Biscuits, Cookies & Crackers
Process Knowedge & Engineering Expertise Baker Perkins comprehensive range of equipment for biscuit, cookie and cracker manufacture is founded on over 100 years experience and expertise. From mixing to sandwiching, every machine is designed to maximise profitabiity through reiabiity, ease of ceaning and ease of use. Because we suppy fu ines - from mixing and forming to baking and sandwiching - we understand the compete process. This awareness of what is happening throughout the operation enabes us to give unparaeed backing to our customers, from panning, through designing, buiding and commissioning, and on to compete ifetime support. Lifetime Support When choosing equipment from Baker Perkins, customers expect and get the best in terms of equipment specification, reiabiity, end-product quaity and ow production costs. Lifetime Support ensures that these expectations are met for as ong as the equipment is in production. We have buit our business on technica exceence and innovation, firmy grounded in unrivaed process knowedge and engineering expertise. We have aways used these to design equipment that meets the needs of the industry, with probems such as better weight contro, reduced maintenance and easier, hygienic operation a being addressed in innovative ways. We offer a broad range of services to hep maintain and improve ine performance and extend usefu ife. This covers everything from repacement parts to major repairs and rebuids and incudes on-site engineering services such as panned maintenance contracts, faut-finding and pant optimisation. There are aso upgrades avaiabe to key features to improve performance and reiabiity. 2
Products Baker Perkins ines incude everything from soft, sweet biscuits and bars to hard, savoury crackers and snacks, as we as cream sandwiches. Increasing product diversity has broadened the appea of cookies and crackers from simpe coffee-time and unchbox stapes to indugent treats and even mea repacements. Baker Perkins product deveopment has kept pace with these changes whie retaining the reiabiity and ow production costs that have characterised our biscuit, cookie and cracker ines for decades. Biscuits & Cookies Baker Perkins manufactures rotary mouders and wirecuts for the compete range of cookies and soft dough products, from pain to indugent gourmet and encapsuated cookies. The soft dough portfoio is competed by frozen dough cookies, baked at the point of sae to provide an enhanced eve of consumer appea. Wirecut Rotary Mouded Encapsuated Cookies Crackers & Snacks Forming a sheet and cutting product shapes from it is the method used when the guten in the four has been deveoped in the mixer and the dough has more eastic properties. Whether sweet or savoury, products made using this process have a ighter, crispier texture than soft dough products. Laminated Sheeted Snacks Sandwiches & Bars The core cookie and cracker technoogies are readiy appied to other products such as cerea, energy and fied bars; ayered biscuits and toaster pastries. Sandwiching systems are avaiabe for a wide range of product sizes and width input/output configurations that enabe a smooth process fow to be achieved. Sandwiches Bars Toaster Pastries 3
Process: Soft Dough Forming Baker Perkins provides best-in-cass rotary mouders and wirecuts for the compete range of biscuit, cookies and fied bars. We provide unit machines for a the main forming processes; more than a century of experience means that we have an unrivaed abiity to combine them into profitabe, efficient, fexibe ines. Wirecut Cookies Dough is mixed by a High Speed Mixer, using a unique, shaftess mixing bade that ensures good dispersion of ingredients with minima damage to incusions. The mixed dough is then transferred to Baker Perkins TruCean Servo Wirecut, where patented fier bock technoogy, die pates and die cups provide precise weight contro for product consistency ahead of baking. An encapsuation modue for fuy-encased fied cookies is aso avaiabe. HIGH SPEED MIXER WIRECUT OVEN Frozen Dough One of Baker Perkins speciaities is the Frozen Dough Machine. The dough piece forming process is the same as a wirecut, but dough pieces are aid onto paper for freezing, rather than baking. The process is based around a Baker Perkins TruCean Servo Wirecut with a series of standard modues for wire cutting, paper sitting and paper cutting. A topping system is aso avaiabe to add finishing touches to the dough pieces for added vaue. WIRECUT TOPPING SYSTEM PAPER DISPENSER PAPER SLITTER PAPER CUTTER 4
Process: Soft Dough Forming Rotary Mouded Biscuits Rotary mouding is the industry-standard method of making soft dough products. Dough is mixed in the High Speed Mixer then transferred to a rotary mouder. Speciaist dies within the rotary mouder set and maintain the product size, shape, weight and thickness, as we as imparting the manufacturer s unique design or branding. Panning is either direct or by a swive panner for enhanced centraisation onto the oven band. HIGH SPEED MIXER ROTARY MOULDER OVEN Bars Baker Perkins wirecuts aow the production of pain bars and bars fied with an unimited variety of sweet and savoury fiings. Mixed dough and fiings are transferred to the forming machines, where they are fed down passages machined into fier bocks to create a continuous strip of fied product. A guiotine then cuts the continuous strip of product into bar engths for baking. HIGH SPEED MIXER WIRECUT GUILLOTINE OVEN 5
Process: Sheet Forming & Cutting Baker Perkins TruCean sheet forming and cutting ines are abe to process a wide range of dough types, incuding crackers, snack crackers and hard sweet products. There is aso an increasing crossover into enzyme raised crackers, baked snacks and softer dough products where a ighter texture is needed. Baker Perkins sheet forming and cutting ines meet TruCean standards, bringing major benefits in maintenance and hygiene, with ow costs and fast changeovers. Sheeted Crackers & Snacks The sheet and cut process is traditionay used on hard and semi-sweet products. After mixing, dough is fed into a sheeter, which forms a compacted sheet of constant thickness and density. The sheeter ensures a consistent and even sheet is fed to the gauge ros. The dough is gauged to the required thickness, reaxed, and then embossed and cut before passing into the oven. The scrap attice is returned to the sheeter for reprocessing. HIGH SPEED MIXER THREE ROLL SHEETER GAUGE ROLLS SCRAP RETURN ROTARY CUTTER OVEN Laminated Crackers & Snacks Laminating gives a ight, faky, crisp texture to crackers and snack products which cannot be achieved in any other way. A sheeter and two gauge ros within a aminator produce a dough sheet that is cut and aid down on a continuousy moving conveyor feeding the first gauge ro. Products are gauged to the chosen thickness, reaxed, and then embossed and cut before seasoning and baking. The scrap attice is returned to the aminator for reprocessing. HIGH SPEED MIXER LAMINATOR GAUGE ROLLS SCRAP RETURN ROTARY CUTTER OVEN 6
Process: Cream Sandwiching Sandwiching creates vaue by adding interest and variety to a product range. To do this profitaby, Baker Perkins sandwiching systems are fuy automated, from cream feed through to ane mutipication. High quaity components ensure Baker Perkins sandwiching systems run faster for onger. Aied to precise weight contro, the resut is a pant that maximises return on investment. Cream Sandwiches Shes are conveyed to the system via infeed magazines. Shes are stripped from the magazines by pairs of pin chains and pushed through the sandwiching machine on support wires; the bottom she has cream deposited onto it before passing under a second infeed magazine, where addition of the top she takes pace. Fina thickness is controed by an adjustabe presser; a Lane Mutipier may then be used at the end of a sandwiching machine to increase the number of anes prior to cooing, chocoate coating and/or wrapping. CREAM FEED HIGH SPEED CREAM SANDWICHING SYSTEM LANE MULTIPLIER Pie Packs For Vending Baker Perkins Pie Pack Sandwiching Machine is a speciaised process for producing two-high pies of sandwiches packed end-to-end for vend packs of between one and six pies. before the second is begun. There is no need for cooing and there are no compex ane merging devices; the pies are coated into the required pack ength and fed directy to a wrapping machine. The Pie Pack Sandwiching Machine has a singe ane, and the two sandwiches are created one above the other. Assemby is sequentia, with the first sandwich competed 7
Equipment: Mixing & Dough Feed High Speed Mixer Baker Perkins muti-purpose High Speed Mixers are suitabe for both hard and soft dough types. Thorough mixing is assured by the unique shaftess bade design, which gives rapid dough deveopment with good dispersion and minima damage of incusions. The High Speed Mixer offers high eves of automation, ease of use and ceaning, and outstanding reiabiity to guarantee ow cost of ownership. Dough Feed Systems Dough feeding systems comprise a range of unit machines and hygienic conveyors to transport dough from the mixer and provide either a buk feed or metered feed to the forming equipment. Each system is designed to match the specific pant output and product type, taking into account any requirements for resting and conditioning of the dough. Equipment: Sheet Forming & Cutting TruCean TM Vertica Cut Sheet Laminator The TruCean Vertica Cut Sheet Laminator is used in the production of aminated products such as crackers, hard-sweet products and baked snacks. The machine offers outstanding weight contro across the width of the pant, achieved by cose contro of dough sheet thickness, sheet positioning and the ay-down process. The unit is compact and easy to operate, with exceent access for ceaning and maintenance. TruCean TM Combination Laminator Baker Perkins unique TruCean Combination Laminator aows the production of a fu range of sheeted and aminated crackers and snacks. It is a cost-effective and simpe means to create a muti-purpose pant. The key to uncompicated fexibiity is an ingenious mitre turn, which feeds the sheeted dough either to the aminator or directy to the first gauge ro via a bypass conveyor. Conventiona dua-purpose pants need two sheeters, one each for aminated and sheeted products; the Combination Laminator saves the cost of the second sheeter, as we as reducing the foor space and cost and compexity of the dough feed system. 8
Equipment: Sheet Forming & Cutting TruCean TM Three Ro Sheeter The three ro sheeter takes either a buk or metered feed of dough from the mixer and forms a compacted sheet ready for the gauge ros. The three-ro arrangement provides optimum contro over the size and condition of the dough sheet. The ros are configured to create a compression chamber which homogenates the dough without damage. The infeed hopper contains a partitioned compartment to integrate returned scrap dough into the underside of the fresh dough, maintaining a high-quaity and consistent surface finish. TruCean TM Gauge Ro TruCean Gauge Ros achieve and maintain the desired thickness of a sheet of dough. Baker Perkins atest design ensures reiabe operation, ow waste and accurate performance. The gauge ros feature an arrangment of fanges, scrapers and take-off conveyors which reduce waste by fuy supporting the dough sheet throughout the process. Repeatabe precision is matched by ow operating costs, with abour and maintenance kept to an absoute minimum. TruCean TM Rotary Cutter The TruCean Rotary Cutter uses a pair of engraved cutter ros to emboss then cut pieces from the continuous sheet of dough received from the gauge ros. As the cut pieces are passed to the oven for baking, the scrap attice is returned to the aminator or sheeter for reintegration into the fresh sheet, minimising waste. The rotary cutter aso features a rapid bypass function that avoids probems from an imperfect dough sheet by enabing it to be diverted to the scrap ift for reprocessing at the touch of a button. 9
Equipment: Soft Dough Forming TruCean TM Servo Wirecut Baker Perkins TruCean Servo Wirecut is especiay designed for the very soft doughs typified by the cassic chocoate chip cookie. High accuracy wirecut machines are the key to high-quaity cookie production. Baker Perkins servo-driven machines can be specified with a range of options to ensure they meet exact requirements; they combine hygienic design with the abiity to contro product weights very cosey, and gap adjustabiity that aows arge incusions such as chocoate chunks, nuts and raisins to be handed without impairment or damage. There is aso a new encapsuation modue that enabes fied cookies to be produced on the same machine. TruCean TM Frozen Dough Machine The TruCean Frozen Dough Machine is a high-output moduar system producing every type and size of cookie dough piece for bake-off operations. Based around a Baker Perkins TruCean Servo Wirecut, the Frozen Dough Machine combines exceptiona reiabiity, fast changeovers, accurate weight contro and exceent hygiene standards. High production rates are maintained whie keeping operating costs ow. The TruCean Frozen Dough Machine produces the fu range of cookies, from bite size to gourmet. 10
Equipment: Soft Dough Forming Series2 Rotary Mouder The Series2 is a high performance rotary mouder designed for efficiency and high output in environments where cose contro of size, weight and texture are essentia. It is fuy adjustabe, enabing the mouder to produce every type of soft-dough mouded biscuit, from thick bars to deicate bite-size pieces. TruCean TM 590 Heavy Duty Rotary Mouder The TruCean 590 is primariy used for mouding demanding products such as energy bars and pet food. The machine is stronger and more powerfu to cope with the extra work required to form these products. The 590 features robust construction and components necessary to hande arge, thick products made from heavy doughs at high speed. High efficiency and precise weight contro minimise waste and giveaway, whie maximum reiabiity with easy ceaning and maintenance keep running costs down. Forming Anciaries A range of units is avaiabe to add vaue and put the finishing touches to cookies and crackers: Jey Topper: deposits jams and jeies onto cookies. Washover Unit: appies egg soution, mik, or simiar iquids onto the surface of the unbaked cookies. Sat / Sugar Sprinker: sprinkes an eveny distributed ayer of granuar materia onto the product. Incudes a recycing system. Swive Panning Conveyor: transfers the products from the forming machine to the oven band. Incudes faciity to mount the sat / sugar sprinker. Doube Eccentric Guiotine: positioned after wirecut to cut continuous strips of product into bar engths. 11
Equipment: Sandwiching High Speed Cream Sandwiching System Baker Perkins High Speed Cream Sandwiching Systems produce round or rectanguar cookie or cracker sandwiches with a singe or co-deposited fiing. Precision engineering ensures that an accuratey metered cream deposit is reiaby and consistenty paced between two deicate shes, even when moving at high speed. The resut is very itte waste or giveaway, eading to high efficiency and ow production costs. 2 to 6 ane versions are avaiabe, with pin chain pitches between 2 and 4 to match a range of she sizes and upstream equipment. Lane Mutipier The Lane Mutipier may be used at the end of a sandwiching machine to increase the number of anes prior to cooing, chocoate coating and/or wrapping. Mutipying the anes aows cooing tunnes to be shorter, ess costy and more efficient, as we as preparing the products for subsequent enrobing or wrapping operations. Baker Perkins Lane Mutipier has been specificay designed to carry out the task genty and hygienicay. Pie Pack Cream Sandwiching System The Pie Pack Cream Sandwiching System produces pies of two cream sandwiches that are coated into packs for vending machines. Athough the main use is for vend packs of between one and six pies, onger retai packs with a card insert are aso possibe. The Pie Pack Sandwiching Machine is directy inked to a fow-wrap machine to form a compact and efficient system for sandwiching, handing and wrapping. Direct-inking to the wrapping machine via a singe ane competey eiminates the need for compex and costy ane merging devices, as we as cooing and handing systems. Cream Feed Baker Perkins Cream Feed provides an accuratey metered suppy of cream to the sandwiching machine. Mixed cream is hed in a water-jacketed hopper, before an auger screw transfers it from the hopper to a manifod that feeds the cream pumps. Each cream pump feeds one ane of the sandwiching machine; the pumps are independenty controabe for accurate deposit weight and consistent positioning. The machine is designed for hygiene, with food-grade pastic and stainess stee used throughout the product contact areas. 12
Equipment: Baking 700 Series Direct Gas Fired Oven Direct Gas Fired (DGF) ovens are seected by biscuit, cookie and cracker manufacturers around the word for their exceent baking characteristics, fexibiity and ease of operation. Heat comes from ribbon burners mounted above and beow the band, assisted by an air circuation (turbuence) system. The 700 Series has the abiity to combine radiant and convective heat in varying proportions aong the ength of the oven: this enabes the idea size, coour, moisture and thickness of product to be consistenty achieved. TruBake TM Convection Oven The TruBake uses an enhanced direct convection heating system to achieve exceptiona product quaity, high throughput and ow operating costs. Precision contro of temperature and airfow creates a stabe and predictabe environment capabe of fast baking and minima fue consumption. A choice of zone ength, oven band and the abiity to be combined with other oven types enabe the TruBake to be configured to the precise needs of any appication. Hybrid Ovens Bakers can combine the best baking methods by specifying a hybrid oven. DGF and direct convection ovens have characteristics that are each idea for one part of the process: combining the benefits of both creates a unit that exacty matches specific needs for any kind of biscuit, cookie, cracker or bar. 13
A Compete Ro and Die Service Baker Perkins ro and die service provides advice and support at every stage of the design, testing and specification process for new or repacement biscuit and cracker ros and wirecut dies. Working from sketches, drawings, modes, or even od ros and dies, we can create a digita 3D mode of the product to make a test engraving or 3D printed moud for evauation and approva. We work cosey with our cients to seect the most appropriate combination of construction, materia and finish for the product and the manufacturing operation. Our advice is based on process knowedge and insight deveoped over many years experience as a suppier of high-performance machinery. With our understanding of the interface between the machine, its ro or die and the product, we are abe to suppy ros and dies that are right first time, run ceany and reiaby, and make a significant contribution to ine efficiency and profit. Why Choose Baker Perkins? Unique process insight Custom design service pus a ibrary of thousands of standard designs Ros and dies to suit every kind of forming machine Fast and accurate 3D design and engraving Test seeves and fat sampes for pre-production review and testing Hep and advice over the phone or on site Range of construction methods, materias and finishes for optimum performance 14
The TruCean Standard The TruCean range of equipment for biscuit, cookies and crackers is designed to meet a industry guideines on hygiene and sanitation. Every detai is engineered to minimise debris accumuation and make thorough and effective ceaning as easy as possibe. The main objective of enhanced sanitation is to eiminate the risk to consumers from cross-contact. Usuay this means aergens and pathogens, but the same high standards are just as important for making Kosher, organic or free-from products. TruCean machines retain a the best-in-cass process parameters and benefits of previous generation equipment, incuding outstanding reiabiity, performance and ease of use. TruCean aows hygiene standards to be raised whie maintaining the owest possibe production costs: ess time ceaning means ower costs and faster changeovers. Rounded corners Hoes eiminated where possibe Anged surfaces for drainage Cabes run in seaed stainess conduit No toos required for ceaning Perforated see-through guards Continuous weds Stand-off mounts Sandwich contacts eiminated 15
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 01/17