IP CO
Leaders in solid and perforated bake oven belts As a brand, Ipco is regarded as a pioneering manufacturer of carbon steel belts to the bakery industry, supplying OEMs and end users alike, throughout the African continent and beyond.
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PCO steel belts are available in solid or perforated form, and are suitable for baking products as diverse as bread, biscuits, brownies, crackers, pastries, sponges, all-butter cookies and pizza bases. The key qualities of a steel belt include outstanding thermal properties for efficient baking; the inherent ease of cleaning of a belt compared with mesh; and the attractive return on investment when considering overall lifetime cost. This long term value for money is due to the durability of this type of belt: It is virtually unheard of for a steel bake oven belt to reach ‘end of life’ due to fatigue stress. During the baking process the belt is placed under considerable thermal stress as heating and cooling takes place every time it completes a revolution. A combination of steel belt grade and special manufacturing phases is used to achieve the necessary thermal properties of the material. These properties give steel belts the durability to operate for decades under what are severely challenging processing conditions. In terms of maintenance, qualities such as good tension and tracking characteristics and resistance to stretching combine to result in significantly less downtime than other belt materials, important considerations when even an hour’s lost production can be costly. This unique combination of qualities doesn’t just come from the inherent qualities of steel of course: Every belt is meticulously engineered to perform as it should, as Ipco global product manager Marko Leber explains. “The baking process requires not only specific thermal properties but also mechanical ones. The belt needs to provide stable working conditions when tensioned
Fast fact: Any build-up of acrylamide can also have a negative impact of on human health and bakeries must make every effort to reduce levels of this potentially carcinogenic byproduct of the baking process. 18 BAKERYREVIEW MARCH 2021
and to transfer the heat from the heating media to the product in an even way. The necessary mechanical properties are created during the production process, engineering long lasting flatness and straightness into the belt. These qualities are essential for an efficient continuous baking process.” In addition to a long working life and low maintenance requirements, the relative lightness of a steel belt can result in lower operating costs.
“The key qualities of a steel belt include outstanding thermal properties for efficient baking; the inherent ease of cleaning of a belt compared with mesh; and the attractive return on investment when considering overall lifetime cost” Solid steel belts are lighter than wire mesh – perforated steel belts lighter still – so cost up to 30% less to heat. Each time the belt exits the baking chamber, it begins to cool and has to be heated up again so the savings are continuous. As much of 25% of an oven’s energy consumption is needed to heat the belt, so these savings can be considerable. The company can produce belts in widths from 800mm to 3 500mm. This makes it possible to achieve significant improvements in productivity without having to invest in factory extensions or new facilities. An oven with a 1 500mm wide belt offers almost twice the productivity of one with an 800mm belt without any increase in the line length. Upgrade to an oven with a 3 200mm belt or larger and throughput is increased by a factor of four.
Minimising the risk of acrylamide build-up However clean a bakery operation, a gradual
build-up of carbon residues on the bake oven belt is unavoidable and this can be detrimental to both the taste and the appearance of a product. As a conveying medium that’s completely flat and smooth, a steel belt has the major advantage of having no gaps, recesses or crevices in which carbon deposits could collect. As a result, steel belts are inherently quicker and easier to clean than mesh belts. Any build-up of acrylamide can also have a negative impact of on human health and bakeries must make every effort to reduce levels of this potentially carcinogenic byproduct of the baking process. As well as minimising the risk of harmful acrylamide build-up, the ‘cleanability’ of a flat belt means less water consumption, reduced use of chemicals/detergents, and – depending on the cleaning method – less energy expended on heat. Quick and effective cleaning also enables rapid changeover from one product to another, enhancing the overall productivity and efficiency of a bakery.
Oven upgrades to solid steel belts The qualities of a steel belt have made it essential to the production of what in recent years has grown to become a worldwide favourite: American-style cookies. These products use real butter, and often chocolate chips too, so need to be baked on a solid belt otherwise melted product would drip through the belt and create a fire risk. The use of a solid steel belt also produces an attractive crisp base. This globalisation in taste has led a number of bakery operations to look at how to capitalise on the opportunities available, resulting in a switch from wire mesh to solid steel systems. While most of IPCO’s work with the bakery industry is focused on the manufacture and supply of steel belts, the company can also support OEMs in system design and supply a full range of conveyor
