Flexible Technology for ProductsYou Can Sink Your Teeth Into

B a k e d G o o d s

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C o n t e n t s

Reimelt Philosophy Page 2 - 3

Fresh Baked Goods Page 4 - 5

Extended Shelf-Life Baked Goods Page 6 - 7

Process Technology Page 8 - 11

Automation Technology Page 12 - 13

It takes:

more than a hundred years of experience...

... and everything that you need for efficient production:

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R e i m e l t P h i l o s o p h y

Systems andComponents

ProcessTechnology Automation

ProjectFinancing

ProjectManagement

Service

Performance

Spectrum

Knowledge of the end product and its requirements such as

Raw MaterialsProcess TechnologyAutomation Level

is crucial to finding the optimal solutionsfor production.

The raw material logistics are of decisive impor-tance for the quality of the end product. Pur-poseful storage, precise weighing and recipecontrol and management are the authoritativefactors.

Properly coordinated raw material handlingensures optimal results in the production pro-cess that are also most economical. Reimelt,with its system solutions, has been a reliablepartner for the food industry for decades. This isalso shown by our extensive international clientlist.

Thanks to our many years of experience, we at Reimelt know precisely what the customerwants concerning "their" end-product – whether it’s whole grain bread or cake, cookiesor pretzel sticks.

The Right Ingredients

for a Integrated Concept.

The Reimelt Principle

Flexible System ExecutionQuality AssuranceOptimized Provisioning StrategyProcess Technology in the Raw MaterialHandling IndustryIntegral Material Flow SupervisionReduction of Production CostsOptimizing the Building Layout

It is the task of the Reimelt experts to alwaysmeet the changing requirements of the market.We develop new solutions for products thatinterest people and in doing so lay the founda-tion for success in the market.

The Complete Solution from a SingleSource:

R e i m e l t P h i l o s o p h y

Storage

- Silo Technology- Big-Bags

Discharge

- Fluidizing - Vibration - Metering

Conveying

- Pneumatic Conveying

- Container Transport

Processing

- Sifting - Mixing - Fermenting - Temperature

Regulation- Conditioning- Size Reduction

Metering

- Weighing Technology

- Volumetric and Gravimetric Metering

Production process

Major Ingredients

Processing/Receiving

Minor Ingredients

Fat ProcessingMixing/BlendingSystem Control

MaterialReceiving

LiquidMetering

MaterialReceiving

Micro Ingredients

Receiving-Sifting

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Systems and Components

Key components developed and manufactured in-houseEquipment designed for constant operation (24 hours/day, 365 days/year) with a longservice-lifeHigh processing-qualityPatented componentsLong-term spare-parts availabilitySanitary design - easy to cleanCompetent consultation for system solutionsaccording to ATEX guidelines

Process Technology

Experience from over 13,000 built systemsExtensive referencesOwn laboratory and central test facilityPatented processesProcess technology consultation during projectEngineering servicesTechnical application trials available by customer order (raw material analysis,conveying, mixing, sifting)

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F r e s h B a k e d G o o d s

The baked goods market of today demandsoptimized production more than ever and theReimelt experts keep this always in mind. As aresult, engineering leads to system solutionsthat ensure an optimal process, individuallysuited to your respective product parameters.

Consistent product quality requires the strictadherence of all process capacities. A task thatReimelt systems accomplish on the one hand,through the most modern system and sensortechnology and on the other hand, throughinnovative control concepts. Consistent qualityis the key to long lasting product success. Mostconsumers will immediately recognize thesmallest deviations in the recipe. This is whyReimelt systems operate precisely and cons- istently.

Pioneering Production Technology

– as Important as Our Daily Bread.

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Your goals:

Cost reductionQuality assurance or improvementCompliance with high hygiene standardsConsistently high level of productionCompensation of varying raw material propertiesComplete material flow recording, batchtrackingError avoidance through automationReduction of faulty batches

Accurate automated metering of small quantitiesIncreasing system availability

The Solutions from Reimelt:

Quality control from raw material receivingto finished product deliveryOptimized storageExtensive know-how for compliance withhygiene standards

Favourable raw material improvementGentle product handlingImproved metering solutionsMinimizing the failure rate through reductionof manual processesCustomized intermediate storage of endproductsSecurity through batch trackingEnergy savings

Picture 1: Outdoor silos for the storage of

major ingredients

Picture 2: Weighing station above a mixer bowl2

The quality of the end product may not beaffected by storage. The most important goal istherefore compliance with the high standards ofhygiene and a production following the "first in– first out"- principle. Reimelt technology con-stantly monitors all product parameters andcontrols the corresponding production process.

At Reimelt, product oriented production means:all raw materials are checked for their specificrequirements with regard to storage and meter-ing so that the optimal process can be imple-mented.

In addition to systems for sourdough and liquidsponge production, Reimelt provides systemsolutions for the complete spectrum of rawmaterial preparation: from temperature regula-ting to drying, moisturizing and homogenizing,from sifting, mixing and grinding to recrystalli-zation.

F r e s h B a k e d G o o d s

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Fresh Baked Goods

Bread· Baguette· Cinnamon bread· Farmers bread· Multi-grain bread· Pita bread· Rye bread· Toast bread· Tortilla· White bread· etc.

Rolls /Buns· Crusty Rolls· Dinner rolls· Hamburger /hotdog buns

· Hot cross buns· Sausage rolls· Sesame/poppy seed rolls

· Water rolls· etc.

Cakes/Pastries· Croissants· Filled donuts· Madeira cake· Muffins· Scones· Sponge cake· Yeast cakes and pastries

· etc.

1. Major dry ingredients

Minor dry ingredients

Sourdough preparation

Soaked grain

Hot soaked grain

Yeast system

Liquid ingredients

Receiving area

Recycled bread system

Cleaning

Mixer

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E x t e n d e d S h e l f - L i f e B a k e d G o o d s

Lasting Quality ...

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It is also valid for extended shelf-life bakedgoods: to reach a uniform quality, optimizedcosts and the highest possible level of automa-tion, variations in the raw material propertiesmust be prevented.

The quality assurance provided by Reimelttechnology begins right at storage, which isperformed according to the product parameters.With the integrated raw material preparationand gentle product handling, Reimelt guaran-tees consistency in quality as well as quantityfor the dough production.

Reimelt provides systems for both sourdoughand liquid sponge production.

Innovative system solutions guarantee perfectresults in every area of raw material prepara-tion. Temperature regulating, drying, humidify-ing, homogenizing, sifting, mixing, grinding andrecrystallization: the system solutions fromReimelt encompass the entire range of rawmaterial processing. Systems for plasticized fatand cream production complete the perfor-mance spectrum. Reimelts expertise in pro-cessing technology offers you the decisivefactors for consistent production processes:pneumatic mixing homogenizes and premixesdry and liquid ingredients. Raw material tem-perature regulation is achieved in the fluidizingzone. Specially developed components ensure a degradation-free, slow-speed conveying forsensitive raw materials, such as granulatedsugar, nuts, fruit or chocolate chips.

Extended Shelf-LifeBaked Goods

· Almond cookies· Biscuits· Bread/ Bagel chips· Bread crumbs· Cheese flavoured· Crackers· Fruit breads

· Fruit cakes· Gallette· Ginger bread· Hard baked cookies· Honey cakes· Pandoro· Panettone

· Pumpernickel bread· Pretzel snacks· Rice cakes· Salted pretzels· Seed cakes· Shortbread cookies· Snack pies

· Soft baked cookies· Wafers· Water biscuits· etc.

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Picture 1: Combined manual, bag and Big-Bag

dumping station

Picture 2: Micro ingredient storage with

recipe controlled weighing and automated

conveying to the processing lines

E x t e n d e d S h e l f - L i f e B a k e d G o o d s

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... Requires Extensive Know-how.

Flavourings

Receiving area

Mixers

Liquid ingredients

Cleaning

1. Major dry ingredients

Sugar grinding

Minor dry ingredients

Micro dry ingredients

Central scaling

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Picture 3: Storage of liquids in containers with

buffer tank

Reimelt systems utilize the most modern sensortechnology and control concepts for compliancewith all process parameters, and therefore en-sure product quality. Here are two examples ofhow the above is actually carried out.

Automated toast bread production

In the automated production of toast bread,the main ingredients, flour and sugar, are storedin outdoor silos. The production of premixes isadvantageous when considering requirements,such as contamination-free production and

Innovative Solutions…

P r o c e s s Te c h n o l o g y

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Toast Bread Production Line

Intermediate flour use bin

Liquid fat metering system

Butter metering system

Recycled bread metering system

Premix receiving hopper

Outdoor silos for sugar, salt and various flours

Premix mixer with manually added ingredients

Premix storage hopper

Pneumatic conveying system

Premix scale with pressure vessel

Yeast metering system

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Picture 1: Secondary-air conveying for

gentle product handling

tracking of raw materials. These mixes are stored in various hoppers, and along with re-cycled bread mash, water and yeast, weighedaccording to the recipe.

For hygienic reasons, butter and fat are meter-ed directly into the mixer. The process controlsystem monitors the premixing of the raw materi-als and the dough development during doughproduction. There are control parameters andindicators, such as time, temperature and energyinput are instrumental for a constant doughquality.

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…with Exemplary Efficiency.

P r o c e s s Te c h n o l o g y

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Picture 2: Dumping station on load cells, directly

above the processing

Breadcrumb Production

Bread crumb dust recycling

Grinder

Oven

Silo for tanker truck filling

Bagging

Slow speed conveying

Compressor

Outdoor silos

Scale / Pneumatic mixer

Oil metering

Premix

Minor ingredients

Loss-in-weight feeder

Water mixing and metering unit

Continuous mixer

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Continuous breadcrumb production

Breadcrumbs are used as a finished product aswell as a recipe ingredient in many other foodproducts. Recipes change between countries,dependent on the eating habits of its peopleand with consideration for further food pro-duction applications.

Color, crumb/granularity and density can beefficiently adjusted at the production lines.

Flour, ingredients and premix raw materials are weighed in batches.

Metering into the mixer is continuous. Here the raw materials are mixed and kneaded with minimal dough warming and very lowenergy transfer. The continuous productionguarantees a constant and reproducible pro-duct quality.

A quality control of the product parameters iscarried out right after the dough production.In this way, faulty production is prevented.

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Fermentation – Biotechnology...

P r o c e s s Te c h n o l o g y

Picture 1: Continuous dry and liquid material

metering with vertical mixer for the production

of liquid sponge

The quality of breads and rolls is largely influ-enced by the liquid sponge. The use of liquidsponge not only saves yeast during dough

Continuous liquid sponge systems:The basis for economical production

Reimelt continuous liquid sponge systems offerthrough their innovative construction decisiveadvantages for baked goods production:

Consistent qualityDischarge into the production at the desired timeProduction preparation and post batch pro-duction is possible

No remaining product in storage tankFlexibility due to short fermentation timeOptimal usage of capacityVery small space requirementsFuture production capacity expansion without problemReduction of chemical baking agents

Flouruse binWater mixing

and metering unit Differential

metering scale

Yeasttank

Continuousmixer

During the continuous liquid sponge productionwater, flour and yeast in suspension are meter-ed into the continuous mixer by differentialscales and liquid meters and immediately mixedwith high shearing forces. After a short time, afinished, homogenized liquid sponge is ready tobe pumped from the mixer to the fermentationtanks. Here great emphasis is placed on the"first in – first out" principle, so that a consis-tent quality of the fresh dough is guaranteed.

Flour storage

Flour metering

Water mixing andmetering unit

Cooling unitStarterliquidsponge

Fermentation tanks

Continuous Liquid Sponge ProductionBatch Liquid Sponge Production

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P r o c e s s Te c h n o l o g y

Picture 2: Fermentation tanks with a 6 ton

usable capacity and down-stream connected

buffer tank

Flour use bin

Fermentation tanks

Storagetank

Heatexchanger

To production

Water mixing andmetering unit

DifferentialmeteringscaleContinuous mixer

Starter liquidsponge

To production

Sourdough storage tank

Fermentation pipe

Central cooling and heating unit

Continuous Sourdough Production

While fermentation tank (1) is being filled,fermentation tank (2) is being discharged withthe same capacity. When tank (2) is empty thenthe "filling/discharging"situation is reversed.In this way the "first in – first out" qualityprinciple is fulfilled. When the fresh liquidsponge is being pumped to the storage tank, itpasses through a heat exchanger and is cooled.The liquid sponge can be taken from the stor-age tank to supply the production lines accord-ing to requirements.

During the sourdough production, mixingis executed in the same manner as the liquidsponge production.

After a short time, the finished, homogenizedsourdough is pumped from the mixer to thefermentation pipe. On the way through thefermentation pipe the dough is continuouslyacidified and goes then into the sourdoughtank.

The continuous mixer constantly recirculatesa specific amount of finished sourdough fromthe tank as a starter liquid sponge. The remain-ing amount is used for production. During thepause in production, the filled fermentationpipe is cooled to the point that fermentationcan continue uninterrupted.

production, it also has a positive effect on theproduct properties of the finished baked goods.

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... for Better Bread.

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A u t o m a t i o n Te c h n o l o g y

Perfect Product Planning

for More Reliable Processes.

Web-Client

Web-Clien

Web-Client

Reimelt has developed the key-componentsPrismaCE and PrismaWEB for a smooth runningprocess automation. These software applica-tions, together with other components, such asthe recipe-metering system Minc99 form thebasis for an optimized production control. Thisranges from a simple scaling system to a totally

automated production system with Internettechnology. Since the single components areretrofittable and expandable, Reimelt configuresthe system to meet your individual require-ments. Here Reimelt know-how comes into play.The Reimelt experts provide a concept thatperfectly matches your requirements. It is theirtask to prepare the system specifications, soft-ware, special interfaces, and train your opera-tors in its use.

Visualization

Picture 1: PrismaWEB

Modern technology coupled with comfort of

use and operational safety for a transparent

production process.

System Visualization Based on Modern Web Technology

Clear representation of the production processSimple operationIntegrated error/fault message systemSafe manual operationTrending analysisUser access via web browserIntegrated maintenance management systemoptionally available

Panel-Based Batch Management

Based on panel-PCsWindows XPSQL data base systemUp to two web-clients possibleLocal operationOptional functions:- Integrated visualisation- Data import / export- Remote maintenance

PrismaWEB/PE (Panel Edition)Minc 99

Recipe Metering for Small Systems

99 recipesUser-friendly structureDegree of protection IP 54Profibus compatibleMetering of liquidsMaster/slave operationApproved for ATEX zone 22, CEOptional DAISY-M-system for PC data handling

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CorporateManagement

Level

ProcessManagement

Level

ControlLevel

WLANPLCSystem

PrismaWEB

ERPSystem

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A u t o m a t i o n Te c h n o l o g y

Batch Tracking in Food Production

Continuous batch tracking in the food industryis becoming increasingly important. It ensures a high production standard that minimizes pro-duction waste and maximizes customer satis-faction.

Information concerning the production processis the basis for maximum product quality. Theprocess automation from Reimelt takes chargeof this important duty – to safegaurd the custo-mer’s good reputation.

Picture 1: Programming the process automation

Picture 2: Creation of wiring and construction drawings

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Process Management Level

Process Control Level

Production Level

PrismaWEB

Batch Management System of the FutureModern technology coupled with comfort of useand operational safety

Web technology, client/server systemSQL data base system, OPC compatibleConnection to ERP, host systemsAccess via web browserOperator friendly menu structureRemote maintenance via VPN/ModemMES functions such as batch tracking,warehouse management, etc.

PrismaWEB2

Reimelt FoodTechnologieGeschäftsbereich der Reimelt Henschel GmbHMessenhäuser Straße 37-45 63322 Rödermark, GermanyTel. +49 6074 691-202Fax +49 6074 691-208info@reimelt.dewww.reimelt.de

Global Presence

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Reimelt Components, RödermarkReimelt FoodTechnologie, RödermarkReimelt Guth Engineering, LandauReimelt Henschel MischSysteme, Kassel

Reimelt Corporation,Tampa

Reimelt Korea Corp., Seoul

Reimelt (GmbH) UK Ltd.,London

Reimelt Ltda.,São Paulo

Reimelt Henschel Asia Ltd., Hong KongReimelt Henschel Trading (Shenzhen) Co. Ltd.

Reimelt France E.U.R.L.,Venissieux / Lyon