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BPC 2022 vol.2
Asked on 23.05.2018.
Weight differences in the same lane of crackers

Good evening. I began to have differences of weight in the same lane of crackers coming from the third pair of gauge rolls. How can it be fixed?

Answered on 23.05.2018.

Have nice evening,

plz check settings of followings:

if your line is old rotary cutter line, then you have to check the balancing of your final gauge rolls from filler gauge. filler gauge is normally used by car makers to check the balancing. see if the distance from near and far side of roll is same or not, if distance is not same adjust it.

if your line is new from currently running suppliers then their is option in its parameters to adjust the both sides of sheet thickness from PLC. You can check that.

Also check the speeds of sheets in all gauge rolls is ok i mean may be sheet is running in extensible from there may be tension in sheet. 

Answered on 23.05.2018.

Yes diameter of gauging rolls along its length of both rolls should be same otherwise will cause variation in sheet thickness.Which will cause weight variation and thickness variation. 

Answered on 26.05.2018.


You can check as follows:

1. If possible you can remove the rolls from the machine and check the rolls by fitting and rotating the rolls on a lathe and check using a dial gauge for true running and correctness in diameter along length

2. Check the parts fitted to the roll for gap adjustment for wear and tear such as any screw assembly which lifts or lowers the rolls. If there is a provision through a coupling to adjust the near and far ends of the roll separately check if the coupling allows both near and far ends to be lifted and lowered together. Check the bearings in which the rolls are fitted and if needed replace them

3. Touch top and bottom roll to each other and check with a filler gauge if there is any gap

4. Sometimes the final gauge rolls are not responsible. You can check if the variation in sheet thickness is arising from the preceding roll assemblies

5. Check the width of the sheet that is entering the final gauge rolls. If width is less than the distance between the side flanges of the rolls there will be less dough at both sides and more dough at the center which can lead to less weight on both sides and more weight at the center of the sheet


Answered on 26.05.2018.

Gauge rollers are slightly tapered at either end to help prevent crushing at the ends of the rollers / journals

I would suggest you look at the sheet thickness before & after the final gauge roller - the reduction ratio may well be too big

Kind regards


Answered on 23.05.2018.

Thank you for, your help.

 In this way.  Must the diameter of the gauging rollers be the same along its lenght? I mean zero differences in its diameters?


Anonymous Answer
Answered on 28.05.2018.

Thank you for your help.

Anonymous Answer
Answered on 29.05.2018.

dough reduction ratio is very important. as a rule of thumb the reduction thickness at each gauge roll should be about 2:1 , although ratios of up to 4:1 are commonly used

obviously the greater the ratio more work and the stress is  into the dough

usually the pair of gage rolls mounted vertically one above the other .

Answered on 29.05.2018.

plz also read the biscuit doctor web page ..details..  I can advice to u  for understanding the rules..

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