Baking & Snack - August 2020 - 66

BUN & ROLL TECH

AS BAKERS SPEED UP THEIR LINES,
IT'S IMPORTANT THEY DON'T
OVERLOOK HOW THIS IMPACTS THE
MOULDER OR ROUNDER.
Two paths diverged for GREATER CAPACITY

Increasing capacity on a bun and roll line can come
in two different ways: bakers can either speed up the
line or make the line wider. Expanding a line's width
enables bakers to run production at the same speed, thus
preserving quality, while still getting more product at the
end of the day.
"The only way to maximize throughput while
maintaining quality is to choose a larger or wider line,"
said Matt Zielsdorf, director of sales, Fritsch USA, a
Multivac company. "For high-quality products, it is better
not to run up the speed of the line, but it also depends on
the product."
Fritsch lines can be up to 1.6 meters (5.2 feet) wide,
producing 10 to 12 rows of buns. That adds up to about
50,000 buns per hour.
New technology, however, is making it possible for
bakers to achieve high speeds and still maintain quality.
Stewart Systems' extrusion divider, for example, can
operate at 150 cuts per minute across eight ports.
"This cut rate used to be difficult to achieve, but new
controls and servo technology have paved the way for
higher performance," said Joakim Nordell, export sales
manager, Stewart Systems, a Middleby Bakery company.
With new drive technology, the Industrie Rex AW from
Koenig Bakery Systems can reach 60 strokes per minute,
producing about 36,000 pieces per hour.
AMF Bakery Systems designed its high-speed Accupan
to run consistently at 150 cuts per minute, which results
in 72,000 buns per hour across eight pockets. It can
accomplish this through precise motion control, easy
operator management and the integration AMF provides
up- and downstream on the production line.
Fast production, however, can wear on equipment,
shortening its lifespan. Equipment must be designed to
withstand the strain. WP Bakery Group USA's Soft Star
CTi can produce up to 36,000 pieces per hour.
"The robust construction of this machine and the line
have all been designed to operate at the 60 strokes per
minute, 24 hours per day," said Ken Weekes, international
sales manager, WP Bakery Group USA.

"Generally speaking, it is up to the dough divider and
rounder to achieve high throughput," Mr. Breeswine
said. "The core of a production line is always the dough
dividing and rounding. It defines the speed and throughput of the machine."
Koenig's Industrie Compact AW and Industrie Rex
AW both balance high weight accuracy and flexibility
with peak speeds. They are continuously adjustable -
which enables fast production - and feature even piston
pressure for high accuracy across dough types. The company's T-REX AW divides and rounds dough at up to
72,000 pieces per hour in 12 rows. It can offer a weight
range of 0.99 to 2.46 oz and process a wide variety of
doughs, including those with inclusions.
"After dividing the dough pieces with a rotating dividing drum, the dough pieces are then turned 180-degrees
in a counter-clockwise direction and transferred to a
spreading finger belt," Mr. Breeswine explained. "This
step allows the dough to rest before the rounding process is started."
After resting, the dough is conveyed through the
sloped rounding ledges. These specially designed ledges
are what enable Koenig Bakery Systems to shape a wide
variety of doughs at high speeds without losing quality.
When it comes to soft, delicate or sticky doughs,
Sottoriva America's series of Athena, Dinamica or Lyra
divider/rounder machines were designed to handle
those products.
"Being able to run the baker's original product formulation without deviation is an important factor when selecting a bun divider/rounder," said Rich Wall, president
of Sottoriva America.
As bakers speed up their lines, it's important they
don't overlook how this impacts the moulder or rounder.
"If you just speed up the machine, you have less time
to round the product, and this means that the baker
must live with a less than perfect mould on high-speed
lines," said Ken Weekes, international sales manager,
WP Bakery Group USA.
In response, WP Bakery Group designed its head
machine with an expanded moulding drum. This provides the same amount of time to round the dough
pieces when the line is sped up. To balance gentle dough
processing with high weight accuracy, Mr. Weekes said
a servo-driven system and pneumatic positioning devices ensure the dough isn't overworked and always
in position.
"In this way, we can ensure that the line keeps running
without the need for operator intervention," he said.
Fritsch's BRWI round moulder processes soft, preproofed doughs in widths of 900; 1,100; and 1,300 millimeters, enabling bakers to increase capacity without
necessarily relying on increasing speed. The machine

66 Baking & Snack August 2020 / www.bakingbusiness.com

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Baking & Snack - August 2020

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