Biscuits, Cookies & Crackers

Transcription

1 Biscuits, Cookies & Crackers

2 Process knowledge and engineering expertise Baker Perkins comprehensive range of equipment for biscuit, cookie and cracker manufacture is founded on 100 years experience and expertise. From mixing to sandwiching, every machine is designed to maximise profitability through reliability, ease of cleaning and ease of use. Baker Perkins provides the widest range of equipment to the industry, and has the largest installed base. From the start, we have built our business on technical excellence and innovation, firmly grounded in unrivalled process knowledge and engineering expertise. We have always used these to design equipment that meets the needs of the industry, with problems such as better weight control, reduced maintenance and easier operation all being addressed in innovative ways. An Innovation Centre enables us to test and develop new technologies and end products. Finding better ways to make current products, for the financial benefit of our customers, and developing new products that attract consumers are continuing aims of our technical team. Because we supply full lines, from mixing and forming to baking and sandwiching, we understand the complete process. This awareness of what is happening throughout the operation enables us to give unparalleled backing to our customers, from planning, through designing, building and commissioning, and on to complete lifetime support. Biscuits, Cookies & Crackers PAGE 2

3 Reliability via Lifetime Support Baker Perkins understands that our customers need production stability, and that this can come only through working with reliable machinery designed for minimum downtime. Baker Perkins has developed a range of services to maximise that dependability. Lifetime Support includes a range of services that maintain peak plant performance. Fundamental functions of asset care, such as the supply of replacement parts and rapid reaction to emergency breakdowns, are backed by a variety of other services to ensure systems are kept in optimum condition. Many customers opt for regular inspection and maintenance contracts, designed to identify and fix problems before they cause plant downtime and loss of profit. Lifetime Support goes a stage further with improvement via upgrades, adaptations and refurbishment. Baker Perkins offers cost-effective methods of updating and adapting plant in mid-life, to extend service life, make an expanded product portfolio, or meet the latest performance, hygiene and safety standards. Lifetime Support services include Replacement parts Service and inspections Moulder, cutter and wirecut dies Performance upgrades Hygiene upgrades Adapting lines for new products Rebuilding / refurbishing Plant relocation Biscuits, Cookies & Crackers PAGE 3

4 Equipment overview Mixing The upgraded range of Baker Perkins high-speed, multi-purpose batch mixers is suitable for both hard and soft dough. A shaftless blade gives excellent dispersion and rapid dough development, which contribute to the consistent quality that is the foundation of cost-effective production. Automatic operation and a choice of controls also contribute to operational efficiency. Soft dough forming Baker Perkins offers a portfolio of rotary moulders, wirecuts and extruders for the complete range of cookies, soft dough biscuits and filled bars. Reliability and versatility, with a low cost of ownership, are the design objectives. Precise weight control on every machine minimises giveaway and waste, contributing to fast payback. Ovens Baker Perkins convection, DGF and hybrid ovens have been developed and refined over many years to bake consistently and reliably, while the latest versions have seen improvements in fuel efficiency and hygiene. The result is high quality products and low production costs right across the cookie and cracker bakery spectrum. Biscuits, Cookies & Crackers PAGE 4

5 High quality, rapid payback The entire range of Baker Perkins equipment for the cookie and cracker sector is designed and engineered with the customer in mind. Reliability - Proven designs using high-quality components ensure trouble-free operation for long periods. Efficiency - Well-informed design targeting the industry s specific needs minimises product waste and energy consumption, maximises product consistency and quality. Sheet forming and cutting Baker Perkins sheet forming and cutting lines produce many leading brands of crackers, snacks and hard sweet biscuits. Tightly controlled, efficient, easy to use systems trigger the financial benefits of low waste and negligible unplanned downtime, with the added advantage of minimal labour requirement. Hygienic Design - Reduced contamination points and easier access for cleaning are benefits being introduced across the forming equipment range to help customers meet or exceed the latest industry hygiene guidelines. Ease of use - Continual application of the latest control techniques makes better use of operators time and reduces the overall labour requirements. Low cost of ownership - Ease of access for cleaning and routine maintenance cuts labour costs. Sandwiching Sandwiching provides a range of options for efficient high-volume production and added-value brand extension. Baker Perkins supplies a series of systems covering a broad variety of product, speed and packaging possibilities. All bring the benefits of minimal waste, tight weight control, high efficiency and ease of use. Biscuits, Cookies & Crackers PAGE 5

6 Mixing and forming - designed to reduce costs Fluctuating ingredient and energy costs plus the need to meet increasing hygiene standards are putting even more pressure on biscuit, cracker and snack manufacturers to reduce costs eleswhere. When designing the latest mixing and forming equipment, Baker Perkins looks carefully at how labour, downtime and waste can be reduced to deliver savings in ingredients and energy, while achieving the necessary improvements in hygiene. By designing machines that are easier to use and clean, more reliable and easier to maintain, all these vital areas are addressed. Systems that can measure equipment performance and alert operators to potential problems play a key role; factories of the future may employ fewer but more highly skilled operators anticipating and averting problems rather than reacting to them. This approach will keep lines running at maximum efficiency for longer, and minimise costs. Designed for hygiene Hygienic design has always been a high priority at Baker Perkins and recent developments in the industry have added fresh impetus. The new TruClean TM range of forming equipment meets or exceeds all the latest guidelines while performance, ease of use and ease of maintenance have all been improved. Designed for reliability All Baker Perkins cookie and cracker equipment is designed to operate well within its capability. An uncompromising approach to the reliability and durability of every component contributes to low downtime and long life. Top quality components Baker Perkins insists on the use of best-in-class components throughout its range. Key parts such as motors and control items come from suppliers recognised for dependability, with worldwide service and support. High Speed Mixers TruClean Wirecut Series2 Rotary Moulder Biscuits, Cookies & Crackers PAGE 6

7 High speed mixers HS Mixers are suitable for both developed and soft dough. The unique shaftless blade achieves thorough dispersion and rapid development that lead to uniform dough consistency, smooth processing and negligible waste. The 150 tilting bowl and easy access for cleaning reduce downtime and labour requirements. Rotary moulders The 390 rotary moulder is a medium output unit suitable for standard products. There are TruClean versions available for situations where sensitive cross-contact risks exist. For higher output applications the larger Series2 offers the ultimate in adjustability and high output. Both machines are proven designs that offer reliability and durability with simple controls, easy cleaning and low maintenance to minimise production costs. Wirecuts The TruClean Wirecut produces soft dough cookies and bars with outputs from 60 to 200 rows/min. It features the unique die and filler block technology that guarantees precise weight control. Variance is just +/-1% on plain dough and +/-2% on dough with inclusions. Labour, downtime and waste are minimised by quick changeover, rapid cleaning and clear, intuitive controls. Sheet forming and cutting Sheet forming and cutting lines are used for every type of developed dough, including crackers, snack crackers and hard sweet biscuits. A typical line includes a laminator or sheeter (or the unique combination unit), gauge rolls and a rotary cutter. They are designed to control costs in five main areas. Weight control precise sheeting and laminating followed by low-deflection gauge rolls (standard or heavy duty) ensure constant sheet thickness. Hygienic designs Stainless steel gauge rolls, no debris collection points and good access to all parts of the line make these units quick and simple to clean. Easy to use the line is controlled by a single, integrated system with operator interfaces on every unit. Changes made to one are automatically cascaded to the others. Reliability decades of design experience and millions of running hours ensure dependable service over many years. Easy to maintain very little routine maintenance is required and there is easy access to all major components. Laminator Line Biscuits, Cookies & Crackers PAGE 7

8 Baking - flexibility and efficiency The baking performance of each of the ovens in the Baker Perkins range has been proven over many hundreds of installations worldwide. Recent developments have focused on improving reliability, fuel efficiency and ease of use as well as enhancing the baking attributes. The result is an oven range offering exceptional performance, stability and low cost of ownership. Jetcirc oven The Jetcirc convection oven offers exceptional product consistency and high throughput with low operating costs, across the full range of biscuits, crackers and baked snacks. Direct Gas Fired (DGF) oven This has long been the most popular baking oven, based on a combination of flexibility and superior baking characteristics, which balance radiant heating and turbulence to achieve the ideal product colour, size, moisture and thickness. Hybrid ovens An oven combining the most appropriate heat transfer method for each stage of the baking process is the preferred option for many bakers worldwide. DGF and convection each have characteristics that are ideal for one part of the process, but not necessarily all of it. Combining the benefits of two types of oven creates a unit that exactly matches a specific need. The most common hybrid ovens have DGF for the first phase of baking and convection for the rest. This gives maximum versatility at the start of the bake - for everything from soft cookies to crackers - and maximum efficiency at the end. Jetcirc oven Direct Gas Fired oven Hybrid oven Biscuits, Cookies & Crackers PAGE 8

9 Adding value via cream sandwiching Baker Perkins cream sandwiching machines combine speed with accuracy to maintain quality and efficiency over long periods of operation, even at very high outputs. A wide range of product size variants, as well as input and output configurations that simplify upstream and downstream handling, enable a smooth process flow to be achieved. The BP Sandwiching Machine can be specified to match a wide array of plant layouts. Available in 2, 3, 4, 5 or 6 lane configurations, with manual or automatic feeding to enable the full output of an oven to be handled with no awkward lane reductions. A dedicated cream feed system with independently controllable deposit weight for each lane and a wide range of lane multiplication options complete the range. An interesting option for the BP Sandwiching Machine and Pile Pack Creamer is the co-deposit stencil, which allows two fillings to be deposited simultaneously. Imaginative, highly differentiated products are achievable. The Pile Pack Creamer uses an in-line version of the BP Sandwiching Machine process to produce piles of two sandwiches. These are collated into pack lengths of 1 to 6 piles and fed directly into a wrapping machine. The absence of both cooling and complicated mechanical handling make this a very cost-effective and efficient machine for both vend and retail packs. Co-deposit stencil Biscuits, Cookies & Crackers PAGE 9

10 The principles of hygienic design Baker Perkins adopted hygiene as an important design consideration in The experience built up designing hundreds of hygienic machines over that period has enabled us to respond very quickly to the 10 Principles of Equipment Design (see panel) introduced by the Grocery Manufacturers Association (GMA). These 10 principles have been adapted from the meat industry for low moisture foods and represent a significant step forward in process design. Baker Perkins machines carrying the TruClean TM name have been designed from the ground up in accordance with these principles. In addition, TruClean TM includes a two-level classification that enables the hygiene features of every machine to be tailored to the specific cross-contact risks and cleaning protocols at the site. Ten Principles of Equipment Design 1. Cleanable 3 2. Made of compatible materials 3 3. Accessible for cleaning and sanitation 3 4. No material collection 3 5. Hollow areas eliminated or sealed 3 6. No niches 3 7. Operates with sanitary performance 3 8. Validated cleaning methods 3 9. Separate processes wherever possible All personnel to meet and follow hygiene and sanitation requirements 3 Biscuits, Cookies & Crackers PAGE 10

11 Moulding, cutting and wirecut die services As a long-established world leader in biscuit, cookie and cracker equipment design and manufacture, Baker Perkins has developed a unique understanding of the interface between the machine, its roll or die and the product. At Baker Perkins we understand that rolls and dies are not simple commodity components - they are critical parts of the forming process that have a fundamental effect on plant performance and product quality. Rolls and dies that run cleanly and reliably make a significant contribution to line efficiency. Successful rolls and dies start with a good design based on a clear understanding of the customer s requirements, while manufacturing using the latest design software and machine tools keeps quality high and lead times down. Why choose Baker Perkins? l Process insight from OEM l Library of thousands of designs l Custom design service l Full range of roll and die types l Available to suit all makes of forming machine l Fast and accurate 3D CAD design and engraving l Hand samples and test sleeves for pre-production review or testing l Fully equipped test lab l Help and advice over the phone or on site l Fast track manufacture l Repair, recoating and reconfiguration of worn, damaged or obsolete rolls and dies Biscuits, Cookies & Crackers PAGE 11

12 Baker Perkins Ltd Manor Drive Paston Parkway Peterborough PE4 7AP United Kingdom Baker Perkins Inc 3223 Kraft Ave SE Grand Rapids MI USA T: F: E: I: Baker Perkins 10/13 T: F: E: