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How to Build a Biscuit Oven

How to Build a Biscuit Oven

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How to Build a Biscuit Oven

Lunghezza:
527 pagine
1 ora
Pubblicato:
Mar 19, 2019
ISBN:
9780463800027
Formato:
Libro

Descrizione

How to Build a Biscuit Oven is an e-book aimed at anybody looking to Manufacture Biscuit Ovens within a tight budget. This could be small biscuit makers, start-up biscuit makers or contract Engineering companies looking to develop new markets. The information included allows someone with basic knowledge to manufacture a biscuit oven.

The Direct Gas Fired Biscuit Oven design included within the book lends itself to low technology manufacture, allowing ovens to be manufactured using basic workshop facilities with minimum investment. The book includes:-

Description of each stage of building and installation with photos
All main assembly/layout drawings
All parts lists
Key component specifications and suppliers
Detail oven specifications

Pubblicato:
Mar 19, 2019
ISBN:
9780463800027
Formato:
Libro

Informazioni sull'autore

Iain graduated from the School of Industrial Design (Engineering) at Royal College of Art in London in 1965 and joined Baker Perkins Ltd. He was Industrial Design Engineer, working in the Technical Department on the design of new biscuit and bakery processing machines until 1975, gaining a thorough technical knowledge of the machines and processes. In 1975, Iain was appointed Market Development Manager at Baker Perkins, involved in developing the Baker Perkins forward planning for new business, product development and acquisitions. In 1979 Iain became International Sales Manager with responsibility for the business in Asia and Africa. In 1990 Iain was appointed Regional Manager Asia Pacific for Baker Perkins and re-located to Indonesia and later in 1997 to China. His appointments included Managing Director of Baker Perkins (Hong Kong) Ltd. and Director of Baker Perkins Japan KK. Iain established a successful manufacturing facility for biscuit ovens in Dalian, China in 1990 for Baker Perkins and subsequently continued a manufacturing capability for Baker Pacific Ltd. in China, India and Indonesia. Baker Pacific companies Iain established PT Baker Pacific Mandiri in Indonesia in 2000. As the business outside Indonesia grew, Baker Pacific Ltd was established in Hong Kong in 2004 and is now our principal operating company, providing process technology and machinery for the biscuit, chocolate and candy industries. Experience in the biscuit industry:- Engineering design of biscuit process machines including a range of baking ovens Biscuit baking oven manufacture in China, Indonesia and India Sales and marketing in Europe, Asia, North America, Africa Project management and service

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Anteprima del libro

How to Build a Biscuit Oven - Iain Davidson

How to Build a Biscuit Oven

Direct Gas Fired Ovens for industrial production

IAIN DAVIDSON

Director, Baker Pacific Ltd.

Author of Biscuit Baking Technology, 2nd Edition

Published by Academic Press 2016

an imprint of Elsevier, store.elsevier.com

Baker Pacific Ltd., 3905 Two Exchange Square, Suite 7443, 8 Connaught Place, Hong Kong

Tel. 852 2522 1114 Fax. 852 2521 1190 email: bakerman@bakerpacific.com.hk

web-site: www.bakerpacific.com.hk www.bakerpacific.net

Iain Davidson

Iain graduated from the School of Industrial Design (Engineering) at Royal College of Art in London in 1965 and joined Baker Perkins Ltd. He was Industrial Design Engineer, working in the Technical Department on the design of new biscuit and bakery processing machines until 1975, gaining a thorough technical knowledge of the machines and processes.

In 1975, Iain was appointed Market Development Manager at Baker Perkins, involved in developing the Baker Perkins forward planning for new business, product development and acquisitions. In 1979 Iain became International Sales Manager with responsibility for the business in Asia and Africa.

In 1990 Iain was appointed Regional Manager Asia Pacific for Baker Perkins and re-located to Indonesia and later in 1997 to China. His appointments included Managing Director of Baker Perkins (Hong Kong) Ltd. and Director of Baker Perkins Japan KK.

Iain established a successful manufacturing facility for biscuit ovens in Dalian, China in 1990 for Baker Perkins and subsequently continued a manufacturing capability for Baker Pacific Ltd. in China, India and Indonesia.

Baker Pacific companies

Iain established PT Baker Pacific Mandiri in Indonesia in 2000. As the business outside Indonesia grew, Baker Pacific Ltd was established in Hong Kong in 2004 and is now our principal operating company, providing process technology and machinery for the biscuit, chocolate and candy industries.

Experience in the biscuit industry

• Engineering design of biscuit process machines including a range of baking ovens

• Biscuit baking oven manufacture in China, Indonesia and India

• Sales and marketing in Europe, Asia, North America, Africa

• Project management and service

ACKNOWLEDGEMENTS

Our Baker Pacific team are responsible for the specification, design, manufacture, installation and commissioning of the ovens featured in ‘How to Build a Biscuit Oven’. John Lilley, Stephen Eldridge, Dave Young and Xu Dan Ping have made our oven manufacturing business and this book possible.

Iain Davidson

//October 2016

Table of Contents

CHAPTER 1: Why build a biscuit oven?

1.1 Growing world-wide market for biscuits

1.2 Limited number of suppliers of quality biscuit ovens

1.3 Biscuit oven manufacture

1.4 Biscuit baking process

1.5 What is required?

CHAPTER 2: What type of oven?

2.1 The Direct Gas Fired (DGF) Oven

CHAPTER 3: Heat transfer and heat ratings

3.1 Heat transfer

3.2 Radiation

3.3 Conduction

3.4 Convection

3.5 Oven designs

3.6 Heat Rating

3.6.1 Crackers

3.6.2 Short doughs

3.7 Multi-purpose ovens

CHAPTER 4: Direct Gas Fired Oven Specifications

4.1. Oven output

4.2 Calculation of Oven Zone Lengths

4.3 Calculating the number and type of burners

4.4 Recommended burners

4.5 Technical Specification for a Multi-purpose DGF Oven

4.5.1 Oven Feed End

4.5.2 Direct Gas Fired Zone 89.9m long with 7 heat control zones

4.5.3 Direct Gas Fired Burners and Gas Equipment

4.5.4 Automatic temperature control

4.5.5 Oven band

4.5.6 Oven band cleaner

4.5.7 Delivery end section

4.5.8 Emergency drive

4.5.9 Oven end extraction hood

4.5.10 Control panels

4.6 Oven safety systems

4.6.1 Oven band

4.6.2 Ignition

4.6.3 Purge system

4.6.4 Over Temperature

4.6.5 Power Failure

4.7 Electrical installation

4.8 Components

4.9 Finishes

4.10 Spare parts

CHAPTER 5: Selecting the oven conveyor band

5.1 Products

5.1.1 Crackers

5.1.2 Semi-sweet biscuits and short dough biscuits

5.1.3 Cookies

5.2 Open wire mesh bands

5.3 Compound Balanced Weave Belts (heavy mesh)

5.4 Steel bands

CHAPTER 6: Purchasing and Shipping

6.1 Purchasing

6.1.1 Contractors for fabrication

6.1.2 Purchase of specialist components

6.2 Shipping

CHAPTER 7: Manufacturing drawings

7.1 Design layout drawings

7.2 Oven construction

7.2.1 Modular construction and build on site

7.2.2 Manufacture and installation of the oven

7.3 Drawing numbers

7.4 Parts Lists

7.5 Electrical drawings

7.6 Control panel fascias

CHAPTER 8: Construction of the Direct Gas Fired Oven

8.1 Stage 1: Oven base structure

8.2 Stage 3: Baking chamber slides

8.3 Stage 4: Baking chambers

8.3.1 Construction and corrosion resistance

8.4 Stage 5: Crown sheets, explosion panels and extraction ducts

8.4.1 Explosion panels

8.4.2 Extraction ducts

8.5 Stage 6: Frames for outer cover and fan supports

8.6 Stage 7 Clean out and inspection doors, insulation, wall sheets

8.6.1 Clean out doors

8.6.2 Inspection doors

8.6.3 Oven insulation

8.7 Stage 8: Extraction fans and dampers

8.8 Stage 9: Air header pipes

8.9 Stage 10: Gas header pipes

8.10 Stage 11: Outer covers for control side

8.10.1 Outer covers

8.11 Stage 12 Gas burners

8.11.1 Eratec MFB burner installation

8.11.2 Burner specification

8.11.3 Flynn burners and gas system

8.12 Stage 13: Oven roof sheets

8.13 Stage 14: Outer covers on non-burner side

8.14 Stage 15 Oven extensions

CHAPTER 9: Oven Conveyor Construction : Feed / Tension End

9.1 Oven band circuit

9.2 Conveyor feed / tension end

9.3 Oven feed end unit: final assembly

9.4 Oven end drum and shaft assembly

9.5 Drum bearing and mount assembly

9.6 Oven feed end frame assembly including linear slides

9.7 Pneumatic tension assembly

9.8 Plough assembly

9.9 Drum scraper assembly

9.10 Oven band tracking: Wander Warning Assembly

9.11 Oven feed / tension end covers

CHAPTER 10: Oven Conveyor Construction: Delivery / Drive End

10.1 Delivery / drive end arrangement

10.2 Drive End Frame

10.3 Delivery end drum

10.4 Bearings, sprockets and drive train

10.5 Motor and Gearbox

10.6 UPS Uninterruptible Power Supply

10.7 Stripping Knife

10.8 Stripping Conveyor

10.9 Drum scraper

10.10 Drive End Band Wander Warning

10.11 Delivery End Outer Covers

10.12 Oven end hood design

10.13 Calculations for oven band drive

10.13.1 Calculation of oven band tension

10.13.2 Calculation of torque required for the conveyor drive

10.13.3 Calculation of electric motor power

CHAPTER 11: Conveyor construction: oven bands

11.1 Wire Mesh Bands

11.1.1 Skid bar supports

11.1.2 Return band supports

11.1.3 Wire mesh oven band cleaning

11.1.4 Wire mesh oven band tracking

11.1.5 Joining wire mesh bands

11.2 Compound balanced weave (heavy mesh bands)

11.2.1 Band support rollers

11.2.2 Heavy mesh band tracking

11.3 Steel bands

11.3.1 Steel band supports

11.3.2 Steel band tracking

CHAPTER 12: Key Components

12.1 Bearings

12.1.1 SKF High temperature bearings

12.1.2 SKF heavy duty bearing assembly for oven end drums

12.1.3 Linear Motion Ball Rail Systems

12.1.4 NSK / RPH bearings

12. 2 Burners

12.2.1 Eratec

12.2.2 Flynn burners

12.3 Clamping elements, clutch, chains, sprockets

12.3.1 Cross and Morse

12.4 Electrical Equipment

12.4.1 Siemens

12.4.2 Schneider Electric / Telemechanique

12.4.3 Danfoss

12.4.4 Mitsubishi

12.5 Electrical Cable and Trunking

12.5.1 Lapp Kabel

12.6 Electrical sensor and monitoring equipment

12.6.1 Euchner

12.6.2 Red Lion Controls

11.6.3 Synatel Instrumentation Ltd.

12.7 Fans and Blowers

12.7.1 Halifax Fan

12.7.2 Moro Srl

12.8 Gas Equipment

12.8.1 Arita Engineering

12.8.2 Donkin

12.8.3 Krom Shroeder

12.9 Insulation and seals

12.9.1 Duratec

12.9.2 Rockwool

12.9.3 TYM Seals and Gaskets Ltd

12.10 Oven bands

12.10.1 Ashworth Bros

12.10.2 Berndorf

12.10.3 Agrati Group La Bridoire S.A.R.L.

12.10.4 Cambridge Engineered Solutions

12.10.5 Sandvik Process Systems

12.10.6 Steinhaus GmbH

12.11 Pneumatic equipment

12.11.1 Festo

12.11.2 Martonair

12.12 Powder Coating Materials

12.12.1 Weilburger Coatings GmbH

12.13 Pressure switches

12.13.1 A J Antunes

12.14 PLC equipment

12.14.1 Allen Bradley

12.15 Motors and gearboxes

12.15.1 Nord

12.15.2 SEW-Eurodrive

12.16 DC motors

12.16.1 Alstron Singapore Pte

12.16.2 Transdrive

12.17 Thermocouples

12.17.1 TC Direct

12.18 Temperature controllers

12.18.1 Omron

12.19 UPS (uninterruptible power systems)

12.19.1 Dale Power Solutions

CHAPTER 13: Oven installation

13.1 Factory layout drawings

13.2 Oven installation equipment

13.2.1 List of equipment required for the installation of a build on site oven

13.2.2 Centre Line

13.3 Oven installation

13.3.1 Installation stages

13.3.2 Stage 1. Oven support structure

13.3.3. Stage 3. Bottom oven sheets and slides to support baking chambers

13. 4. Baking chambers

13.4.1 Welding of the baking chambers

13.4.2 Installation of oven band supports in the baking chambers

13. 5. Crown sheets, explosion panels, extraction ducts

13.6 Frames for outer covers

13.7 Clean out doors and Inspection doors

13.8 Extraction fans and dampers

13.9 Air header pipes

13.10 Gas header pipes

13.11 Outer covers, insulation, main air pipe

13.12 Gas burners and equipment

13.13 Roof sheets

13.14 Outer covers

13.15 Electrical installation

13.16 Oven band installation

13.16.1 Oven band tracking

13.16.2 Joining wire mesh oven bands

13.16.3 Joining Compound Balanced Weave bands

13.16.4 Joining steel bands

13.16.5 Oven band cleaner

Bibliography

14. Disclaimer

OPERATION AND MAINTENANCE MANUAL

1. General safety instructions

1.1 Emergency Shutdown

1.2 Guards and Safety Devices

1.3 Installation Safety

1.4 Commissioning Safety

1.5 Operation Safety

1.6 Cleaning and Maintenance Safety

1.7 Oven temperature

1.8 Compressed Air

1.9 Regulations

1.10 Work Practices

1.11 Running the Equipment without Safety Systems

1.12 Oven hazards: Fire

1.13 Oven band stop

1.13.1 If the Mains Power supply has failed

1.13.2 If the Emergency Stop button has been pressed

1.13.3 If a band wander trip has occurred

1.14 Specified ratings

2. Delivery of the oven

2.1 Oven identification

2.2 Prolonged Storage

2.3 Protection for Storage

3. General Description of the oven

4. Oven specification

4.1 Oven zones

4.2 Automatic temperature control

4.3 Baking band

4.4 Oven band tension section

4.5 Oven band drive section

4.6 Emergency DC drive

4.7 Extraction hood

4.8 Main electrical control panel

4.9 Components

4.10 Oven Safety Systems

4.10.1 Baking Band

4.10.2 Gas Supply

4.10.3 Ignition

4.10.4 Over Temperature

4.10.5 Power Failure

5. Oven operation

5.1 Before starting the oven

Main Control Panel

5.2 Lighting the Burners

5.3 Heating up / start of production

5.4 Production

5.5 Quality checks

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