Der Mann

The new bakery factory was opened in the year 2004 and is located in Vienna 23, Perfektastr. 100 with 14,600m² floor space. It was planned and built in accordance with the most modern aspects and individual ideas. At the moment approximately 80 individual branches are supplied three times a day with an enormous selection of products from the modern craft enterprise.

The ‘Brotway’ is a 250m long visitor corridor of the new baking centre and allows deep insight into the production process of a modern bakery and confectionary and explains the installations and the production steps from raw material until the final product audio-visually. The ‘Brotway’ is also a location of artistic encounter through culture and beneficiary exhibitions whereby the definition of work of confectionary art receives a new dimension.

200 employees have a modern job in the baking centre and attached Café. ‘Der Mann, der verwöhnt’ employs  700 employees.


The objectives of automation:

1.   At 4 target points: breadline - small pastry line – organic  line - and confectionery – the required raw materials are recalled and precisely measured automatically via a recipe computer. Other raw ingredients such as olives, raisins, nuts etc. will be controlled and registered by online hand- add-ingredient scales next to the 56 automatically measured raw materials.

2. The delivered main component flour should be manage- able by a raw material access accounting system and a  sampler.

3.   The medium components such as grains, whole grains,  and mixed flour, etc. should be metered via 8 bag dum- ping stations as a day silo automatically to the bread and small pastry line.

4.   The small components should be transported automatic- ally via 2 individual Compo lines.

5.   The mixed flour is transported to the breadline via a big bag station with a crane.

6.   The delivery, storage, transportation and processing of raw materials must be hygienic and as far as possible dust-free.

7.   The 3-stage rye sourdough, organic sourdoughs as well as the wheat pre-dough should be produced fully automatic-  ally according to own recipe.

8.   The organic line works as a separate line without  contamination.

9. The aromatic sourdough production as well as yeast  fermentation is computerised and controlled for quality.

10. The oil is automatically metered at 3 target points.

11. The dough temperature controls should ensure the  dough quality.

12. A traceability of raw materials and recipes with evaluations and statistics should be accessible from within the office.

13. All ATEX and IFS guidelines must be followed.


The components of automation:

Storage 1: The large components: 2 outdoor silos and 9 indoor silos, round with aluminium fluidised bed double discharge and silo attachment filters with a discharge capacity of 4 to/h. The total silo capacity amounts to 200 tons of flour. The flour is controlled by a sampler in the pipeline filling the silo.

Storage 2: The medium components: 1 Big bag and 8 bag dumping stations for approx. 5 tons whole grain, mix etc. The ‘day silos’ are filled and centrally suctioned from a platform. The transportation of the flour to the target points for acceptance takes place pneumatically.

Storage 3: The small components consist of 2 ingredient machines Compo 3000 with each 16 ingredient containers, each with 400 litres capacity for salt, bread improvers, grains, spices, etc. The weighing and discharge capacity amounts to 12 loads per hour, per line. One line is metered to the bread line; the other line is metered to the small pastry machine. The feeding takes place pneumatically and the filling of the Compo takes place by means of direct dumping from bags into the Compo. The insertion of the bags is connected to the central suction system.

Flour-ingredient feeding: The first flour feeding system leads to bread preparation line and the sourdough and pre-dough machines. The second flour feeding line goes to the organic target point for acceptance. The third flour feeding line goes to the small pastry acceptance station branching to the confectionery acceptance station. The other medium and small component feeding lines go to the bread and small pastry container weighing machines, while the flour and container weighing-machine for ingredients are operated as individual weighing stations because they may be filled simultaneously. Pipe filter machines are used behind the silos.

Storage – production: The production and storage system for pre-dough consists of 5 sourdough machines for automatic 3-stage rye sourdough with a capacity of 2,500 litres. One wheat pre-dough machine with a capacity of 2,500 litres, 1 refrigerated aroma sour dissolver with a fermentation container with 600

Liquid metering: Four water mixing and metering equipments are assigned to the target points – bread, small pastries, organic line, and confectionery. Another equipment is used for the water feeding to the 8 pre-dough machines as well as the 2 yeast containers and for their automatic cleaning with hot water. The organic sourdough is metered to the organic line. The rye and wheat pre-dough is metered to the small pastry line, the aromatic sourdough is metered to the bread line. Oil is metered to the bread and small pastry line as well as to the confectionary line.

Weighing: The weighing of flour, medium and small components takes place in separate containers with jet filters. The container weighing-machines are located on the first floor with a pipeline to the respective kneading stations with suction hoods over the stations. There is a floor scale beneath each kneader. Every station has a hand-add ingredient scale controlled by an online recipe computer for hand-add ingredients such as raisins, spices, nuts, fat, ice, etc. on the hand-add ingredient scale table.

Dust removal: Two central exhaust systems suck dust from the 4 suction hoods. The bag dumping stations, the pre-dough machines as well as the Compos are connected to the dust exhaust system.

Controls: The load control of the facility is performed decentrally in a stainless steel control cabinet. 6 touch-screen command units of 15“ are linked to the office and remote messaging and remote maintenance.


Equipment overview

Pos. Description
A Big bag stations
B Indoor silo, round, fluidised bed
C Recipe computer
D Big bag station
E Bag dumping‚ day stock‘ silo
F Ingredient dispenser, Compo 4000
G Bag dumping station
HSour dough machine rye
ISour dough machine wheat
JSour dough machine organic
KAromatic sour machine
LAromatic sour storage tank
MYeast dissolver
NYeast storage tank
Pos. Description
O Oil storage tank
P Cold water production plant
Q Chilling unit for liquid tanks
R Flour weighing hopper
S Ingredients weighing hopper
T Aircontrol-central dust aspiration
USample taker
VDust aspiration hood
WFloor scale
XHand-add ingredient scale
YWater mixing and dosing device
ZPigging system - cleaning system

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Any questions?
+43 7673/2261
office@hb-technik.at

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