated

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Bread Talk To Open More Boutique Bakeries In Vietnam

More than 300 boutique bakeries in many countries and territories, BreadTalk offers a wide variety of breads and cakes.BreadTalk, a pioneer in revolutionizing the image of the bakery industry with its trademark open kitchen, allows customers to view the entire baking process from flour mixing to hot breads from the oven.Bread Talk  now plan to expand its  franchise retail  business in Vietnam.
 
Vietnam’s Binh Minh Toan Cau Joint Stock Co. plans to set up more than 10 BreadTalk boutique bakeries in HCMC in 2011 under a franchising agreement with the Singapore-based chain of boutique bakeries. Two such bakeries called BreadTalk have already been opened in HCMC.

Ly Qui Trung, chairman of the local company, said at the opening on Wednesday of the second BreadTalk boutique bakery at 02 Cao Thang Street in the city’s District 3 that next year his company would open some 10 more bakeries in the city.

The third BreadTalk boutique bakery at Maximark Cong Hoa Supermarket on Cong Hoa Street, District Tan Binh will be up and running next month.

“This is part of Binh Minh Toan Cau Joint Stock Co.’s plan to increase the number of its stores in the city from two to more than 10 next year,” said Trung.

He said that the second BreadTalk boutique bakery in Vietnam with the investment capital of more than VND5 billion was the biggest bakery of BreadTalk boutique bakery chain in the world. The store covers some 150 square meters.

In the coming time, his company would open BreadTalk boutique bakeries at supermarkets and department stores, he said, adding each bakery in the city should cost some VND5 billion.

BreadTalk, a premium bakery brand of Singapore, has more than 300 boutique bakeries worldwide including Singapore, China, Indonesia, the Philippines, India, Kuwait, Malaysia, Hong Kong, Thailand, South Korea, Oman, Bahrain and  Vietnam. 


source 
http://english.thesaigontimes.vn

Local Bakery Equipment Manufacturers Draws Huge Crowd At Techmart2010

  
Techmart 2010 organised  by NSIC  has  wide representation of small scale industries  from areas like bakery , textiles , dairy , leather and handicraft .Its  held  along with annual Indian trade fair at Pragati Maidan ,New Delhi.

Major  attractions has been   live  demonstration  of  manufacturing process  by these small  bakery equipment manufacturers  where  one can see cookies preparation and baking .Products were offered to visitors  fresh from oven .Capacities displayed were from  30kg-50kg/hr  of production .

Some of the bakery equipment suppliers were

Pritul Machines: Mixers , Rotary  Ovens ,

Growthway Technologies: Mixer , Rotary  Ovens , Depositors

Ever Bake :  Rotary Ovens

Goodlife  :  Rotary Oven , Mixers and Depositors

In addition to  bakery equipment manufactures One can visit packaging machinery section which  could be used in cookies , cakes  and biscuit packagin

Companies present were

Jawla Engineering Pvt Ltd  -  HFW  , Vertical form fill machine

Shri Vinayak Packaging Machine  P ltd - Shrink wrap , Sealers , Vertical form fill machines


Entrepreneurs  looking for  starting small bakeries   could visit   these manufacturers /Suppliers  in Hall No-14  at TechMart 2010 .

Lighter Oven Bands Could Result In Energy Saving

Energy  savings   strategies for bakeries  includes  oven  band heating   .  Oven bands are of various types  which are used to convey  wet  products  to the oven  for baking . Normally this type of oven bands are required in biscuits , cookies , pizza , Swiss rolls  manufacturing using tunnels oven with length varying from 150 ft - 300 ft  . Heat   balance of oven   shows that  product itself requires 30- 40%  for its own heating , 10 - 20 %  is required for  oven heating and balance heat  used for heating of  make up air ,oven  and losses. Oven band  have repeated cycle of heating and cooling .

Heavier Belt  requires more heating  than the lighter belt .Type of belt used in oven  impacts the energy cost of the product. So  any reduction  in the thickness  of band  would result is less energy  required for band heating .
Many  manufacturers have  switched to  lighter oven bands for energy savings .



Report by Reading bakery Systems

Imaforni Intl S.p.A - World Major Bakery Equipment Manufacturers - A Profile

Imaforni have been serving world bakery industry  for long . It has installation across the globe and  bakery equipments have been installed in numerous bakeries in world . Imaforni  have been pioneer in bakery technologies  its manufacturing expertise and  services  had made  them  world leader in bakery equipments .Established  in 1962   This  Italian  bakery  equipment brand  has established  its popularity among bakery manufacturers for better design and service .Imaforni  has installed and have equipments  in  more than  110 countries  with 170 people employed  in the company .

Equipment manufacturing  are categorised  in following section in  Imaforni Intl Spa

Bakery

Imaforni  market leading mixing and forming equipment is based on over 50 years experience of the specialist needs of high-output plant bakeries producing a wide product range. Other areas of expertise include baking, and there is specialist equipment for the production of niche products such as Pizza , swiss rolls and cookies

Hard  Sweet Biscuits / Cracker/ Soft Dough /Cookies

pic courtesy - Imaforni

Hard sweet biscuits and cracker/ soft dough / cookies  unit  have following units  such as Laminators , cutting or moulding units , gauge rolls , baking ovens ( tunnel oven s )  , Mixers , Packaging machines, depositors , oil Sprays , cooling conveyors

Muffins . layer cakes  ,Pizza and   Swiss rolls

Swiss rolls  have sponge sheets  baked into oven  with other decorating devices   which perform different functions such as  fillings , rolling , shearing   etc these rolls are then packed in hfw packing machine .

Cake plant s have  planetary  mixers with which   batter    are prepared   and placed in paper boxes and these are placed in moulds  for baking .The depositor may be made with a double head to produce two-colour products. For the production of more sophisticated products, it is also possible to position two depositors one after the other. The task of the oven is to transform the liquid material into a tasty, edible, appealing food; consistent temperature and uniform baking are essential factors for obtaining the desired lift and quality

After  Sales  Service

Imaforni   takes complete project from design to commissioning stage  from  customer . through their Aftermarket services  from Italy and regional centres .Imaforni  provides excellent support in terms of spares for their equipments such as moulds , dies , moulders and cutters  , service contracts , benchmarking , optimising ,inspection and measuring equipments.

  

Brief History
It was in 1962 when Demetrio Castello and Ugo G. Bademer put a name to their passion for the design and manufacture of industrial equipment: Imaforni was born.Today Imaforni is an international world leader, and its vast know-how has made it a landmark in terms of the reliability of its equipment and the innovation of its design.Since 1962 Imaforni has been coming out with  innovative products in field of biscuit , bread , cake  manufacturing equipment .The major competitors  for Imaforni  are  Baker Perkins , Werner Pfliederer

HQ
IMAFORNI INT'L S.p.A.
37030 Colognola ai Colli - via Strà, 158 - Z.I.
VERONA - ITALY

Phone: +39 045 617.47.11
Fax: +39 045 615.00.65
website : www.imaforni.com
Email : info.ima@imaforni.it

Best 4 Ways To Keep Your Daily Bread Fresh

An  useful article  for everyone   who  buys bread  on daily basis  . Certain  steps to keep your bread fresh .

Stale bread is tasteless bread. That is how we use to describe bread that loses its crustiness and delicious airy characteristic. So why not learn ways to keep bread fresh until dinner tonight or better yet, breakfast tomorrow? When baking your own bread or buying newly baked bread, you must remember that there are certain steps to follow to prolong its crispiness and retain its baked oven taste. Here are some good ideas.

1. Avoid wrapping warm or hot bread too soon because the hot air that would be trapped inside the packages could cause condensation and moisture. When this happens, the moisture could seep in to the other parts of the bread and make it limp or soggy.

2. When storing the bread keep it on room temperature while in paper, sealed plastic bags or airtight break box. It can last up to one week if it is on secured and clean container. Keeping the bread as well inside the fridge can prevent the molds from quickly contaminating it although other bread makers may not recommend it because accordingly if the temperature fails molds may still grow on it.


3. If you want to store bread for longer periods, wrap the loaf in foil and put it inside airtight plastic bag and keep it inside the freezer. If possible, the loaf must be whole to prevent freezer burn but if you want to cut out a slice make sure the remaining part are once again stored in the same condition.

4. Frozen bread needs thawing at room temperature. When thawing completes, warm the bread in the oven with a 350 degrees Fahrenheit for around ten minutes to make it crispy again. If there is no oven available, slices can be put into the toaster.

Maryann loves to cook and really enjoys writing about her experiences. She recently purchased a new KitchenAid toaster that does way more than what she ever imagined. The author also has a hearing impairment. This has made it quite challenging for her in the kitchen. To fix the problem, Maryann came up with a solution and would like for you to check out a review for how she never missed the timer at http://beltonehearingaids.org/beltone-touch-hearing-aid-review.

Article Source: http://EzineArticles.com/?expert=MaryAnn_Reynolds

Types of Industrial Biscuit Ovens

Various  types of biscuit ovens  are used in biscuit industry  for production of   varieties of biscuit .  Selection  parameter  for   any biscuit  oven are capacity ( which covers length ,width  and speed ) , products , baking time  and type of fuel  .Normally in bakery parlance  ovens are defined as per  width and no of  baking zones .

Biscuit ovens are mainly  classified  under  following  types

Direct gas fired

 The gas fired  oven is used  for those product  that require  great heating power . They can burn natural gas  or LPG . The gas  is mixed  with air  in a special  mixing pipe  based on  the Venturi tube  principle . In each zone  the heat at  top and bottom  can be  independently set by regulating  the two combustion  air fans which controls  the volume of gas  fed  to the  burners . A bar graph potentiometer  set by operator  can be  used to select the heat ratio between  top and bottom . Each zone is equipped with a suitable humidity  extraction system .


Indirect   radiating  cyclotherm oven

 The Indirect Gas / Diesel fired ovens  also known as  cyclotherm  oven - transfer heat  to the product   by radiation . Each zone consists of  set of tubes  at the top and bottom  of the baking  wire band  through which  the hot air  which has been previously heated  by burner flows .

At the end  of each baking  zone the hot gasses are collected  by a plenum and returned  by blowing  fan to the burner  where they  are heated  up again  to the working  temperature  and sent back  to the tube circuit . The heating  system  is there for  completely  independent  and the products  of combustion   does not  comes in contact with dough being baked . Each zone  has  extraction fan to remove humidity from  baking chambers .

Convection oven 
The convection  oven  is suitable  for baking delicate products  like cookies , wire cut  or sponge . Its baking chamber  is constituted  by a plenum  duct positioned  on the top and bottom  of the baking wire band  where hot air is  gently  blown out of  properly  designed  slats  and comes  in  contact  with the dough . The heat transfer  is mainly by convection . The convection  type of oven can be  direct  or indirect . In those cases  where the available fuel  is natural gas or lpg  and the reduction  of baking time is a necessity the direct convection  is the  correct choice .  In the  In direct   convection type of  oven  the  air is heated  up by passing through  a dedicated  heat exchanger  hence  baking  never comes into contact  with the dough .Humidity  is removed through extraction fans in each zone .

 

Hybrid  Oven

Hybrid ovens are those  ovens which have combination of any of the above types of ovens.  Sections are divided  into different type of heating  systems , depending upon  product and its baking  requirement .
  


Electric  Oven

Electric ovens  are  not so popular with  manufacturers due to low cost of lpg,cng or diesel as compared to  electricity . Oven  consist of electric heater s  which  en capsuled into radiating pipes  . These are then set  for set temperatures by thermostats .

Biscuit Production Line

Biscuit production line consists of following equipments with brief  description

Mixers
All  ingredients are mixed into mixers  to prepare  dough  with desired characteristics . Normally two stage mixing is done  in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer .

Dough Elevator or Dough Tipper

Dough bowl  are either taken to tippers where dough is decanted into mixer bowl  which is beneath the tipper at level lower  to the tipper  or  dough bowl is  carried to certain height  and then tilted to decant the bowl into laminator hopper .

Dough Laminator

Laminator main function is to reduce the  mass of dough into uniform sheet or laminate for further reduction in gauge roll . Laminators have sets of roller where this dough is acted upon  and are converted into dough sheet .

Gauge Rolls

These gauge rolls have set of cylindrical rollers which rotates in reverse direction so as to  give  push to the next gauge rolls . Three stand to four stand of gauge rolls are used in normal biscuit  production line . Speed of rolls ae set as per the baking time and increases  as we proceed further .

Moulding /or  Cutter Unit

These are equipment  which cuts the dough sheet into desired shape and size . Plant out put are calculated as per the design of the moulder or cutter . These cutters or moulders have dies , cups or inserts which are fixed on the cavities or  surface of the moulder or cutter .
Now days engraved moulders and cutters are available . Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cups .

Moulder are used for short dough  where as cutters are used for hard dough variety

Scrap return conveyor

These conveyors  returns the  scrap dough back to mixers which are again used for production thus minimising waste .

Swivel Panner
Swivel panner  is  installed at the feed end of oven where it centres the dough piece entrance on baking oven band  it has swivel arrangement on which it balances the  web or centres the web  so that wet dough pieces enter s oven in straight line .

Baking Oven

Dough pieces then enters oven  and travels on wire band for baking . Burners generates heat which is circulated through ducts or pipelines  to bake wet  dough pieces . length and width of oven are designed as per the capacity required . Oven speed is adjusted as per the standards baking time for particular variety


Stripper Conveyor

Stripper conveyors are provided  at  the delivery end of oven so that  baked biscuit are cooled and doest not come into contact of any surface when hot . Stripper conveyors has wire mesh which carries these hot baked biscuit .


Cooling Conveyor

These conveyors  are provided in biscuit production line to   bring down temperature of   hot biscuits which comes out from oven . normally they 1.5 -2 times of  oven length .


Magnetic Stacker

Stacker are used to  distributes and   arrange biscuits  in a line and are thus could be stacked easily for packing process . These biscuits  are made to pass of plates which acts as guides which makes these biscuits to fall into space between the guides .


Packing Table

Biscuit s travels into guidelines on packing table where either they are fed into  into  packing machine automatically or are fed into feeding chutes  manually by operators .


Packing Machine
Biscuits are fed into packing  machine for packaging   there are various types of biscuit packing such as pile type , on the edge  and cream sandwich type . Horizontal flow wrap machines are  mostly used to pack with flexible packaging .

Biscuit  Process Flow Diagram 
Bread Process  Flow  Diagram 
Accesories & Additional Equipments For  Biscuit Production

Cookies Production Line Equipments And Process

Cookies  production line  process  uses  different configuration  for variety of products  with  following  equipments  apart from ovens , mixers and packing machines .

Major  process used in cookie production line are  -  wire cutting , depositing  and rotary moulding

Wire  Cutting  have several  different method  of cookies production . These categories  of products can be manufactured  starting from  a single machine .The basic machine  consists  of  two grooved rolls which extrude  the dough  through sets  of dies in order  to give  the dough pieces their shape .  A filler block  is inserted  between the  rolls  and  the die plate  in order to equalise  dough distribution  across the width  and provide the optimum  weight control . A wire cut mechanism  can be added  for the production  of plain wire cuts or products with inclusions. Rout Press products  are cut by means  of a guillotine  cutter positioned  before or after the oven ,depending upon the type of final product .By adding the crimping device  soft centred cookies can  be formed  where the centre filling  can be jam or cream .

Options in wire cutting

Plain wire cut
Wire cut with inclusion
Two  color dough
Soft centre
Fruit Bars

Depositing  consist of head  which have  pair of grooved  rolls which evenly  feed the  dough to set of dosing  pumps positioned underneath. The one pump one nozzle  concept ensure  uniformity of weight across the width .The machine is fully servo controlled  movement of heads are driven independent motors . Depositors can have wire cut mechanism  attached  or  a rotating nozzle mechanism can be added  in order to produce swirl or twisted dough piece. Jam depositor can also fitted for  cookies product flexibility.

Rotary Moulding  consists  of  set of moulder , pressure roller  and   extraction  roller  which  releases the cookies with help of knife . Moulder s can have  cups of  different shapes  and size . Moulding process are suitable for high volume production with low baking time .Most of the manufacturers integrate moulding with  hard dough   cutter variety .


Biscuit 

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Bakery Equipments - Rusk Manufacturing Equipments

Rusk s  are bread baked twice . This toasted  bread are popular in many countries  and people prefer to have it as tea time snacks  as well as  nourishing food for children .

Rusk has advantage of shelf life  as it can stored for longer time . Rusk are available in many shape and sizes  and flavours .

The Process of Rusk manufacturing starts  with  dough preparation in spiral mixer or kneader . followed by  dough feed and moulding . The dough is then  proofed  and baked in tin moulds .Once the baking is completed then these bread bars are cooled and then cut into slices .These slices are then  toasted  in a secondary baking process  and conveyed for packaging .

Following equipments  are used in Rusk Manufacturing

• Spiral Mixers
• Dough Divider
• Hander Up ( coned shaped moulder )
• Inter prover
• Moulding
• Final Prover
• Baking oven  or Tunnel oven
• Bread Depanner
• Bread Cooling
• Bread Slicer
• Toast Oven
• Product stacking
• Packing Machine

More on  bakery  production  equipments

Biscuit  production line
Bread production line 
Cookies  production line
Wafer biscuit production line

Swing Tray Baking Oven s

In Bread manufacturing process baking oven is the major equipment. There are various baking ovens for bread manufacturing ,for any higher capacities manufacturers often opt for Swing tray baking ovens .Other model for baking oven for higher volumes of bread production is contray ovens .

Swing Trays main drive moves sprockets and chain with which the racks are  hinged with the chain and this tray swings both ways .These racks hold bread moulds  and carry them  to complete the baking cycle

Burners can be of ldo ( diesel type ) or cng ( gas type ) . hot air is circulated through circulating fan in headers either through top and bottom headers or middle and bottom headers .

  

Swing tray ovens can be designed for 5000 – 50000 loafs per day capacity.

  

Some of the features in Swing tray Ovens

• Preferred for higher volumes
• Oven chain can be hand-cranked in an emergency  
• The tray's movement is intermittent and controlled by a digital timer  
• Insulated for maximum fuel-efficiency  
• Flue gas does not come in contact with food item being baked  
• Imparts solid top and bottom heat to loaves under baking for uniform results across the length of the tray  
• Lidding and Unlidding is automatic in swing tray ovens  
• Requires a larger area than other baking oven for the same capacity 
• Safety Explosion doors are provided as safety against any explosion

Types Of Baking Oven

Baking ovens are major equipment  for  any bakery process  . Major function of baking oven is to  heat the wet dough ,batter  to  a temperature  where it becomes  baked with desired texture and taste . Baking removes  the moisture which helps in improving shelf life of the baked products plus it kills any microbes  in the dough at a higher temperature .Accessories to baking oven are  circulating fan , steam extraction , chimneys , safety explosion doors , fire tube , burners , drive ,temperature controller and indicators , fuel system with  baking moulds  and wire bands.Bakery ovens selection also take dimensions  into consideration such as height ,width , weight , chimney dimensions , foundation method  , electrical wiring and automation.Types of oven used in bakery are classified on several  factors .

Baking Ovens  are  of various types used for baking breads , cookies , biscuits , cakes ,pizza and cream rolls

Types of oven for baking  can be classified by

Physical  Characteristics

• Rack  Oven / Deck Oven
• Rotary Rack oven
• Travelling  Oven
• Tunnel  Ovens
• Swing Tray Ovens
• Con Tray  Ovens
• Manual Loading
• Automatic Loading

Heating

• Direct  Heating ovens
• Indirect  Heating Ovens
• Hybrid Ovens

Loading

• Top  Loading Ovens
• Front Loading

Fuel  Used

• Diesel  Ovens
• Gas Ovens
• Electric Ovens
• Infra red

Wire Bands

• Articulated Wire  bands
• Flat Steel bands
• Modular bands

Length or Width

• 1.5 mtr  Band width Oven
• 1.2mtr Band width Oven
• 1.0 mtr Band width Oven
• 0.8 mtr Band width Oven
• 4/5/6/7/8 Zone Ovens

As Per Design

• Mark III Oven
• TRP   Ovens
• Mark II  Ovens

Tension  Arrangement

• Pneumatic
• Mechanical

learn more  on bakery business 

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