The initial task for the Buyer is to define the products to be made and the output (kg/h) to be produced. The control and safety systems can be specified as PLC with HMI or hard wired panels. Other important initial considerations are the factory space and services available, including fuel gas/oil, electricity, compressed air.
The specification should cover considerable detail based on the Buyer’s requirements. The following is an example of a specification for a small snack cracker and semi-sweet biscuit line.
FIG: 1 Overview of Biscuit Production Line
Snack cracker
Dimensions: | 48.0 mm diameter |
Thickness: | 4.9 mm |
Weight: | 3.0 g |
Appearance: | Evenly blistered |
Texture: | Light and crispy |
pH: | 5.5 |
Moisture: | 1.5 – 2.0% |
Production output
Oven length: | 50.0m |
Oven band width: | 1200mm |
Output: | 750-1000 kg/h |
FIG 2: Baker Perkins High Speed Mixer
FIG 3. Dough tub lift and tilt
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Dough sheet width 1200mm
FIG 4: Biscuit cutting machine from Dingson Food Machinery, China
Equipement products
Fig: 5 Baker Pacific Direct Gas Fired Oven
Note: The air pressure may alternatively be controlled by variable speed blowers or by motorised valves
FIG 6. tna oil spray with spinning discs
FIG 7: Two tier cooling system
2.6. CRACKER STACKING MACHINE
2.7. PACKING TABLE
The following are important considerations:
Usually 2-4 suppliers will be selected and asked to quote. The quotations can then be compared and a selection of the two best proposals will be made for detail discussions, visits to reference lines and the supplier’s factory.
The following is a typical comparison made between 3 suppliers, from Asia and Europe. The comparison highlights the differences in specification and commercial terms offered and will form the basis for negotiations with the selected suppliers.
Supplier A | Supplier B | Supplier C | |
MIXER | Horizontal | Vertical spindle | Horizontal |
Capacity | 500kg hard dough | 500kg hard dough | 550kg |
Drive | 50kW | 32kW | |
Speeds | 30 / 60 rpm | 20 / 30 rpm | Variable speed |
Mixing blade | "Z" blade | 2 spindle | |
Dough tub | 1 included | 1 included | 1 included |
Water jacket | included | N/A | included |
DOUGH FEED | Horizontal arrangement | Vertical tub tilt unit | Horizontal arrangement |
Live bottom bin with guillotine | Live bottom bin with guillotine | ||
Dough transfer conveyor to sheeter | Dough transfer conveyor to sheeter | ||
1.2m wide | 1.2m wide | ||
Metal detector included | N/A | Metal detector included | |
DOUGH SHEETER | 4 ROLL SHEETER | 3 ROLL SHEETER | 4 ROLL SHEETER |
Width | 1200mm wide | 1250mm wide | 1200mm wide |
Hopper | Scrap incorporation included | ||
Roll diam. | 310 / 270 diam rolls | 310 / 270 diam rolls | 310 / 270 diam rolls |
BISCUIT CUTTING MACHINE | |||
Width | 1200mm | 1250mm | 1200mm |
1st Gauge roll unit |
310mm rolls |
310mm rolls |
310mm rolls |
2nd Gauge roll unit | Not included | 310mm rolls Servo motors for gap setting |
310mm rolls Servo motors for gap setting |
Final Gauge roll unit | 400mm rolls Servo motors for gap setting |
410mm rolls Servo motors for gap setting |
400 mm rolls Servo motors for gap setting |
Conveyors | Food grade plastic Manual tensioning Auto tracking |
1350mm wide Rough pattern PU Pneumatic tension Manual double roll tracking |
Food grade plastic Auto tension and tracking of final gauge roll belt |
Relaxation conveyor | Length / width not specified Manual tensioning Manual tracking |
3300mm long x 1350mm wide Pneumatic tensioning Auto tracking |
2.0m long x 1200mm wide Auto tracking and tensioning |
Air blowers | None specified | One ambient / hot air | Air blowers included |
Rotary cutter | 2 roll type, separate emboss and cut rolls, synchronised:250mm diam. Pneumatic tracking By-pass facility |
2 roll type,separate emboss and cut rolls: 200-250mm diam. |
2 roll type, separate emboss and cut rolls: Servo controlled pressure rolls Auto tracking and tensioning |
Scrap lift conveyor | Scrap cutter Manual tensioning Auto tracking |
Pneumatic tensioning Manual tracking |
included |
Side scrap return conveyor | included 300mm wide | included 240mm wide | included |
Reciprocating conveyor feed to laminator | included | included 240mm wide | included |
Salt sprinkler | Roll type mounted over panner | Belt type | Rotating blade with perforated plate for depositing salt |
Salt recovery conveyor and panner | Salt recovery by a plastic belt with nose bar | Wire mesh recovery conveyor | Salt sprinkler over panner with transverse conveyor for excess salt |
Panner | Fixed panner combined with salt recovery Food grade plastic belt |
Swivel panner 1350mm wide PU belt |
Swivel panner 1200mm plastic belt Manual nose lift |
CONTROL SYSTEM FOR FORMING MACHINES | Electrical panel Cascade system UPS option |
Cascade system Siemens S7 PLC |
PLC control with HMI panels |
BAKING OVEN | |||
Length / width | 1.2m x 48m long Hybrid oven Direct Gas Fired / Convection oven 4 zones |
1.25 x 42m DGF |
1.2m x 48m Hybrid DGF/Indirect Convection oven 4 zones |
Oven band | Steinhaus F4012k-st on rollers Pneumatic tensioning Auto tracking system Pre-heat: 6 burners |
Wire-mesh band Pneumatic tracking Pneumatic tension Pre-heat: 8 burners |
Wire mesh on rollers Auto tracking Pneumatic tensioning Pre-heat: 6 burners |
Gas train | Not specified | Not specified | Not specified |
DGF oven | DGF 3 zones, 36m long Baking chamber: Aluminum steel 70 burners (12 - 3 zone burners) Thermocouples: 2 per zone 1750 kWh installed |
60 burners 1080 kWh installed Modular constr. 3m long modules Thermocouples 4 per zone |
DGF 3 zones, 36m long 76burners (including 5-3 zone burners) |
Convection oven | One zone, 12m long 1- modulating burner 250kWh 1- thermocouple + 1 - safety thermocouple |
N/A | Indirect system with heat exchanger One zone 12.1m long 1- Riello modulating burner |
Combustion air supply | Not specified | Not specified | Not specified |
Inspection windows | 1 per zone | 1 per zone | Not specified |
Clean out doors | 1 per zone | 1 per zone | Not specified |
Insulation | 130 kg/m3 | 80kg/m3 | Mineral wool |
Extraction | 1 - extraction fan per zone | 1 VS extraction fan per zone | 1 - extraction fan per zone |
Band cleaner | Triple brush group | Not specified | Double brush for outside of band |
Stripping conveyor | Included Material not specified |
Not specified | Steel mesh belt 1.3m wide Cross conveyor for emergency discharge |
OIL SPRAY | |||
Oil application | 2 - 15% | Separate pumps for top and bottom spray | |
Spinning discs | Fixed speed spinning discs | 14 spinning discs | Spinning disc system |
Filter mist unit | Vapour recovery hood | Filter mist unit included | Hood with suction unit and filter |
Drain conveyor | 3.0m Plastic belt |
2.0m Stainless steel mesh |
3.0m Plastic belt |
COOLING CONVEYOR | 55m long 1.2m wide DC drives Auto tracking Manual tensioning |
60m long 1350mm wide SEW drives 3 sets of blowers |
58m 1300mm wide 4 conveyors and 2 - 180 degree bends Auto tracking and pneumatic tensioning |
BISCUIT STACKER | Adjustable star wheel stacker 1.2m wide Magnetic guides |
Adjustable star wheel stacker 1.25m wide |
Adjustable star wheel Stacker 1.4m wide Guides for 24 lanes |
PACKING TABLE | 1.2m wide 12m long Auto tracking Manual tensioning |
1450mm wide 12m long Pneumatic tensioning Pneumatic tensioning |
1.4m wide 12m long Guides for 24 biscuit lanes |
COMPONENT SUPPLIERS PLC INVERTERS ELECTRICS BEARINGS DRIVES PNEUMATICS |
PLC Omron / Siemens / Allen Bradley Danfoss / Omron inverters SEW drives Legrand / Siemens / Omron electrics Pneumatics Omnitec / Festo Bearings FAG / SKF |
Siemens S7 PLC Danfoss inverters SEW drives Telemechaniqe / Schneider electrics Pneumatics AIRTAC Bearings NSK |
Suppliers except burners and metal detector not specificed |
PRICE | UDS 1,420,000 FOT | USD 1,230,000 Packed and crated |
USD 2,250,000 incl. packing, supervision of installation and commissioning |
TERMS | 30% deposit, 70% prior to shipment |
30% deposit, 65% prior to shipment, 5% on completion | To be agreed |
DELIVERY | 6 - 7 months | 6 months | To be agreed |
It is recommended that 2 – 3 suppliers are shortlisted for negotiations. Visits should be made to see the factories of the potential suppliers and to see relevant production lines in operation. At this stage the specifications of the equipment can be finalised with each supplier.
After the decision by the Buyer on the potential suppliers, the price and commercial terms of the contract may be negotiated, usually with two potential suppliers. A final decision on the supplier can now be made by the Buyer.
The following are typical headings for a contract to buy a production line.
CONFIRMED ORDER
Our experience of over 40 years includes working with suppliers of biscuit, cookie and cracker production lines from Europe, USA and Asia. The following are some guide lines we have found valuable in selecting a supplier for a production line. An important part of our business now is sharing the experience of purchasing a production line and assisting bakeries in selecting suitable suppliers for new projects and negotiating successful contracts.
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Leading image: Packing table
Iain Davidson Baker Pacific November 2019