5 minute read
Slicing and bagging: Consistency in cutting & packaging flexibility
Making the cut
The next best thing since sliced bread might just be the technology behind consistency for all types of bread and versatile bagging options for ever-changing requirements.
+The design and setup of a combined solution covering bread slicing and packaging are dictated by the characteristics of the product and their best fit in bagging choices. Bettendorf Stanford Inc. (BSI) examines the product texture, makeup, consistency, temperature at the time of slicing, and the bakery operation itself to determine the best slicer and bagger combination. When slicing loaf bread, BSI offers the choice between band slicers and reciprocating slicers, each coming with several types of infeeds based on the product, from those fed via an elevator and flight, top- and bottom-belted systems, as well as side-belted systems. Each infeed works best with its designated type of product, in combination with a band slicer or a reciprocating slicer; products can range from sweet breads, fruit breads, hardcrusted, dense rye breads, sourdough, artisan-style loaves, to pan breads, soft white/wheat breads, and even gluten-free breads. The main factor in selecting the type of blade and slicing technology for loaf breads is how sticky the loaf is: if it has a high sugar content like cinnamon raisin or is difficult to slice (like gluten-free bread), then a reciprocating slicer is the best way to go, BSI recommends. Band slicers are the best choice for standard types of bread such as white or wheat bread.
Stepping up to the challenge
When slicing and packaging breads in high volumes, BSI observes two key challenges that arise with a manufacturer who upgrades from a semi-automatic to a fully automatic line: bag sizing and product consistency. As most production facilities start out with hand-fed slicing and manual bagging, there is a wide variation in product size and consistency. This manual operation allows for bakeries to put very different product sizes into the same size bags, Atkins explains, which saves money when purchasing one-size-fits-all bags in bulk. “The problem with going from this human touch operation to a fully automatic line is that a machine only does what it is set up/programmed to do, within its normal operating range. This means that customers will need to watch that their product does not vary more than the machine's tolerances allow. They also will need to make sure to size bags according to each different product and the count size they want to run,” Justin Atkins, director of sales at BSI, illustrates. To connect a bread slicer to automatic baggers, a flighted conveyor is typically used. This conveyor can be a one piece intermediate conveyor that acts as the slicers discharge and the baggers infeed to keep the foot print short, or you can have a flighted slicer discharge timed 1:1 to the bagger’s flighted infeed. Either option has the ability to automatically remove double loafs from a flight.
Challenges to meet in these processes also come from “Ensuring the stable operation of the line, including cutting high-quality bread slices, automatically placing the cut product in the bag, and securely closing the bag. Also, if slices of bread aren’t precisely of equal size, the product packaging is damaged or improperly closed, then the consumer’s perception will be negative,” Jūratė Žukauskaitė, area sales manager at Dovaina also shares.
Fresh off the R&D drawing board
Lithuanian specialist Dovaina has announced its latest innovation in
© BSI
automated slicing and packaging, at iba.CONNECTING EXPERTS, the virtual event held mid-March: the DPPL-55 MUI fully automatic line. It features double bag closing (sealing and clipping), an integrated metal detector and it can run different types of products. “All of these process steps are important to product safety and the customer’s first impression,” Žukauskaitė told us.
The DPPL line is designed for various types of bread slicing and packaging: it can support different shapes, sizes, slice thickness variations, and packaging in halves. Several bagging & closing options are available: hot sealing, clip band, twist band, or tape. The main benefit in such a specialized line is in productivity, the company highlights: the DPPL line’s productivity is 3,000-3,600 fully sliced and packed products per hour, meaning 50-60 pieces per minute. To do this, it only requires one passive operator for line control.
Bread loaves are fed into the slicer in two ways: manually or from spiral coolers. Upgrades the DPPL-55 MUI brings over its predecessors include the double closing of bags, hot sealing and clip band/twist band, and the integrated metal detector for quality inspection. With this line, operators can check all products with the metal detector and use clip bands (with metal wire) for bag closing. “To have full productivity of an automatic line, there are a few important aspects to consider: equal product sizes and up to five different sizes within the same group of products. For DPPL lines, the differences between nthe same group of products can be up to 15-20mm,” the specialist from Dovaina explains.
Automation goals
For automated operations on a slicing and bagging line, recipe settings can be saved to help operators change from one product to the next. For bread, the slice thickness and loaf width are among the presets. Atkins explains: “The loaf width changes the timing to match the loaf size and the automatic lattice adjuster will open or close the blades to the preset slice thickness in the saved recipe.”
For a consistent workflow, BSI uses accumulation conveyors with photo eyes for bread lines, to ‘tell’ the conveyor whether or not to change speed to maintain a steady flow of product. BSI loaf bread systems can run up to 70 loaves per minute on Hybrid 65 baggers and BSI-75 slicers for standard breads. BSI-55 baggers are suited for up to 55 loaves per minute of continuous running speeds. Atkins goes on to explain, “Gluten-free and those sticky, hard to slice breads end up running anywhere between 30 and 50 loaves per minute on our model RSC reciprocating slicer.” To improve efficiency, it should be noted that different products slice better at specific temperature ranges and work best with certain types of blades.
With various possible combinations of slicers, wrapping machines, and feeding systems, the right solution is a matter of matching and mixing, depending on the desired result in terms of product characteristics and shelf-life. +++
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