INDUSTRIAL PRODUCTION LINES
Baking Technology for the Industrial Production
of Durable Baked Goods
WP BAKERYGROUP
The WP BAKERYGROUP – with this corporate
portfolio, we have brought ourselves comprehensively into line with the requirements of bakeries
worldwide. Today, we are in a position to be
able to offer complete solutions – from project
planning to fitting out complete bakeries (trade
and industry), as well as supplying used machines.
A central element of our corporate philosophy is a networked thinking which spreads across all individual stages
of production. We call it “Process Management”, the targeted control of individual production stages and the machinery used – as fast as possible with the smallest possible loss
of materials to achieve the desired result, even with small
production volumes, as well as an unrestricted reproducibility of results that have been achieved. And all that with an
extremely high output.
Any unit can be “docked on” at any time if required for
manufacturing a product – there are adequate interfaces
for “foreign products”.
WP CompetenceCenter
_ Dough/Mixing. Emil Kemper GmbH, Rietberg
_ Rolls. Emil Kemper GmbH, Rietberg
_ B read. Werner & Pfleiderer Haton B.V., NL-Panningen
_ Ovens. Werner & Pfleiderer Lebensmitteltechnik GmbH, Dinkelsbühl
_ I nstore Baking. Werner & Pfleiderer Sachsen GmbH, Sohland
_ Refrigeration. Werner & Pfleiderer Koeling Benelux B.V., NL-Panningen
_ L aminating. Werner & Pfleiderer Lebensmitteltechnik GmbH, Dinkelsbühl
_ E ngineering. Werner & Pfleiderer Industrielle Backtechnik GmbH, Tamm
_ Used Machines. Werner & Pfleiderer Sachsen GmbH, Sohland
_ B akery Software. BackNet E&S GmbH, Muggensturm
www.wpbakerygroup.com/competencecenter
INDUSTRIAL PRODUCTION LINES
INDUSTRIAL PRODUCTION LINES
The professional development, manufacture, installation and servicing of
industrial machines for the production of bakery goods calls for a comprehensive
know-how and decades of experience. Multi-shift operation at full capacity,
accomplishing ­o ptimum, reproducible product qualities, control systems in
state-of-the-art ­technology, ­hygienic standards that comply with highest demands
as well as short cleaning and ­m aintenance times are essential ­requirements
faced by modern system concepts. ­Requirements that are satisfied at
a high level by the individual companies ­b elonging to WP ­B AKERYGROUP.
Based
on
these
demands,
we
supply
individually
equipped
­industrial
production lines which are renowned for their reliability all over the world.
_ 1
INDUSTRIAL PRODUCTION LINES
Werner & Pfleiderer Industrial Bakery Technologies – we have been developing, planning, manufacturing, installing and servicing industrial installations for the production of
baked goods for more than 125 years. We are now one of the leading suppliers of highly
automated inline concepts for the continuous production of an extensive variety of goods –
ranging from raw materials handling to the transfer to automatic packaging machines. In the
WP ­BAKERYGROUP we hold a key position in the “industrial solutions“ sector. Our product
portfolio includes machinery concepts for the production of bread and rolls, hard and soft
­biscuits, pretzels, crisp bread, rusk, cakes, croutons, breadcrumbs etc.
We provide technical solutions that satisfy the highest demands. In co-operation with our
­customers, we develop concepts which not only meet the requirements of the market, but
are also trendsetting for future industrial production.
2 _ 3
Raw materials handling_Processing_Application_Baking_Cooling_Transferring
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INDUSTRIAL PRODUCTION LINES
INDUSTRIAL PRODUCTION LINES
for the continuous production of baked goods
Industrial production lines manufactured by Werner & Pfleiderer Industrial Bakery Technologies
are always designed to meet the individual requirements of the customer. The plant dimensions and
equipment vary depending on the products to be manufactured and the scheduled output per hour. The
modules produced by WP BAKERYGROUP are always practice-proven machines or assembly groups that
have been consistently advanced and on which wide experience has been gained. From raw materials
handling through dough processing and dough moulding, the plant configurations include machines for
any conceivable type of processing, an immense range of dough processing facilities and oven combinations, as well as a wide assortment of conveying, positioning and portioning systems.
The degree of automation in the production lines ranges to fully automated lines with central control
and monitoring units, depending on the customer’s requirements. We always liaise closely with the
manufacturers of downstream packaging machines.
Industrial production lines from WP are always supplied complete, ready-for-operations and commissioned, and are delivered on schedule – production at the customer‘s premises may commence.
4 _ 5
PRODUCTION LINES
MODULES
_Hard biscuit/cracker
production lines
Kneader, continuous dough processing and feed
Laminator, gauge rollers
Cutting machine
Hybrid oven combinations
Conveying, cooling and stacking
_Soft biscuit production lines
Kneader, continuous dough processing and feed
Laminator/sheeter + gauge rollers
Continuous moulding machine
Depositors
SNK tunnel oven and oven combination
Conveying, cooling and stacking
_Production lines for pretzels
Kneader, continuous dough processing and feed
Laminator/sheeter + gauge rollers
Rotary cutter, moulding machine, extruder
Lye bath with sprinkler & cutting machine
SNK tunnel oven and oven combination
Cooling, transfer and packing
_Cake production lines
Mixer, continuous dough feed/portioning in tin moulds
Oven combination
Automated demoulding
Product cooling, product injection
Conveying and transfer to packing
_Crisp bread production lines
Pre-mixers
Crisp bread moulding machine
Flour duster & dusting flour conditioning
Dockering rolls & dough strand cutting machine
Tunnel oven
Cutting & stacking machine
Conveying and transfer to packing
_Rusk production lines
Kneader, continuous dough processing and feed
Dough processing, intermediate proofer, long moulder
Final proofer
Tunnel oven
Bread depanning, bread cooling
Bread cutting and bread slice seating system
Toast oven
Product stacking device
_Breadcrumb production machines
Kneader, continuous dough processing and feed
Portioning
Belt-type proofing channel
Tunnel oven
Bread cooling
Crushing, drying, grinding
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INDUSTRIAL PRODUCTION LINES
HARD BISCUIT/CRACKER PRODUCTION LINES
Hard biscuit/cracker production lines The process route for the production of hard biscuits or crackers
starts with the dough-making. This is followed by the dough lamination and gauge rolling. After that, the
products pass through a rotating cutting machine. The next stage involves an SNK tunnel oven or a suitable
oven combination.
The number of oven modules is adapted to the required baking time in relation to the desired
maximum capacity.
Finally, the products are conveyed to the packaging machines via a cooling conveyor and stacking unit.
1Twin-shaft high-capacity mixer of the ZK type with controls that enable the memory of up to
50 ­recipes. The two Z-shaped kneading arms are optimally suitable for homogeneously kneading
a great variety of dough types.
2Automatic dough feed unit with dough portioning, metal detector and feeding conveyor to the
downstream processing machine (laminator, four-roll-sheeter). Four-roll-sheeter in compact construction
for producing a continuous dough sheet.
3 Laminator for the production of cracker and hard biscuit doughs.
4 4.1 Gauge rollers, 4.2 Double cut-out unit, 4.3 Dough net separation and returning
5SNK tunnel oven in modular design with different heating systems (direct, indirect, convection
and combinations).
6Automatic stacking machine for piling up biscuits. A follower aligning device ensures that the biscuits
are stacked in precise lines. Depending on the product type, penny stackers may be employed.
1
2
3
4
6 _ 7
4.1
Hard biscuits and crackers
–Cream crackers, soda crackers, cocktail
crackers, cracker mix, potato crackers
–Classical hard biscuits, biscuits for ­children,
zoo-type biscuits, basic biscuits to be
refined with chocolate
4.2
4.3
5
6
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INDUSTRIAL PRODUCTION LINES
SOFT BISCUIT PRODUCTION LINES
Soft biscuit production lines The process route for producing soft biscuits starts with making the doughs.
This is followed by dough feeding, dough moulding and placing the dough strip on a steel belt. The next stage
involves an SNK tunnel oven. The number of oven modules is adapted to the required baking time in relation to
the desired maximum capacity.
Finally, the biscuits are conveyed to the packaging machines via a cooling conveyor and stacking unit.
1 Batch-type mixer for the preparation of soft doughs.
2 Rotary moulding machine for the scrapless moulding of biscuits and cookies.
3 Extruded products, cut at the transfer point to the baking belt.
4 SNK tunnel oven, ideally suited for the production of soft biscuits and fine baked goods.
5 Biscuits at the oven discharge end.
6 Natural cooling and transport to packaging machine.
7 Biscuits at the feeding section of staking machine.
1
2
4
8 _ 9
3
Soft biscuits
–Soft biscuits or fine baked goods are
produced on tunnel ovens with wire-mesh
belts or solid steel belts.
–The doughs are moulded (moulded
articles), cut (wire-cut articles), extruded
(extruded biscuits) or dressed (deposited
articles).
5
6
7
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INDUSTRIAL PRODUCTION LINES
PRETZELS AND LYE BATH ARTICLES PRODUCTION LINES
Pretzels and lye bath articles production lines The process route for producing lye bath articles is started
by portioning the filling mass volume and the extrusion process. Cutting groups or biscuit moulding machine
comprise the following step. The final topping of the products is carried out in the lye bath which
incorporates a salt applicator and a cutting machine. The next stage is an SNK tunnel oven.
The number of oven modules is adapted to the required baking time in relation to the desired maximum
­capacity. The final transport to the packaging machine is carried out by cross and longitudinal belts, the
length of which is dimensioned to correspond to the required cooling time.
1The SP extruder is used for extrusion and filling mass portioning and intended to provide uniform dough
strands over the entire baking width. Filling masses are homogenised, temperature-controlled, filtered and
portioned and then guided to the extrusion head.
2The GH biscuit moulding machine is used for the production of a wide range of pretzels or cocktail
biscuits, simply by interchanging the moulding rolls. The machine is of a multipurpose type and suitable for
optimum biscuit moulding.
3.1Fresh and return dough are sheeted in the cut-out group and conveyed to the rotary cutting machine for
the production of small and large pretzels via special roll sheeters.
3.2Synchronised cut-out rolls are equipped with a special return-dough system.
4.1The moulded, cut or extruded dough pieces are passed through the temperature-controlled lye bath.
After this, the desired topping is applied.
4.2The dough strands are cut to length or grooved by a special guillotine. The transfer to the oven is carried
out on the basis of defined parameters and results in optimised loading of the baking belt.
5The SNK tunnel oven provides for an excellent development of the articles to be baked. Convection and
radiation can be ideally combined to obtain an optimum baking process.
6Transfer of baked sticks onto the cross conveyor belt with downstream cooling route and transport to
the packaging machine.
1
2
3.1
3.2
4.1
10 _ 11
Pretzels and lye pastries
– Moulded or cut-out pretzels
– Extruded or cut-out sticks
–Co-extruded sticks, filled with spicy
mixtures
–Sticks as sweet biscuit, co-extruded
and filled with sweet mixtures
–Toppings with salt, sesame,
cheese or spice mixes
4.2
5
6
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INDUSTRIAL PRODUCTION LINES
CAKE PRODUCTION LINES
Cake production lines Dough making, followed by dough feed and moulding and/or dough portioning in tin
moulds are the beginning of the process route for the production of cakes. Once baking has been concluded,
the cakes are released from their moulds, cooled and then transferred to the packaging machines.
The size/length of the ovens is adapted to the required baking time in relation to the desired maximum ­capacity.
Dough processing with vertical batch-type mixer
Dough portioning in tin moulds with filling equipment
Oven loader
Tunnel oven
Product cooling
Product injection
Transport to packaging machines
Mould reversing device
Mould cleaning device
Mould greasing facility
12 _ 13
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INDUSTRIAL PRODUCTION LINES
CRISP BREAD PRODUCTION LINES
Crisp bread production lines The process route for producing crisp bread starts with dough making.
Dough aeration, dough cooling and dough application and several flour dusting steps then follow. The next
stage involves a special tunnel oven with very high baking temperatures.
The number of heating zones or the length of the oven is adapted to the required baking time in relation
to the desired maximum capacity.
Finally, the products are conveyed to the packaging machines after having passed through a cooling
conveyor including several cutting and stacking units.
1 Dough processing with pre-mixer, swelling bins, combinator for dough cooling and aeration.
2Flour duster for upper and lower flour as well as sprinklers for seeds. The continuous dough sheet
which has been formed in a special dough sheet moulder is inserted in a dusting flour bed.
3Synchronised pair of dockering rolls with cleaning devices for applying the characteristic
crisp bread surface.
4Suction device for removing the dusting flour from the dough surface. The removed dusting flour
is processed and returned to the process circuit.
5The special high-temperature crisp bread oven is equipped with two gas burners each for top heat
and bottom heat. Once the baking process has been finished, the dough sheet is cut to it’s final size
in a cross and longitudinal cutting device.
6 The arranged crisp bread slices are conveyed to the packaging machine via a conveyor belt.
1
2
3
4
14 _ 15
2
Crisp bread
– Crisp
–Crisp
– Crisp
– Crisp
– Crisp
5
5
bread
bread
bread
bread
bread
with
with
with
with
with
milk
spelt
sesame
caraway
fibres
6
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INDUSTRIAL PRODUCTION LINES
RUSK PRODUCTION LINES
Rusk production lines The process route for producing rusk starts with making the doughs. This is ­followed
by dough feed and moulding steps. The dough is proofed and baked in tin moulds. Once baking has been
concluded, the bread bars are released from their moulds, cooled and then cut to slices. The slices are
toasted in a second baking process and conveyed to the packaging machines.
The size/length of the ovens is adapted to the required baking time in relation to the desired maximum capacity.
1Dough processing using a spiral-type kneader; dough dividing and moulding machine,
conical round moulder, intermediate proofer, long moulder and placing the dough strands in moulds
2 Feeding into final proofer
3 Tunnel oven
4 Bread depanner
5 Bread cooling
6 Bread slicing and bread slice feeding system
7 Toast oven and product stacking for packaging
1
2
3
16 _ 17
5
4
6
7
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INDUSTRIAL PRODUCTION LINES
BREADCRUMB PRODUCTION MACHINES
Breadcrumb production machines A continuous mixer usually is at the beginning of the process route.
This is followed by dough feed and moulding steps. A belt-type proofing channel is used for the proofing
process, the next stage involves a tunnel oven.
In the course of the process shown, individual breads are produced which, once baking has been concluded,
pass through a cooling route. Afterwards they are reduced to smaller pieces which are then dried and milled.
The size/length of the oven is adapted to the required baking time in relation to the desired maximum ­capacity.
1 Continuously dough processing using the ZPM kneader
2 Portioning
3 Transfer from belt-type proofing channel to oven
4 End of tunnel oven
5 Bread cooling and transport to bread crushing mill.
1
2
3
18 _ 19
1
4
5
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INDUSTRIAL PRODUCTION LINES
Raw materials handling . Portioning. Kneading
Dough processing
°C
Recording the dough quality
and output measurement
Monitoring the height of bulges and the width of the sheet
using speed control
20 _ 21
AUTOMATION
Convenience of operation, reproducibility of product qualities at all times as well as a high availability of
the industrial production lines made by Werner & Pfleiderer are in direct proportion to their high degree of automation. Measurements and controls – all can be dealt with by one central computer, either
program-controlled or with the intervention of the operator of the production line. A great number of
various sensors are installed in pairs for safety reasons. Their operability is checked by the system itself.
The sensors consistently monitor the parameters affecting the quality of manufacturing process, such
as for instance dough quality and output, height of bulges, sheet width and speeds, oven humidity and
temperature, product moisture content and temperature. Their measuring results directly influence the
settings on the line modules – a completely self-regulating system. The whole manufacturing process
is documented in every detail and can be traced on product line and host level by persons with the
relevant authorisation and adjusted manually, whenever necessary. The entire automation system can
be monitored or serviced remotely by way of internet access.
Baking
Cooling . Arranging . Feeding
°C
Recording and controlling the humidity in the oven
and the oven temperature
Controlling the moisture content of the product
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INDUSTRIAL PRODUCTION LINES
CHECK
Pos I
Consultancy
Planning . Design . Equipment . References
Pos II Equipment Materials . Component groups . Electronic components . Mechanical components
Pos III Modularity
Workflow . Space requirement
Pos IV Capacity
Number of pieces/h . Weights
Pos V Quality
TA . Dough qualities
Pos VI Cost
Investment . Current cost
Pos VII Workflow
Interfaces . System Workflow
Pos VIII System responsibility
Complete system integration . Set-up of individual sequences
Pos IX Service
Service presence . Self-Service . Remote maintenance
Pos X Group know-how
Process thinking . Interface know-how . Solutions from one source
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22 _ 23
PROCESS
_Inquiry
_Production analysis
_Project planning
_ Engineering
_Production
_Acceptance I
_Delivery
_Installation
_Integration
_Operational start-up
_Training
_Acceptance II
_Service
tammen.de
Werner & Pfleiderer
Industrielle Backtechnik GmbH
Frankfurter Straße 17
71732 Tamm
Germany
Fon +49 (0) 71 41 - 20 20
Fax +49 (0) 71 41 - 202 - 111
info@wpib.de
www.wpib.de
The WP BAKERYGROUP possesses
subsidiaries in France, Italy, Belgium,
Russia and the USA.
Agencies with Service Departments
can also be found in all regions of
www.wpbakerygroup.com
© 2008 by WP BAKERYGROUP, Stand 03/08, printed in Germany, ® = Registered Trademark
All specifications are non-binding and the right is reserved to make amendments that serve technical advancement.
WP BAKERYGROUP
0408_0.75_0102
the world.