Case studies: Ingredient dosing for pastry production
Customer
The customer is one of the world’s leading major bread and baked goods manufacturers. The installation was implemented in their production centre in South America.
The customer needed to install a new ingredient handling system (solid and liquids transfer) for a new plant for pastry production.
Project
The customer’s recipes and the available layout formed the basis for developing a plan to handle 90% of solid and liquid ingredients.
The challenge was to produce 30 batches an hour in two mixers, while ensuring repeatability and food safety.
Over 90% of ingredient processing is now automated, significantly reducing dosing and ensuring repeatability in all our recipes.
Over 90% of ingredient processing is now automated, significantly reducing dosing and ensuring repeatability in all our recipes.
Why INOXPA?
The customer chose INOXPA to provide the service based on the experience with this type of installation and their ability to design and manufacture large greenfield projects. Solids handling knowledge proved a very important factor in their decision, plus being able to lead the process from project design through to start-up.
The project’s main challenge involved the large number of ingredients for dosing and the significant amount of batches per hour required by the mixing system. A multi-stage system was designed to enable high speed ingredient dosing and checking for the use of so many recipes.
INOXPA solution
In this installation, the tortilla line dosing point is fed using a 300L solids scale, a water dosing point with a flow meter, and a fat dosing point with a flow meter.
There are 2 dosing points for the bread line, using 2 x 400L scales for solids and 2 x 300L scales for solids, 2 water dosing points with a flow meter and 2 fat dosing points with a flow meter.
Installation characteristics
The main ingredient is fed to the solids scales from 2 INOXPA-designed silos by vacuum-driven pneumatic transfer. The product passes through a magnetic trap and sieve to remove any potential residues.
Water is supplied from the customer’s own supply and dosed in the required amount using the flow meter and valves.
The fat is supplied from an existing tank, we provide pumping and control of the required amount for dosing using the flow meter and valves. The installation is heated using hot water as the piping is jacketed.
Minor ingredients are supplied using a structure comprising big bags and micro-ingredient loading stations: 4 big bags, 1 station for 3 micro-ingredients with 1 scale for micro-ingredients for tortillas, 1 station for 4 micro-ingredients with 4 scales for micro-ingredients for bread, and a buffer tank. The micro-ingredients pass through a magnetic trap and sieve to eliminate potential residues.
INOXPA’s own team developed the electrical panels, the PLC and the SCADA system.
Special features
- Vacuum-driven pneumatic transfer ensures the entire installation is cleaned better and reduces the risk of ATEX explosion points from developing. The heating of critical ingredients with a high fat percentage or with a delicate characteristics is also avoided.
- The strong point of the INOXPA’s installations is a faster recipe production and high precision dosing.
- Silos with flat bottom for mass flow discharge and with up to 3 outlets to enable the simultaneous feeding of 3 lines.
- The skids are manufactured in stainless steel in line with the FDA guidelines.
- FAT performed at our installations to validate the entire system prior to shipping to Chile.
- Work conducted together with the customer, developing a new made-to-measure system, fulfilling the strictest food safety and quality standards.
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Ingredient dosing for pastry production
