Baking & Snack - December 2019 - 56

SHEETING/LAMINATING

such as product quality. "First, listen to the customer to
clearly understand what products they determine to be
the most important out of their portfolio to automate,
then calculate which production lines or automated solutions will have the highest return on investment for
the customer's portfolio," advised Hans Besems, executive product manager, AMF Bakery Systems.
Where to automate often requires determining where
a workforce has the greatest impact - and payback -
for a bakery. "The biggest labor savings lie in forming
and shaping the product where normally a specific skill
is required, so there we will look to automate production," Mr. Besems said. "In semi-automated production
solutions, we can still integrate manual labor based on
the customer's preferred processes."
In addition to automating simple and repetitive tasks,
consider eliminating heavy lifting such as emptying a
mixing bowl into a hopper to feed a laminating line, according to Mr. Nikkels. "Downstream, the panning of
products can be automated easily and brings more efficiency," he pointed out.

Running every which way
With a broad portfolio, production often is like a relay
race. While the speed of individual product runs remains vital to overall performance, it's the quickness of
the transitions from one item to another that determines
how well the operation finishes.
To determine line flexibility, assess production needs
by answering a few fundamental questions. "Are you cutting, crimping or scoring? Are you applying fillings?"
Mr. Moline asked. "Makeup is one of the most flexible and
easiest areas where you are able to change out systems."
With a little extra floor space, he added, bakers can install a couple of cutting stations that are permanently affixed to the sheeting line without having to change those

machine components when needed. Two rotary cutting
stations, for instance, can provide crimping, cutting or
scoring on a single product. Likewise, Mr. Moline said,
two different cutters can support creating two separate
products with quick changeovers.
Moreover, a guillotine will cut swirl breads or cinnamon rolls by length. Installing a guillotine that "walks"
with the product - or moves along with the speed of the
conveyor - allows production lines to avoid an angled
cut on taller products, Mr. Moline explained.
Another tip to streamline changeovers involves
integrating a second filling depositor, according to
Mr. Besems. "AMF Tromp sheeting lines are incredibly
flexible in terms of product variety," he said.
Minipan offers its Multipurpose Line for Specialty
Bread with multiple shaping units such as a blade cutter
for regular shapes, a moulding device for hot dog rolls or
panned bread, and a rounder for hamburger buns and
rolls. "This way you can achieve many products starting
from one single sheet," Mr. Fusari said.
To ensure versatility, Mr. Breeswine recommended that
bakers reserve enough floorspace for multiple makeup
systems, such as forming stations or seeding units on
frames. However, if footprint remains an issue, take advantage of vertical space with feeding belts that steeply
ascend or by installing intermediate proofing or adding
resting time above the sheeting line. "There are hardly
any process steps that cannot be automated, whether
it is filling pastry or curling dough," Mr. Breeswine explained. "Some customers even order cutting or curling
systems that create products that look hand-made."

Tools for all trades
Simplifying the physical removal and replacement of
cutters and depositors also enhances versatility and efficiency. "The most important factor in achieving the

Simplifying changeovers for sanitation and maintenance
ral breaks to make the longest
Some changeovers are easy.
changeovers."
Others require careful planning.
Rademaker equipment pro"Going from butter to margavides "section splits" that allow
rine requires a cleaning of the
for cleaning to occur in one
fat pump, but if this is done at
section of the process while the
the end of the day or during a
remaining parts complete the
shift change, the longer time is
production run. "This design
mitigated by the fact that the line
is valuable on long production
was going to be down for cleanlines with inline fermentation
ing anyway," noted John Giacoio,
where the process time from
vice-president of sales, Rheon
mix to product panning could
USA. "It is important to look at
be up to 3 hours," said Nick
the changeovers that need to
Magistrelli, vice-president of
take place over the day or even
sales, Rademaker USA.
during the week to use natu56 Baking & Snack December 2019 / www.bakingandsnack.com

Koenig offers the "H" hygienic
design series of equipment that's
completely washdown due to
sealed bearings. By using protective covers, the industrial Menes-H
bakery system also provides
convenient accessibility and
protects against injury. Conveyor
belts can be released without
tools. Additionally, frameless
equipment with easy-to-fold safety
claps allows full access to all belts
and modules without tools, noted
Richard Breeswine, president and
CEO, Koenig Bakery Systems.

Baking & Snack - December 2019

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