VISIT
A quantum leap When Ebbing Bakery installed the Smartline Model I dough band line, which had just been launched into operation in 2001, it was a first in the industry. 16 years later, the company opted for the Rondo line for the second time, now in its new generation.
The pastry hall is kept at a constant temperature of 19 °C; the Smartline can be seen in the background
By Helga Baumfalk
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The new Smartline Type 10 has been in operation since 2017. “We added a new hall for the production of pastries in 2012 because we wanted to decentralize the processes in our production and set up a separate, air-conditioned room in which we could also process butter,” explains Daniel Ebbing, head of the bakery. The dimensions and design of the latest Smartline generation were taken into account following the construction of the new pastry hall, in preparation for the future. The modernization of the dough band line, which involved replacing its 2001 predecessor model, came five years after the new hall became operational. Five machine generations lie between the two versions. The new dough band line is now arranged in an L-shape, measures 10 m x 10 m in angle and feeds the downstream Polyline make-up line in a single-shift operation. At a constant room temperature of 19°C, soft yeast doughs and laminated doughs are rolled out on the dough belt line today. A total of around 40 products run through the machine, including the spelt corner (Dinkel-Ecke), a type of bread roll, chocolate croissants (or rather chocolate rolls), sausage rolls* and seasonal products such as the stollenstrudel. When the new investment was considered, an additional capability was important to Daniel Ebbing: “It needed to roll out the shortcrust pastry for the cakes and tarts.” The
www.bakingbiscuit.com 03/2022
previous model was not capable of doing this, he says. “Until 2017, we still fed the shortcrust doughs by hand over a sheeter. With the quantities we need, it’s clear that we’ve already made a quantum leap with the new model.” Today, the bakers reduce the shortcrust pastry dough via the Smartline to a final thickness of less than 3 mm, in two steps. Shortcrust doughs are quite demanding for a dough belt system – as they are so short, they can tear easily. In addition to the dough belt system, the 200 sqm pastry hall also contains a 12 sqm cooling cell and a croissant system from Rondo. It was even possible to take over some tools from the old Smartline from 2001, which lowered the overall investment. “We’ve done an all-around move,” says the company boss, “and automated the dough feed at the
Products that the bakery produces on the dough band line: 1) Yeast doughs: spelt corner, stollenstrudel, poppy seed plaits, bee sting cake, sheet cake, paninos and various seasonal products. 2) Laminated doughs: chocolate croissants, sausage rolls, cheese/crispy sticks, puff pastry plaits, pudding pretzels, fruit Danish pastries and various seasonal products. 3) In addition: Gingerbread cookies, filling dots
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