Forming

In  forming sections  the dough is passed through several rolls  to form sheets , these
sheets are then converted into One uniform sheet of desired  thickness it is normally
6-5mm.

Moulders and cutters are used to cut sheet or convert dough  into desired shape and size

Stages in forming

laminators : Dough after mixing in  tipped into laminators hoppers r  with some mechanical
/pneumatic tilting . There are two type of  laminators.

Horizontal type laminators : If space is not the constraint  then horizontal type laminators
are the best selection as the maintenance and repairs are easily done. The lamination and
the controls are visible . Changing webs and rolls are very easy .Pneumatics and servo
motors are used in now modern day laminators for automated speed to be synchronised
with  rest of the plant .11-14 sheet per batch



Vertical type laminators : Vertical type of laminators have been there for very long its
useful if space is aconstraint.Dough is passed through three stage rollers  and after
lamination of sheet it cut into sheets which are then carried to   rollers through inclined
webs .


Gauge roll stands . Reduction in sheet is achieved through  numerous gauge roll s stand .
Popular  are three stand gauge rolls or four stand gauge roll . Reduction are achieved in  
stages  as not to create too much stress on the sheet , webs are provided in between for
relaxation even an additional web is provided prior to cutter to release stress from dough
sheet.Best results are  achieved  through four stand gauge rolls . These gauge roll are of
different dia depending upon the plant  capacity  could be as small as 6" ,8"' , 10" , 12''
and 14'' . Speed are set as per plant and cutter rpm . Guage roll speed has to be
increased in every stand so as to maintain the flow of sheets .



Dough sheet conditioning : Dough sheet conditioning is done as per the ambient
conditions in the plant .

Steam spray - to moist the web surface

Blower : to dry  the dough surface.

Flour dusting : to dry the wet surface of the dough .


Above process is mainly for  cutting Variety .



Toppings : Toppings are done through mechanical, vibratory or sprays . means where a
hopper is placed above the plant line after the cutter   . The toppings  could be milk , salt ,
sugar or  cashew , pista bits .


Rotary cutter :

Rotary cutter consists of  cups  which are a attached to the cutter shell.This shell is then
fixed to the shaft and drive mechanism . Two types of rollers are popular One is complete
on mould shell where  cups are attached in the cavity designed for the cups with dowel
pins .


Second concepts is also very popular  when shell has several  rings fitted over it .

This helps in easy removal of damaged part and also very helpful in taking various trials .

Cuter is coupled with rubber roller of shore hardness  approx -80-85 . Rubber roller or the
pressure roller helps in releasing  wet  biscuit .

RPM : Rotary cutter speed is set  as per plant capacity and baking time , Variety .


Band coverage  efficiency : It is ratio of
total surface area of cutter -moulder / no biscuit cups



Moulding  Roller :It is applied for short dough  ,The dough is prepared in lumps these are
then fed to die roll through either reciprocating conveyor to The hopper  or a rotary
conveyor which allows these dough crumbs to spread uniformly on The die roller surface .
These die roller have dies engraved  into it . Dough pieces are then released by feed
roller which pushes The dough into The dies.



MOULDERS AND  CUTTERS

LAMINATORS









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