Transcript Serton Enginy Complete integrated breadcrumb production line

Breadcrumb Machines
?
Why
Breadcrumbs
• Food industry - it is growing fast and having
problems in finding good breadcrumb suppliers.
• Animal feed industry – most of animal food has a
high percentage of breadcrumbs.
• Final consumer – supermarkets and other points
of sales.
“The market for ready to eat meals in the five largest European
countries - the UK, Germany, France, Italy and Spain - increased 5%
between 2006 and 2007 to reach approximately 8.4 billions euros.
Sales of RTE meals are forecast for a further 18% growth and will
reach 9.9 billion euros by 2011.”
- researchbuy.com
101 uses for breadcrumbs!
• For breading fish, meat and vegetables.
• As a binding or thickening agent for soups and sauces.
• For adding to paste-dough based products. (Croquettes, köfte,
stuffing, scotch eggs, nuggets, Christmas puddings, etc).
• Breadcrumbs can be soaked and adding back into the dough.
In certain types of bread it can help with hydration in the
production process.
• For adding to delicatessen products as a way of improving
texture and increasing water retention: (sausage meat, sliced
processed meat, etc.)
• As animal feed: (fish, birds, other animals).
CARACTERISTICS OF THE LINE
• Footprint as small as 2 x 4.5 metres
• Crumbs par-baked, surplus or unsold bread
• Can be integrated into crust removing unit
• Sealed and hygienic unit
• Plants from 150-5000 kilos per hour
• Optimised for energy efficiency
Mode of operation (compact plant)
• Our unique MTV shedder mill consists of a two stage system
of revolving blades that cut the bread into small pieces.
– Designed without crevices to eliminate danger of
fermentation.
• The reduced bread is transferred by fluidised air conveyor
system.
– This can be any length so the plant can be situated away
from the bread source.
• Surplus air is removed by means of a cyclone separator.
Mode of operation (cont…)
• The crumbed bread is heated in a constantly revolving chamber.
The chamber’s internal cellular structure ensures product is
uniformly distributed to increase the surface area of the product and
to balance the cylinder. Those particles with higher moisture content
remain in the dryer for a longer period of time.
– resulting in constant level of moisture in the final product and
avoiding over-dry or toasted particles.
• Located behind the dryer is a combustion chamber whose burner
produces and maintains the BTU’s required for the system.
•
– which is in turn based on the humidity in the product.
Mode of operation (cont…)
• The crumb now passes through our vertical axis aspirated MTM
crumber mill with smooth internal surfaces and cyclonic separation
of product from air.
- Incorporates easily interchangeable internal sieve.
• This feeds into the plansifter grading machine which
automatically filters the desirable breadcrumb size and separates
the dust from the crumb.
- Dust produced 0.5%. Fines 15% (125-200 microns).
•
Breadcrumbs pass to silo via pneumatic conveyer.
Production Flowchart
Feeder
Mill
Cutter / Mill
Plansichter
Dryer
Silo
Hot air generator
Compressed air unit
Performance Specifications
Chart demonstrates how the system performs based
on the removal of humidity throughout the process:
Bread Humidity Chart (Compact PR-350 Kg/h RDP)
PRODUCT:
White Bread
Standard B
Return B
Partially baked
Standard Bread
Standard Bread
250
350
470
Continuous
Continuous
Continuous
0,28
0,29
0,32
Initial Humidity (%):
36
30
25
Final Humidity (%):
8
8
10
Air (max. 350ºC.)
Air (max. 350ºC.)
76
78
78
Bread Crumb Production: (Kg/h)
174
272
392
Approx. Consumption: Therms/h
68 (270000 BTU)
67 (265860 BTU)
67 (265000 BTU)
Bread types
Input Capacity (Kg/h):
Process:
Apparent Density: (Tm/m)
Heating Fluid:
Water to evaporate: (Kg/h)
Air (max.300ºC.)
Performance Specifications
Chart demonstrates how the system performs based
on the removal of humidity throughout the process:
Bread Humidity Chart (PR-500 kg/h RDP)
PRODUCT:
White Bread
Standard B
Return B
Partially baked
Standard Bread
Standard Bread
420
500
600
Continuous
Continuous
Continuous
0,28
0,29
0,32
Initial Humidity (%):
37
30
25
Final Humidity (%):
8
8
10
Air (max. 350ºC.)
Air (max. 350ºC.)
Water to evaporate: (Kg/h)
120
119
100
Bread Crumb Production: (Kg/h)
297
380
500
Approx. Consumption: Therms/h
110
102
89
Bread types
Input Capacity (Kg/h):
Process:
Apparent Density: (Tm/m)
Heating Fluid:
Air (max.300ºC.)
Performance Specifications
Chart demonstrates how the system performs based
on the removal of humidity throughout the process:
Bread Humidity Chart (PR-1000 kg/h RDP)
PRODUCT:
White Bread
Standard B
Return B
Partially baked
Standard Bread
Standard Bread
770
1000
1200
Continuous
Continuous
Continuous
0,28
0,29
0,32
Initial Humidity (%):
37
30
25
Final Humidity (%):
8
8
10
Air (max. 350ºC.)
Air (max. 350ºC.)
Water to evaporate: (Kg/h)
243
240
200
Bread Crumb Production: (Kg/h)
527
760
1000
Approx. Consumption: Therms/h
212
204
180
Bread types
Input Capacity (Kg/h):
Process:
Apparent Density: (Tm/m)
Heating Fluid:
Air (max.300ºC.)
Performance Specifications
Chart demonstrates how the system performs based
on the removal of humidity throughout the process:
Bread Humidity Chart (PR-2000 kg/h RDP)
PRODUCT:
White Bread
Standard B
Return B
Partially baked
Standard Bread
Standard Bread
1500
2000
2300
Continuous
Continuous
Continuous
0,28
0,29
0,32
Initial Humidity (%):
37
30
25
Final Humidity (%):
8
8
10
Air (max. 350ºC.)
Air (max. 350ºC.)
473
478
383
Bread Crumb Production: (Kg/h)
1027
1522
1917
Approx. Consumption: Therms/h
440
410
380
Bread types
Input Capacity (Kg/h):
Process:
Apparent Density: (Tm/m)
Heating Fluid:
Water to evaporate: (Kg/h)
Air (max.300ºC.)
SILO
CICLON
MOLINO TROCEADOR
TROMMEL-SECADOR
MOLINO
GENERADOR DE CALOR
PLANSICHTER
TRANSPORTE NEUMATICO
PLANTA COMPACTA PAN RALLADO PR-250
PR 2000
Dedicated bread
crumb line (Panalca)
Latest breadcrumb installations by Serton
2005
PANALCA-2, Alcala de H., Madrid
DIATOSTA, Aveiro, Portugal
RUIPAN, Fuenlabrada, Madrid
LUCENA, Malaga, Spain
1600kg/h
350kg/h
3000kg/h
350kg/h
2006
GALLO, Cordoba, Spain
PANRICO, Tenerife, Spain
ARTADI, Zumaia, Spain
In process, New Jersey, United States
1600kg/h
1000kg/h
1500kg/h
350kg/h
Why Serton Enginy?
• 80% installed capacity in Spain is Serton
• 30 years of experience
• Flexible, low cost base
• Design and build
• Long history of repeat orders from est. clients
Serton Enginy, S.L.
Travessera de Les Corts, 164 / 08028 Barcelona
tel: (+34) 933 300 250 Fax (+34) 933 300 754 /
www.sertonenginy.com / [email protected]