Baking & Snack - August 2020 - 70

BUN & ROLL TECH

A turnkey production line
promotes continuous
production because
every machine is well
integrated into the line.
AMF Bakery Systems

the entire line with any deviation from steady state."
AMF designs turnkey solutions from its variety of
systems to avoid stoppages and ensure that lines keep
moving as efficiently as possible. For example, bakers
can choose continuous mix systems or high-speed horizontal mixing systems that can be integrated with dough
delivery pumps, chunkers and conveyors. The company
can design production all the way through packaging.
Another benefit of a continuous process is consistency. When product follows the same path, it has the best
chance of achieving the best quality while still running
at high speeds.
"When products follow the same path rather than
parallel routes, it has a positive impact on the consistency," Mr. Nordell said.
This exposes each product to the exact same time,
temperature and humidity, he explained. And because
production keeps moving, external forces like pan stoppages aren't exerted onto the product, causing it to lose
some of the structure, and efficiency can be maintained.
"In the continuous process, pans and products are in
constant motion with limited acceleration, deceleration,
stopping, interruption or waiting," Mr. Nordell said.
For example, continuous proofers and ovens don't
require grouping at the infeed so transfers into the
machine are smooth. This reduces risk of the proofed
products collapsing. Mr. Nordell did caution that bakers need to consider pan sizes and rates as capacity increases. Pan rate should not exceed 35 per minute, he

70 Baking & Snack August 2020 / www.bakingbusiness.com

suggested. Otherwise, bakers could experience problems
in pan handling and shaking as well as seeding and splitting operations.
Programmable lines also keep production consistent
and in motion. When WP Bakery Group installs a new
line, optimal settings for the products are programmed
into the equipment, enabling the operators to create the
same quality product across shifts day after day.
"The main challenge for throughput is ensuring that
the system runs continuously without any hang ups,"
Mr. Weekes said. "We take great care to ensure that everything on the line is controlled from positioning to the
amount of pressure placed onto the products. This all
ensures that high-speed lines are run efficiently."
Downtime and changeovers are the biggest challenges to continuous production and impossible to eliminate altogether. Bakers can take steps either through
equipment choices or operational strategies to minimize interruptions.
"High-speed lines are designed to run continuously,
in some cases for days or weeks at a time," said Bruce
Campbell, vice president, dough processing technologies, AMF. "Therefore, any time a high-speed line is
stopped, there is some loss in efficiency, and product quality may be inconsistent on start-up with a
new product."
He recommended smaller batch sizes and equipment
designs that can improve efficiency. AMF dividers minimize dough waste at the changeover, and the Accupan


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Baking & Snack - August 2020

Table of Contents for the Digital Edition of Baking & Snack - August 2020

Baking & Snack - August 2020 - 1
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