Bread Rolls Grain Holding Uses Kbnig's First PU Integral Oven in Russia to Bake Small Baked Goods in Its Kostroma Plant

20 21 Baking Report Backtechnik-europe Backtechnik-europe Report Baking

I I Bread rolls Grain Holding uses Kbnig's first PU Integral oven in Russia to bake small baked goods in its Kostroma plant.

1 1 [1] A projecting transfer belt, which is loaded from the final proving chamber's outfeed belt, transfers the products onto the baking trays inside the PU Integral oven. [2] The sliding system pushes the baking trays from the first tower into the second. [3] The 30 baking trays installed measure 2,500 by 1,000 millimetres each, thereby offering a usable baking surface of 75 square metres in total.

providing a brief historical over ori, in order to increase the quality goods. At Grain Holding, the oven view. With a daily output of 120 and quantity of production." is used for baking small baked tons of baked goods, the compa goods. A projecting transfer belt, ny--which makes and produces all The oven which is loaded from the final the bakery items it offers itself proving chamber's outfeed belt, -rigorously follows the corporate The PU Integral automatic indus transfers the products onto the policy issued by general mana trial baking oven in Kostroma hot baking trays inside the oven. ger Andrej Wasiliewitch Alexeew: includes two towers, in which The PU Integral houses a total of "We produce a small range of the revolving baking trays move 30 baking trays made of sheet steel products adapted to the Russian according to the same princi with a footprint of 2,500 by 1,000 market, with which we strive for ple as a paternoster lift or eleva millimetres each, resulting in a market leadership in the markets tor. The oven is characterised by usable baking surface of a total of we serve. We achieve this goal by independent baking zones which, 75 square metres. Konig has inte making targeted investments in thanks to temperature, air volu grated a spraying system into the our businesses with the intention me, and humidity control, ensure input station, whereby the dough of raising the degree of automati- good product quality for all baked pieces are sprayed with water even

mall baked goods in Russia In this plant, Grain Holding relies conveyor ovens. Another reason -contrary to the German on Austrian machine and plant was the reduced number of inter S speaking countries--are not manufacturer Konig's production face issues along the production K� the type of bakery item customers line expertise: from processing all line, by using Konig systems in tend to ask for the most. Grain the way to the ovens. We would the areas of roll processing, final Holding's achievement of success like to expand especially on the PU proving chamber, and oven. "Here fully establishing Kaiser rolls and Integral automatic oven with its at this location, the oldest indus other types of small baked goods independent baking zones, which trial bakery in Kostroma--Bread on the Russian market, therefore, was installed in the capital city of Combine Number One--was foun cannot be rated highly enough. Kostroma province for the first ded in 1935. In 1993, the factory This includes the area around time in Russia. One of the rea went to the Russian Bread corpo Kostroma as well as the city its sons for choosing this particular ration before Grain Holding took [4] In order to improve the quality of the baked goods, the input station as well as the output station shown here are elf, where one of the group's five compact oven was the small foot over the bakery in 2007," general equipped with spraying systems. [5] Konig uses an industrial PLC control system, type Siemens Simatic S7, with a colour monitor to operate and control the oven. [6] Packed in polybags, the small baked goods are delivered to all the well-known production installations is based. print as compared to traditional manager Alexey Dudin explains, supermarket chains and other customers within a delivery radius of approximately 300 kilometres.

Backtechnik 01/2016 Backtechnik 01/2016 22 Baking Report Backtechnik-europe echni ,.

Backtechnik europe is the renowned trade magazine for the bakery industry and, bakery chains in Europe. In large compa nies, technical solutions are needed with an overall conceptu al deisgn. Practical reports and on-site reports from European A��.. 1�Awa,d2015- Waru Prize-winning innovations productions as well as technical innovations or scientific que stions are the main focus of Backtechnik europe. The whole range of topics covers process technology of baked goods, snacks and confectionary. With its in-depth editorial con tent from raw materials to process technology and reports, [7] Even the weighing process is already automated as much as possible, significantly reducing the error rate during the production process. [8] The bread roll production line's pre-prover comes equipped with 500 swing trays. [9] The adjustab Backtechnik offers readers precise background knowledge le stepped belt transfers the dough pieces from the bread roll line to the final proving chamber using a 90 degree angle. required for a successful production. before the actual steaming takes to constant and well-distributed from where it is then poured into place. A loading trolley then posi- heat. When the baking trays are the roller hopper. Using rotating tions the baking trays below the ready for output below tower two, star rollers, optimised dough pieces An Expertise ibaAward 2015: first tower. Two hydraulic cylin- the hydraulic cylinders lift the Joa- are transferred to the dividing area for rolls Prt:e-11.TY"lingO'lQl.at}:::ns ders now lift the baking tray until ding trolley until the baking trays of the five-row Industrie Rex I it reaches the first position and the are released from the latch locking machine. The horizontally moving latch system fixes the tray in place. mechanism. The trays can now be slider now presses the dough into Before this process can start, the moved down a position. The tray the openings of the dividing drum. sliding system needs to push the now lying on the loading trolley Any surplus amount of dough is uppermost baking tray from the is conveyed to the output, where a returned to the dividing area via first and into the second tower, in removal mechanism ensures that a scraper. After being rotated 180 order to create the required space the ready-baked products are gent- degrees anti-clockwise, the dough below. For the individual zones ly pushed off. All processes inside pieces are discharged to an inter- within the PU Integral oven, Konig the Konig oven are displayed gra- mediate belt. It is only by separa- uses an innovative sealing system. phically. To this end, the machi- ting the dividing and rounding Movable metal seals separate the ne and plant manufacturer uses process steps that a high perfor- D YES, I am ordering Backtechnik europe (6 editions per year} for an annual purchase price individual baking trays, thereby an industrial PLC control system, mance of up to 50 cycles per minu- of 170 euros (subscription price 131 euros incl. VAT plus foreign shipping and handling von creating the independent zones as type Siemens Simatic S7, with a te can be achieved and the dough 39 euros inc. VAT}. described above. The steam rea- colour monitor, which is also used can relax. Subsequent rounding of My subscription is valid for 12 months and renews by itself unless I cancel in writing 8 weeks before the subscription expires. ching the baking chamber by way for controlling and operating the the dough pieces takes place inside Privacy Policy: Your personal data will only be used by Backtechnik in order to carry out the order. I agree that you will send me of steam pipes is produced exter- oven. an oscillating rounding drum. Pro- further product information over specialist publications by the publisher and you will keep me up-to-date over special offers. 11: nally. The amount of steam, which perties and size of the drum depend Please send this information to my indicated e-mail address/fax no., or please call me under the indicated phone number. I!' is initially set by Konig techni- Processing on dough consistency and dough ,ii cians and later on falls into the weight. In its lowermost position, First name/Last name operator's area of responsibility, is The weighing process alone is proof the dough pieces are transferred controlled by electromagnetic val- of the high degree of automation. to the spreading belt and conveyed Street/No. Zip code/City Country ves. Twogas-powered burners--one All ingredients are weighed and into the pre-prover. The pre-prover Phone (incl. country cod e)/fax E-mail order to: for each tower--handle the baking kneaded in a fully-automated pro- is equipped with 500 swing trays, :I temperature, and supply the hea- cess, using a Diosna kneader with which travel empty through the Payment (in Europe): Invoice: D SEPA Direct Debit Mandate: D fax: +49 541 580544-98 1, ting registers with heating gas. bottom discharge. From the knea- UV sterilisation system and the Account-Number/lBAN SwiftBIC Using the installed ventilators, it der, the dough is transported into drying zone with fan and heating I is possible to change the direction the pre-portioning hopper of the system, in order to minimise con- Payment (countries outside the EU): Invoice: D Paypal: D by post: of the airstream, thereby ensuring dividing and rounding machine, tamination. Additional system fea- Subscribers outside the EU can pay the purchase price via paypal. You will receive a payment request vla email. Therefore your INGER Verlagsgesellschaft mbH that the baked goods are exposed which has a capacity of 240 litres, tures include a pre-rolling unit, a E-Mail Address is indispensable in this form of payment. Luisenstra8e 34 E-Mail Address Expiry Date D-49074 Osnabruck / Germany Date/Signature Backtechnik 01/2016 24 Baking R e p o rt Backtechnik-europe Backtechnik-europe R e p o rt Baking. 25

[10] The purchase of the PU Integral oven in 2014 also included purchase of the final proving chamber, in order to further automate the production of small baked goods. [11] A retracting unit transports the dough pieces to the swing trays inside the final proving chamber, which has the same width as the oven and a working width of 2,500 millimetres. [12] Two of a total of six ventilators are attached to the upper section of the final proving chamber, which ensure that the air inside the [13] The brush cleaning system with its rotating cup brushes cleans the tilted, empty swing trays outside of operating hours. proving chamber is evenly distributed. [14] Konig uses high-end materials to ensure continuous operation of the production line. stamping station with a Kaiser and tors--four small ones in the lower quality with which the Konig line company, we continue to rigorous strategy has proven successful in star stamping tool, a forming sta section and two in the upper sec is manufactured, and which we are ly follow the path to automating recent years, and Grain Holding's tion, and a sprinkling unit. After tion--ensure even distribution of very satisfied with," Dudin explains our lines. For this, we have set up success is affirmation of our cor travelling through the line, Konig the heated air by means of heating the positive development. In con an investment plan, which we fulfil porate policy." has installed an adjustable stepped elements and, as a result, an even clusion, Alexeew adds: "Here at our even when times are harder. This Gregor Vogelpohl belt to allow perpendicular transfer climate inside the proving cham at a 90 degree angle from the flow ber. Here, too, a UV sterilisation direction to the right and onto the system and a drying zone with fan retracting unit of the subsequent reduce the risk of mould forming I, module. on the swing trays as much as The new original Alveograph possible. These measures for good Alveo�� by CHOPIN Technologies The final proving hygiene are supported by the use of chamber a brush cleaning system. Rotating cup brushes clean the tilted, emp The Alveograph is internationally recognized and standardized. It is used daily by wheat Together with the PU Integral ty swing trays outside of operating breeding, grain storage, milling and baking oven, the final proving chamber hours. industries to measure the viscoelastic was installed in 2014 in order to propertiesof wheat flours. significantly increase the degree of Conclusion The new Alveolab is more accurate and Phone: +8 4967 630350 automation on the bread roll pro easier to run. Key steps of the test are now Email: [email protected] duction line. With a working width Since only a small variety of small fully automated to limit the impact of the Website: www.grainholding.ru of 2,500 millimetres, the system baked goods are produced in large operator. Morevoer, dough bubbles are made in General Manager, "Podolskij a fully temperature and humidity controlled Chlebokombinat": accommodates the same measure quantities on the Konig line, choo chamber. Andrej Wasiliewitch Alexeew ments as the oven, making it ulti sing the PU Integral automatic oven Bakery visited: OAO "Russkij hleb" mately possible to transfer the was the right decision to make. With the Alveolab, new test protocols can be UI. Lenina, 81 fully proved, delicate dough pieces The oven system can continuous easily designed to meet specific applications 156013 Kostroma and make the alveograph analysis an even Russian Federation to the PU Integral in one go and ly work and operate, and achieves better predictor of flour performance. Founded: 1935 without unnecessary detours. The high hourly and daily outputs. In General Manager, Kostroma: Alexey Dudin dough pieces rest in a total of Kostroma, the industrial baking Head of Technology: 600 swing trays and are proving oven is in operation 15 hours a day, Michael Solovyev in a controlled atmosphere. Here, seven days a week--and the trend is Employees: 300 Konig assumes ownership of the rising. "Small baked goods are not Transport fleet: 70 vehicles For more information Delivery radius: 300 km temperature and air circulation, typically Russian, but they are very flash this code or visit Baked goods production: while the steam is again provided well received by our customers. I www.chopin.fr 120 tons/day externally. A total of six ventila- am sure this is also a result of the

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