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Dual bakery line automates production

By staff reporter , 11-May-2006

A twin lane indexing line fills and decorates a wide range of bakery items, such as desserts, celebration cakes, patisserie products, and puddings.

UK-based Turbo Systems claims the system is ideal for bakery and food manufacturers looking to automate production and reduce labour costs.

Manufacturers turn to automation as a means of speeding up lines, making production more efficient and reducing labour requirements.

The system was originally built for a dessert patisserie suppliers in the UK. Turbo Systems said yesterday it can redesign the processing line to meet individual size and capability requirements.

"It has already increased production for one customer by 100 per cent and has seen the company save seven operators per shift," the company stated in a press release.

The system cuts and slits products then injects sweet fillings, such as chocolate sauce or cream. It comes equipped with special nozzles and decorating


heads, which deposits toppings, such as fondant or sprinkles, and creates bespoke pattern effects with jam, for example.

"In fact any depositing, filling or decorating requirement of cakes can be achieved on the line," Turbo Systems stated.

The system also has a manual loading station where operators can place cakes into clear, plastic trays, ready for wrapping. It works in-line with


most lid closing machines and wrap labelling applicators, the company stated.

The dessert patisserie customer who originally ordered the system uses one side of the line to produce fresh cream chocolate éclairs and the other for making fresh cream and jam finger doughnuts.

The line took approximately four weeks to install, and is now operating at 20 cycles or 40 packs per minute, Turbo Systems claimed.

On the éclair side the line consists of a twin acetate-dispensing unit for two and four pack products. It has a manual loading station for inserting éclairs into acetate trays, a twin D102 Turbo Depositor with cream injection heads on rise and fall nozzles, and a twin M102 Turbo Depositor with a hot water circulation system and spreading nozzles that deposit fondant toppings at 40° C.

The other side of the line has a manual loading station for placing finger doughnuts into indexing track pallets. It uses an automatic, four-across circular cutting machine for slitting doughnuts, and a plough and guide rail system for opening the slits in doughnuts for the insertion of fresh cream.

A twin D102 depositor and special decorating heads to give roped cream pattern effect. A twin M102 depositor and piping nozzle puts a jam stripe decoration on top of the doughnuts.

Clive Butcher, Turbo Systems' UK sales manager, said the dessert patisserie customer has reduced manual labour costs and improved product quality at the same time.

"And we can adapt the system to provide bespoke solutions and allow all bakery and patisserie manufacturers to benefit from this type of automation." he stated.

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