Baker Perkins is showing new equipment and end product technology for the biscuit, cracker and bar industries at Interpack (Hall 4 Stand C21). . This includes a new 3-roll sheeter and gauge roll; a new servo-driven version of its well-proven wirecut range; an innovative encapsulating system for totally enclosed, filled cookies; and an HS High Speed mixer.
The new TruClean 3-roll sheeter and gauge roll for crackers and snacks completes the upgrade of Baker Perkins range of sheet forming and cutting lines to TruClean standards, bringing major benefits in maintenance and hygiene, with lower costs and faster changeovers. Time for a typical cleaning routine for a line can be reduced by up to 40%.
These Baker Perkins lines comprise either a 3-roll sheeter or a laminator to take a bulk feed of dough and form it into a sheet, ready to pass through gauge rolls which achieve the chosen thickness, and then a rotary cutter before baking.
The TruClean approach to hygienic design was instigated to meet a clear demand from the industry for higher standards. It involved radical re-design of machinery in order to reduce debris and places where it could collect, and make access much easier where it is needed.
Improving visibility and access for cleaning, simplifying removal and replacement of components and assemblies, cutting the number of components, and reducing accumulation of debris were the principal design requirements – all achieved without compromising fundamental process performance parameters and attributes such as output and weight control.
The key benefit is a significant reduction of the time required to clean a line to the required standard, leading to lower costs and faster changeover
The new TruClean Servo Wirecut for soft-dough cookies and bars is a more versatile and flexible version of the well-proven TruClean Wirecut.
A patent has been applied for on the new wirecut mechanism, which uses servo motors to drive the wirecut mechanism, bringing improved automation and flexibility to production. The two-axis servo system provides infinite variability to the cutting and return paths, enabling optimum cutting performance to be achieved, even at high speeds or on difficult dough. Tailored profiles can be created for each individual product and loaded at the touch of a button.
The remaining parts of the wirecut process – hopper, feed rolls, filler block and dies – are carried over from the previous version of the TruClean wirecut, ensuring that product characteristics, high-accuracy weight control and easy cleaning are maintained.
In other areas, ease of operation, cleaning and maintenance have all been improved. Setting up is all done from the HMI and once a profile has been developed and tested it can be saved as a recipe for one touch set-up.
An innovative encapsulating module enabling high-value filled cookies to be made on any Baker Perkins wirecut machine is being highlighted.
A patent has been applied for the system. For the first time, cookies totally enclosed by dough can be produced on a module attached to a standard wirecut machine – previously a separate unit was necessary.
The process involves pumping a continuous stream of filling into the centre of the dough cylinder formed at the wirecut die. A set of iris-die cutters crimp the dough and filling, forcing the dough to completely enclose the filling.
Fillings can include any ingredients which are low enough in viscosity to be pumped, including chocolate, caramel, cream, peanut butter or jam.
The encapsulation module is available as an option on the new TruClean Servo Wirecut but may be fitted to any installed Baker Perkins wirecut to convert the machine from a standard unit to one that can do both cookies and encapsulated cookies.
Well proven HS (High Speed) multi-purpose batch mixers handle every type of dough for biscuits, cookies and crackers. They offer high levels of automation, ease of use and cleaning, and outstanding reliability to guarantee low cost of ownership.
The unique Baker Perkins shaftless mixer blade processes every type of dough, and ensures good dispersion with rapid dough development; it gives optimum performance in every mixing phase. The blade allows the ingredients to move freely in the bowl; delicate inclusions are incorporated evenly without damage or smearing
Loading and discharge are fully automatic to reduce labour costs and mix cycle times - three batches can be achieved every hour.