Combining work steps

König developed a multifunctional dough sheet punching station with row number flexibility that combines several work steps in a single module.

+König, the Austrian plant constructor, presented the new dough sheet punching station for the first time at the 2018 iba trade fair. It comprises a high-capacity, multifunctional module with row number flexibility for decorative punching, cutting out, stamping and molding – all in a single step. When producing donuts, for example, gauging, pressing flat and punching out take place with controlled pressure in a single step. This procedure guarantees even and absolutely symmetric shaping as well as maximized process safety. The punching station is also usable for products such as pizza, bagels and cookies. The various tools are upgradable at any time. The number of rows can also be freely chosen, and the user can set the number of rows depending on the product. The punching station offers high performance of up to 80 strokes/ minute at the same time, due to the punching station’s synchronous movement. This corresponds to an output capacity of 57,600 pieces/hour in 12-row operating mode. König’s Managing Director Wolfgang Staufer explains: “Our aim with this dough sheet punching station was to set a new benchmark for versatile, gentle dough piece shaping. Positive customer feedback has confirmed to us that we have achieved this objective.”

Minimal set-up times

With this solution, König offers a wide variety of possible applications from punching to stamping and cutting out in a single module. Staufer adds that tool-free punch tool changing allows this with minimized set-up times. Thus the new dough sheet punching station combines several work steps in a single operation: a special multistage design of the punch toolheads tool holders shapes dough pieces on the conveyor belt in a single step.

The way it functions can be explained by taking pizza snacks as an example: a centering ring encircles the round dough piece pressed flat on the conveyor belt, and the dough is gently and sequentially shaped outwards from the middle by extendable molding tools. Cold-pressing the dough pieces handles the structure of the dough and pores gently and avoids shear stresses. The dough sheet punching station is also usable both for dough pieces from a dough sheet or from dough dividers, and is compatible with König’s industrial construction kit.

Donut plant

As König said, the new dough sheet punching station was used for the first time on an industrial donut line for 20,000 pieces/ hour in a large Russian bakery. The plant, which is 108 meters long, produces donuts of various sizes in ten rows. The new punching process is said to have improved dough piece quality when manufacturing donuts, since it avoids damaging the dough’s skin, which improves would worsen the baked product’s quality and flavor by avoiding due to oil or fat penetration during the subsequent deep-frying step. The punching station’s synchronized movement also allows a larger number of dough pieces to be processed than in the past.

Individual punch tool heads kits can also be easily interchanged for different donut sizes, and can be removed for cleaning without using additional tools. Regarding this order, Wolfgang Staufer says: “Our customer decided to choose us based on the technology and individually customized plant design we use – we are very proud of the confidence shown in us, and of this innovative plant.” +++