Baking & Snack - June 2019 - 74

CRACKER TECHNOLOGY

And while automation and controls are critical to
keeping cracker dough on track, operators must remain
attentive when monitoring production.

Balancing the dough sheet
A consistent dough sheet is always critical for consistent crackers at the end of the line. Uniformity starts
at ingredient handling and must be carried throughout
processing. Without dough consistency, processing efficiency and final product quality can be affected. "Any
variations will have a direct impact on how the dough
behaves when it's processed and how much further attention will then be required by the operator to maintain a balanced control of the forming equipment," said
Andy Green, technical development manager, Spooner
Vicars Bakery Systems. "As production speeds increase,
resultant problems materialize sooner and become
more difficult to correct."
Dough consistency starts with ingredients as they are
the building blocks of the dough. Mr. Green also stated
that to ensure the repeatability of each dough batch,
storage and ingredient handling must be optimal and accurate as they are delivered to the mixer. What comes
out of the mixer will have the biggest impact on the
sheeter as the cracker dough sheet speeds through the
gauge rollers.
"One of the biggest pain points in most cracker
production is what you get from the mixing room,"
Mr. Smith said. "If your dough is not consistent coming
out of the mixing room, then you're going to have problems running it through the machine and baking it."

As dough enters the sheeter, it's vital that it is reduced to the proper thickness across the width of the
line. This prevents any product weight variations as
the crackers are formed. At the installation of a cracker line, process rollers should be properly aligned

Operators should be looking
at dough as it comes out of
the mixer to confirm that it
is the right consistency
and flowing correctly.
to prevent weight variation, Mr. Green explained.
"Fundamentally, the accuracy of the equipment installation and the alignment of all process rollers need to
be ensured to rule out this element should product
weight variations occur anywhere during the forming
process," he said.
At high speeds, reduction ratios must be smaller
to prevent too much load from being placed on individual rollers and ensure accuracy of the entire dough
sheet. "We recommend four reduction stations after
the lamination process, including the finish gauge
roll station," Mr. Smith said. "In some cases, we recommend larger diameter rollers. We have found the
larger diameter induces less stress in the dough sheet

Spraying on target
Cracker production doesn't end
at the oven, and spraying toppings on crackers at high speeds
comes with its own challenges.
"Balancing speed with quality
spray is the principle of all spraying whether at low or high production rates," said Norm Searle, sales
and marketing executive, GOE.
"Across the band, accuracy of application, repeatability and reliability are the goals. A sprayer must
deliver on these goals regardless
of line speed."
When crackers are moving quickly
through a sprayer, they don't have
as much time to absorb the oil. GOE

74 Baking & Snack June 2019 / www.bakingandsnack.com

addresses this by providing extended sprayers and drain conveyors
to increase time on the equipment.
"Drain conveyors at the outlet of the
sprayer provide additional time for
the oil to be absorbed," Mr. Searle
explained.
To achieve an accurate and
even coating, Spraying Systems
Co. uses Precision Spray Control
(PSC) to apply a coating directly
onto the cracker and nowhere else.
"PSC applies the proper amount of
coating weight even when the line
speeds change and/or products
change," said Josh DeVoll, director of market solutions, Spraying

Systems Co. "The flow rate of the
nozzles is automatically adjusted
by the system controller ensuring
the proper volume is released."
Another challenge high speeds
present to coatings is the wind
tunnel effect. "This manifests itself
at the inlet and outlet causing a
vacuum effect at the inlet and a
wind current at the outlet,"
Mr. Searle said. "If not addressed,
this will cause inaccuracy of the
applied oil and dangerous oil mist
migration outside of the sprayer."
GOE's RIDeMIster eliminates
these issues and if offered on all of
the company's spraying systems.


http://www.bakingandsnack.com

Baking & Snack - June 2019

Table of Contents for the Digital Edition of Baking & Snack - June 2019

Baking & Snack - June 2019
Contents
Contents
Editorial - A rising tide floats all boats
Newsfront - Oreo connects with young consumers
Flowers CEO discusses the future and Project Centennial
News - Bühler opens CUBIC innovation campus
Nestle USA to exit pizza DSD network
PepsiCo UK launches taste guarantee promotion
Mondelez, Bimbo keeping an eye on CBD
Hostess moving main distribution center to Kansas
In Brief/People
Food Safety Series - PROTECT AGAINST PATHOGENS
Doughnut Peddler - GO EAST, YOUNG MAN
Custom metalwork for signature donuts
Smith family values still guide the company
International Series: Latin America - BRIDGING THE CULTURAL CROSSROAD
Warning labels fuel broader array of health initiatives
Enzymes - A RECURRING REACTION
Inclusions - ENGAGING THE SENSES
TECHNICALLY SPEAKING - ON THE WIND
Cracker Technology - BALANCED CONTROL
Spraying on target
Mixing - ZEN AND THE ART OF MIXING
Icing and Glazing - SMOOTH AS SILK
Line Isolation - HOLD THE LINE
Weighing and Scaling - CONSISTENT ACCURACY
SANITATION STRATEGIES - SOLVE FOR X
Meeting Preview: IBIE - PERFECTING ARTISAN
IBIE Artisan Education
Meeting Preview: Pack Expo - PINNACLE OF PACKAGING
Events
Featured Innovation Center
Ingredients & Formulating
Equipment & Packaging
Patents
New on the Shelf
MARKETPLACE
AD INDEX
NEW PRODUCT SPOTLIGHT
Baking & Snack - June 2019 - Baking & Snack - June 2019
Baking & Snack - June 2019 - Baking & Snack - June 2019
Baking & Snack - June 2019 - 2
Baking & Snack - June 2019 - 3
Baking & Snack - June 2019 - 4
Baking & Snack - June 2019 - 5
Baking & Snack - June 2019 - 6
Baking & Snack - June 2019 - 7
Baking & Snack - June 2019 - 8
Baking & Snack - June 2019 - Contents
Baking & Snack - June 2019 - 10
Baking & Snack - June 2019 - Contents
Baking & Snack - June 2019 - Editorial - A rising tide floats all boats
Baking & Snack - June 2019 - 13
Baking & Snack - June 2019 - 14
Baking & Snack - June 2019 - 15
Baking & Snack - June 2019 - Flowers CEO discusses the future and Project Centennial
Baking & Snack - June 2019 - 17
Baking & Snack - June 2019 - Mondelez, Bimbo keeping an eye on CBD
Baking & Snack - June 2019 - In Brief/People
Baking & Snack - June 2019 - Food Safety Series - PROTECT AGAINST PATHOGENS
Baking & Snack - June 2019 - 21
Baking & Snack - June 2019 - 22
Baking & Snack - June 2019 - 23
Baking & Snack - June 2019 - 24
Baking & Snack - June 2019 - 25
Baking & Snack - June 2019 - 26
Baking & Snack - June 2019 - 27
Baking & Snack - June 2019 - 28
Baking & Snack - June 2019 - 29
Baking & Snack - June 2019 - Doughnut Peddler - GO EAST, YOUNG MAN
Baking & Snack - June 2019 - 31
Baking & Snack - June 2019 - 32
Baking & Snack - June 2019 - 33
Baking & Snack - June 2019 - 34
Baking & Snack - June 2019 - 35
Baking & Snack - June 2019 - Custom metalwork for signature donuts
Baking & Snack - June 2019 - 37
Baking & Snack - June 2019 - 38
Baking & Snack - June 2019 - Smith family values still guide the company
Baking & Snack - June 2019 - 40
Baking & Snack - June 2019 - 41
Baking & Snack - June 2019 - 42
Baking & Snack - June 2019 - International Series: Latin America - BRIDGING THE CULTURAL CROSSROAD
Baking & Snack - June 2019 - 44
Baking & Snack - June 2019 - 45
Baking & Snack - June 2019 - 46
Baking & Snack - June 2019 - Warning labels fuel broader array of health initiatives
Baking & Snack - June 2019 - 48
Baking & Snack - June 2019 - 49
Baking & Snack - June 2019 - 50
Baking & Snack - June 2019 - Enzymes - A RECURRING REACTION
Baking & Snack - June 2019 - 52
Baking & Snack - June 2019 - 53
Baking & Snack - June 2019 - 54
Baking & Snack - June 2019 - 55
Baking & Snack - June 2019 - 56
Baking & Snack - June 2019 - 57
Baking & Snack - June 2019 - 58
Baking & Snack - June 2019 - 59
Baking & Snack - June 2019 - 60
Baking & Snack - June 2019 - Inclusions - ENGAGING THE SENSES
Baking & Snack - June 2019 - 62
Baking & Snack - June 2019 - 63
Baking & Snack - June 2019 - 64
Baking & Snack - June 2019 - 65
Baking & Snack - June 2019 - 66
Baking & Snack - June 2019 - 67
Baking & Snack - June 2019 - 68
Baking & Snack - June 2019 - 69
Baking & Snack - June 2019 - 70
Baking & Snack - June 2019 - TECHNICALLY SPEAKING - ON THE WIND
Baking & Snack - June 2019 - 72
Baking & Snack - June 2019 - Cracker Technology - BALANCED CONTROL
Baking & Snack - June 2019 - Spraying on target
Baking & Snack - June 2019 - 75
Baking & Snack - June 2019 - 76
Baking & Snack - June 2019 - 77
Baking & Snack - June 2019 - 78
Baking & Snack - June 2019 - 79
Baking & Snack - June 2019 - 80
Baking & Snack - June 2019 - 81
Baking & Snack - June 2019 - 82
Baking & Snack - June 2019 - Mixing - ZEN AND THE ART OF MIXING
Baking & Snack - June 2019 - 84
Baking & Snack - June 2019 - 85
Baking & Snack - June 2019 - 86
Baking & Snack - June 2019 - 87
Baking & Snack - June 2019 - 88
Baking & Snack - June 2019 - 89
Baking & Snack - June 2019 - 90
Baking & Snack - June 2019 - 91
Baking & Snack - June 2019 - 92
Baking & Snack - June 2019 - 93
Baking & Snack - June 2019 - 94
Baking & Snack - June 2019 - Icing and Glazing - SMOOTH AS SILK
Baking & Snack - June 2019 - 96
Baking & Snack - June 2019 - 97
Baking & Snack - June 2019 - 98
Baking & Snack - June 2019 - 99
Baking & Snack - June 2019 - 100
Baking & Snack - June 2019 - 101
Baking & Snack - June 2019 - 102
Baking & Snack - June 2019 - 103
Baking & Snack - June 2019 - 104
Baking & Snack - June 2019 - Line Isolation - HOLD THE LINE
Baking & Snack - June 2019 - 106
Baking & Snack - June 2019 - 107
Baking & Snack - June 2019 - 108
Baking & Snack - June 2019 - 109
Baking & Snack - June 2019 - 110
Baking & Snack - June 2019 - 111
Baking & Snack - June 2019 - 112
Baking & Snack - June 2019 - Weighing and Scaling - CONSISTENT ACCURACY
Baking & Snack - June 2019 - 114
Baking & Snack - June 2019 - 115
Baking & Snack - June 2019 - 116
Baking & Snack - June 2019 - 117
Baking & Snack - June 2019 - 118
Baking & Snack - June 2019 - SANITATION STRATEGIES - SOLVE FOR X
Baking & Snack - June 2019 - Meeting Preview: IBIE - PERFECTING ARTISAN
Baking & Snack - June 2019 - 121
Baking & Snack - June 2019 - IBIE Artisan Education
Baking & Snack - June 2019 - 123
Baking & Snack - June 2019 - 124
Baking & Snack - June 2019 - Meeting Preview: Pack Expo - PINNACLE OF PACKAGING
Baking & Snack - June 2019 - Events
Baking & Snack - June 2019 - 127
Baking & Snack - June 2019 - 128
Baking & Snack - June 2019 - 129
Baking & Snack - June 2019 - Featured Innovation Center
Baking & Snack - June 2019 - 131
Baking & Snack - June 2019 - Ingredients & Formulating
Baking & Snack - June 2019 - 133
Baking & Snack - June 2019 - 134
Baking & Snack - June 2019 - 135
Baking & Snack - June 2019 - Equipment & Packaging
Baking & Snack - June 2019 - 137
Baking & Snack - June 2019 - 138
Baking & Snack - June 2019 - 139
Baking & Snack - June 2019 - Patents
Baking & Snack - June 2019 - 141
Baking & Snack - June 2019 - New on the Shelf
Baking & Snack - June 2019 - MARKETPLACE
Baking & Snack - June 2019 - 144
Baking & Snack - June 2019 - 145
Baking & Snack - June 2019 - 146
Baking & Snack - June 2019 - 147
Baking & Snack - June 2019 - 148
Baking & Snack - June 2019 - 149
Baking & Snack - June 2019 - 150
Baking & Snack - June 2019 - 151
Baking & Snack - June 2019 - 152
Baking & Snack - June 2019 - AD INDEX
Baking & Snack - June 2019 - NEW PRODUCT SPOTLIGHT
Baking & Snack - June 2019 - 155
Baking & Snack - June 2019 - 156
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