Baking & Snack - June 2019 - 78

CRACKER TECHNOLOGY

Digital control systems
on today's high-speed
cracker lines automatically adjust downstream to any changes
made by operators.
Bühler

Without control over the sheet as it flies through
processing, the conveyors can over- or under-feed
the gauge rollers. This results in inconsistent reductions and lost dough. To stay in control of the process
through the sheeter, RBS employs a laser-based dough
flow control system. Lasers at each gauge roll measure
the height of the sheet as it approaches the roller and
then automatically adjust the speed of the conveyor
as needed to maintain the desired height, preventing
over- or under-feeding.

Once the production line is set correctly, the latest
control systems help operators keep the process moving. "The modern technology in control systems and
digital control systems allow operators to make adjustments in one location, and everything behind it will
automatically adjust," Mr. Parlour said. "In addition,
we can develop centerlining guidelines that keep the
line running within them."
Not only are cascade controls critical, but Mr. Green
said intuitive HMI displays also help operators make
quick and efficient adjustments as production moves.

A consistent dough sheet is
always critical for
consistent crackers at
the end of the line.

The operator variable

Spooner Vicars also employs a laser to measure dough
height as the dough sheet is reduced.
As dough moves through the line, transfer points become a risk to the smooth product flow that is so critical
to efficient and fast production. Transfers are a place for
the dough to get off-track and distorted. Much of this is
addressed up front during line design and installation,
Mr. Green explained.
"All conveyor transfer points need to be designed
with adjustment and set optimally to ensure precise
product transfer without distortion," he said. "Autoweb tracking/guidance systems must be sensitive
enough to ensure a quick response to match the higher conveyor speeds and ensure positional accuracy of
the product between transfer points."

78 Baking & Snack June 2019 / www.bakingandsnack.com

While automation is the heart of high-speed lines, that
doesn't mean operators are off the hook. Faster production speeds mean if something goes wrong, the problem
- and its consequences - will escalate quickly, so operators must remain vigilant. Failure to do so can lead to
wasted product and increased downtime.
"The operator has to be attentive to the equipment at
all times," Mr. Smith said. "He or she must be thinking
one or two steps ahead of the process so they can be actively watching for problems instead of reacting to them
as they arise."
The live nature of cracker dough makes operators essential to consistent high-speed production, no matter
how much automation is incorporated. "Situations will
always arise throughout the course of a production shift
that will demand the attention of the operator to make
appropriate changes to the set points of the equipment
to account for variations in dough consistencies and ambient conditions," Mr. Green explained.
Operators should be looking at dough as it comes out
of the mixer to confirm that it is the right consistency
and flowing correctly. They should be checking varia-

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Baking & Snack - June 2019

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