From silo to truck. Kaak FPS Kaak Bakeware Benier DrieM Daub MCS LhotellierR2A Multiparts

Transcription

1 Turn Key Concept From silo to truck Kaak FPS Kaak Bakeware Benier DrieM Daub MCS LhotellierR2A Multiparts

2 Kaak Group continuous optimization in bakery technology Bread is one of life s necessities. It has been for centuries and all over the world. Through the years industrial bread production has developed substantially. The Kaak Group connects the traditional bread baking craft with state-ofthe-art industrial bakery technology. With a full range of products and services and a unique total service concept the Kaak Group supports you in your business. We enable you to guarantee the delivery of top quality to your customers, providing you with the tools to stay ahead in a competitive environment. 2

3 Chronology Kaak Group End 19 th century The company is founded by Bernard Kaak and at the start of the 20th century the business continued with the first production of sheet metal bakeware 1960 s Craft bakeries become more industrialised. Kaak starts to act as a supplier of conveying systems, soon after which the first automated bakery lines are produced 1990 Jan Kaak, 4th generation, takes over the company. Kaak is divided into two divisions: Kaak Food Production Systems (machine construction / automation) Kaak Bakery Supplies (bakeware) 1991 The Dutch company Benier, specialists in dough handling systems, as well as its sales agencies Benier UK and USA, join the Kaak Group 1997 The Kaak Group further expands with the integration of Daub, the renowned German manufacturer of thermal oil heated ovens 2005 The Italian company MCS becomes a member of the Kaak Group, complementing the product range with various types of tunnel ovens and proofers 2007 Lhotellier R2A, the French specialist in coating of baking straps, sheets and moulds joins the Kaak Group 2009 With the addition of DrieM, dough sheeting technology becomes available within the Kaak Group 3

4 Kaak Group total concept from Silo to Truck Based on more than 100 years of experience, the Kaak Group offers bakery companies all over the world the equipment they require for the production of many types of bakery products. Every member of the Kaak Group supplies the highest quality products and support, each highly specialized in their own field. You can trust us to deliver a total concept for a single production line or, when your needs require it, a complete bakery from Silo to Truck. Based on our knowledge and experience we can effectively combine the best components available to create the optimum integrated solution for you. Turn Key Concept The Baking Process: Silo Mixing Dough handling Final Decorating Baking Pan Cooling Freezing Crate Packaging proofing handling handling Pizza Bakeware: Conveyor systems: System control: 4

5 Dekamarkt Apeldoorn is a satisfied Kaak Group customer The production site in Apeldoorn, which serves about 180 supermarkets on a daily basis, was modified by the Kaak Group to be able to produce not only free-standing bread, but also tin bread. The majority of the existing equipment is used for the production of both product types, whereby a minimal number of changes were needed to create this multi-functional production line. This tailor-made solution enables Dekamarkt to run its production with maximum flexibility. 5

6 Dough handling Final proofing Decorating Pan Crate Baking handling Cooling Freezing handling Bakeware Conveyor systems System control Kaak Food Production Systems The roots Kaak Food Production Systems is the origin of today s Kaak Group. Our division with its headquarters in Terborg has a double function within the Group. Firstly, as a producer of transport and storage systems, proofers, the Multi-Step oven as well as cooling and freezing systems. Secondly, our extensive engineering department is the technical brain when it comes to the translation of customer requests into customized solutions, acting as the binding link between the different Kaak Group members. The Kaak factory and offices in Terborg comprise over m 2. Kaak Food Production Systems offers you: Engineering and production of complete production lines Customized solutions Heavy duty reliability (24 hrs, 7 days per week) Reliable, solid service organization The Multi-Deck Final Proofer 6

7 The Kaak Multi-Spiral systems are known for their reliability, heavy duty and high capacity. This system can be used for cooling, freezing, proofing and pasteurization. The Multi-Step Final Proofer The Multi-Step Oven 7

8 Dough handling Final proofing Decorating Baking Pan Crate handling Cooling Freezing handling Bakeware Conveyor systems System control Benier Affection for dough For more than 100 years, Benier Nederland has designed and built dough production and dough handling systems for all types of dough. The main focus is placed on dough quality and gentle dough handling, during dough dividing, rounding, proofing and moulding. In close customer collaboration the specific needs and wishes with respect to the product and business are discussed and the best solution is offered, either through standard machines or customized equipment and tailor made solutions. This provides our customers with an optimal basis to produce various products with the highest quality. Giving rest to the dough develops its quality, resulting in a better performance. Many years of experience, with all kinds of dough consistencies, results in dough handling know how. The Benier moulding principle reflects this know how. 8

9 Benier smart product lines: Maximized for performance, especially with the flexibility to adapt to changing demands and wishes Complete process management High quality components, combined with process reliability and newest innovation technology Quick and easy to clean with a minimum of down time As round as round can be Benier offers a wide range of rounders for quality rounding performance of all kinds of dough, weight ranges and capacities. Take control of your dough by having a very gentle and accurate dividing operation. 9

10 Dough handling Final proofing Decorating Pan Crate Baking handling Cooling Freezing handling Bakeware Conveyor systems System control DrieM Dough sheeting technology DrieM was founded as an independent company in 2009 and is the latest member of the Kaak Group. The Kaak Group already offered classic dough lines (products made from single pieces / balls) and with the addition of DrieM we now complement this with dough sheeting lines. DrieM is specialized in dough sheeting technology and active in the latest developments within the bakery industry. An important industry trend is towards Artisanal breads such as Ciabatta or Focaccia with a higher added value compared to traditional types of bread. d Artagnan sheeted breadline Overview of dough forming, sheeting and make up part of the line. Capacities up to 3000 kg/hr. DrieM has developed an Artisanal bread production line (d Artagnan) specifically designed for the needs of today s larger bakeries. A high capacity Artisanal bread line that produces the best quality products at the highest possible efficiencies. Almost any size of rolled buns or Baguettes as well as all sorts of cut products can be produced using our unique dough sheeting technology. The d Artagnan bread line was designed after intensive consultation with some of the most renowned producers in the market. The result of this is a line, designed according to the highest standards in hygiene, ease of operation and maintenance. 10

11 Dough DrieMer (Patent applied) The Dough DrieMer forms a perfect dough sheet and is the heart of the d Artagnan line. Hier moet nog een bijschrift komen- Tionsed min ut nulputating elis ad do etue con utpat augait, vel euis delestrud ex ex etue. Double action guillotine Designed to cut dough strips or any other form you like. Ergonomically designed for quick and easy product changeovers and optimum product performance. 11

12 Dough handling Final proofing Decorating Baking Pan Crate handling Cooling Freezing handling Bakeware Conveyor systems System control Daub Engineering art with tradition Daub Backtechnik is a traditional Hanseatic company that has maintained a strong presence in the oven market since With its ovens based on thermal oil technology, Daub is recognized as a worldwide leader. Daub ovens operate around the globe in both craft and industrial bakeries. The thermal oil heating principle, both over and under the product, guarantees a high and consistent baking result. Furthermore, baking on stone is a technology in which Daub Backtechnik has a lot of experience. This contributes to the quality of the baked product. It does not matter whether the products are baked in a Daub deck, rack or tunnel oven, or whether they are baked on wire mesh, hinged plate or natural stone the baking result is always top-quality! Daub Thermo-Roll oven The Daub Thermo-Roll provides flexibility, while being highly economical with a small personnel requirement. Due to the low handling effort, a baker can operate several ovens simultaneously. Baking on stone is an advantageous option, which does not require extra handling. This remains easy since the stone plates are installed inside the oven. Furthermore, freestanding products can be fed in directly on the stone plates. Finally the low energy consumption makes the Daub Thermo-Roll an environmental friendly choice. The Daub Thermo-Roll oven 12

13 Daub thermal oil ovens: Automatic Hanseat ( m 2 baking surface) The configuration of this multideck oven is adapted to the products and processes in the bakery. Using either single or multiple loading systems, the oven can run in step-continuous or batch mode. Several production lines can be combined while using only one oven. The compact construction with up to eight decks enables an optimum use of the production area available. Additionally, the oven can also be equipped with stone plate belts. Backmeister (8 40 m 2 baking surface) This craft oven combines maximum baking surface with minimum space requirements, at a favourable price. Above and under: The Daub Automatic Hanseat. Reversier Hanseat (20 40 m 2 baking surface) Craft bakers as well as industrial bakers make use of this oven. It combines very short loading times with high productivity and flexibility. Cross Line Hanseat (30 96 m 2 baking surface) This oven is a typical semi-industrial oven. It is a synonym for highest baking flexibility and productivity for craft batches, with a fully automatic production on up to 12 decks! Modular Tunnel ( m 2 baking surface) Quality, quantity and economy are the main advantages of this industrial tunnel oven. Equipped with one or two decks, optionally with stone plate belts, this thermal oil oven meets the highest industrial requirements. 13

14 Dough handling Final proofing Decorating Pan Crate Baking handling Cooling Freezing handling Bakeware Conveyor systems System control MCS Baking technology on an industrial scale Ala, in Northern Italy, is the home of MCS. Started in 1974, MCS has built a strong reputation in the field of automatic industrial lines for the production of bread and pizza. Their automatic proofing systems and cyclotherm tunnel ovens combine high capacity with absolute reliability and flexibility. The ovens, heated by means of radiation as well as convection, are suitable for a large variety of baked goods: from traditional (hearthbaked) bread to all types of panned bread, hearth rolls, all kinds of fine bakery ware and even most pizza types. MCS can develop tailor made lines, matching customer requirements for special high added value products. Tunnel ovens: a special stone plate conveyor providing strong bottom heat is also available for crusty products like Ciabatta bread. MCS high temperature direct gas fired ovens, provided with stone plate conveyors are ideal to bake high quality Pizzeriatype pizzas. 14

15 MCS Product Range: Cyclotherm tunnel ovens, wire mesh or stone plate conveyor High temperature gas fired tunnel ovens, wire mesh or stone plate conveyor Direct gas fired tunnel ovens, wire mesh or steel band conveyor Free-standing bread lines (Batons, Ciabatta, Hearth-baked bread) Pizza lines (cross sheeting / hot pressing on conveyors or trays / sheeting) Pre-fermentation systems, pre-proofers, final proofers Cooling systems Scoring units, flour dusters, water sprayers, seeders, etc. The new MCS Cyclotherm ovens offer: Excellent quality in final baked products Modular design to suit specific customer needs High efficiency thanks to a maximized heat exchange Possibility of fully automated recipe management Different solutions for proofing are available: Stabilized tray proofers for freestanding bread Swing tray proofers for products on trays/straps/peelboards Cradle and swing cup proofers for Batons and Pizza dough pieces Norià type proofers for products on trays/straps 15

16 Dough handling Final proofing Decorating Baking Pan Crate handling Cooling Freezing handling Bakeware Conveyor systems System control Kaak Bakeware You bake we care The success of your products not only depends on the production line chosen, also the product carriers play an important role. A bread pan or baking tray may seem a simple and straight forward product, but when it is not tailored to your baking line and product requirements, you will not achieve the optimal result. That is why Kaak custom designs and manufactures all its bakeware to meet your specific needs. We make straps, pans and baking trays for every product your customers demand. Our range of bakeware is tailor-made, and therefore almost limitless. The coatings used are precisely suited to the baked products and its processing parameters. Kaak Bakeware, your partner in bakery supplies: Engineering from idea to final product Fully automated production of moulds through use of industrial robots Extensive agency network, providing local support for our customers The close collaboration with Lhotellier R2A ensures expertise in all possible non-stick coating types 16

17 Every alternative The number of variants in bakeware is unlimited and always subject to change.we do not just offer standard shapes and sizes but also individual products.the number increases constantly, not only in terms of shape but also in terms of size. Today, we offer everything: from single cake moulds to large strapped bread moulds. Being our major activity 90 years ago, the production of bakeware still plays an important part in the Kaak Group. 17

18 Dough handling Final proofing Decorating Baking Pan Crate handling Cooling Freezing handling Bakeware Conveyor systems System control Lhotellier R2A Non-stick coatings Lhotellier R2A has been applying non-stick coatings focused exclusively on the bakery industry since Our long experience has enabled us to develop a wide range to meet the specific needs of your production. Our coatings are applied on all types of materials (such as steel, stainless steel, aluminum) and for all types of bakeware (straps, moulds, sheets, etc.) whether new or used. This know-how makes Lhotellier R2A your ideal partner and expert for all your coating needs. All our coatings meet the European regulations for products in contact with food. Multi-Flon We offer a wide range for your applications in bread, pastries and crackers. The Lhotellier Multi-Flon (fluoropolymer) coatings are well known for their quality and performance. They provide high resistance to abrasion, chemicals and corrosion. Our research and development department is continuously working on the expansion of this range in order to anticipate your needs change. Multi-Sil R Our rubber silicone range is renowned for its longevity. It will meet all of your particular needs in Brioche dough applications. It combines strong anti-adhesion with high temperature resistance. Multi-Sil G Our experience of over 40 years in silicone resins resulted in a coating with an exceptional non-stick performance. It is particularly suited for very sweet liquid doughs (such as Madelines). 18

19 Lhotellier R2A, your partner in coating We can help you to improve the quality of your products by defining the most suitable coating for your specific product needs. 19

20 Dough handling Final proofing Decorating Baking Pan Crate handling Cooling Freezing handling Bakeware Conveyor systems System control Multiparts Conveyor systems Multiparts is one of the youngest members of the Kaak Group (2007) and has grown into a leading and reliable provider of standard conveyor systems in the bakery industry. Kaak Multi-Way conveyor belts have made a demonstrable impact on the bakery industry over the years. Today, these plastic, modular conveyor belts are the most widely used of their kind in the global bakery industry. The hygienic stainless steel conveyor systems offered by Kaak Group have been a trusted industry product for years. Multiparts combines its expertise and experience with fast delivery times and offers conveyor systems and its own range of plastic, modular conveyor belts. Thanks to an extensive product catalogue, Multiparts can guarantee extremely quick delivery within 2-4 weeks for standard modular conveyor solutions. Our conveyor systems have helped us acquire extensive experience with the following: Chain conveyors (1, 2, 3 & 4 tracks) Multi-Way (plastic modular conveyor belt) Baked goods Cloth conveyor belts Roller conveyors Cord conveyor belts Strapped pans / baking trays Unbaked (dough) products Crates / boxes Stand-alone strewer with controller 20

21 Custom solutions Are you looking for a custom conveyor solution for your company? Multiparts is happy to help. Contact us to receive an obligation-free solution for your business. Our custom solutions, which include control and installation, are available within a matter of weeks. Conveyor specials and parts We guarantee quick delivery on an extensive range of specials used in the bakery industry. These include: Power-free conveyors Strewers Flour and seed strewers Horizontal and vertical switches Chuted conveyors 90-degree pick-and-place machines Spiral chutes Stoppers Diverters 21

22 Dough handling Final proofing Decorating Baking Pan Crate handling Cooling Freezing handling Bakeware Conveyor systems System control KSW Central Intelligence Control, monitoring, preventive maintenance, documentation, traceability the increasing requirements for intelligent processes and equipment are the special field of KSW, Kaak Software Worldwide. In the complex arena of competition and legal requirements, their differentiated recipe control and the monitoring of production parameters ensures the desired quality standards are met and quick error diagnosis and the identification of solutions help to prevent down time. Visual indication of error messages with direct access to the digital operating manual. 22

23 RECIPE MANAGEMENT MONITORING / TRENDING OUTPUT CONTROL Historical Temperature Monitoring Historical Humidity Monitoring Fault Diagnostics Plant Monitoring Output/Batch Control Statistical Production Data input input input INTEGRATION WITH SILOS Mixing Automatic setting of: - mixing time - temperature - speed Fault diagnostics Etc. Dough handling Automatic setting of: - proofing time, temperature and humidity - scaling of rounder - checkweigher Fault diagnostics Etc. Final proofer Strap storage Ovenloading Decoration Automatic setting of: - proofing time, temperature and humidity - scaling of specific strap or sheet - choice of type of decoration or cutting Fault diagnostics Etc. Oven Automatic setting of baking program - temperatures per zone - baking time - control of convection turbos - control of steam Fault diagnostics Etc. Unloading Depanning Cooling Freezing Automatic setting of machine parameters by recipe - depanner - cooling time Fault diagnostics Etc. INTEGRATION WITH PACKAGING MACHINES Human Machine Interface (HMI) with 3D presentation of the baking line. 23

24 Kaak Group Varsseveldseweg 20a 7061 GA Terborg (NL) T +31 (0) F +31 (0) E info@kaak.nl