Industrial bakery 'Korn'
Description
The company
The large bakery, Korn’s, is situated in the city of Gorna in Bulgaria.
The well-run business is eager to deliver excellent baking quality at a consistently high level. It operates 24 hours a day with two continuous furnaces. The product quality is continuously checked by in-house quality control officers. A persistent rationalisation of the business was achieved by the new raw material processing facility.
The objectives of automation
The components of automation
- Flour and water should be automatically conveyed to two kneading points and weighed. In addition other hand-added ingredients such as salt, yeast, etc., should be weighed by an online ingredient scale based on the recipe and controlled by the computer.
- The delivered flour should be manageable by a silo weighing machine and raw material access accounting.
- The delivery, storage, conveyance and processing of raw materials should be hygienic and extensively dust-free.
- 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
Storage 1:
The large components consist of 3 square outdoor silos insulated with aluminium fluidised bed discharge and a discharge capacity of 6 to/h. The total silo capacity amounts to 120 tonnes of flour. The silo filter consists of cover filter. The silos are situated outside the bakery on a concrete foundation. The silo bulking and flour feeding is pneumatically carried out by blowers from the machine room. The silo filing takes place by a pipeline for each silo with additional tank lorry overfill protection linked to the full signal. Under each of the silo cells is situated a silo weighing machine for checking the flour delivery and contents. Moreover a tank lorry presieve is integrated in each of the filling pipeline.
Flour-ingredient feeding:
The flour feeder system consists of a feeder line to the bakery with branching to two target points for acceptance in the same finish as the first. The hourly capacity of the flour feeder lines amounts to 6 to/h.
Liquid metering:
Two water mixing and metering equipments for hot, cold and icy water are provided at both target points. A dough temperature control system is additionally included with appropriate temperature sensors.
Weighing:
The weighing of flour is done in two hopper weighing machines with standard filters. The weighing machines are pneumatically filled. Each has a capacity of 150 kg. These weighing machines are situated in the production room. A dust suction hood with exhaust and infeed for water equipment are situated below the flour weighing machines. The target point has an online hand-add ingredient scale controlled by the recipe computer for other ingredients like salt, yeast, raisins, spices, nuts, fat, ice, etc. Small ingredient containers are integrated in the hand-add ingredient scale table.
Dust removal:
Two dust-adjustable exhaust systems suck the dust from the 2 suction hoods over the kneaders at the target points.
Controls:
The load control of the facility is performed decentrally in 5 switch cabinets. The Backcontrol software is used. Two 15” touch-screen command units have links to the office and remote maintenance.
