SOFTDOUGH & COOKIES
The basic ingredient. We know how. Ever since we first started, in 1962, we have always felt ourselves to be part of our customers recipies. This is why we have always given them our technology, passion, reliability and quality. Being the basic ingredient is not just a motto for us but a real, constant commitment. We have put innovation at the heart of our business, always pushing the boundaries of our experience. We never take it for granted, always making it available to our customers around the world. Expanding out expertise, broadening our scope, always driven by passion and daring: what we call Know-how is a goal that we shift forward by one step every day. This is positive energy and one that we want to share with all our partners.
SOFTDOUGH & COOKIES The process 03 An important sector in the biscuit manufacturing world is that of softdough & cookies, which includes an ample family of products for which manufacturing is based on three main processes: wire-cutting, depositing and rotary moulding. In the first two categories, each process has its own core-forming unit. Additional devices can be added to this unit in order to enhance the range and appearance of products to be made: flexibility is a must! In the following pages we explore the manufacturing processes used for soft-dough & cookies. The process Deposited & Wirecut Rotary moulder SOFTDOUGH & COOKIES Rout press, Wirecut & Co-extruder
Rout press, wirecut & co-extruder These categories of products can be manufactured starting from a single machine. The basic unit consists of two grooved rolls which extrude the dough through a set of dies in order to give the dough pieces their shape. A fillerblock is inserted between the rolls and the die plate in order to equalize dough distribution across the width and provide optimum weight control. The basic machine is configured as a rout press. A wirecut mechanism can be added for the production of plain wirecuts or products with inclusions. Rout press products are cut by means of a guillotine cutter positioned before or after the oven, depending on the type of final product to be obtained. By adding the crimping device, soft-centre cookies can be formed where the centre filling can be jam or cream. Fruit bars can be cut before or after the oven depending on the type of final product to be obtained. Optionally, the unit can be fitted with two separate filling hoppers in order to produce fillings with two different tastes within the same row of products. The key advantages of this unit are flexibility, high-speed performance, user-friendliness, and ease of access and cleaning.
SOFTDOUGH & COOKIES Rout press, wirecut & co-extruder 05 Fillerblock. Chocolate chunk cookies coming out from the 1.700 mm wide oven s chamber. Plain wirecut in production.
06 SOFTDOUGH & COOKIES Rout press, wirecut & co-extruder Rout press configuration HOPPER GROOVED FEEDING ROLLERS DIE & DIE PLATE Rout press products extrusion dies. FILLERBLOCK Rout press products cutting device.
SOFTDOUGH & COOKIES Rout press, wirecut & co-extruder 07 Wirecut configuration HOPPER HOPPER SEPARATION PLATE GROOVED FEEDING ROLLERS GROOVED FEEDING ROLLERS FILLERBLOCK FILLERBLOCK DIE & DIE PLATE WIRECUT MECHANISM DIE & DIE PLATE WIRECUT MECHANISM
View of the pipes which convey the filling from the hopper to the co-extrusion box.
SOFTDOUGH & COOKIES Rout press, wirecut & co-extruder 09 Co-extrusion configuration GROOVED FEEDING ROLLERS HOPPER GROOVED FEEDING ROLLERS HOPPER FILLERBLOCK DIE & DIE PLATE FILLERBLOCK FILLING FILLING STAGGERED PATTERN DIES STAGGERED SHUTTERS
3Extruder The 3Extruder consists of 3 separate extruding heads in the same unit. Each head consists of a pair of grooved rolls which evenly feed the dough to a set of dosing pumps positioned underneath. A single outlet is connected to on each pump, thus ensuring consistent weight of the pieces of dough across the width. Minimum stress is applied to the dough while it is being extruded. A wide range of products can be manufactured by this unit, from traditional plain wirecut to more sophisticated ones, e.g. two-colour dough with soft centre consisting of cream or jam, or even 3 different colours of dough. The unit is very simple to regulate as all movements are made by dedicated servomotors without the use of mechanical cams: a user-friendly touch-screen operator interface panel ensures flexible control of all possible adjustments to the machine. The design of this unit allows tool-free dismantling for access and cleaning purposes.
HOPPER SOFTDOUGH & COOKIES 3Extruder 11 GROOVED FEEDING ROLLERS VOLUMETRIC PUMP Center filled twisted bars. DIE & DIE PLATE
SOFTDOUGH & COOKIES 3Extruder 13 What possibilities? PLAIN WIRECUT WIRECUT WIH INCLUSIONS TWO-COLOURS DOUGH SOFT CENTER FRUIT BARS 2-COLOURS DOUGH, 1 CREAM/JAM (soft center or bars) 1-COLOUR DOUGH, 2 CREAMS/JAMS (bars) 3Extruder 3-COLOUR DOUGH (wirecut and/or bars) Rout press, Wirecut & Co-extruder
Depositor The head consists of a pair of grooved rolls which evenly feed the dough to a set of dosing pumps positioned underneath. The one pump-one nozzle concept ensures uniformity of weight across the width. The machine is fully servo controlled: all the movements of the head are driven by independent motors positioned on both external sides of the unit. No shafts or cams drive any movements: this means that all possible adjustments can be set from the touch-screen operator interface e panel with its in-built recipe storage system. Flexibility is therefore guaranteed: a wide and extremely varied range of dough can be handled. Flexibility is also enhanced as a wirecut mechanism can be added d as an option to the unit, making the machine suitable for the production of wirecut products, with or without inclusions. When working in its depositor configuration, a rotating nozzles mechanism can be added in order to produce swirl or twisted dough pieces. To enhance its flexibility and produce enriched products, a synchronised jam depositor can be fitted to the unit.
SOFTDOUGH & COOKIES Depositor 15 Volumetric pump. Detail of soft dough depositing.
16 SOFTDOUGH & COOKIES Depositor Depositor configuration HOPPER GROOVED FEEDING ROLLERS JAM DEPOSITOR (optional) UP & DOWN HEAD MOVEMENT VOLUMETRIC PUMP DIE & DIE PLATE FOLLOW THE BAND MOVEMENT
18 SOFTDOUGH & COOKIES Depositor Wirecut & swirl configuration HOPPER HOPPER GROOVED FEEDING ROLLERS GROOVED FEEDING ROLLERS VOLUMETRIC PUMP VOLUMETRIC PUMP UP & DOWN HEAD MOVEMENT DIE & DIE PLATE SWIRLING DIES FOLLOW THE BAND MOVEMENT
20 SOFTDOUGH & COOKIES 2Heads Depositor 2Heads Depositor HOPPER HOPPER The unit is composed of two moving heads installed on one fixed base which permits, in a small footprint and with reduced investment, to easily and efficiently deposit two color dough, even swirled, thus enhancing the flexibility of production. Each head consists of grooved rolls which evenly feed the dough to a set of dosing pumps positioned underneath. The one pump-one nozzle concept ensures uniformity of weight across the width. The machine is fully servo controlled: all the movements of the twin head are driven by independent motors positioned on both external side of the unit, while the dough deposit can be finely tuned independently from each head. No shaft or cams drive any movements: this means that all possible adjustments can be set from the touch-screen operator interface panel with its in-built recipe storage system. GROOVED FEEDING ROLLERS VOLUMETRIC PUMP Flexibility is therefore guaranteed: traditional single deposit, or two colors dough deposits can be handled at easy, thus broading the variety of products to be manufactured on one unit. Flexibility is also enhanced as a wire cut mechanism can be added as an option to the unit, making the machine suitable for the production of single or two colours wire cut products, with or without inclusions. When working in its depositor configuration, a rotating nozzles mechanism can be added with the scope to produce swirl or twisted dough pieces. DIE & DIE PLATE
Rotary moulder The unit is designed for the production of shortbread dough. It offers high performance in terms of running speeds, quality of dough pieces formed and consistency of production. Fine-tuning adjustment of the height of the knife ensures precise control of the weight of each single dough piece. Automatic tensioning and tracking of the belt are standard. For high production rates, with a very long oven and short baking time, Imaforni can deliver the unit with forming rolls measuring 390 mm in diameter; with such rolls diameter, the quality of the extraction of the dough pieces from the mould to the belt is smooth and perfect. The machine can be customized to suit the baker s needs: the control system can be fully servo motorized and all the adjustments can be made by servomotors through a visual screen operator interface with a recipe storage system. The safety, sanitation and hygiene design meet the highest market standards. Mould change over and belt replacement can be tool-free operation.
SOFTDOUGH & COOKIES Rotary moulder 23 HOPPER FORCING ROLL KNIFE MOULDING ROLL EXTRACTION ROLL WEB
24 SOFTDOUGH & COOKIES Rotary moulder Details of egg wash distribution. Details of sugar sprinkling distributor.
26 SOFTDOUGH & COOKIES Auxiliary devices Auxiliary devices EGG WASH (brush/roller type) SUGAR SPRINKLER GLAZING UNIT (spray type) VARIOUS TOPPINGS Ink Printer Device: it works in phase with the rotary moulder. Jam/Cream depositor with moving head and separate conveyor. It works in phase with the rotary moulder.
Flexibile line for Softdough & cookies production. ROTARY MOULDER 2EXTRUDER GUILLOTINE CUTTER DEPOSITOR OVEN PRESSURE ROLLER INFEED OVEN DRUM 12.830 mm
28 SOFTDOUGH & COOKIES Test & development Test & development Depositor Rout press - Wirecut Co-extruder 3Extruder Rotary moulder Imaforni has had its own Test & Development Center since 1999. The 4th generation of machines are currently available consisting of a complete 1200 mm wide industrial production line composed of a wirecut/soft-centre machine, a depositor/wirecut unit, a 3Extruder and a rotary moulder. The oven has a hybrid configuration with radiating (cyclotherm section), and convection heating. The conveyor is a solid steel band. Second pilot line is available for the development of cracker snack and hard sweet biscuits. The oven consisting in a 1.200 mm wide state of the art on Direct Gas Fired heating system complete with wiremesh conveyor. Both ovens are fitted with their own Energy Recovery System. The lines are available to those customers interested in testing new processes, existing recipes or new products. Our staff, with their vast technological background, are at your disposal.
30 SOFTDOUGH & COOKIES Test & development R&D. For market-proof processes.
The information contained in this document are subject to variation. Imaforni reserves the right to make technical modifications without prior notice. Any copying of the information or of the pictures included here is strictly forbidden. Some of the equipment illustrated in this document are outsourced.
IMAFORNI INT L S.p.A. via Strà 158-37030 Colognola ai Colli Verona - Italy T. +39 045 6174711 F. +39 045 6150065 info.ima@imaforni.it www.imaforni.com