Biscuits, Cookies & Crackers

Biscuits, Cookies & Crackers Process knowledge and engineering expertise

Baker Perkins’ comprehensive range of equipment for biscuit, cookie and cracker manufacture is founded on 100 years experience and expertise. From mixing to sandwiching, every machine is designed to maximise profitability through reliability, ease of cleaning and ease of use.

Baker Perkins provides the widest range of equipment to An Innovation Centre enables us to test and develop new the industry, and has the largest installed base. From the technologies and end products. Finding better ways to start, we have built our business on technical excellence make current products, for the financial benefit of our and innovation, firmly grounded in unrivalled process customers, and developing new products that attract knowledge and engineering expertise. consumers are continuing aims of our technical team.

We have always used these to design equipment that meets Because we supply full lines, from mixing and forming the needs of the industry, with problems such as better to baking and sandwiching, we understand the complete weight control, reduced maintenance and easier operation process. This awareness of what is happening all being addressed in innovative ways. throughout the operation enables us to give unparalleled backing to our customers, from planning, through designing, building and commissioning, and on to complete lifetime support.

Biscuits, Cookies & Crackers | PAGE 2 Reliability via Lifetime Support

Baker Perkins understands that our customers need production stability, and that this can come only through working with reliable machinery designed for minimum downtime. Baker Perkins has developed a range of services to maximise that dependability.

Lifetime Support includes a range of services that Many customers opt for regular inspection and maintain peak plant performance. Fundamental functions maintenance contracts, designed to identify and fix of asset care, such as the supply of replacement parts and problems before they cause plant downtime and loss of rapid reaction to emergency breakdowns, are backed by profit. a variety of other services to ensure systems are kept in optimum condition. Lifetime Support goes a stage further with improvement via upgrades, adaptations and refurbishment. Baker Perkins offers cost-effective methods of updating and adapting plant in mid-life, to extend service life, make an expanded product portfolio, or meet the latest performance, hygiene and safety standards.

Lifetime Support services include • Replacement parts • Service and inspections • Moulder, cutter and wirecut dies • Performance upgrades • Hygiene upgrades • Adapting lines for new products • Rebuilding / refurbishing • Plant relocation

Biscuits, Cookies & Crackers | PAGE 3 Equipment overview

Mixing Soft dough forming The upgraded range of Baker Perkins’ high-speed, Baker Perkins offers a portfolio of rotary moulders, multi-purpose batch mixers is suitable for both hard wirecuts and extruders for the complete range of and soft dough. A shaftless blade gives excellent cookies, soft dough biscuits and filled bars. dispersion and rapid dough development, which Reliability and versatility, with a low cost of contribute to the consistent quality that is the ownership, are the design objectives. Precise weight foundation of cost-effective production. Automatic control on every machine minimises giveaway and operation and a choice of controls also contribute waste, contributing to fast payback. to operational efficiency.

Ovens Baker Perkins‘ convection, DGF and hybrid ovens have been developed and refined over many years to bake consistently and reliably, while the latest versions have seen improvements in fuel efficiency and hygiene. The result is high quality products and low production costs right across the cookie and cracker bakery spectrum.

Biscuits, Cookies & Crackers | PAGE 4 High quality, rapid payback

The entire range of Baker Perkins equipment for the cookie and cracker sector is designed and engineered with the customer in mind.

Reliability - Proven designs using high-quality components ensure trouble-free operation for long periods.

Efficiency - Well-informed design targeting the industry’s specific needs minimises product waste and energy consumption, maximises product consistency and quality.

Hygienic Design - Reduced contamination points and easier access for cleaning are benefits being introduced across the forming equipment range to help customers meet or exceed the latest industry hygiene guidelines.

Sheet forming and cutting Ease of use - Continual application of the latest Baker Perkins sheet forming and cutting lines control techniques makes better use of produce many leading brands of crackers, snacks operators’ time and reduces the overall and hard sweet biscuits. Tightly controlled, efficient, labour requirements. easy to use systems trigger the financial benefits of low waste and negligible unplanned downtime, with Low cost of ownership - Ease of access for the added advantage of minimal labour requirement. cleaning and routine maintenance cuts labour costs.

Sandwiching Sandwiching provides a range of options for efficient high-volume production and added-value brand extension. Baker Perkins supplies a series of systems covering a broad variety of product, speed and packaging possibilities. All bring the benefits of minimal waste, tight weight control, high efficiency and ease of use.

Biscuits, Cookies & Crackers | PAGE 5 Mixing and forming - designed to reduce costs

Fluctuating ingredient and energy costs plus the need to meet increasing hygiene standards are putting even more pressure on biscuit, cracker and snack manufacturers to reduce costs eleswhere. When designing the latest mixing and forming equipment, Baker Perkins looks carefully at how labour, downtime and waste can be reduced to deliver savings in ingredients and energy, while achieving the necessary improvements in hygiene. By designing machines that are easier to use and clean, more reliable and easier to maintain, all these vital areas are addressed.

Systems that can measure equipment performance and Designed for reliability alert operators to potential problems play a key role; All Baker Perkins cookie and cracker equipment is factories of the future may employ fewer but more highly designed to operate well within its capability. An skilled operators anticipating and averting problems rather uncompromising approach to the reliability and durability than reacting to them. This approach will keep of every component contributes to low downtime and lines running at maximum efficiency for longer, and long life. minimise costs. Top quality components Designed for hygiene Baker Perkins insists on the use of best-in-class Hygienic design has always been a high priority at Baker components throughout its range. Key parts such as Perkins and recent developments in the industry have motors and control items come from suppliers recognised added fresh impetus. The new TruCleanTM range of for dependability, with worldwide service and support. forming equipment meets or exceeds all the latest guidelines while performance, ease of use and ease of maintenance have all been improved.

High Speed Mixers TruClean™ Wirecut Series2 Rotary Moulder

Biscuits, Cookies & Crackers | PAGE 6 High speed mixers Sheet forming and cutting HS Mixers are suitable for both developed and soft dough. Sheet forming and cutting lines are used for every type of The unique shaftless blade achieves thorough dispersion developed dough, including crackers, snack crackers and and rapid development that lead to uniform dough hard sweet biscuits. consistency, smooth processing and negligible waste. The 150˚ tilting bowl and easy access for cleaning reduce A typical line includes a laminator or sheeter (or the unique downtime and labour requirements. combination unit), gauge rolls and a rotary cutter. They are designed to control costs in five main areas. Rotary moulders The 390 rotary moulder is a medium output unit suitable for Weight control – precise sheeting and laminating followed standard products. There are TruClean™ versions by low-deflection gauge rolls (standard or heavy duty) available for situations where sensitive cross-contact risks ensure constant sheet thickness. exist. For higher output applications the larger Series2 offers the ultimate in adjustability and high output. Hygienic designs – Stainless steel gauge rolls, no debris collection points and good access to all parts of the line Both machines are proven designs that offer reliability make these units quick and simple to clean. and durability with simple controls, easy cleaning and low maintenance to minimise production costs. Easy to use – the line is controlled by a single, integrated system with operator interfaces on every unit. Changes Wirecuts made to one are automatically cascaded to the others. The TruClean™ Wirecut produces soft dough cookies and bars with outputs from 60 to 200 rows/min. It features the Reliability – decades of design experience and millions unique die and filler block technology that guarantees of running hours ensure dependable service over precise weight control. Variance is just +/-1% on plain many years. dough and +/-2% on dough with inclusions. Easy to maintain – very little routine maintenance is Labour, downtime and waste are minimised by quick required and there is easy access to all major components. changeover, rapid cleaning and clear, intuitive controls.

Series2 Rotary Moulder Laminator Line

Biscuits, Cookies & Crackers | PAGE 7 Baking - flexibility and efficiency

The baking performance of each of the ovens in the Baker Perkins range has been proven over many hundreds of installations worldwide. Recent developments have focused on improving reliability, fuel efficiency and ease of use as well as enhancing the baking attributes. The result is an oven range offering exceptional performance, stability and low cost of ownership.

Jetcirc™ oven Hybrid ovens The Jetcirc™ convection oven offers exceptional An oven combining the most appropriate heat product consistency and high throughput with low transfer method for each stage of the baking process operating costs, across the full range of biscuits, is the preferred option for many bakers worldwide. DGF crackers and baked snacks. and convection each have characteristics that are ideal for one part of the process, but not necessarily all of it. Direct Gas Fired (DGF) oven Combining the benefits of two types of oven creates a This has long been the most popular baking oven, based unit that exactly matches a specific need. on a combination of flexibility and superior baking characteristics, which balance radiant heating and The most common hybrid ovens have DGF for the first turbulence to achieve the ideal product colour, size, phase of baking and convection for the rest. This gives moisture and thickness. maximum versatility at the start of the bake - for everything from soft cookies to crackers - and maximum efficiency at the end.

Jetcirc™ oven

Direct Gas Fired oven Hybrid oven

Biscuits, Cookies & Crackers | PAGE 8 Adding value via cream sandwiching

Baker Perkins cream sandwiching machines combine speed with accuracy to maintain quality and efficiency over long periods of operation, even at very high outputs. A wide range of product size variants, as well as input and output configurations that simplify upstream and downstream handling, enable a smooth process flow to be achieved.

The BP Sandwiching Machine can be specified to match a An interesting option for the BP Sandwiching Machine and wide array of plant layouts. Available in 2, 3, 4, 5 or 6 lane Pile Pack Creamer is the co-deposit stencil, which configurations, with manual or automatic feeding to allows two fillings to be deposited simultaneously. enable the full output of an oven to be handled with no Imaginative, highly differentiated products are awkward lane reductions. A dedicated cream feed system achievable. with independently controllable deposit weight for each lane and a wide range of lane multiplication options complete the range.

The Pile Pack Creamer uses an in-line version of the BP Sandwiching Machine process to produce piles of two sandwiches. These are collated into pack lengths of 1 to 6 piles and fed directly into a wrapping machine. The absence of both cooling and complicated mechanical handling make this a very cost-effective and efficient machine for both vend and retail packs.

Co-deposit stencil

Biscuits, Cookies & Crackers | PAGE 9 The principles of hygienic design

Baker Perkins adopted hygiene as an important design consideration in 1984. The experience built up designing hundreds of hygienic machines over that period has enabled us to respond very quickly to the 10 Principles of Equipment Design (see panel) introduced by the Grocery Manufacturers Association (GMA). These 10 principles have been adapted from the meat industry for low moisture foods and represent a significant step forward in process design.

Baker Perkins’ machines carrying the TruCleanTM name have been designed from the ground up in accordance with these principles.

In addition, TruCleanTM includes a two-level classification that enables the hygiene features of every machine to be Ten Principles of Equipment Design tailored to the specific cross-contact risks and cleaning protocols at the site. 1. Cleanable 3 2. Made of compatible materials 3 3. Accessible for cleaning and sanitation 3 4. No material collection 3 5. Hollow areas eliminated or sealed 3 6. No niches 3 7. Operates with sanitary performance 3 8. Validated cleaning methods 3 9. Separate processes wherever possible 3 10. All personnel to meet and follow hygiene and sanitation requirements 3

Biscuits, Cookies & Crackers | PAGE 10 Moulding, cutting and wirecut die services

As a long-established world leader in biscuit, cookie and cracker equipment design and manufacture, Baker Perkins has developed a unique understanding of the interface between the machine, its roll or die and the product.

At Baker Perkins we understand that rolls and dies are not Why choose Baker Perkins? simple commodity components - they are critical parts of l Process insight from OEM the forming process that have a fundamental effect on plant l Library of thousands of designs performance and product quality. l Custom design service l Full range of roll and die types Rolls and dies that run cleanly and reliably make a l significant contribution to line efficiency. Successful Available to suit all makes of forming machine rolls and dies start with a good design based on a clear l Fast and accurate 3D CAD design and engraving understanding of the customer’s requirements, while l Hand samples and test sleeves for pre-production manufacturing using the latest design software and review or testing machine tools keeps quality high and lead times down. l Fully equipped test lab l Help and advice over the phone or on site l Fast track manufacture l Repair, recoating and reconfiguration of worn, damaged or obsolete rolls and dies

Biscuits, Cookies & Crackers | PAGE 11 Baker Perkins Ltd Baker Perkins Inc Manor Drive 3223 Kraft Ave SE Paston Parkway Grand Rapids Peterborough MI 49512-2027 PE4 7AP USA United Kingdom

T: +44 1733 283000 T: +1 616 784 3111 F: +44 1733 283004 F: +1 616 784 0973 E: [email protected] E: [email protected]

I: www.bakerperkinsgroup.com/biscuit