Baking & Snack - August 2020 - 79

becoming more important for industrial processes."
Rademaker's newest control platform enables data exchange with third-party equipment.
"This advanced data processing permits online
monitoring and optimization of equipment efficiency,"
Mr. Magistrelli said. "The use of the combination of process and recipe information allows for easy and faster
startups leading to lower flour and ingredient usage."
Sheeting lines have evolved over the years to include a
bounty of belt-speed features and gap settings.
"This is a benefit to the customer as this allows the
operator the ability to select predetermined recipes,
and the line will automatically set up the speed and gap
opening of the reduction units and intermediate conveyors that make up the system," Mr. Magistrelli said.
Matt Zielsdorf, director of sales, Fritsch USA, a
Multivac company, described the concept as a "continual
cascade" that has become part of the standard installation on all its industrial lines. Fritsch's Soft Dough
Sheeter relies on a front-end sensor control to ensure
that the hopper always contains the same amount of
dough, eliminating fluctuations in the process.
"The line operator inputs a certain number of pieces,
for example, and the machine automatically calculates
the speed at which the line must run to produce beautiful, regular products," Mr. Zielsdorf said. "All parameters
are adapted automatically and do not have to be manually adjusted."
In recent years, Moline modernized its cascade control system to adapt to the constantly changing density
of yeast-raised dough in various production environments. Such fluctuations may cause a gassy dough to
tear on sheeters or stretch out of a dough former.
"If you are to monitor density changes, you can make
the necessary speed adjustments on the fly automatically," Mr. Moline said. "Any time we speed up a conveyor
into a sheeter, we're able to make the same proportional
adjustment all the way upstream and back toward the
dough former, so making a change in one place won't
cause a problem someplace else. If there are variations
in proofing or baking times, we have the whole system
adjust proportionally to that change."
While many makeup departments are now temperature-controlled, unanticipated fluctuations in mixing and
fermentation will impact product consistency on the frontend of the process, noted Coen Nikkels, manager of marketing and business development, Rondo Industrial Solutions.
That's where PLC controls and even the early stages of AItechnology can provide operators with assistance.
"The temperature and consistency of the dough
mass may differ from batch to batch and from day to
day for whatever reason," Mr. Nikkels said. "However,
the product should still be the same. We are develop-

ing supporting functions that will automatically change
the settings of different components on the line when
dough characteristics like temperature, consistency and
weight change."
Minipan relies on photocells and load cells to react to
process variations.
"Everything is strictly controlled, including multirollers, gauging units, drawing units and blade cuts, according to the dough," Mr. Fusari said. "In this way, we
guarantee that the line always works properly, at its full
capability, and with perfect portion control."
To simplify production, Mr. Magistrelli said,
Rademaker increased the standard size of its HMI to
make it easier for operators to interact with the screens.
Moreover, its most advanced control systems now include energy-efficient drives that provide less variance
and additional process stability.

Today's lamination lines
accommodate changeovers
that allow bakers to create
a variety of products on
one line.
Middleby Bakery

Taking charge of change
While single-purpose lines are designed to crank out
a high volume of baked goods, the inherent versatility of sheeting technology often encourages bakers to
produce multiple items on one line. To accommodate
changeovers, Spooner Vicars, a Middleby Bakery company, relies on its latest A-PEX equipment to provide
flexible, mechanical adjustments and integrated controls
functionality, noted Andy Green, technical development manager.
"Incorporating the latest technologies enables full recipe control of speeds and roller-gap adjustments to ensure consistency of product and ease of operation for the
operator," he observed. "The advances in control PLCs,
component devices and software have enabled full integration of equipment diagnostics interface with custom-

www.bakingbusiness.com / August 2020 Baking & Snack 79


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