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Bakers Circle

The new frozen dough production facility was built in the Jebel Ali free trade zone, Dubai in 2015. A long term contract with the world‚s largest fast food chain was the motivation of Bakers Circle India to expand to the Middle East. From this new facility Bakers Circle Middle East will supply their customers in 17+ surrounding countries with frozen dough.

The production facility was designed under the supervision of Mr. Dev Lall, the founder and M.D of Bakers Circle, with the goal to produce the highest quality bread on a fully automatic line 24/7. The fully automatic ingredient handling system, supplied by HB-Technik GmbH, is connected to two bottom-discharge mixers from San Cassiano which supplies an industrial dough sheeting machine from Rademaker.

Due to the high ambient temperatures in Dubai and the requirement of low dough temperature, an industrial liquid ice system (HBICE) was integrated into the ingredient handling system, which is continuously supplying 400 kg per hour of ice slurry.

The objectives of automation

1. A production line for manufacturing of approx. 2000kg per hour of frozen dough baguettes should be installed and fully automated from ingredient handling to packaging.

2. The dough sheeting line (Rademaker) is supplied from 2 San Cassiano bottom-discharge mixers, which are fed with 10 ingredient batches with each 200 kg per batch.

3. Automated ingredient handling, preparation and dosing of micro/ macro/ main ingredients (2 types of flour), middle ingredients (gluten, sugar, bran), micro ingredients (7 ingredients like salt, dry yeast) as well as liquid ingredient (oil, water)

4. A low temperature requirement on dough should be ensured by gentle conveying and cooling of the ingredients and components. It is also necessary to use a chilled water system and ice to keep the dough temperature down.

5. The problems which normally occur in using ice like hygiene problems, not able to keep it in a storage, no reliable automation and dosing- should be solved.

6. Quality assurance and control through consistent ingredient handling and dosing without the possibility of human error.

7. Highest hygienic standards for the whole production, but especially for the ingredient handling solution were demanded to allow certifications like FSSC 22000.

8. Full traceability of batches, recipes and ingredients has to be guaranteed. Production planning and analysis of production data of the ingredient handling system should be centralized in the office.

The components of automation

Storage - major ingredients: The 2 main-/macro ingredients (flour) are composed of 2 silos in various configurations. The silos are located in the ingredient storage room and are equipped with all construction- and design features according to ATEX explosion protection guidelines.

Storage - macro ingredients: 3 middle ingredients (gluten, sugar, bran) are stored in 3 middle component silos or day-stock silos with a capacity of 2-4 m3. The hoppers are equipped with vibration discharge unit, combined with pneumatic vibropads.

Storage - micro ingredients: All 7 micro ingredients (e.g. salt, dry yeast, spices, additives) are stored in a Compo 4000 automated micro ingredient dispenser with 7 hoppers, each 150 litres capacity. Each hopper is equipped with a precision dosing screw discharge. Pneumatic discharge supports are installed as standard to ensure constant product supply. 2 weighing and conveying belts were installed to reach the dosing capacity of 10 batches with all 7 ingredients per hour. This results in parallel dosing of 2 ingredients with a system accuracy of +/- 5-10 grams.

Ingredient conveying: Due to the high ambient temperatures, a vacuum conveying system with an integrated air-cooling and drying system was installed. The air, which is used for conveying, is cooled from 50 °C to approx. 10 °C, to make sure that the ingredients do not increase in temperature during transport.

Dough cooling: A system for chilling water for supplying the mixers and pre-cooling of water for the HB-ICE liquid ice slurry system was installed, with a capacity of 800 litres per hour, at an inlet temperature of 25 °C and a condensation temperature of over 55 °C.

Dough cooling: HB-ICE Continuous liquid ice slurry: An industrial HB-ICE liquid ice slurry system with a continuous capacity of 400 kg per hour provides the required cooling capacity for the dough. In this application the system is operated with approx. 3% salt content. The system was pre-installed in a container which was delivered as a unit. A storage hopper for salt, a brine dissolver with buffer tank, as well as a 1500 litres HB-ICE liquid ice slurry storage tank are integrated in the system. The dough production line is supplied with HB-ICE liquid ice slurry over an insulated ring pipe.

Liquid dosing: Vegetable oil which is stored in a 500 litre stainless steel tank, is recipe controlled, conveyed and dosed to the dough mixers through a stainless steel pipeline with a pump and a dosing counter.

Weighing: Weighing of major, macro and micro ingredients is done in weighing hoppers with Jetfilter systems. The weighing hoppers can hold 150 & 100 kg and are loaded pneumatically. One weighing hopper for main ingredients and one weighing hopper for middle- and micro-ingredients was installed for parallel dosing. They were mounted on a frame over the mixers with an outlet tube and a junction box to the 2 automated mixers. HB-ICE liquid ice slurry is dosed to an insulated liquid scale, which depletes it‚s content to the requesting mixer according to the recipe.

Dust removal: A centralized dust aspiration system HB-Aircontrol was installed and placed in the ingredient storage room. All potential dust sources, like the bag dumping stations, mixers and the automated micro ingredient dispensers are connected.

Storage filling: Major ingredients delivered in bags and will be fed to the silos over a dedicated bag dumping station. For the macro ingredients a separate bag dumping station was installed. The operator has to connect the dumping station to the required silo with a flexible tube and a coupling to start the filling. A position sensor makes sure, that the right filling-pipe is connected to avoid false loading of ingredients to a wrong storage. The Compo micro ingredient dispenser is filled manually with bags from the top over a platform.

Control system: The electrical load control with PLCs is designed for a setup with one main electric panel and several decentralized electric panels. The recipe control system HB-Backcontrol controls the whole automated ingredient handling system and provides an interface to the mixers for a completely automated operation of the production. HB-Backcontrol offers functions and features for production planning and production controlling over the touchscreen, which is located in the production hall, as well as from the office and over the internet. Full traceability of batches, recipes and ingredients is a standard feature and offers many standard-reports and analysis options for easy usability. All data is centrally collected in a database and is available for further utilization over various interfaces.

Technic: A room for technical equipment like blowers, the air cooling- and drying-unit and the main electric panel was constructed and equipped. Sufficient ventilation and noise protection is ensured with this setup and the blowers were separated from the explosion protection zones according to ATEX.

Equipment overview

Pos. Description
A Indoor silo angular
B Day stock silos
C Bag dumping stations for silo filling
D Air drying and chilling unit
E Central dust aspiration station
F Micro ingredient dispenser Compo
G Industrial liquid ice system
Pos. Description
H Magnetic separators
I Weighing hopper for micro and middle ingredients
J Weighing hopper for flour
K Oil tank
L Water chiller
M Liquid ice weighing scale


Installation example DE
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Installation example EN
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Installation example in englisch