Baker Perkins will be exhibiting the latest technology for the Biscuit, Confectionery, Breakfast Cereal, Snack Food and Ingredient Production sectors at Interpack in Düsseldorf, Germany, 4th - 10th May 2017.
Find us in Hall 4, Stand C21.
At the show, we will be exhibiting:
- NEW - TruClean™ Three Roll Sheeter and Gauge Roll
- NEW - TruClean™ Servo Wirecut
- NEW - Encapsulation Module for High-Value Filled Cookies
- High Speed, Multi-Purpose Batch Mixer
- NEW - ServoForm™ Mini Small-Batch Depositor
- NEW - Opportunities for Functional and Healthcare Confectionery
- NEW - Automated High Capacity Lollipop Depositing Technology
- Cooking Systems for Every Type of Hard and Soft Confectionery
- NEW - Redesigned SBX Master™ twin-screw extruder range
- NEW - Pre-conditioner for extruders
- MPF24 laboratory extruder for product development
Full details of the show can be found at www.interpack.com
New Technology for the Biscuit Industry at Interpack 2017
Baker Perkins is showing new equipment and end product technology for the biscuit, cracker and bar industries at Interpack. This includes:
- A NEW TruClean™ three roll sheeter and gauge roll
- A NEW servo-driven version of our well-proven wirecut range
- A NEW, innovative encapsulating system for totally enclosed, filled cookies
- A High Speed, Multi-Purpose Batch Mixer
The new TruClean™ three roll sheeter and gauge roll for crackers and snacks completes the upgrade of Baker Perkins’ range of sheet forming and cutting lines to TruClean™ standards, bringing major benefits in maintenance and hygiene. Time for a typical cleaning routine for a line can be reduced by up to 40%.
These Baker Perkins lines comprise either a three roll sheeter or a laminator to take a bulk feed of dough and form it into a sheet, ready to pass through gauge rolls which achieve the chosen thickness, and then a rotary cutter before baking.
The TruClean™ approach to hygienic design was instigated to meet a clear demand from the industry for higher standards. It involved a radical re-design of machinery in order to reduce debris and places where it could collect, and make access much easier where it is needed.
Improving visibility and access for cleaning, simplifying removal and replacement of components and assemblies, cutting the number of components, and reducing accumulation of debris were the principal design requirements – all achieved without compromising fundamental process performance parameters and attributes such as output and weight control.
The key benefit is a significant reduction of the time required to clean a line to the required standard, leading to lower costs and faster changeovers.
The new TruClean™ Servo Wirecut for soft-dough cookies and bars is a more versatile and flexible version of the well-proven TruClean™ wirecut.
A patent has been applied for on the new wirecut mechanism, which uses servo motors to drive the wirecut mechanism, bringing improved automation and flexibility to production. The two-axis servo system provides infinite variability to the cutting and return paths, enabling optimum cutting performance to be achieved, even at high speeds or on difficult dough. Tailored profiles can be created for each individual product and loaded at the touch of a button.
The remaining parts of the wirecut process – hopper, feed rolls, filler block and dies – are carried over from the previous version of the TruClean™ wirecut, ensuring that product characteristics, high-accuracy weight control and easy cleaning are maintained.
In other areas, ease of operation, cleaning and maintenance have all been improved. Setting up is all done from the HMI and once a profile has been developed and tested it can be saved as a recipe for one touch set-up.
An innovative encapsulation module enabling high-value filled cookies to be made on any Baker Perkins wirecut machine is being exhibited.
A patent has been applied for the system. For the first time, cookies totally enclosed by dough can be produced on a module attached to a standard wirecut machine – previously a separate unit was necessary.
The process involves pumping a continuous stream of filling into the centre of the dough cylinder formed at the wirecut die. A set of iris-die cutters crimp the dough and filling, forcing the dough to completely enclose the filling.
Fillings can include any ingredients which are low enough in viscosity to be pumped, including chocolate, caramel, cream, peanut butter or jam.
The encapsulation module is available as an option on the new TruClean™ Servo Wirecut but may be fitted to any installed Baker Perkins wirecut to convert the machine from a standard unit to one that can do both cookies and encapsulated cookies.
Baker Perkins’ well proven HS (High Speed) multi-purpose batch mixers handle every type of dough for biscuits, cookies and crackers. They offer high levels of automation, ease of use and cleaning, and outstanding reliability to guarantee low cost of ownership.
The unique Baker Perkins shaftless mixer blade processes every type of dough, and ensures good dispersion with rapid dough development; it gives optimum performance in every mixing phase. The blade allows the ingredients to move freely in the bowl; delicate inclusions are incorporated evenly without damage or smearing.
Loading and discharge are fully automatic to reduce labour costs and mix cycle times - three batches can be achieved every hour.
Confectionery Technology at Interpack 2017
Baker Perkins will emphasise why depositing is growing in popularity in the confectionery and healthcare industries at Interpack. High levels of accuracy and hygiene are combined with low production costs and an ability to make products that are unachievable with other methods.
These attributes make depositing attractive across the hard candy, lollipop, standard and 3D jelly, gum, toffee, caramel, fudge and fondant sectors. The accuracy, hygiene and efficiency of depositing also make it uniquely suitable for medicated and healthcare products.
Exhibits at Interpack will include:
- The NEW ServoForm™ Mini small-batch depositor for hard and soft confectionery
- NEW opportunities for Functional and Healthcare confectionery
- A working demonstration of Baker Perkins’ NEW stick placing technology for flat lollipops
- Cooking systems for every type of hard and soft confectionery
The ServoForm™ Mini is a flexible depositing system for small batch production which can make a wide range of hard candy, soft candy and lollipops.
It offers outputs up to 54kg/hr (120 lb/hour) and brings the benefits of depositing - high quality, high efficiency and versatility - to companies producing confectionery in small batches, including those needing to make a variety of products on one line.
The characteristics of depositing, which enable validation, makes this the only viable process for the growing variety of functional and healthcare confectionery carrying over-the-counter medications and dietary products typically fortified with vitamins, minerals, fibre or real fruit juices.
Any product that claims a functional benefit must have the active ingredients present in the quantities claimed. This requires the active ingredient to be accurately dosed; that it suffers minimal heat or mechanical degradation, and that the finished portions are precisely controlled.
Furthermore, the appearance and organoleptic properties of the product have to be high quality to provide reassurance and justify the price. This all has to happen in a process that is reproducible, hygienic and capable of validation: depositing meets all these requirements.
Compared to conventional methods such as die forming, starch mogul or cut-and-wrap, depositing provides a high quality, smooth product with accurate weight, size and shape characteristics. The process offers rapid payback through minimal scrap, low production costs and hygienic operation.
Simplicity of operation, flexibility and rapid changeover are major benefits. Control of the depositing process is fully automatic with recipe storage and recall enabling the depositor to be set up at the touch of a button.
Baker Perkins has developed a family of products for the lollipop sector – the latest addition is the soft-centred double-ball lollipop.
The main types are the classic ball lollipop, and flat lollipops in a variety of shapes.
By varying the colours, flavours, patterns, fillings and textures within these shapes it is possible to create an unending flow of new product ideas to stimulate and sustain the interest of consumers.
Cooking systems for hard and soft confectionery will be represented by a Turbofilm™ plate pack cooker and a Microfilm™ rotary evaporator.
The unique swept thin-film Microfilm™ process provides precise and consistent cooking of the full range of confectionery syrups. The cooking process is extremely rapid and delivers consistent high quality on every product. The Baker Perkins range of cookers also includes the Turbofilm™, for jellies, and the Carablend™ toffee cooker.
Extrusion Technology for Breakfast Cereals, Snack Foods and Ingredient Production
A new generation of extrusion equipment for the food industry will be launched by Baker Perkins at Interpack. The SBX Master™ twin-screw extruder range for cereal, snacks and other food applications has been re-designed and a new pre-conditioner added to the range to increase flexibility.
On display at Interpack will be:
- A NEW, redesigned 80mm SBX Master™ twin-screw extruder
- A NEW extruder pre-conditioner
- An MPF24 pilot scale extruder, on display for the first time
The flexibility of Baker Perkins’ SBX Master™ extruders has been improved by increasing power, torque and speed. This, along with a range of barrel lengths, increases the variety of end products that can be made, while barrel diameters between 50mm and 125mm give an output range from 500 to 2,300kg/hr.
Improved cooling also contributes to broadening the range of products that can be made, and also improves quality and consistency. The new design features water distribution channels located closer to the internal surface of the barrel to improve both responsiveness and the rate of heat transfer. Flow rate is increased, and cooling can be controlled and adjusted to individual product profile.
The SBX Master™ is now a totally modular machine, so future extension of the barrel and all the associated services to expand or change a product portfolio is speedy and uncomplicated.
The arrangements for mounting the die and cutter have been simplified to make changeover, cleaning and maintenance faster and safer. The die is supported on a hinged arm that enables it to be moved quickly and safely, especially when hot, while the cutter slides in and out of position on rails. This is a pneumatic, pushbutton-operated system that automatically puts the cutter directly in front of the die as soon as the extruder is ready, leaving only fine adjustment to the operator. This minimises time and waste generated during set-up, changeover or if a blade change is required during a run.
A gearbox condition monitoring system that reduces unexpected downtime is available on all new SBX extruders and can also be fitted to existing machines. This simple system continuously monitors the frequency and amplitude of vibrations within the gearbox, allowing the ongoing condition of vital components to be measured. The principal benefit is elimination of unforeseen loss of production due to gearbox repair or replacement: maintenance scheduling is significantly enhanced.
Twin-screw extrusion brings significant benefits to the food industry. Extrusion is hygienic and energy efficient: all the action is in the short barrel – ingredients in, product out seconds later. If it is possible to make a product with an extruder, it is almost certainly the cheapest, most efficient and most compact method of making it. Conventional processing typically involves a great deal more equipment, time and cost.
Twin-screw extrusion technology is at the heart of versatile systems producing a wide range. A standard system is a flexible way to enter a market at a low capital cost; extrusion systems can be expanded as a business grows and more complex products, or even a completely different product range, are required.
The pre-conditioner is an addition to the Baker Perkins SBX Master™ range. The pre-conditioner mixes, heats and hydrates wet and dry ingredients plus steam in a two-chamber system. The first stage inputs energy in a high intensity mixing phase; the second allows the energy and moisture to equalise throughout the pre-conditioned mass, eliminating any tendency to clump and achieving a mix profile for successful extrusion processing.
It adds flexibility in the cereal and snack sectors when applied to denser materials such as half products formed in the extruder and expanded elsewhere – flaked cereals and multi-grain loops are typical. It is also ideal for high-protein products where energy input in the preconditioner replaces mechanical shear energy in the extruder.
Hygiene levels are high: a wash-in-place water spray system is an option and there is unrestricted access for manual cleaning.
The MPF24 is a laboratory tool for product development.
It is used to try out new ideas, assess ingredients, provide test marketing samples, and even make small production batches of product with high-value ingredients. It does so without loss of production time - scale up is accurate thanks to comparable geometry.
The machine can be stopped and the clam-shell barrel opened at any time to note the state of processing, allowing screw and heat transfer profiles to be optimised. The machine is mobile; available with a full selection of cutters and dies; and sophisticated controls include data capture, trending, and recipe management.
Our MPF19 benchtop extruder can be used for research and development of snacks, cereals, ingredients and pellets:… twitter.com/i/web/status/8…13 February 2017 06 February 2017