. Bakery Equipment . Dough dividers and rounders Hygiene concept Compact lines for small bakery products Modular lines for small bakery products Automation Bakery Equipment Bread lines World of Fortuna Dough dividers and rounders Key for your success When producing small bakery goods the dividers and rounders are crucial for the further processing. They are at the beginning of the production chain. Out of shapeless dough they form even little dough Divider and rounder Primus 2-pockets pieces with perfect surfaces therefore being the key for the whole process. If they do not deliver good quality the plant cannot make up this deficit. The best thing is to be on the safe side right away and chose the proven Fortuna technology. We provide high-quality dividers and rounders for different performance classes and fields of application. For handicraft pastries in absolute top form! Technical specifications Number of pockets 2-pockets Maximum hourly output* 2,400 pcs Scaling range 40-100 g (infinitely adjustable) Divider and rounder Primus 4- to 6-pockets Machine weight approx. 530 kg Power approx. 1 kW Technical specifications Number of pockets 4-pockets 5-pockets 6-pockets Maximum hourly output* 5,300 pcs 6,600 pcs 8,000 pcs Scaling range 24-60 g 24-60 g 24-60 g (infinitely adjustable) 30-70 g 30-70 g 30-70 g 35-80 g 35-80 g 35-80 g 40-100 g 40-100 g 40-100 g 50-125 g 50-125 g 60-150 g Special scaling ranges available on request Divider and rounder Magnus 3- to 7-pockets Machine weight approx. 700 kg Power approx. 1.5 kW Technical specifications Number of pockets 3-pockets 4-pockets 5-pockets 6-pockets 7-pockets Maximum hourly output* 9,000 pcs 12,000 pcs 15,000 pcs 18,000 pcs 21,000 pcs Scaling range 12-380 g 12-370 g 12-340 g 12-170 g 12-110 g (depends on size of pistons Special scaling ranges available on request and dividing drums) Machine weight approx. 1,900 kg (6-pockets) Power approx. 4.5 kW Winner o f the * depending on the dough used 2 2 2011 Equipment Helpful hoppers In order to facilitate your daily work in the bakery we offer a wide choice of hoppers for our dividers and rounders, which allow a comfortable dough feed. Depending on your individual needs and the available space in your bakery, you can choose between different versions. The hoppers are different in size, function and material; they are available either permanently installed or movable or foldable for better cleaning. Additional oiling of the hopper walls or the dough flow control are only two of many other options for a perfect start to your production of pastries. Plastic hopper - foldable (up to 160 kg) Top hopper - movable (up to 240 kg) Dough chunker - movable (up to 400 kg) ple is equipped with a rotatable turret on which you can mount different punching tools. This creates a greater variety of shapes and causes short changeover times when changing products. Cutting tools and a device for double-bread rolls open up further possibilities in order to extend your product program. We would also like to bring your individual motive or logo on the dough piece. What type would you like? Your customers love variety? Then Fortuna is exactly the right choice because we do everything to allow you a production of a large choice of goods without much effort. Our stamping unit for examDinner roll Double roll Kaiser roll Button roll Star Pressed roll Tartaruga round After work Double cross Sun Three star Football Tartaruga long Three-cut Double-cut roll Marraqueta Poznan´ roll Houska (extract from the complete list) 3 Hygiene concept – the clean solution Who does not know this problem: mould deposit on proofing trays, cloths and baking trays. In the bakery, where flour, warm temperatures and moisture meet, prevail the ideal conditions for the spread of the troublesome and extremely stubborn mould spores. Once the grey „mould stains“ are settled in the proofing cloths, it is hardly possible to get them out of the fabric even by means of intensive cleaning. Together with practitioners from the bakery industry, Fortuna has developed a proofing cloth, which stops the mould formation and fulfils the highest hygiene requirements. FortunaCARE is breathable, resistant to dirt and moisture and is therefore especially easy to clean. Due to the special coating, impurities remain on the Material properties: Impregnation: Carrier material made oft 100 % polyester Invisible, molecular protection Rear side with polyurethane coating Colourless and odourless 100 % breathable and antibacterial No discolouration through ultraviolet light Washable up to 60° C Semi-hydrophobic In accordance with HACCP standard and German Consumer Goods Ordinance Resistant to food surface and cannot enter into the fabric. A condition therefore is the constant cleaning of the line depending on the extent of production. FortunaCARE can be used as a liner for proofing trays and baking trays. Due to the precise cut the TÜV-tested cloths are suitable for almost all proofer systems. They are available both with adhesive strips and with hook and loop tape. Neutral pH The clever way to cool down your bakery products Your dough pieces can quickly and effectively cool down on these new baking trays which are made of plastic with a sophisticated technology of grids in the floor thus being designed in accordance with the baker’s needs: they are stable, stackable and much lighter than traditional baking trays made of metal or wood. In this way, they make the work in the bakery easier – day by day, tray by tray. Also when it comes to hygiene the plastic baking trays are the first choice. Since the trays are cast in one piece, they can be easily and thoroughly cleaned. Wood splinters – as can be found when using wooden baking trays – or other foreign objects do not come into contact with your bakery products at all. Moreover, in combination with FortunaCARE proofing cloths the trays meet the highest hygiene standards. The advantages at a glance: Lighter than traditional trays made of metal or wood Suitable for use with foodstuffs, in dishwashers and for freezing Integrated hollow chambers store the cold for hours No skin formation on the dough pieces Stackable and very robust 4 2 2011 Hygiene concept Fortuna sets new standards The state technical school for food technology in Kulmbach, Germany, carried out laboratory experiments and tested the hygiene cloths thoroughly. The result is: If the cleaning and hygiene requirements are complied with hardly any mould growth can be found when using the FortunaCARE cloth on the swing trays. transmitted from other sources and, despite the FortunaCARE coating, settle on the surface. However, with an undamaged surface they do not enter into the fabric and are then effectively killed by the UV light. Important is the duration of exposure to the UV radiation which should be at least 9 seconds. The frames are made of stainless steel Nevertheless, we additionally integrate a UV disinfection station for the empty swings of our plants because fungal spores can also be But that’s not all. When constructing our plants we do much more to provide a plus of hygiene in the production process: We use FDA-certified belts The swing tray chains are made of nonrusting material Large, wide doors allow an easy access Shaft-mounted motors and direct drives replace high-maintenance chain drives The stamping cups are made of dough repellent plastic Cup cleaning unit and flour dust suction (optional) Frames made of stainless steel Non-rusting swing tray chain Easy access due to wing doors No high-maintenance chain drives FDA-certified belts Stamping cups made of dough repellent plastic Cup cleaning unit Flour dust suction Plastic baking tray with FortunaCARE 5 Compact line concept Compact plant with Primus The 2-pocket bread roll system with long moulding unit and intermediate proofing unit offers high performance on minimal space. It is used for the production of round and longmoulded dough pieces in handicraft quality. Due to the compact 2-pocket version it even fits in the smallest bakery. Long moulding unit Working width 270 mm Intermediate proofing 4 minutes Manual discharge of the dough pieces Panning device with Primus The Fortuna panning device is the ideal solution to deposit round dough pieces from the divider and rounder directly on the sheet pans or the proofing tray. It is particularly easy to use and fits in every bakery. Universal deposit device for all common types of bread rolls Working width 600 mm Very precise panning Variably adjustable panning programmes Continuously moving discharge belt Long moulding unit (optional) Double roll device (optional) Ideal for the filling of sheet pans and proofing trays with the dimensions 58 x 78 cm, 58 x 98 cm and 60 x 40 cm with intermediate frame 6 2 2011 Compact line concept Combined plant Premium K with Primus From now on the well-proven combined bread roll line Fortuna Premium K is also available as a short version. With a length of merely 4 meters it is a real space miracle and offers at the same time all functions of an ordinary 4-pockets Premium K. With it, both round and long bread rolls are a success, as well as stamped or cut products. Even double-bread rolls belong to the repertoire. This versatile line is ideal for an output up to 4.000 pieces per hour! 4-pockets Bypass (optional) Hourly output approx. 4,000 pieces Double roll device (optional) Compact construction design with a length of only 4 meters Exact final panning Working width 600 mm 17 pulses per minute Intermediate proofing 10 minutes Adjustable long moulding pressing board, can be removed for cleaning Cutting unit with pulling knive Stamping unit with rotatable turret for a greater variety of shapes Computer controlled with SPC and operating panel Automatic UV disinfection and drying of the swing trays before every new filling Panning via discharge belt on proofing trays, e.g. pans or trays 60 x 40 cm, 58 x 78 cm or 58 x 98 cm Oscillating device for shifted deposition Machine on wheels (optional) 7 Automation technology More efficiency for your bakery Many work steps, formerly performed by hand in a laborious and time-consuming manner, can be automatised. Fresh impetus to automation is given by the process technology, which slowly but surely is finding its way into our bakeries. You can optimize the operational procedure in your production even more with transport systems. The empty trays or bins are filled at the deposition station and introduced automatically into the ready transport system. Piled empty bins Like this you can put into effect the continuous automation of the production processes as well as considerable cost savings. Fortuna therefore offers diverse solutions, which can be adjusted individually to the bakery. Info The arrangement of the elements can be adjusted individually to the client’s space conditions. 1 Individual empty bins 2 3 7 4 6 Piled full bins 90° corner conveyor Individual full bins 5 90° corner conveyor 4 Info The maximum capacity of the line amounts to 900 to 1,100 bins per hour, depending on the construction. Dough pieces 8 2 2011 Automation technology That‘s the way it works operator places a pile of empty bins up to a height of 1.30 m on the rear con1. The veyor belt, which offers space for 3 piles. The pile automatically moves into the de-piling machine. From there the bins come out one by one. 2. 3. 4. 5. 6. 7. There is also an option to place folios in the bins with a corresponding device. The bins are transported in a 90°-angle and placed by pairs under the deposition of the Fortuna bread roll line. Info The system is also available in a semi-automatic version. At this the empty bins are brought to the line in an automatic way, whereas the full bins are taken out and piled up manually. There they are positioned in an exact way. Afterwards the filled bins come out automatically from the deposition station, so that again two empty bins can enter the station. The full bins are transported forth in a 90°-angle. In the piling machine the bins are piled up to a height of 2.20 m and brought out from the front conveyor belt. The pile is pulled onto a carriage by the operator and transported away. 9 Modular line concept Combined plant Premium K with Primus This combined bread roll line is made for the rational production of formed and cut bread rolls in best artisan quality. Equipped with a long moulding unit, stamping-cutting unit and seeding unit, it covers all options of bread roll production. Short setup times make product changes especially easy. The mobile seeding unit, with its different seeding containers for ruff and fine seeds, makes possible even more variety. Due to the integrated refeeding of the seeds, the excessive seeds are automatically reconducted into the seeding containers. One of the line’s highlights is the deposition for the connection to an automation system for trays. Therewith the labour-intensive manual operation of the deposition can be omitted and the plant’s capacity can be completely exploited. Additionally the Fortuna constructing engineers have developed a clever system in order to fill the trays of a 6-pockets line as if it was a 4-pockets line. Because of this technical finesse it is possible to use the full product length of cut bread rolls also in a 6-pockets line. Combined stamping-cutting unit Dough pieces are delivered into round or long cups, depending on the product, and cut or stamped | Turret for a quick change of different types of bread rolls 4 6 5 7 Cup cleaning unit Panning unit for the connection to an automation system Self-supporting panning unit for the connection of pan or tray transport system provided by the client | 58 x 78 cm standard tray or 60 x 40 cm tray 7 10 Rotating brushes for cleaning the swing trays 3 2 2011 Long moulding unit Bypass For the creation of products such as long rolls with cut or Houska Transport of round dough pieces from the divider and rounder directly to the panning unit 1 2 2 4 3 1 Seeding unit Seeds recirculation Moistening of the dough pieces via injectors | Pinpoint accurate seeding | The unit can be taken out from the line for cleaning purposes 5 Excessive seeds are reconducted into the corresponding seeding container by means of the seeds recirculation 6 11 Modular line concept Berliner plant with Magnus It goes and goes and goes. With an hourly output of up to 4,700 pieces this plant produces Berliners at a high rate and with an absolutely constant quality and a weight accuracy that is second to none. In order to have a constant dough flow it is fed through a hopper with a capacity of 160 kg. With the integrated addi- tional oiling the extremely soft Berliner doughs can be processed without problems. After the moulding process the dough pieces pass the fully climate-controlled proofer for 100 minutes of which 10 minutes are intended as stiffening zone. Subsequently they arrive via a panning belt at the grease pan. Due to the integrated upper belt long moulder and the side discharge other products can be executed as well with the plant. Additionally it provides smart hygiene solutions like the dust flour suction and the cup cleaning unit. In addition, all transport pans are equipped with the FortunaCARE hygiene cloth. All in all, a time-saving and above all very clean system! 2 1 Divider and rounder Magnus as special version Cup cleaning unit 3-pocket divider and rounder with special moulding drum and moulding belt for Berliner doughs | Pivoting mechanism provides the transfer to 9 pockets 1 12 Rotating brushes clean the swing trays | Integrated dust flour suction with circulating air filter meets highest hygienic requirements 2 2 2011 Stiffening section Transfer unit Automatic passing to the grease pan (9-pockets) Cooling zone of 10 minutes 4 6 3 4 6 5 Picture without isolating cladding Fully climate-controlled proofer Line in operation – enclosure of cooling Equipped with turning and pressing unit as well as automatic UV disinfection | Drying blower for the empty swings The enclosure of the air-conditioned proofing cabinet makes it possible to control, filter and cool the air 3 5 13 Modular line concept Combined plant Profiline K with Magnus With a capacity of up to 9,000 pieces per hour the combined bread roll line makes a big variety of round and long moulded products. The assortment varies from the classical Kaiser-, cut bread roll, Houska, Kärntner- and botton bread roll to the Poznan´ roll, a Polish special- ity rich in tradition. The final proofing unit is designed for a throughput time of 30 minutes. If required, the dough pieces get directly to the panning unit via a direct throughput, without final proofing. And in order the mildew has no chance to extend in the proofing unit, the transporting trays are equipped with the hygienic textile FortunaCARE. This dirt-repelling, antibacterial cloth inhibits the mould formation and thus contributes considerably to the improvement of the hygiene during the production process. 5 2 4 3 Final proofing unit (fully climate-controlled) Combined stamping-cutting unit (following) Dough pieces are delivered in round or long cups, depending on the product, and cut or stamped | Turret for a quick change of different types of bread rolls Throughput time of 30 minutes | Automatic UV disinfection and drying blower for the empty swings | Cups covered with FortunaCARE hygienic textile 5 14 1 1 2 2011 Seeding unit (extendable) Distribution belt Moistening of the dough pieces by means of injectors | Pinpoint accurate seeding | Exchangeable seeding containers Transport of the dough pieces without final proofing to the panning unit 4 3 Program control Touch display for the comfortable plant control and changeover of the products 2 15 Bread line Panus The components Our product line Fortuna Panus for the dividing and rounding of bread doughs consists of various components, which can be oper- ated as a complete system. At the construction we set an especially high value on the exact portioning and a mode of operation gentle with the dough. Like this the sensitive proofing cells of the dough are being preserved as far as possible. Suction divider Panus Dough friendly dividing process with pressing pistons by means of oil hydraulics Production output of up to 3,000 pieces per hour Scaling range 50-2,000 grams Processing of all common doughs with high weight accuracy Short changeover and cleaning time Cone round moulding unit Panus Length of the moulding channel approx. 3,600 mm Equal and exact oil distribution Moulding drains do not have to be adjusted even with different dough weights Belt rounder Panus Rounding length 3,000 mm Production output of up to 2,500 pieces per hour Scaling range 300-2,000 grams Especially apt for rye-, wheat- and mixed doughs Long moulding unit Panus 3 rollers gently shape the dough Moulding board can be adjusted to different doughs or dough shapes Moulding path up to 2,000 mm Easy cleaning 16 2 2011 Bread line Panus The configuration There are two configurations to chose from, both being widespread among our clients. At configuration 1 the proofing unit makes it easier to continue processing the doughs, thus it is mainly used for wheat doughs. However configuration 2 is perfectly apt for the processing of rye- and brown bread. Configuration 1 incl. proofing unit (especially for wheat doughs) Suction divider Cone round moulding unit Proofing unit Long moulding unit Configuration 2 (especially for rye- and brown bread) Suction divider Belt rounder Long moulding unit 17 Ecological Bakery Mauerer Ecological bread of the finest The ecological bakery and confectionery Mauerer GmbH Öko-Bäckerei Konditorei from Munich has completely committed itself to the fabrication of delicious organic bakery products. With the new bread line Fortuna Panus the bakery produces a huge assortment from toast to rye bread and crust bread. In the traditional eco-bakery it is of course out of bounds to use artificial additives for the improvement of the dough quality. For this reason processing the organic Mauerer doughs is a real challenge. Partly the bread doughs are very difficult to handle and require extreme gentle handling. Not surprisingly, so far they have been weighed manually because of quality reasons and haven’t been passed through an automatic line. But there was a change when Fortuna launched a new product line for the dividing and rounding of bread doughs. Flexible and gentle with the dough With the new Fortuna Panus the organic bakery Mauerer has made seven different kinds of bread every day since March 2011 – and with a total dough charge of only 800 kilograms. The 18 assortment comprises whole grain-rye bread, sunflower seed- and crust bread, as well as „Gassenhauer“-, farmhouse- and spelt bread or toast- and white tin loaf. „Due to the short setup time the product changes have become really easy“, compliments Daniel Hagl, the general director. „This flexibility has enthused us from the very beginning. It allows us to process many small charges through the line and, despite the fact of automatic dough processing, keep the vast product variety, which our clients appreciate so much.” A further plus factor of the line, according to Hagl, is the extremely gentle dough handling during the mode of operation, making it possible to preserve the sensitive dough structure. Consequently, the products still taste like handmade. Also the relation between price and achievement is more than attractive. Thus the general director’s résumé turns out to be throughout positive: „In the meantime the line has passed its baptism of fire and is a real benefit for our bakery. With it we can bring out the best of every single grain and will also in the future be able to pamper our clients with our demanding eco-bread assortment.” Eco? Logical! Founded in 1936, the eco-bakery Mauerer is an authentically traditional business, meanwhile carried by the third generation. Already back in 1993, long before the organic-boom, the first ecological bakery products were introduced into the assortment. Five years later the complete adjustment of the assortment to ecological ingredients and process of manufacture took place. The bakery’s good fame is known far beyond Munich’s boundaries, thus also clients from Nuremberg, Tegernsee or Starnberg can enjoy the fine organic bakery products. 2 2011 Bakery Eymann Good for generations Semi Askar‘s bakery presents itself in a modern and traditional way at the same time. At the bakery Eymann the products are made manually and according to traditional, original recipes, so that they taste to the clients as much as it has been the case for generations already. However the machines used in the bakery meet the latest hygienic prescriptions and guarantee the outstanding quality of the bakery products. The delicacy of the Eymann bakery, the „Pretzel“, which is still made on hot plates of stone, and also the Star bread roll are outermost popular among the clients. For that reason Semi Askar decided end of 2010 to buy a new bread roll line for stamped bread rolls and with a side discharge for the feeding of the wrap machine. „It was an important criterion for me that the quality of our pretzels would not be changed by the automatic handling of the dough”, explains the master baker. „Because the pretzel is the showpiece of our bakery.“ The customer Convincing presentation After a baking test in the Fortuna-show bakery Semi Askar quickly new which automatic line to choose. „The concept of the combined bread roll line Fortuna Premium K perfectly matches our company and the quality is absolutely convincing“, explains Askar. He was especially fascinated by the vast product variety that can be made with the line. „With the new line we can produce much more than originally planned and we can introduce new products in our assortment“, the master baker happily utters. He was also convinced by the line‘s compact construction technique, with a total length of only four meters, the divider and rounder included. „The line offers really a big output on a small surface. It is versatile and flexible, extremely gentle with the dough and very easy to clean due to the removable casing. For me a real all-rounder!“ In 1988 Semi Askar, the owner of the company, started his apprenticeship in the bakery Eymann in Aalen, rich in tradition. Ten years later, after having graduated successfully from the master school, he inherited the bakery and has been carrying it until today according to well-proven family tradition. Since 2001 Eymann-clients can also enjoy the bakery’s delicacies fresh from the oven, directly onsite, in the coffee shop of the bakery. It is the ideal place for the little break in between and a popular meeting point for young and old. Special features of the equipment: Intermediate proofing unit with climate control Side discharge for pretzels or winded products at the end of the proofing time Stamping-cutting unit for star bread rolls, cutted bread rolls and crosswise-pressed bread rolls Automatic UV disinfection and drying of the swing trays before every new filling Machine on wheels 19 Bakery Bertschi „Zum Brotkorb“ Baking bread rolls at Bertschi The Swiss bakery Bertschi supplies about 1,000 products to more than 450 clients in the region around Zurich and in Switzerland. Bertschi worked mainly by hand in the past, but has now changed over to a bread roll plant for part of the production. Four months ago, the bakery decided to acquire a bread roll plant from the Fortuna Maschinenbau Holding AG Company from Bad Staffelstein, Germany. One of Bertschi’s decisive purchasing criteria was the ability to manufacture a wide range of the highest quality products. The plant also needed to be able to process doughs with a long bowl fermentation time of up to 120 minutes. Fortuna’s technology has enabled Bertschi’s quality standards to be implemented successfully. Fortuna’s 4-row Premium K small baked goods plant, 12.6 m long, manufactures a maximum of 7,200 bread rolls/h in straight-through mode and approx. 4,800 items/h in intermediate proofing unit operation. 26 products are produced in the plant. Initially, the Magnus KI 4 divider-rounder is filled with dough. Due to the soft dough flour duster which it contains, the Magnus can process very soft doughs with long floor times without any problems. Bertschi needs this facility: the company uses long-term floor times for its baked goods, in which almost no dough is proofed for less than 2-3 h. This means that dough pieces with a dough yield of up to 172 with pure wheat dough are run in the Premium K. The customer The plant provides two long moulding systems to roll long dough pieces: the flat belt long roller for endless long moulded products, e.g. plaits, and the over-belt long roller with an additional wrapping function. It is removable, enabling operation with and without the wrapping function. If the driven over-belt is adjusted to run in the same direction, the dough pieces are pressed flat in a round shape instead of being long-rolled. For example, Hamburg bread rolls or small flatbreads are produced. After the intermediate proofing unit, the bread rolls are pressed or embossed in the stamping station while they lie in plastic stamping cups. Changeover, e.g. from emperor’s rolls to button rolls, is via a 180°-rotatable revolver turret. Complete re-tooling of the revolver turret is possible within a couple of minutes, since the carrier plate with the stamping tools mounted on the revolver turret is removable. A customised construction for Bertschi is the blue step belt at the end of the bread plant, which can perform offset transfers. This enables long products to undergo further processing in two rows. (The extensive original version of this article can be found in issue no. 03/2011 of baking+biscuit as well as on www.bakingbiscuit.com.) Husband and wife Emil and Anna Elisabeth BertschiLinder founded the bakery in 1896 in Zurich’s Marktgasse 115 years ago. Three generations of the Bertschi family managed the business before it was taken over in 1986 by Christian and Annemarie Hertig, who at that time, had already been working for Bertschi for eight years. By the late nineteen-nineties the premises no longer met the entrepreneur’s needs, so the entire production operation was relocated to Glattbrugg. This was also linked to the end of its own sales outlet in the Zurich old town – Bertschi has been purely a supply operation since then. Today, however, Christian Hertig says that was only a temporary solution and now at last after ten years in the rented building, an 8,000 m² plot of land has been purchased in Kloten, not far from Zurich airport. Issued in baking+biscuit 03/2011 Fortuna Maschinenbau Holding AG Auwaldstraße 1 · 96231 Bad Staffelstein · Germany Phone: +49 9573 9630-0 · Fax: +49 9573 9630-96 www.fortuna-schroeder.de · [email protected] and are registered trademarks of Fortuna Maschinenbau Holding AG.
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