INDUSTRIAL PRODUCTION LINES

Baking Technology for the Industrial Production

of Durable Baked Goods

WP BAKERYGROUP

The WP BAKERYGROUP with this corporate

portfolio, we have brought ourselves comprehensively into line with the requirements of bakeries
worldwide. Today, we are in a position to be
able to offer complete solutions from project
planning to fitting out complete bakeries (trade
and industry), as well as supplying used machines.

A central element of our corporate philosophy is a networked thinking which spreads across all individual stages
of production. We call it Process Management, the targeted control of individual production stages and the machinery used as fast as possible with the smallest possible loss
of materials to achieve the desired result, even with small
production volumes, as well as an unrestricted reproducibility of results that have been achieved. And all that with an
extremely high output.
Any unit can be docked on at any time if required for
manufacturing a product there are adequate interfaces
for foreign products.

WPCompetenceCenter

_ Dough/Mixing. Emil Kemper GmbH, Rietberg

_ Rolls. Emil Kemper GmbH, Rietberg

_ B read. Werner & Pfleiderer Haton B.V., NL-Panningen

_ Ovens. Werner & Pfleiderer Lebensmitteltechnik GmbH, Dinkelsbhl

_ I nstore Baking. Werner & Pfleiderer Sachsen GmbH, Sohland

_ Refrigeration. Werner & Pfleiderer Koeling Benelux B.V., NL-Panningen
_ L aminating. Werner & Pfleiderer Lebensmitteltechnik GmbH, Dinkelsbhl
_ E ngineering. Werner & Pfleiderer Industrielle Backtechnik GmbH, Tamm
_ Used Machines. Werner & Pfleiderer Sachsen GmbH, Sohland
_ B akery Software. BackNet E&S GmbH, Muggensturm

www.wpbakerygroup.com/competencecenter

INDUSTRIAL PRODUCTION LINES

INDUSTRIAL PRODUCTION LINES

The professional development, manufacture, installation and servicing of

industrial machines for the production of bakery goods calls for a comprehensive
know-how and decades of experience. Multi-shift operation at full capacity,
accomplishing o ptimum, reproducible product qualities, control systems in
state-of-the-art technology, hygienic standards that comply with highest demands
as well as short cleaning and m aintenance times are essential requirements
faced by modern system concepts. Requirements that are satisfied at
a high level by the individual companies b elonging to WPB AKERYGROUP.
Based

on

these

demands,

we

supply

individually

equipped

industrial

production lines which are renowned for their reliability all over the world.

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INDUSTRIAL PRODUCTION LINES

Werner & Pfleiderer Industrial Bakery Technologies we have been developing, planning, manufacturing, installing and servicing industrial installations for the production of
baked goods for more than 125 years. We are now one of the leading suppliers of highly
automated inline concepts for the continuous production of an extensive variety of goods
ranging from raw materials handling to the transfer to automatic packaging machines. In the
WPBAKERYGROUP we hold a key position in the industrial solutions sector. Our product
portfolio includes machinery concepts for the production of bread and rolls, hard and soft
biscuits, pretzels, crisp bread, rusk, cakes, croutons, breadcrumbs etc.
We provide technical solutions that satisfy the highest demands. In co-operation with our
customers, we develop concepts which not only meet the requirements of the market, but
are also trendsetting for future industrial production.

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Raw materials handling_Processing_Application_Baking_Cooling_Transferring

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INDUSTRIAL PRODUCTION LINES

INDUSTRIAL PRODUCTION LINES

for the continuous production of baked goods

Industrial production lines manufactured by Werner & Pfleiderer Industrial Bakery Technologies
are always designed to meet the individual requirements of the customer. The plant dimensions and
equipment vary depending on the products to be manufactured and the scheduled output per hour. The
modules produced by WPBAKERYGROUP are always practice-proven machines or assembly groups that
have been consistently advanced and on which wide experience has been gained. From raw materials
handling through dough processing and dough moulding, the plant configurations include machines for
any conceivable type of processing, an immense range of dough processing facilities and oven combinations, as well as a wide assortment of conveying, positioning and portioning systems.
The degree of automation in the production lines ranges to fully automated lines with central control
and monitoring units, depending on the customers requirements. We always liaise closely with the
manufacturers of downstream packaging machines.
Industrial production lines from WP are always supplied complete, ready-for-operations and commissioned, and are delivered on schedule production at the customers premises may commence.

4_5

PRODUCTION LINES

MODULES

_Hard biscuit/cracker
production lines

Kneader, continuous dough processing and feed

Laminator, gauge rollers
Cutting machine
Hybrid oven combinations
Conveying, cooling and stacking

_Soft biscuit production lines

Kneader, continuous dough processing and feed

Laminator/sheeter + gauge rollers
Continuous moulding machine
Depositors
SNK tunnel oven and oven combination
Conveying, cooling and stacking

_Production lines for pretzels

Kneader, continuous dough processing and feed

Laminator/sheeter + gauge rollers
Rotary cutter, moulding machine, extruder
Lye bath with sprinkler & cutting machine
SNK tunnel oven and oven combination
Cooling, transfer and packing

_Cake production lines

Mixer, continuous dough feed/portioning in tin moulds

Oven combination
Automated demoulding
Product cooling, product injection
Conveying and transfer to packing

_Crisp bread production lines

Pre-mixers
Crisp bread moulding machine
Flour duster & dusting flour conditioning
Dockering rolls & dough strand cutting machine
Tunnel oven
Cutting & stacking machine
Conveying and transfer to packing

_Rusk production lines

Kneader, continuous dough processing and feed

Dough processing, intermediate proofer, long moulder
Final proofer
Tunnel oven
Bread depanning, bread cooling
Bread cutting and bread slice seating system
Toast oven
Product stacking device

_Breadcrumb production machines

Kneader, continuous dough processing and feed

Portioning
Belt-type proofing channel
Tunnel oven
Bread cooling
Crushing, drying, grinding

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INDUSTRIAL PRODUCTION LINES

HARD BISCUIT/CRACKER PRODUCTION LINES

Hard biscuit/cracker production lines The process route for the production of hard biscuits or crackers
starts with the dough-making. This is followed by the dough lamination and gauge rolling. After that, the
products pass through a rotating cutting machine. The next stage involves an SNK tunnel oven or a suitable
oven combination.
The number of oven modules is adapted to the required baking time in relation to the desired
maximum capacity.
Finally, the products are conveyed to the packaging machines via a cooling conveyor and stacking unit.

1 Twin-shaft high-capacity mixer of the ZK type with controls that enable the memory of up to
50recipes. The two Z-shaped kneading arms are optimally suitable for homogeneously kneading
a great variety of dough types.
2 Automatic dough feed unit with dough portioning, metal detector and feeding conveyor to the
downstream processing machine (laminator, four-roll-sheeter). Four-roll-sheeter in compact construction
for producing a continuous dough sheet.
3 Laminator for the production of cracker and hard biscuit doughs.
4 4.1 Gauge rollers, 4.2 Double cut-out unit, 4.3 Dough net separation and returning
5 SNK tunnel oven in modular design with different heating systems (direct, indirect, convection
and combinations).
6 Automatic stacking machine for piling up biscuits. A follower aligning device ensures that the biscuits
are stacked in precise lines. Depending on the product type, penny stackers may be employed.

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4.1

Hard biscuits and crackers

Cream crackers, soda crackers, cocktail
crackers, cracker mix, potato crackers
Classical hard biscuits, biscuits for children,
zoo-type biscuits, basic biscuits to be
refined with chocolate

4.2

4.3

6
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INDUSTRIAL PRODUCTION LINES

SOFT BISCUIT PRODUCTION LINES

Soft biscuit production lines The process route for producing soft biscuits starts with making the doughs.
This is followed by dough feeding, dough moulding and placing the dough strip on a steel belt. The next stage
involves an SNK tunnel oven. The number of oven modules is adapted to the required baking time in relation to
the desired maximum capacity.
Finally, the biscuits are conveyed to the packaging machines via a cooling conveyor and stacking unit.

1 Batch-type mixer for the preparation of soft doughs.

2 Rotary moulding machine for the scrapless moulding of biscuits and cookies.
3 Extruded products, cut at the transfer point to the baking belt.
4 SNK tunnel oven, ideally suited for the production of soft biscuits and fine baked goods.
5 Biscuits at the oven discharge end.
6 Natural cooling and transport to packaging machine.
7 Biscuits at the feeding section of staking machine.

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Soft biscuits
Soft biscuits or fine baked goods are
produced on tunnel ovens with wire-mesh
belts or solid steel belts.
The doughs are moulded (moulded
articles), cut (wire-cut articles), extruded
(extruded biscuits) or dressed (deposited
articles).

7
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INDUSTRIAL PRODUCTION LINES

PRETZELS AND LYE BATH ARTICLES PRODUCTION LINES

Pretzels and lye bath articles production lines The process route for producing lye bath articles is started
by portioning the filling mass volume and the extrusion process. Cutting groups or biscuit moulding machine
comprise the following step. The final topping of the products is carried out in the lye bath which
incorporates a salt applicator and a cutting machine. The next stage is an SNK tunnel oven.
The number of oven modules is adapted to the required baking time in relation to the desired maximum
capacity. The final transport to the packaging machine is carried out by cross and longitudinal belts, the
length of which is dimensioned to correspond to the required cooling time.

1 The SP extruder is used for extrusion and filling mass portioning and intended to provide uniform dough
strands over the entire baking width. Filling masses are homogenised, temperature-controlled, filtered and
portioned and then guided to the extrusion head.
2 The GH biscuit moulding machine is used for the production of a wide range of pretzels or cocktail
biscuits, simply by interchanging the moulding rolls. The machine is of a multipurpose type and suitable for
optimum biscuit moulding.
3.1 Fresh and return dough are sheeted in the cut-out group and conveyed to the rotary cutting machine for
the production of small and large pretzels via special roll sheeters.
3.2 Synchronised cut-out rolls are equipped with a special return-dough system.
4.1 The moulded, cut or extruded dough pieces are passed through the temperature-controlled lye bath.
After this, the desired topping is applied.
4.2 The dough strands are cut to length or grooved by a special guillotine. The transfer to the oven is carried
out on the basis of defined parameters and results in optimised loading of the baking belt.
5 The SNK tunnel oven provides for an excellent development of the articles to be baked. Convection and
radiation can be ideally combined to obtain an optimum baking process.
6 Transfer of baked sticks onto the cross conveyor belt with downstream cooling route and transport to
the packaging machine.

3.1

3.2

4.1

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Pretzels and lye pastries

Moulded or cut-out pretzels
Extruded or cut-out sticks
Co-extruded sticks, filled with spicy
mixtures
Sticks as sweet biscuit, co-extruded
and filled with sweet mixtures
Toppings with salt, sesame,
cheese or spice mixes

4.2

6
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INDUSTRIAL PRODUCTION LINES

CAKE PRODUCTION LINES

Cake production lines Dough making, followed by dough feed and moulding and/or dough portioning in tin
moulds are the beginning of the process route for the production of cakes. Once baking has been concluded,
the cakes are released from their moulds, cooled and then transferred to the packaging machines.
The size/length of the ovens is adapted to the required baking time in relation to the desired maximum capacity.

Dough processing with vertical batch-type mixer

Dough portioning in tin moulds with filling equipment
Oven loader
Tunnel oven
Product cooling
Product injection
Transport to packaging machines
Mould reversing device
Mould cleaning device
Mould greasing facility

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INDUSTRIAL PRODUCTION LINES

CRISP BREAD PRODUCTION LINES

Crisp bread production lines The process route for producing crisp bread starts with dough making.
Dough aeration, dough cooling and dough application and several flour dusting steps then follow. The next
stage involves a special tunnel oven with very high baking temperatures.
The number of heating zones or the length of the oven is adapted to the required baking time in relation
to the desired maximum capacity.
Finally, the products are conveyed to the packaging machines after having passed through a cooling
conveyor including several cutting and stacking units.

1 Dough processing with pre-mixer, swelling bins, combinator for dough cooling and aeration.
2 Flour duster for upper and lower flour as well as sprinklers for seeds. The continuous dough sheet
which has been formed in a special dough sheet moulder is inserted in a dusting flour bed.
3 Synchronised pair of dockering rolls with cleaning devices for applying the characteristic
crisp bread surface.
4 Suction device for removing the dusting flour from the dough surface. The removed dusting flour
is processed and returned to the process circuit.
5 The special high-temperature crisp bread oven is equipped with two gas burners each for top heat
and bottom heat. Once the baking process has been finished, the dough sheet is cut to its final size
in a cross and longitudinal cutting device.
6 The arranged crisp bread slices are conveyed to the packaging machine via a conveyor belt.

14_15

Crisp bread
Crisp
Crisp
Crisp
Crisp
Crisp

bread
bread
bread
bread
bread

with
with
with
with
with

milk
spelt
sesame
caraway
fibres

6
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INDUSTRIAL PRODUCTION LINES

RUSK PRODUCTION LINES

Rusk production lines The process route for producing rusk starts with making the doughs. This is followed
by dough feed and moulding steps. The dough is proofed and baked in tin moulds. Once baking has been
concluded, the bread bars are released from their moulds, cooled and then cut to slices. The slices are
toasted in a second baking process and conveyed to the packaging machines.
The size/length of the ovens is adapted to the required baking time in relation to the desired maximum capacity.

1 Dough processing using a spiral-type kneader; dough dividing and moulding machine,
conical round moulder, intermediate proofer, long moulder and placing the dough strands in moulds
2 Feeding into final proofer
3 Tunnel oven
4 Bread depanner
5 Bread cooling
6 Bread slicing and bread slice feeding system
7 Toast oven and product stacking for packaging

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INDUSTRIAL PRODUCTION LINES

BREADCRUMB PRODUCTION MACHINES

Breadcrumb production machines A continuous mixer usually is at the beginning of the process route.
This is followed by dough feed and moulding steps. A belt-type proofing channel is used for the proofing
process, the next stage involves a tunnel oven.
In the course of the process shown, individual breads are produced which, once baking has been concluded,
pass through a cooling route. Afterwards they are reduced to smaller pieces which are then dried and milled.
The size/length of the oven is adapted to the required baking time in relation to the desired maximum capacity.

1 Continuously dough processing using the ZPM kneader

2 Portioning
3 Transfer from belt-type proofing channel to oven
4 End of tunnel oven
5 Bread cooling and transport to bread crushing mill.

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INDUSTRIAL PRODUCTION LINES

Raw materials handling . Portioning. Kneading

Dough processing

Recording the dough quality

and output measurement

Monitoring the height of bulges and the width of the sheet

using speed control

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AUTOMATION
Convenience of operation, reproducibility of product qualities at all times as well as a high availability of
the industrial production lines made by Werner & Pfleiderer are in direct proportion to their high degree of automation. Measurements and controls all can be dealt with by one central computer, either
program-controlled or with the intervention of the operator of the production line. A great number of
various sensors are installed in pairs for safety reasons. Their operability is checked by the system itself.
The sensors consistently monitor the parameters affecting the quality of manufacturing process, such
as for instance dough quality and output, height of bulges, sheet width and speeds, oven humidity and
temperature, product moisture content and temperature. Their measuring results directly influence the
settings on the line modules a completely self-regulating system. The whole manufacturing process
is documented in every detail and can be traced on product line and host level by persons with the
relevant authorisation and adjusted manually, whenever necessary. The entire automation system can
be monitored or serviced remotely by way of internet access.

Baking

Cooling . Arranging . Feeding

Recording and controlling the humidity in the oven

and the oven temperature

Controlling the moisture content of the product

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INDUSTRIAL PRODUCTION LINES

CHECK

Pos I

Consultancy

Planning . Design . Equipment . References

Pos II Equipment

Materials . Component groups . Electronic components . Mechanical components

Pos III Modularity

Workflow . Space requirement

Pos IV Capacity

Number of pieces/h . Weights

Pos V Quality

TA . Dough qualities

Pos VI Cost

Investment . Current cost

Pos VII Workflow

Interfaces . System Workflow

Pos VIII System responsibility

Complete system integration . Set-up of individual sequences

Pos IX Service

Service presence . Self-Service . Remote maintenance

Pos X Group know-how

Process thinking . Interface know-how . Solutions from one source

www.wpbakerygroup.com/industry/check

22_23

PROCESS

_ Inquiry
_ Production analysis
_ Project planning
_ Engineering
_ Production
_ Acceptance I
_ Delivery
_ Installation
_ Integration
_ Operational start-up
_ Training
_ Acceptance II
_ Service

tammen.de

Werner & Pfleiderer

Industrielle Backtechnik GmbH
Frankfurter Strae 17
71732 Tamm
Germany
Fon +49 (0) 71 41 - 20 20
Fax +49 (0) 71 41 - 202 - 111
info@wpib.de
www.wpib.de

The WP BAKERYGROUP possesses

subsidiaries in France, Italy, Belgium,
Russia and the USA.
Agencies with Service Departments
can also be found in all regions of

www.wpbakerygroup.com

2008 by WP BAKERYGROUP, Stand 03/08, printed in Germany, = Registered Trademark

All specications are non-binding and the right is reserved to make amendments that serve technical advancement.

WP BAKERYGROUP

0408_0.75_0102

the world.