PRODUCTION
Making the cut A bread’s crust is its first impression and illustrates the baker’s signature skill. Automated scoring systems can dependably reproduce the craftsmanship of a cut made by an experienced hand. Vision systems and robotics are its eyes and steady hands behind any desired patterns carved into the dough.
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Automated scoring systems consistently execute cuts, using conventional cutting, ultrasonic cutting, or waterjet technology. Conventional blades are a simple and cost-effective scoring tool; they follow the shape of a product to score it with cuts made at a consistent depth. Robots can even use multiple blades of this type, as they are lightweight, which will increase production capacity – although with some loss in quality. They may tear the dough, instead of cutting it, making rough edges that, after baking, can tear the packaging. These blades need to be replaced quite often, and the disassembly and cleaning process is complex. The angle of the blade and the single cutting edge limits the possible scoring patterns. Ultrasonic blades use high-frequency vibrations to slice the dough. Dough tearing is limited with this technology, which also prevents the dough from sticking to the blade. With some limitations, the ultrasonic drag blade offers the most versatility in the range of motion, making it suitable for a large variety of products. With waterjet cutting performed by robots, the most
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complex shapes and designs can be made on doughs of any density, texture and size. This scoring technology excels in efficiency, hygiene and speed. Each blade has advantages and disadvantages and, depending on the bakeries’ needs, one may be more suitable than another. The Katana robotic scoring system developed by ABI LTD incorporates a variety of interchangeable technologies for specific process requirements: conventional blades, ultrasonic drag blades, ultrasonic plunge blades, custom blades and waterjet. The different types of blades can be stored within the scoring cell for automatic tool changeover. Specialists from ABI LTD highlight the applications in which each technology excels: + Conventional blades are ideal when a rippled finish is desired, or for higher production rates with the multi-blade configuration. They are the ideal scoring technology for some artisan breads, rolls and buns. + Ultrasonic drag blades are the most flexible in terms of customizing the
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cut properties and can execute intricate scoring patterns. This makes them the choice for artisan breads, rolls, buns, and baguettes. Ultrasonic plunge blades are the solution for faster scoring: the blade has one cutting edge with a fixed length and moves in a simple, vertical motion that can be repeated quickly. They work well with certain types of buns, breadsticks, and rolls. Custom blades are an option that offers more efficient scoring, as they are developed according to specific cutting needs. ABI manufactures blades according to the requirements of the bakery and their products. Waterjet scoring uses highly pressurized water as the most hygienic option for scoring. The stream of water splits the dough surface. This type of scoring offers the flexibility to accommodate a variety of scoring patterns.
The concept behind the automatic cuts There are three important components in the Katana robotic scoring system: its vision system, the Katana platform
