WP BAKERYGROUP: Connected processes

Connected processes

© WP BAKERYGROUP

+Bakeries are on the cusp of significant improvements in the efficiency of all manufacturing processes, thanks to innovation in digitization and technology enabling a higherthan-ever degree of accuracy. This is particularly visible in high-volume manufacturing plants, where such solutions contribute to baking efficiency, as well as to product and process safety. As an important added benefit, new technologies contribute to the overall sustainability of the operation.

Digitalization can offer a wide range of opportunities, from monitoring production to optimizing processes and analyzing resource availability in real-time. To take advantage of improvements that digitalization has to offer, smart equipment is needed. This doesn’t necessarily have to mean existing technology has to be replaced; software can help equipment become intelligent. Some bakery machinery already comes equipped with an interface for remote control, analysis, or production monitoring – such as ovens from Werner & Pfleiderer, the mixers from WP Kemper, or other WP Bakerygroup products.

WP Bakery Control Software

WP Bakery Group developed the WP Bakery Control Software to help make equipment smart. This tool records all process parameters and analyzes the resulting data to control production in real-time. Installation is as easy as plug & play, after which it can run on mobile devices for remote access of current and historical data. Working with the WP Bakery Control application begins with oven integration. The app can store, display and export data regarding the oven, the recipe and the production and contributes to optimizing the baking capacity and energy utilization. By improving the control of the baking sequence according to the capacity used, bakeries have also achieved noticeable gains in the freshness of the products sold.

WP Oven-Control

In addition, the WP Oven-Control connects all production ovens and in-store baking ovens to a single computer. From there, recipes can be adjusted and added to all of the selected ovens. It also features functions for remote diagnosis

and preventive maintenance. The app collects production data in real-time, associated with running the baking programs. Depending on the baking program, temperature curves are recorded as well. This information helps bakeries achieve a continuously consistent high quality in all their branch stores, for example. WP’s service department can also connect to the app, if requested, to help sort out any errors that might occur.

WP Connect

This digital monitoring system uses hundreds of data points to continuously diagnose the condition and assess the functionality of the machine. In this way, potential malfunctions are identified before they occur, to avoid production downtimes. The comprehensive technical information that is continuously processed and mapped describes in detail the production reliability of the machine. For example, the currents acting on the drives are maintained within the specified range at all times, which is of utmost importance for the machine’s operation and long-term upkeep. WP Connect associates all process data with the identity of the equipment, recording details about the type and the serial number of the machine, the software version used, the number of operating hours and units produced, the maintenance operations carried out, the next maintenance service, and malfunctions, should they occur. It diagnoses all relevant information related to the dough to ensure it meets all desired parameters: the flow of the dough, the filling levels on the roller frame, the dimensions of the dough pieces, their weight, and the oiling temperature. It also includes information about the current operator and the recipe in use. All this information helps to expedite service work significantly.

Robotics

Technology and applications are boosting the use of robotic solutions with numerous opportunities in bakeries, especially in the field of collaborative robots. The possibilites are virtually limitless to match requirements, thanks to their flexibility, making them suitable for any applications from loading and unloading machines, to cutting or tray handling. Possible applications are shown below.

WP BAKERYGROUP

Von-Raumer-Str. 8–18 91550 Dinkelsbühl, Germany Phone: +49 9851 905-0 Fax: +49 9851 905-8346 E-mail: info@wpbakerygroup.com Website: www.wpbakerygroup.com

WP Kemper GmbH

Lange Str. 8-10 33397 Rietberg, Germany Phone: +49 52 44 40 20 E-mail: info@wp-kemper.de Website: www.wp-kemper.de

Werner & Pfleiderer Haton B.V.

Industrieterrein 13 5981 NK Panningen, The Netherlands Phone: +31 77 307 18 60 E-mail: sales@wp-haton.com Website: www.wp-haton.com

WP Lebensmitteltechnik Riehle GmbH

Heinrich-Rieger-Str. 5 73430 Aalen, Germany Phone: +49 73 61 55 800 E-mail: info@riehle.de Website: www.wp-riehle.de

Werner & Pfleiderer Lebensmitteltechnik GmbH

Von-Raumer-Str. 8-18 91550 Dinkelsbühl, Germany Phone: +49 98 51 90 50 E-mail: info@wp-l.de Website: www.wp-l.de © WP BAKERYGROUP Werner & Pfleiderer Industrielle Backtechnik GmbH Frankfurter Str. 17 71732 Tamm, Germany Phone: +49 71 41 20 20 E-mail: info@wpib.de Website: www.wpib.de The WP BAKERYGROUP is the world’s largest manufacturer of machinery and equipment for bakery business of all sizes.

COMPANY REPORTS

© WP BAKERYGROUP

1. Articulated robots

The main application for which the WP Bakery Group supplies robotic solutions is tray handling. The robots can perform a variety of movements that are required for different tasks and are particularly well suited for simple assignments such as moving trays independently. Some of the actions these versatile robots can perform include: Tray loading/unloading In combination with a machine, robots can position and place trays or lift them, as needed. For example, they can be assigned to remove empty trays from tray trolleys or stacks from unloading stations and place them on conveyor belts, which then transport the empty trays underneath the deposit belt of a running machine, and deliver a full tray to the loading station. The second robot in this scenario takes the full baking trays from the conveyor belt and places them into an empty proofing trolley. Further automation steps can be added along the process such as supplying and removing the proofing trolley.

Emptying trays One robot or two can be installed to empty the baking trays, each with an output of four trays per minute. As the trolleys are conveyed to the unloading station, the robot removes the trays and slides the products onto a conveyor belt. Before placing the trays back into the trolley, they are cleaned at a cleaning station. When two robots are used for this process, they remove trays from trollies positioned in four unloading stations.

Articulated robots can perform all the movements of a human arm. However, the robots do not share the human limitations in their range of motions. Thanks to their 360-degree joints, more freedom of movement can be programmed. The safety of the team in the workspace is taken into consideration as well, so that the robots can be set up without the use of a space-demanding protective cage. An environment scanner is placed to monitor when people enter the work area, to prevent accidents that might otherwise occur.

© WP BAKERYGROUP

2. Delta robots

Delta robots such as cutting systems are an important solution in the production of baked goods, and are often used together with articulated robots.

Cutting Delta robots can be programmed to cut different patterns into dough. Applications can range from pretzels and bread rolls to baguettes. A 3D camera system recognizes the dough pieces and applies the selected cutting shapes. Ultrasonic, rotating knives or water jets can be used to perform the cuts. The choice of the robot that is the best fit for the operation at hand is determined by several factors: the product itself and its characteristics will be the first aspects to be looked at, as well as its weight, the type of cut and the desired cutting angle. It is important to match the products to the cut, for best results. Smaller products, in particular, can move when the knives are rotating, which can result in inconsistent or substandard cuts. When cutting is carried out with water jets, water streaks can appear along the cutting marks of lye products, for example. Monitoring is continuous and it helps to improve process performance on the spot. The products are measured so that when they are not correctly positioned, the robot immediately reacts and adjusts its action to the position it has scanned and identified. Live process monitoring is also an option. As they operate, the robots will continuously specialize in their actions based on the data they gather. The cutting parameters are automatically determined.

WP Robot at work

WP Riehle has connected a robotic module to the COMJET automatic lye application unit for increased efficiency when manufacturing lye products. The robot makes accurate cuts into the dough pieces, after the lye application: lyedipped dough pieces move automatically into the robot cell, which is equipped with camera technology that uses a laser-3D triangulation method with up to 78 cameras to visually record the dough pieces. Robots then make precise cuts exactly as specified. Different cutting techniques are available: ultrasound, water jet, rotating knife and fixed blades. The ultrasound knives are available in titanium alloys with various cutting widths. The mechanical knives are available with regular cutting blades, rotating circular knives or serrated blades. The water cutting technique generates a fine jet of water that can cut into and through the individual products.

As the lye application process is fully automated, only one operator is needed to run the plant to apply lye to up to 300 trays/hour. Feeding proofed dough can be done with a roll-off device. Peelboard feeding is now also available. The loading trolley is automatically docked onto the loading system, and all subsequent process steps run fully automatically. The dough pieces are received at the loading station and fed into the lye application machine. In addition, the belt speed can be adjusted according to individual products. After this process, the dough pieces are deposited directly onto a baking tray or transferred to a cutting plant. The COMJET has a 180-liter lye tank, which can also be equipped with lye tank heating. Special models can be built to link directly to downstream processing machines – e.g. tunnel ovens or shock-freezers.

Handlling: Doing the heavy lifting

For safe handling of the dough, automated lifters ensure the bowl or box is lifted/lowered quickly and gently, to the required heights, and tipped to feed lines such as the PANE or PANE PUR dough strip lines. Throughout this process, the characteristics of the rested dough are preserved. This process is especially handy for the trend for products with soft dough with a long resting time. The lifters are designed with a compact layout to minimize the space they need in the production area. The large-capacity lifters incorporate safety technology and the control of the filling level is also automated. Uniform lifting is ensured in day-to-day operations, regardless of the amount of dough in the bowl. They can be customized to specific mounting positions and tipping directions. +++