Bread
Integrated Mixing & Forming Systems For high-voume production of tin bread, Baker Perkins range of integrated mixing and forming systems offers a combination of output, efficiency and product quaity that bakers around the word rey on for the profitabiity of their businesses. Precise mixing, accurate weight contro and gente dough handing a contribute to performance that enabes them to achieve ow production costs and consistent high quaity. Low Production Costs Ingredient costs are reduced as ess yeast and improvers are required to achieve the same bread quaity. Gente handing preserves the ce structure deveoped in the mixer so the dough proves and bakes we to achieve the required voume, coor and softness, at a ower cost. Production costs are further reduced as gente handing eiminates the sticking and smearing that ead to jams. It aso means that a ot ess ceaning and maintenance are necessary. Consistent High Quaity Optimum dough deveopment is achieved by the integrated high speed mixing system and gente dough handing throughout the process preserves the dough structure created in the mixer. This heps it to prove very eveny and fi the tin we, giving an attractive appearance and a good crumb structure. The shape, coor and resiience required for premium or sandwich bread can be achieved with a standard recipe; aternativey, standard products can be made using a ower-cost recipe. Hygiene A machines in the range are designed for hygienic operation and easy ceaning. This incudes a wash-in-pace system for the Tweedy mixer and fu wash-down capabiity for the Accurist2.1 divider. Whie a compete, integrated system offers the utimate in ow costs, high quaity and hygienic operation, every machine makes a contribution; instaing individua units wi resut in an immediate and measurabe improvement in pant performance. The most common appications for compete Baker Perkins systems are tin and toast bread in singe- or four-piece formats. They are particuary suited to the production of bread for sandwichs where the even texture, good coor and square-sided shape provide high eves of consumer appea. Tweedy Mixer Accurist Dividers Conica Rounder First Prover Mutitex4 Mouder 2
Process Integrated Mixing and Forming Systems A typica Baker Perkins mixing and forming system comprises two Tweedy mixers, an Accurist2.1 divider, Conica Rounder, First Prover and two Mutitex4 mouders with panning bends. For an 800g oaf this pant woud be rated at 9,200 per hour. For such a high output the amount of equipment required is particuary sma, which not ony keeps capita costs and footprint down but aso reduces abor and maintenance costs. High Efficiency The Tweedy mixer s integrated contro system ensures that dough is not mixed unti it is required by the pant. It manages pairs of mixers as a singe entity and can dynamicay adjust to compensate for stoppages and schedue changes. Dough is never wasted or eft standing before it is used so efficiency does not suffer the knock-on effects of ageing dough. The Accurist2.1 divider offers outstanding weight accuracy, which aows average scaing weight to be reduced. With the proper maintenance this scaing weight can be sustained for over 10,000 hours (or 18 months at 130 hours per week). Ensuring efficiency on the Mutitex4 starts with accuratey pitching dough pieces on the infeed to avoid doubes. Centraizing ros at the entry to the machine prevent the dough pieces jamming against the side guides and hep with accurate pacement in the tin, whie spring-oaded sheeting ros ensure that any doubes that do occur pass through without stopping the machine. Accurate, repeatabe settings make running adjustments unnecessary, even at the start of a run, meaning that100% efficiency is achieved from the very first dough piece. TWEEDY TWEEDY MIXER MIXER ACCURIST2.1 DIVIDER CONICAL ROUNDER MULTITEX4 MOULDER FIRST FIRST PROVER PROVER 3
Gas Ce Retention for Quaity and Consistency There is more to making high-quaity bread at high output than simpy mixing, dividing and shaping the dough pieces. High-speed processing requires absoute precision at every step whie quaity can be achieved ony by handing the dough very genty. It starts with mixing a dough that has a good ce structure and then retaining this through the subsequent operations, each of which pays a vita part in creating the perfect oaf. Tweedy Mixer The Tweedy is a high-speed mixer for a types of mechanicay deveoped dough, incuding no-time and straight dough for tin and variety bread, rye bread, ros and pizza. It is the definitive mixer for the Choreywood Bread Process (CBP). MIXING Whie the dough is deveoped by high shear and controed energy input the gas ce structure is created by appying pressure and vacuum in the mixing chamber. Pressure appied near the start of mixing assists with dough deveopment and mixes more air into the dough. Appying partia vacuum towards the end of mixing causes the ces in the dough to expand to form bubbes which are then sub-divided by the action of the mixer into sma ces. When the vacuum is reeased these ces are compressed, resuting in a arge number of fine and eveny distributed ces in the dough. Mixing under pressure and vacuum creates a structure of fine ces in the dough. Dough Discharge Accurist 2.1 Divider The Accurist2.1 uses a servo-controed ram to divide dough by drawing it from a hopper and pushing it into pockets of known voume. The servo-contro system stops the movement of the ram at a pre-determined pressure, which is enough to fi the pockets but not damage the dough. This achieves the optimum baance of accurate weight contro and retention of ce structure. DIVIDING Draw dough from hopper Genty push into division box The dough is divided genty to maintain the ce structure but some interna stresses are created. 4 Division box owers Dough pieces ejected
Conica Rounder The rounder shapes the divided dough pieces into bas and conditions the surface for easier handing downstream. The open profie, shaow anges and 3-dimensiona path of the troughs provide a very gente roing action that rounds and conditions the pieces whie maintaining the dough structure. ROUNDING Rounded Dough Bas First Prover Athough minima, the dough pieces wi have picked up interna stresses during dividing and rounding. This stress is randomy distributed and, if uncorrected, woud ead to tearing of the dough surface during mouding and an uneven rise during proving and baking. Reaxing the dough makes it behave more predictaby and enhances the quaity and consistency of the end product. Rounding genty shapes and conditions the dough pieces whie retaining the gas ce structure. FIRST PROVING Individua Prover Pockets Mutitex4 Mouder The main job of the mouder is to put as much tension into the dough piece as possibe whie preserving the ce structure. This is achieved by a muti-roer sheeting head that genty reduces the dough sheet thickness in a series of sma steps. The dough is kept under tension as it is coied and mouded into its fina shape. The first prove reaxes the dough pieces. The structure of fine ces is restored. FINAL MOULDING The tension ensures that the dough rises eveny and strongy in the prover and oven, giving the fina oaf increased voume and a reguar, straight sided shape, as we as a fine crumb structure that improves coor, softness and resistance to tearing. The gas ces are stretched and coied eveny to give a cose-grained crumb structure to the bread. Tighty Coied Dough Piece 5
Equipment Tweedy Mixer High-speed and consistent mixing of mechanicay deveoped dough. Suitabe for most types of bread, ros and pizza. Accurate integrated weighing system for precise recipe contro Hygienic ingredient patform with washdown area Highy efficient mixing pate design for rapid energy input Wash-in-pace system for mixing bow and id Acousticay seaed to reduce noise Fuy automatic contro system with schedue management Accurist2.1 Divider High-output servo-controed divider deivering sustained high accuracy whie preserving dough structure. 2.5g to 3.5g SD on 900g pieces maintained over 10,000hrs Up to 10,800/hr for 800g dough pieces Adjustabe ram pressure minimizes dough damage 15 minute cean down with fu foam cean-and-rinse capabiity Low-usage oiing system improves hygiene and reduces costs 3,000, 5,000 and 9,000 per hour mechanica dividers avaiabe Conica Rounder Precision-engineered for ow-stress shaping and surface conditioning of dough pieces. Integrated air bowers for hygienic, dust-free operation Long-asting non-stick surface coating minimizes ceaning Adjustabe troughs aow precise set up for consistency Tight toerances minimize chipping Soft start/stop protects machine and avoids power spikes First Prover Reiabe and hygienic resting of the dough pieces prior to fina mouding. Individua pockets are air dried for reiabe discharge Synchronised bucket feed for accurate pocket fi at high rate Air circuation system prevents buid up of moisture on dough surface Quick-change pockets made from hygienic meta-detectabe pastic mesh Stainess stee construction and easy access for ceaning Mutitex4 Mouder The utimate bread mouder, the Mutitex4 uses a uniquey gente process to obtain maximum quaity from the avaiabe ingredients. Gente sheeting and tight coiing optimize voume and texture Ingredient costs may be reduced without affecting quaity Runs continuousy without jamming Repeatabe settings aow fast and efficient changeovers Controed panning enhances shape and produces consistency 6
Lifetime Support For as ong as a machine is in production we wi continue to offer parts, service, upgrades, rebuids and training that increase performance and service ife whie reducing running costs. Service contracts are taiored to the specific requirements of each site and are proven to be an economica way of keeping pants running reiaby and profitaby. Process Support and Training Fu process support is avaiabe at the evauation stage of a project and throughout the ife of the pant. From on-site tests and consutations through to deveopment trias in our Innovation Centre we work with you at every stage to get the process and equipment specifications exacty right. Custom training packages can be incuded with commissioning or service contracts and foow-up courses are avaiabe aso. Service A service contract is the most cost-effective way of ensuring that your pant performs reiaby and efficienty throughout its ife. Contracts are taiored to suit individua sites but generay incude reguar inspection and maintenance visits with guaranteed pant performance and comprehensive reporting. Fixed costs, guaranteed response times and spares stock management can aso be incuded. Repacement Parts Fitting genuine Baker Perkins parts guarantees equipment performance and extends service ife. Our parts service is comprehensive and incudes 24/7 emergency breakdown cover. Service contracts can be extended to incude bonded stock at our factory or consignment stock on your sites. Rebuids and Upgrades Our rebuid and refurbishment services keep your machines running as reiaby and efficienty as when they were new whie od machines can be given a new ease of ife by a range of upgrades drawn from the atest versions of our current machines. A our parts are made to the origina drawings using the correct materias so they fit first time and perform as expected. Where designs have been improved since the machine was suppied the upgraded parts are offered as an aternative. 7
Baker Perkins Ltd Manor Drive Paston Parkway Peterborough PE4 7AP United Kingdom T: +44 1733 283000 F: +44 1733 283004 E: bptd@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 Baker Perkins 09/15