Gostol – Gopan is completing the installation of 2 production plants in the Golden Harvest bakery on the island of Malta:
plant for the production of tin bread of different weights and sizes and free-bottom
baked round loaves
plant for the production of rolls and bund of different weights, sizes and shapes.
Tin bread production plant
The plant starts with the volumetric dough divider MARK that ensures a quick and simple adjustment of dividing weights and production capacities, as well as a high dividing accuracy that is additionally controlled and adjusted on the automatic check-weigher. The dough pieces obtain the round shape on the conical rounder SABOTIN 3 that features centrally adjustable tracks and cone with adjustable speed, which ensure optimal rounding at any dough weight and production capacity. Prior to the final moulding, the dough pieces rest in the intermediate proofer ; the resting time can be adjusted by changing the outlets’ position. The tailor-made long moulder makes sure the round dough pieces obtain a perfect long-loaf shape; the inbuilt panning device automatically fills the tins with loaves. When producing round loaves (a local specialty) the rested dough pieces are carried to a second conical rounder and from here they are manually deposited on wooden peel-boards. The proofing takes place in an automatic final proofer designed for proofing of tins, peel-boards and baking trays. The final proofer ensures an optimal proofing of the products by setting the proper climatic conditions in the proofer, meaning by adjusting the temperature and humidity. When producing toast, the tins are manually covered with lids after the final proofing. After proofing, tin bread is automatically loaded on the wire-mesh belt of the cyclothermic tunnel oven. The peel-boards carrying the round loaves are conveyed in front of the oven’s inlet, where an operator manually removes the loaves off the peel-boards and deposits them on the wire-mesh belt. The cyclothermic tunnel oven offers an excellent control and regulation of the baking process depending on the product being baked (regulation of the upper and bottom temperature on every 3 meters along the oven, baking diagram setting in 4 zones along the oven). The oven is equipped with the forced-air circulation system ½Biterm½ that improves the intensity and uniformity of the baking process and hence reduces the baking time. The oven’s unloading is automatic as well, separated for free-bottom baked round loaves and tin bread; the latter is conveyed to an automatic depanning unit. After cooling in a special tunnel the empty tins are conveyed back to the panning station, while bread is sent to cooling, slicing (optional), packing and dispatch.
Buns and rolls production plant
This plant is designed mainly for the production of McDonald’s buns. The plant starts with 2 special-purpose make-up plants; 1 specialized in McDonalds buns, while the other outputs different types of buns and rolls.
The rest of the plant is analogous to the formerly described tin bread production plant. After depanning, the baking trays are conveyed back to the respective make-up plant, while the products, after cooling, are packed and dispatched.
The unique feature of these 2 plants is that they are completely interchangeable; in case of 1 plant’s standstill (i.e. during maintenance operations, energy saving measures, lack of production orders, technical breakdowns etc.) the other plant automatically accepts the moulded dough pieces for their final proofing and baking.
Other key features of both plants are the high level of their automatisation, perfect adaptability to the specific requirements of every single product and the complete execution in stainless-steel granting the equipment a long life-span.
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