Biscuit service and rolls lifetime support for biscuit equipment
Baker Perkins Lifetime Support for biscuit plant The accumulated experience of over a century s leadership in biscuit equipment enables Baker Perkins to offer production expertise and problem-solving know-how that others simply cannot match. This principle is at the heart of a range of Lifetime Support services that ensure installed plant operates efficiently throughout its life and can be adapted and upgraded as technology or production needs move on. The purpose of all our support services is to ensure that every plant runs at maximum efficiency and minimum cost, whatever its age. A speciality is the design and manufacture of rolls and dies, based on an unrivalled understanding of the interface between the machine, its roll and the product being made. The objective, again, is to ensure the high levels of quality and efficiency that contribute to a profitable business. Supporting equipment throughout its life Baker Perkins support is worldwide and encompasses services that maximise reliability and reduce costs. Fundamental functions of asset care such as replacement parts and field service ensure that lifetime costs are kept to a minimum, while an extended range of other services is aimed at improving performance, increasing service life and reducing running costs. As production requirements change plants can be upgraded, extended or modified to maximise the return on the initial investment. Lifetime Support Biscuit service and rolls PAGE 2
The moulding and cutter roll experts Baker Perkins is the only equipment manufacturer with an in-house roll design and manufacturing capability. This brings to the design process a unique understanding of how dough and forming machine characteristics affect the performance of each roll. We know how to produce rolls that retain their dimensional accuracy under even the most arduous production conditions and deliver absolute consistency over the life of the roll. Rolls are a critical part of the forming process and by combining imaginative design with true process insight and manufacturing expertise we are able to supply rolls that are right first time, run cleanly and reliably and make a significant contribution to line efficiency and profit. Biscuit service and rolls PAGE 3
Specialist support for biscuit manufacturers Shrinking maintenance budgets, a shortage of skilled engineers and rapidly changing production demands are typical of the challenges faced by biscuit manufacturers. Lifetime Support includes both maintenance and plant improvement services to help manufacturers overcome these challenges. Maintenance Maintenance services include a comprehensive 24/7 replacement parts service along with a team of field service engineers available for maintenance contracts, inspection and repairs, fault-finding and emergency breakdown assistance. Replacement parts Experienced staff are available to identify parts from the original records and expedite orders, while fast-track manufacturing, extensive stocks of frequently used parts and rapid delivery methods keep lead times to a minimum. All parts are made to the original drawings to minimise fitting time and ensure that machine performance and service life are not compromised. Where available, upgraded components are offered. Field service As well as assistance with emergency breakdowns and fault-finding Baker Perkins offers tailor-made service contracts to maintain equipment. These ensure that critical items of equipment are regularly inspected, maintained and occasionally upgraded to optimise performance, and avoid unplanned downtime caused by breakdowns. Plant improvement Baker Perkins offers cost-effective methods of upgrading and adapting plant in mid-life, to improve performance; meet an expanded end product portfolio; or match the latest performance, hygiene and safety standards. Typical upgrades Flexiflame ribbon burners An invaluable tool for biscuit makers seeking to improve consistency, reduce product scrap and increase profit. These burners maximise heat balance across and down the oven for a completely even bake. Larger/additional oven doors An access door upgrade kit can address a number of problems: damaged oven doors leak expensively heated air and cost money; small doors make access for cleaning difficult; some ovens have insufficient doors for effective cleaning. Variable speed mixer drives The variable speed mixing upgrade brings major advantages compared with conventional two-speed mixers, with the potential to improve product consistency and operational efficiency. Independent drives on rotary moulders Independent drives to all three rolls enable the process conditions for every individual product to be optimised, raising quality and consistency. Flexiflame ribbon burners Variable speed mixer drives Biscuit service and rolls PAGE 4
Adaptation As production needs change it is often necessary to adapt a line to make a wider or even a completely different range of products. This might involve drive and control upgrades, oven extensions, fitting a different type of oven band, or adding new forming units to a line. Newer equipment is designed from day one with this in mind. Baker Perkins philosophy is to design machines with a common core and an extensive range of optional modules. Machines specified with a particular set of options can be quickly upgraded when requirements change by changing or adding to these modules. For example, an EM390 rotary moulder originally specified for conventional products can be adapted to handle more difficult dough with the addition of independent roll drives and a heated forcing roll. Refurbishment Machinery life can be extended by refurbishment or rebuilding, taking the original specification and incorporating where possible the latest developments and techniques. This is a cost-effective way to improve quality, efficiency and profit when circumstances do not justify investment in new plant. Plant moves and training Baker Perkins will undertake plant relocation on a turnkey or commissioning-only basis, and also assume responsibility for training new operators. By using our knowledge and experience in this way you can be sure that the line will perform in its new location as well as, or better than, previously. Independent drives on rotary moulders Oven extension modules
The complete moulding and cutter roll service As a long-established leader in biscuit equipment design and manufacture, Baker Perkins engineers have developed a unique understanding of the interface between the machine, its roll and the product being made. At Baker Perkins a roll is not simply a roll it is a critical part of the forming process. In combination with the forming machine the roll sets the product size, shape, weight and thickness as well as imparting the manufacturer s unique design or branding. Rolls that run cleanly and reliably also make a significant contribution to line efficiency. A successful roll starts with a good design based on a clear understanding of the customer s requirements, while manufacturing using the latest 3D design software and machine tools keeps quality high and lead times down. Why choose Baker Perkins? Process insight from the OEM Custom design service plus a library of thousands of standard designs Rolls to suit every kind of forming machine Fast and accurate 3D design and engraving Test sleeves and flat samples for pre-production review and testing Help and advice over the phone or on site Best-in-class weight control Biscuit service and rolls PAGE 6
Rolls and dies for every application Experience over many years and thousands of rolls provides our designers with exceptional insight into the specific needs of rolls and dies for every type of end product. Rotary moulding rolls These rolls consist of a one-piece tube made in lead-free bronze, with a steel through-shaft to minimise deflection. Sectional rolls and test sleeves are also available. Clean extraction is secured by paying close attention to design of draft angles and corner radii, as well as careful selection of the surface finish or coating. Rotary cutter rolls These are available in engraved lead-free bronze, or injection moulded polymer. Bronze rolls are a single piece construction with stub shafts; polymer rolls comprise replaceable panels fixed to a solid steel base roll. Cutter rolls can be supplied as pairs of individual cutting and printing rolls, or with both processes combined on a single roll. Wirecut dies Die shape and size are determined by the dough properties and machine speed. In combination with patented filler block technology, die plates and cups enhance weight control and consistency. Biscuit service and rolls PAGE 7
Baker Perkins Ltd Manor Drive Paston Parkway Peterborough PE4 7AP United Kingdom T: +44 1733 283000 F: +44 1733 283004 E: bpltd@bakerperkins.com I: www.bakerperkins.com Baker Perkins Inc 3223 Kraft Ave SE Grand Rapids MI 49512-2027 USA T: +1 616 784 3111 F: +1 616 784 0973 E: bpinc@bakerperkins.com I: www.bakerperkins.com