In the renowned winter skiing region of Muehlbach am Hochkoenig (Land Salzburg), the Bauer family extended the existing bakery in central location by an imposing new building. The business has at present a useable area of 2.250 m².
The modern family-run business caters to the surrounding hotels and inns and also operates 8 branches. The quality of bread and pastries of the business is known to be far above the usual fare.
The Bauer bakery employs about 48 staff. The traditional bakery is attached to a beautifully appointed café with an exclusive terrace extension.
The objectives of automation
The objectives of automation
- At 2 target points: Bakery and confectionery should call up as many raw materials as possible automatically and over the recipe computer. The precise weighing and metering as well as raw-material management was one of the main objectives. Other raw materials such as olives, raisins, spices, nuts, etc., should be controlled and recorded by online hand-add ingredient scales. The special small components should be stored in weighing tables with ingredient scales and hygienic ingredient containers.
- The delivered raw materials should be manageable by a raw material access accounting system.
- The delivery, storage, conveyance and processing of raw materials should be hygienic and extensively dust-free.
- The 3-stage rye sourdough as well as the wheat predough should be produced fully automatically according to own recipe.
- The aromatic sourdough production as well as yeast fermentation container should be computerised and controlled for quality.
- A traceability of raw materials and recipes with evaluations and statistics should also be available at the office.
Components of automation
The components of automation
The major components consisting of 4 rectangular indoor silos made from aluminium with fluidized bed and a conveyor capacity of 1.5 to/h.
The total capacity is 30 to of flour. The silo filter consists of ceiling filters. The silos are in the raw materials warehouse in accordance with ATEX regulations. The silo
ventilation and flour transportation is carried out by a blower device in the machine room. The silo filling happens via a cistern truck connection point on the building´s
outer wall and individually laid filling pipes.
The medium - sized constitutions constist of 8 components in the compo integrated raw materials. A podium is used for palett storage and ergonomic filling. The transport of
goods to the target sites is carried out by a blower device in the machine room.
The small compontents consist of 1 ingredient dispenser "Compo 3000" with 16 ingredients and containers of 60 Liters capacity.
The stainless steel Compo is used for salt, baking tools, seeds, spices, sugar, etc. The weighing- and output capacity is 8 batches per hour. The compo is located
in the raw materials warehouse according to ATEX. The promotion of small components is carried out by a blower device in the machine room.
The compo filling is done by a dumpingstation directly into the compo.
Flour - Ingredients promotion:
The flour promotion consist of a conveyor line for the bakery with a division to the sourdough- and predough devices and their automatic flour filling. Another seperate
conveyor line leads to the confectionery. All the flour and ingredient lines are pneumatic because of hygiene. The pipes are made of stainless steel.
After the silos a rotary sifting machine is installed in the pipeline.
Storage - Production:
The predough production and storage has 1 Europro sourdough machine for automatic 3-stage-rye sourdough with a capacity of 1.000 Liters. 1 Bread mixing machine, chilled with a
capacity of 300 Liters. Furthermore a yeast dissolver for yeast bags, cooled and with a capacity of 300 Liters.
The machines are equipped with a automatic cleaning program. The yeast pipeline is made as a isolated pipering and is copurified through an automated cleaning system with the
yeast dissolver. The oil storage- and dispenser as well as the container brine metering are also installed in the same storage space for liquid components.
3 water mixing and dosing equipment for hot, cold and icewater are assigned to the target sites bakery and confectionery.
Another device is the automatic water supply of the 3 predough machines and the yeast device and its automatic cleaning with hot water.
Rye sourdough, restbread, yeast, oil and brine are dosed to the bakery.
The weighing of flour, medium and small components can be achieved in a weighing hopper with jet filters. The balance is filled pneumatically with a capacity of 150kg.
A scale located in the bakery, the second scale in the confectionery on the first floor with drain pipes to 2 kneaders with a dust exhaust system on the respective mixer station. For special ingredients such as raisins, spices, nuts, grease, ice, etc., each target site has a backcontrol guided online ingredient hand scale. Micro-ingredients container are integrated into the manual- ingredients weighing table.
1 Central dust exhaust station sucks the dust via the 2 dust exhaustings on the receiving places off. Likewise, the ingredient dispenser is connected to the dust exhaust system.
The load control system is locally implemented in 6 stainless steel control cabinets. As software "backcontrol" has been elected. 4 Touchscreen command posts in 15" design are running with office connectivity and remote signaling and remote maintenance.