Handle with automated care

Automating bakeware handling saves time and precious human resources. It also ensures that trays, pans and tins are handled exactly as instructed by the tray and coating manufacturers, time and again.

+Streamlining bakeware handling alleviates manual labor requirements and increases productivity for several operations, from loading and unloading racks, to stacking, transporting, cleaning, depositing and retrieving trays. Such tasks are performed with reliable consistency and virtually eliminate damage from accidental mishandling. Handling automation can take many forms: to load and unload racks, solutions such as Minipan’s automatic system can be customized to fit specific bakery requirements, and can be used by artisan and industrial operations. The equipment developed by the Italian specialist receives the trays via a conveyor and transfers them to an elevator that fills empty racks continuously. The system can work with trays and racks of any size.

Some of the latest alternatives to choose from were presented at interpack 2023. The IQ-Move Spider, recently developed by Döinghaus, for instance, enables automated tray handling for ultrasonic cutting with a vertically movable working unit for cake sheet handling: entire rack trolleys with baking trays go into the system from the docking station, saving operating time and straining manual work requirements. The baking trays are automatically pulled out of the rack, and the sliced cake sheets are returned after cutting.

Handling on the line

For automatic or even semi-automated production lines, several bakeware handling methods can be incorporated to minimize manual intervention required and production downtimes. Their features address the type of tray, pan, or tin, while keeping in mind preserving the integrity of the products.

Cakes are especially unforgiving when it comes to handling; from the moment they are deposited, through to filling, decorating, depanning, cutting, packaging, and conveying throughout, and therefore accuracy ensures efficient processing, for the product and its support. Several depanning options can be employed for best results. SAM Machinery, a cake machinery manufacturer from Türkiye, illustrates four types of depanning technology that can be incorporated into its cake production plants – which were also highlighted at interpack. Its axial depanners, controlled by servo motors, flip the pans on the axis of the conveyor, then hammer the pans with a pneumatic system for product release. With the rainbow unloading system, the products are transferred from the pan to the conveyor on a side. The same hammering method is applied to release the products. With needle depanning, the needles used vary according to the types of cakes, while vacuum depanners use vacuum pads, which makes them suitable for all types of pans (the pads themselves are customized according to the products). Moreover, pans can also be automatically lubricated before depositing for cake lines such as these, to precisely spray the required amount of lubricant in the product enclosures of each tray, while monitoring the temperature of the oil. Any excess oil is drained and collected for reuse. SAM’s lubrication spray system uses custom-made spray guns with air-splitting nozzles that can be automatically adjusted according to the size of the pan.

Magnets at work

Magnetic handling systems can be used to automate tray storage in bakeries. They can work with various bread tins, straps, bun trays and lids and can lift single items or several in a single lifting motion. The system developed by Eclipse Magnetics, for instance, can handle up to 16 straps simultaneously, off-loading and stacking them into storage areas, or placing them onto conveyors to enter production. These systems provide several benefits, which include avoiding direct contact with the tins and eliminating damage risks. Moreover, the magnets can be used for several types of bakeware, with no need for adjustments or damage to the coatings.

Automated cleaning

Tray cleaning can also be automated, ensuring process efficiency and maximizing the lifespan of the bakeware. The system JEROS highlighted at interpack, for example, is developed for industrial bakeries and can clean up to 10,000 trays in 24 hours. It can be used for large two-sided trays as well as perforated trays (max. 60° edge), which go through a brush system with the soiled side down, so that they can immediately be ready to use once cleaning is finished, without having to turn them.

The correct handling of the products and their trays not only ensures the optimum results with consistency, but will also preserve the hygiene, safety and integrity of the trays and that of the lines. +++