American Pan: Pan design and handling for automated bakery systems

Pan design and handling for automated bakery systems

+Automation in bakery systems drives innovation for the design of baking pans in several ways, including features that improve how they run on automated conveyors, how they are stacked, and how coatings are protected.

Bakeries are facing unprecedented challenges relating to demand for product and workforce shortages. These two forces combined have resulted in the latest push for automated systems in bakeries. In turn, these automated systems continue to affect the design of baking pans resulting in several innovations including: + Enhancements to run on automated conveyors + Increased pan size and capacity while trying to minimize pan mass + Nesting and stacking designs for safe efficient storage + Designs to protect coatings while running on automated systems

Designing for automation

Many automated oven systems require specific designs to be compatible with their conveyor

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systems. From trays that connect to conveyors, to tin sets with special strap designs, making sure a pan can run smoothly on an automated system is essential.

“Automated baking systems have unique pan requirements to ensure smooth operation,” states Michael Cornelis, Vice President of International Sales and Development for American Pan. “Features like rounded pan corners and precise manufacturing to adhere to tolerances help ensure the pans will work efficiently with the system.” Explaining this further, he states, “Along with running smoothly on conveyors, pans and lids are often stored in specifically engineered spaces and must meet exacting size specifications.”

Mr. Cornelis also discusses the new design for completely sealed pan frames which prevents contaminants from entering the pan frame during baking, washing or even the pan refurbishment process. “This design helps prevent contamination of baked products by eliminating particles or liquid from getting into the frame and subsequently damaging the product.”

Handling larger pans

Trays and tin sets for automated systems are also typically larger than standard pans. This could require additional supports or strengthening elements to be added to the pan design. Cross braces, structural ribs and other metal forming techniques are used to improve durability.

Due to larger pan designs and additional supports or straps for automated systems, pans inevitably become heavier. The size of the pans, coupled with the weight, often makes the pans too large for bakery employees to handle.

Increasing the size of baking trays and tin sets increases throughput but creates a challenge for employees that are required to work with or handle the pans. Even when using proprietary ePAN® material, the weight of the bakeware can be increased significantly. This requires the use of robotics or other mechanisms to assist with moving the trays and tin sets on and off the line. These systems are used to remove lids off bread tin sets, move pans on and off the conveyors, and even transport pans to and from pan storage areas. To work with automated equipment for these functions, pans and lids must be designed properly to work within machine parameters and prevent damage to the pans or coatings. “It’s about being able to get the pans on and off the production line safely and efficiently,” according to Jesper Albertsen, European Sales Director

INNOVATION

ePAN® material and designs ePAN ® baking trays and tins use a hightensile strength aluminized steel to create pans that are up to 20-50% lighter and substantially stronger than traditional designs. In addition to being lighter and stronger, ePANs ® offer: + Extended Pan Life: The use of high-tensile strength aluminized steel creates a stronger pan and reduces the potential for pan damage. + Energy Efficiency: These pans heat and cool up to 25% faster than traditional pans, decreasing oven energy requirements and space for cooling. + Easier on Your Bakery: ePANs® remove thousands of pounds from the bakery cycle and reduce wear on conveyors, stackers and other pan handling equipment.

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INNOVATION

Stacking designs Stacking baguette trays with interlocking ribs in frame

Stacking bread tin set with special straps to nest and protect tin coating

Bun trays for automated system with stacking design for American Pan. “Once off the line it is also important that they stack together securely to decrease the amount of space needed to store them and ensure that they nest safely to prevent any hazards.”

Safe stacking

Larger pan designs present storage challenges – the larger the pans, the more space required for storing them. New stacking designs, engineered over the last several years, have increased in demand especially for industrial systems. Stacking features allow bakeries to stack multiple identical units together. These features depend entirely upon specific applications. But all provide enough room without taking up too much precious space, thus leaving room for other day-to-day bakery activities.

Trays that use a screen or other type of insert placed inside a frame can be equipped with a stacking rib. Bread tins can be manufactured with notched designs on the strap, allowing for safe and efficient stacking of these large and heavy sets.

Protecting the coating

One of the biggest issues when it comes to automated handling and stacking of pans has always been damage to the bakeware coating. The tools on robotic equipment or contact with other metal baking pans can scratch the coating and cause premature failure.

New pan designs and coating techniques allow the coating to be applied in such a way that it will not come in contact with other metal surfaces that could scratch the coating. This could include applying coating below the contact line or creating a special stacking design that prevents the metal surface of one pan from contacting the non-stick coating of another.

Maximizing pan life

Over time, pans will inevitably experience wear and damage. Metal may get dented or warped due to bakery conditions and can cause automated line jams, resulting in bakery downtime and an

increased need for maintenance. In addition, all coatings eventually begin to break down, and non-stick properties are diminished; however, pan life can be extended through service options including refurbishment and screen replacement.

Pan refurbishment

Bakeware performs best when it is clean, straight, and maintains its natural coating properties; thus, bakery pan refurbishment and recoating should occur regularly. Bakeware that is refurbished on a regular schedule has been proven to save bakeries time and money. Pans that have lost the easy release properties of their non-stick coatings will result in baked products sticking to the pan. Products that stick to the pan are damaged when pulled off and often scrapped. Poor performing coatings also require more oil or spray when these release agents may otherwise not be needed.

Pan refurbishment services include cleaning pans to remove the old coating and other residue and then applying a new coating to achieve the same release characteristics as new pans. In addition, hydraulic presses can be used for some pans to reduce warping and remove dents. This extra step helps improve overall pan performance and prevents line jamming and other issues.

Baking screen replacement

If your tray is designed with a baking screen that is attached to a frame, then screen replacement is an option to extend the life of the tray. Many designs use rivets to attach the screens to the frame; however, the TabLock Baking Screens from American Pan are constructed using a patented attachment system for easy and economical replacement of baking screens. The trays come with custom tools that allow old screens to be removed and new screens to be inserted while remaining in the bakery. There is no need to ship them to a service center. In addition, because there are no rivets or other fastening devices that require drilling, the threat of metal shavings contaminating baked products is eliminated. +++

INNOVATION

Stacking designs Automated cake tray design stacked on special assembly for safe travel and storage

TabLock baguette tray with stacking rib and screen removal tool