An extra dimension

Minimizing separating agents is an ability of DÜBÖR’s latest development in the machinery area, the Precision Spray Unit or PSU.

+It involves spray volumes in the order of magnitude from 1/1,000th of a ml per cavity, and it also involves precision, because that’s decisive to ensure the product releases cleanly from the mold nevertheless. One important advantage: less separating agent means lower cleaning costs.

The amounts sprayed by a PSU are rather small, considering that as a rule around four grams of oil is needed on a bread pan to ensure effective separation. Precision spraying is suitable for almost all mold variants. Project manager Bernhard Rieping says: “Oval, round, areas, objects, irregular shapes like a heart shape, a bar with indentations or shapes that have a certain uniformity but no fixed geometry, we can now do all of those.” He says individually customized molds can be met with in the market much more often in recent years.

Project examples

+ Spraying with glazing agent: Bread dough pieces in six-pan clusters are sprayed with glazing agent in a feed-through process. The requirement was to spray the dough pieces exactly, but not the metal mold. The plant detects the start of the dough piece, begins the spray process and stops it at the end of the dough piece.

+ Manufacturing waffles/poffertjes: Baking trays leave the oven and are moved into position, and the spray unit applies spray agent using one horizontal and one vertical arm. Each arm carries nine spray valves, corresponding to the number of cavities. The challenge in this application was to with only a few clearly laid-out hose connections are cycle quickly, because the horizontal baking tray is filled with batter immediately after being moved into position. Moreover, for efficiency reasons, the whole area should not be sprayed. According to Rieping: “The high speed of the baking trays made it necessary to achieve a spray performance of three cycles per second. We exceeded the requirement. The PSU that was installed achieves a performance of up to four cycles per second. We were the first to go into series production with a plant in this performance range.” The application involved manufacturing poffertjes. (Poffertjes are a Benelux countries specialty.)

Size, area, shape of the mold being sprayed any

Cavity size from 6 mm diameter

Arrangement of cavities any

Product shape any

Product change from 1 second

Spray volume/cavity from 1/1,000th of a ml

Viscosity 0.5 to 2,500 mPas

Suitable for release agent, glazing agent, water, food color etc. etc.

Cycle time from 0.25 seconds

+ Fine bakery wares: In this case, the requirement was to wet continuously moving cavities without spraying the whole mold. Rieping explains: “We solved the requirement by actuating several spray valves sequentially. The plant runs continuously. It detects the start and end of the cavities.

+ Praline manufacture: Before they are coated with chocolate, the surface of pralines is sticky. The plant sprays release agent into the cavities, they are filled with the mix, and after a short cooling process they are demolded and coated with chocolate.

Spray valves

A PSU can be equipped with various spray valves, some developed by the company itself. The aim is to be able to fulfil all of the customer’s spray pattern requirements. For example, a spray cone can be compressed by switching on the cone air, which converts a circular spray pattern into an elongated one.

Bernhard Rieping: “What makes all the difference with the PSU is fast spray valve actuation, precision of the amount of spray, and spray pattern uniformity. We work with a setting accuracy of 1/10 bar for the control air and release agent pressure, and as far as spray air is concerned, we work in the region of 1/100 bar. The ability to regulate the control time in the order of magnitude of 1/1000th second is important. We require this accuracy to spray into the mold the exact amount of non-stick agent needed to release the product cleanly from the mold, but leaving only a minimum amount of release agent in the mold.” +++

++ IBIE announces 2019 BEST in Baking – Industry Awards

The International Baking Industry Exposition (IBIE) has opened the application process for the 2019 BEST in Baking awards program. In partnership with Snack Food & Wholesale Bakery, the newly enhanced BEST in Baking Program has been expanded to recognize IBIE suppliers and bakers that have made particularly notable achievements that foster better plant efficiency, improved bakery formulas and product innovation, streamlined operations, workforce development programs and otherwise drive continued growth of the baking industry.

“The BEST in Baking industry awards program provides our baking community the opportunity to celebrate and showcase leaders in the industry, working to bring category excellence

1th International Richemont Sourdough Congress

The 1st International Richemont Sourdough Congress will take place in Lucerne on 9th May. Richemont Technical College and the International Richemont Club have engaged experts from the areas of research, applications and nutritional science to come to Switzerland as speakers. The aim is to bring the science and experience about the sourdough process and its effect up to the latest state of the art. At the same time, the Congress is designed to be a platform for exchanges and networking beyond the day itself. The program is rounded off by a presentation and tasting of breads and baked products from various countries. Those invited to take part include specialists from bakeries, mills, other food-processing businesses and the agricultural industry, as well as medical experts and advisers focusing on nutrition, together with specialist subject teachers, food bloggers and journalists.

and thought leadership to important industry defining topics,” said Joe Turano, IBIE Chair. “This program honors suppliers and bakers committed to excellence from sustainability and supply chain innovation to workforce development.”

The BEST in Baking Award categories have expanded beyond Sustainability with several new categories, including Workforce Development, Sanitation, and Product Innovation. The winners will be featured in show materials and in the BEST in Baking Lounge during IBIE 2019, September 8-11 in Las Vegas, Nevada.

Nominations are due by April 30, 2019. Complete category information, qualifications and entry details are available online. Please visit: www.ibie2019.com/exhibit/best

The IBIE will be held in Las Vegas, Nevada/USA on September 7-11, 2019. +++