"Mann Bakery" in Vienna
The company that was established in 2004 in Vienna 23 at 100 Perfektastraße, with 14,600m² of usable floor space, was designed and built according to state-of-the-art point of views and individual ideas. Today about 70 of its own outlets, among others, are supplied with a wide variety of products from the workshop three times every day. The “breadway”, a 250-metre-long visitor’s corridor in the new baking centre, provides good views of the production process of a modern bakery and cake-shop, and provides audiovisual explanation of the systems and the production process from raw material to finished product. The breadway also serves as a kind of artistic encounter through cultural and charity exhibitions that give the concept of the art of baking a whole new dimension.
Currently altogether approx. 180 employees have found a modern place of work in the baking centre and the connected café. All in all the “Mann Bakery, the man who will spoil you” employs around 700 people.
The objectives of automation
The objectives of automation
- At 4 target points: The required raw materials for bread and biscuit lines, organic range and confectionery should be automatically called up on the recipe computer and precisely metered. Besides the automatically metered 56 raw materials, other ingredients such as olives, raisins, nuts, etc., should be controlled and recorded by an online hand-add ingredient scale.
- The delivered large components flour should be manageable by the sampler and material balance.
- The medium components like grains, shreds, mixed flour, etc., should be automatically metered to the bread and biscuit lines over 8 bag dump stations as surface silos.
- The small components should be automatically metered over 2 separate Compo lines for bread and biscuit lines.
- The component salt should be added to the dough at a later point of time.
- The delivery, storage, conveyance and processing of raw materials should be hygienically 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 organic line should work as a separate line free of contamination.
- The aromatic sourdough production as well as yeast fermentation container should be computerised and controlled for quality.
- The oil metering should automatically take place at 3 target points.
- The dough temperature controls should ensure the dough 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 large components consist of 9 round indoor silos with aluminium fluidised bed double discharge and a discharge capacity of 4 to/h. The total silo capacity amounts to 150 tonnes of flour. The silo filter consists of an attachment filter. The silos are situated in the raw materials storage space according to ATEX guidelines. The silo bulking and flour feeding is carried out by blowers from the machine room. The silo filling takes place over a tank lorry control cabinet attached to the outer wall of the building and individually laid silo filling pipelines with samplers.
The medium components consist of 8 bag dump stations with aluminium fluidised bed discharge, with a discharge capacity of 0.5 to/h. The total capacity amounts to about 5 tonnes of shreds, mixtures, etc.
The stations are attached to the central exhaust system. A platform facilitates pallet storage and ergonomic filling of the “surface silos”. The bulking and conveyance of material to the target points for acceptance takes place pneumatically by blowers from the machine room.
The small components consist of 2 ingredients machines "Compo 3000" "with 16 ingredient containers and 400 kg capacity for salt, baking tools, seeds, spices, sugar etc. Compos are stainless steel.The weighing and venue capacity is 12 batches per line. The Compofilter consist Aufsatzrüttelfiltern. Compos found in the raw material warehouse according to ATEX. The promotion of small components is separated. One Line charges into the bread line a second line charges to the biscuits plant. The transportation is carried out on pneumatic by a blower device in the machine room. "Salt later" und the compofilling occurs via a "tube station" by a dumping station. The dumping station is connected to the central exhaust system.
The flour feeding system consists of a feeder line to the bread processing with branching to the sourdough and predough machines and to their automatic flour filling. Another separate flour feeder line goes to the organic products acceptance target point. The next flour feeder line leads to the biscuit acceptance target point with branching to the confectionery target point. The other feeder lines for medium and small components lead to the bread and biscuit container weighing machines, whereas the flour and ingredient weighing machines are finished as own weighing station respectively due to the simultaneous filling. For hygienic purposes, all flour and ingredient lines are pneumatically driven. The pipelines are made of stainless steel. Pipe filter machines are respectively used behind the silos.
Storage - Production:
The predough-production and storage consists of 3 Europor sourdough machines for automatic 3-stage rye sourdough with a capacity of 2500 Liters each, 1 restbread dissolver with 600 Liters and a cooled restbreadstoragetank with 600 Liters capacity. Furthermore a yeast dissolver for yeast bags with 500 Liters and a yeaststoragetank with 500 Liters capacitiy. The machines are equipped with a automatic cleaning program. The yeast and wheat leaven - pipes are automatically cleaned with a pig cleaning system. The oil storage and dispensing system is also installed in the same storage space for liquid components.
Four water mixing and dosing equipments for hot, cold and icy water are assigned at the target points – bread, biscuit, organic line and confectionery. Another equipment facilitates the automatic water feeding of the 6 predough machines as well as the 2 yeast equipments and their automatic cleaning with hot water.
The rye and wheat predough are metered to the biscuit line. Aromatic sourdough is metered to the bread line. Oil is metered to the bread and biscuit lines as well as to the confectionery target point.
The weighing of flour and medium components as well as the “later adding of salt” take place in separate container weighing machines with jet filters. The weighing machines are pneumatically filled. The capacity is between 80-150 kg. The weighing machines are situated not in the bakery, but in the first floor with downpipe for the dust suction hood over the respective kneading stations. A bottom-checking weighing machine is situated under the kneaders. Every target point has an online hand-add ingredient scale controlled by the recipe computer for special ingredients like raisins, spices, nuts, fat, ice, etc. Small ingredient containers are integrated in the hand-add ingredient scale tables.
2 Central dust exhaust stations with Jetfilters suck, adjustable, via the exhaust hoods over the kneading of the target sides the dust off. Likewise, the dumpingstations, the predough machines, the ingredient dispenser and the silos are connected to the dust exhaust system.
The load control of the facility is performed decentrally in 26 stainless steel switch cabinets. Five 15” touch-screen command units have links to the office, remote messaging and remote maintenance.