HIGH SPEED BUN MAKE-UP LINE

Lower Your Cost of Ownership

•Hygienic Wash-down Design

•Lower Formula Cost (Scaling Weight & Dough Conditioners)

•Toolless Design Reduces Time for Clean Up & Changeover

•Up to 150 Cuts per Minute

•Lower Maintenance Cost

•Servo Driven

Burford’s seeders, toppers, sifters and pan shakers are a perfect match for our Bun Divider

Around 1.4 million dough pieces already leave the production facility every day, for which the employees process around 28 tons of butter and approx. 60 to 70 tons of flour on a total of 13 lines. This involves producing sweet and savory dough pieces, of which slightly over 30% are exported. Bakeries are the main customers in Germany, but in the neighboring countries, in Russia or in Japan they also like to rely on dough pieces from Fürth. All the channels such as hotels, filling stations and the food retail are served here.

Production

Wolf ButterBack has always been committed to using highquality ingredients, e.g. pure diary butter and a long dough resting time of up to eight hours, to produce high-grade frozen dough pieces with the required quality. All the products from the foundation era are still in the program today, and Wolf ButterBack currently has more than 150 unfilled, sweet and savory dough pieces as well as donuts in its standard product range. According to marketing expert Tanja Böttcher: “Altogether, however, we have around 650 products in the sales range.” Explaining the assortment, authorized company signatory Ernst Stengel says “In addition to our own products in a wide variety of weight ranges and different variants, we also manufacture dough pieces using customers’ own recipes.” Standard procedure for all laminated doughs – regardless of whether they are produced in Factory 1, 2 or 3 – is that the doughs are cut after laminating. After that, the staff put the pieces onto a tray and into a numbered rack trolley. This rack then goes into the cooler, where the dough can rest. Stengel says “This ensures more aroma and flavor, and thus premium quality.” It also guarantees product traceability.

Basically, all the factories are autonomous. They each have their own flour and sugar silos, and can be operated independently of one another. Of the three, Factory 1 with six production lines specializes in smaller batch volumes and on high-end products involving a large skilled labor input.

Staff manufacture high sales volume products on the four production lines in Factory 2, e.g. unfilled or sweet filled croissants. The medium-term plan is for Factory 2 to make exclusively unfilled products. It is also the location of the plant manufacturing butter donuts.

Factory 3 makes high sales volume products with sweet or savory fillings and currently has two production lines, although the first construction phase has the capacity to install up to six production lines. According to Stengel: “The start of construction phase two is scheduled for 2025 onwards.”

For the production plants in the newly-built factory, Wolf ButterBack also focuses on state-of-the-art technology, including in relation to servicing and maintenance. This is why the company cooperates closely with plant constructors, e.g. by using prototypes such as automatic final position detection for croissant dough pieces.

Executive Board Member Ernst Stengel says the factories’ capacity utilization is good, although still with room for further growth. What the experts are more concerned about, however, is fluctuating raw materials prices, especially for butter, but the company’s position is altogether satisfactory and it is fit for the future. +++