softdough & cookies · softdough & cookies 2heads depositor 20 cat_softdough_rev12gea.indd...

SOFTDOUGH & COOKIES

cat_Softdough_rev12GEA.indd 1 22/07/16 14.55

The basic ingredient. We know how.

Ever since we first started, in 1962, we have always felt ourselves to

be part of our customers’ recipies. This is why we have always given

them our technology, passion, reliability and quality.

Being “the basic ingredient” is not just a motto for us but a real,

constant commitment. We have put innovation at the heart of our

business, always pushing the boundaries of our experience. We never

take it for granted, always making it available to our customers

around the world.

Expanding out expertise, broadening our scope, always driven by

passion and daring: what we call Know-how is a goal that we shift

forward by one step every day. This is positive energy and one that

we want to share with all our partners.


An important sector in the biscuit manufacturing world is that of softdough & cookies,

which includes an ample family of products for which manufacturing is based on three

main processes: wire-cutting, depositing and rotary moulding.

In the fi rst two categories, each process has its own core-forming unit.

Additional devices can be added to this unit in order to enhance the range and

appearance of products to be made: fl exibility is a must!

In the following pages we explore the manufacturing processes used for soft-dough

& cookies.

The process

SOFTDOUGH & COOKIESThe process

03

SOFTDOUGH & COOKIES

Rout press, Wirecut & Co-extruder

Rotary moulder

Deposited & Wirecut


Rout press, wirecut& co-extruderThese categories of products can be manufactured starting from a single machine.

The basic unit consists of two grooved rolls which extrude the dough

through a set of dies in order to give the dough pieces their shape.

A fi llerblock is inserted between the rolls and the die

plate in order to equalize dough distribution across

the width and provide optimum weight control.

The basic machine is confi gured as a rout press.

A wirecut mechanism can be added for the production of plain wirecuts

or products with inclusions. Rout press products are cut by means

of a guillotine cutter positioned before or after the oven,

depending on the type of fi nal product to be obtained.

By adding the crimping device, soft-centre cookies can be formed

where the centre fi lling can be jam or cream. Fruit bars can be cut

before or after the oven depending on the type of fi nal product

to be obtained.

Optionally, the unit can be fi tted with two separate fi lling hoppers

in order to produce fi llings with two different tastes within

the same row of products.

The key advantages of this unit are fl exibility, high-speed performance,

user-friendliness, and ease of access and cleaning.


Fillerblock.

Plain wirecut in production.

Chocolate chunk cookies coming out from the 1.700 mm wide oven’s chamber.

SOFTDOUGH & COOKIESRout press, wirecut & co-extruder

05


Rout press confi guration


06

Rout press productsextrusion dies.

HOPPER

FILLERBLOCK

DIE & DIE PLATE

GROOVED FEEDING ROLLERS

Rout press productscutting device.



07

HOPPER

HOPPER

FILLERBLOCK

WIRECUT MECHANISM WIRECUT MECHANISM

SEPARATION PLATE

FILLERBLOCK

DIE & DIE PLATE DIE & DIE PLATE



Wirecut confi guration


View of the pipes which convey the fi llingfrom the hopper to the co-extrusion box.



09

Co-extrusion confi guration

HOPPER HOPPER

STAGGERED SHUTTERS

STAGGERED PATTERN DIES

FILLERBLOCK

FILLERBLOCK

FILLINGFILLING

DIE & DIE PLATE




3ExtruderThe 3Extruder consists of 3 separate extruding heads in the same unit.

Each head consists of a pair of grooved rolls which evenly feed

the dough to a set of dosing pumps positioned underneath.

A single outlet is connected to on each pump, thus ensuring

consistent weight of the pieces of dough across the width.

Minimum stress is applied to the dough while

it is being extruded.

A wide range of products can be manufactured

by this unit, from traditional plain wirecut to

more sophisticated ones, e.g. two-colour dough

with soft centre consisting of cream or jam,

or even 3 different colours of dough.

The unit is very simple to regulate as all movements

are made by dedicated servomotors without the use of mechanical cams:

a user-friendly touch-screen operator interface panel ensures fl exible

control of all possible adjustments to the machine.

The design of this unit allows tool-free dismantling

for access and cleaning purposes.


SOFTDOUGH & COOKIES3Extruder

11

HOPPER


VOLUMETRIC PUMP

DIE & DIE PLATECenter fi lled twisted bars.


SOFTDOUGH & COOKIES3Extruder

13

What possibilities?

3Extruder Rout press, Wirecut& Co-extruder

PLAIN WIRECUT

TWO-COLOURS DOUGH

SOFT CENTER

FRUIT BARS

2-COLOURS DOUGH, 1 CREAM/JAM

(soft center or bars)

1-COLOUR DOUGH, 2 CREAMS/JAMS

(bars)

3-COLOUR DOUGH(wirecut and/or bars)

WIRECUT WIH INCLUSIONS


DepositorThe head consists of a pair of grooved rolls which evenly feed the dough

to a set of dosing pumps positioned underneath. The “one pump-one nozzle”

concept ensures uniformity of weight across the width.

The machine is fully servo controlled: all the movements of the head are

driven by independent motors positioned on both external sides of the unit.

No shafts or cams drive any movements: this means that all possible

adjustments can be set from the touch-screen operator interface panel

with its in-built recipe storage system.

Flexibility is therefore guaranteed: a wide and extremely

varied range of dough can be handled.

Flexibility is also enhanced as a wirecut mechanism can be added

as an option to the unit, making the machine suitable for the

production of wirecut products, with or without inclusions.

When working in its depositor confi guration, a rotating nozzles

mechanism can be added in order to produce swirl or twisted

dough pieces.

To enhance its fl exibility and produce enriched products,

a synchronised jam depositor can be fi tted to the unit.

interface panel

Flexibility is also enhanced as a wirecut mechanism can be added


SOFTDOUGH & COOKIESDepositor

15

Detail of soft dough depositing.

Volumetric pump.


Depositor confi guration


16

HOPPER

JAM DEPOSITOR(optional)


VOLUMETRIC PUMP

DIE & DIE PLATE

FOLLOW THE BAND MOVEMENT

UP & DOWNHEAD MOVEMENT


Wirecut & swirl confi guration


18

HOPPER HOPPER



VOLUMETRIC PUMP

VOLUMETRIC PUMP

DIE & DIE PLATE

SWIRLING DIES

FOLLOW THE BAND MOVEMENT



HOPPER

HOPPER


VOLUMETRIC PUMP

DIE & DIE PLATE

The unit is composed of two moving heads installed on one fi xed

base which permits, in a small footprint and with reduced investment,

to easily and effi ciently deposit two color dough, even swirled,

thus enhancing the fl exibility of production.

Each head consists of grooved rolls which evenly feed the dough

to a set of dosing pumps positioned underneath. The “one pump-one

nozzle” concept ensures uniformity of weight across the width.

The machine is fully servo controlled: all the movements

of the twin head are driven by independent motors positioned

on both external side of the unit, while the dough deposit

can be fi nely tuned independently from each head.

No shaft or cams drive any movements: this means that

all possible adjustments can be set from the touch-screen

operator interface panel with its in-built recipe storage system.

Flexibility is therefore guaranteed: traditional single deposit,

or two colors dough deposits can be handled at easy,

thus broading the variety of products to be manufactured on one unit.

Flexibility is also enhanced as a wire cut mechanism can be added

as an option to the unit, making the machine suitable for the production

of single or two colours wire cut products, with or without inclusions.

When working in its depositor confi guration, a rotating nozzles

mechanism can be added with the scope to produce swirl

or twisted dough pieces.

2Heads Depositor

SOFTDOUGH & COOKIES2Heads Depositor

20


Rotary moulderThe unit is designed for the production of shortbread dough.

It offers high performance in terms of running speeds, quality of dough

pieces formed and consistency of production.

Fine-tuning adjustment of the height of the knife ensures precise

control of the weight of each single dough piece.

Automatic tensioning and tracking of the belt are standard.

For high production rates, with a very long oven and short baking time,

Imaforni can deliver the unit with forming rolls measuring 390 mm in diameter;

with such rolls diameter, the quality of the extraction of the dough pieces

from the mould to the belt is smooth and perfect.

The machine can be customized to suit the baker’s needs:

the control system can be fully servo motorized and all the adjustments

can be made by servomotors through a visual screen operator

interface with a recipe storage system. The safety, sanitation

and hygiene design meet the highest market standards.

Mould change over and belt replacement can be tool-free

operation.


SOFTDOUGH & COOKIESRotary moulder

23

HOPPER

EXTRACTION ROLL

KNIFE

FORCING ROLL

MOULDINGROLL

WEB


SOFTDOUGH & COOKIESRotary moulder

24

Details of egg wash distribution. Details of sugar sprinkling distributor.


SOFTDOUGH & COOKIESAuxiliary devices

26

Auxiliary devicesEGG WASH

(brush/roller type)

SUGAR SPRINKLER

VARIOUS TOPPINGS

GLAZING UNIT (spray type)

Ink Printer Device: it works in phase with the rotary moulder.

Jam/Cream depositor with moving head and separate conveyor. It works in phase with the rotary moulder.


Flexibile line for “Softdough & cookies” production.

2EXTRUDER GUILLOTINECUTTER

DEPOSITOR

PRESSUREROLLER

INFEED OVENDRUM

ROTARYMOULDER

12.830 mm

OVEN


Imaforni has had its own Test & Development Center since 1999. The 4th generation of machines are currently

available consisting of a complete 1200 mm wide industrial production line composed of a wirecut/soft-centre machine,

a depositor/wirecut unit, a 3Extruder and a rotary moulder.

The oven has a hybrid configuration with radiating (cyclotherm section), and convection heating. The conveyor is a solid steel band.

Second pilot line is available for the development of cracker snack and hard sweet biscuits. The oven consisting

in a 1.200 mm wide state of the art on Direct Gas Fired heating system complete with wiremesh conveyor.

Both ovens are fitted with their own Energy Recovery System.

The lines are available to those customers interested in testing new processes, existing recipes

or new products. Our staff, with their vast technological background, are at your disposal.

Test & development

Depositor

Rout press - WirecutCo-extruder

3Extruder

Rotary moulder

SOFTDOUGH & COOKIESTest & development

28


R&D. For market-proof processes.

SOFTDOUGH & COOKIESTest & development

30


The information contained in this document are subject to variation.Imaforni reserves the right to make technical modifi cations without prior notice.

Any copying of the information or of the pictures included here is strictly forbidden.Some of the equipment illustrated in this document are outsourced.


IMAFORNI INT’L S.p.A.via Strà 158 - 37030 Colognola ai Colli Verona - ItalyT. +39 045 6174711 F. +39 045 6150065

[email protected] www.imaforni.com


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