Gostol-Gopan d.o.o. has equipped already hundreds of Russian bakeries in the past. One of the last achievements is a combined industrial plant for the production of 330 g wheaten long loaves and 600 g wheaten toast bread installed in the TAGILHLEB bakery in Nizhni Tagil.
The dough is mixed on spiral mixers with removable bowl that assure a high mixing quality for different kinds of flour. A bowl lifting and tilting device unloads the bowls’ content into the dough divider’s hopper. The dough divider is from the KRAS family of volumetric dividers, which assures a wide dividing range, accuracy and simple handling.
The dough pieces are rounded on a conical rounder SABOTIN 1 before entering the intermediate proofer; this has the possibility of adjusting the proofing time according to the product’s characteristics by moving the proofer’s outlets.
The typical long loaf shape is obtained on an industrial long moulder with numerous adjustment possibilities – all with the aim of obtaining the desired product shape and quality. The long loaves are loaded into the final proofer with the assistance of an automatic loading device. The final proofing takes place into a perfectly insulated chamber under totally controlled climatic conditions. In addition, it is possible to adjust the proofing time according to the product’s characteristics without affecting the production capacity of the plant.
The proofed products are gently deposited onto the outlet conveyor where a scoring device decorates the loaves with cuts; their depth, number and inclination are fully adjustable.
When producing toast, the long moulder is moved above an automatic panning device that makes sure the long loaves are loaded into empty pans; the movement of the machine is facilitated by special tracks. Once the pans have been filled with the loaves, an operator covers them with the proper lid and transfers them manually on deck trolleys.
The loaded trolleys are brought to stable final proofers, which allow the setting of optimal climatic conditions by adjusting the temperature and relative humidity.
After proofing, the loaded trolleys are brought to the tunnel oven’s inlet. The conveyor transferring the free-baked long loaves from the final proofer to the tunnel oven is lifted enabling the free access of the trolleys to the tunnel oven’s wire-mesh belt.
The cyclothermic tunnel oven allows a fine adjustment of the baking diagram (upper and bottom temperature regulation on every 3 m segments) according to the specific product’s characteristics.
The pans’ lids are manually removed after baking and the toast bread is deposited on a bread conveyor that carries the loaves to the next processing stage – the cooling. The empty pans are carried back to the panning device on a pan conveyor, while the removed lids are carried to the same location on a separate – lid – conveyor.
The plant’s automatisation diminishes to the minimum the amount of manual work required thus ensuring a constant quality of the products. The plant’s main feature is the possibility of combining the production of free-baked long loaves and toast bread almost entirely on the same plant – only the proofing is done on separate proofers, which on the other hand ensures optimal proofing conditions for both product kinds. The conveyors’ system makes sure the mixing and the make-up plant are used for both product kinds. This gives the plant a key advantage over other solutions – the flexibility of use.
