Integrated & automated confectionery production at Interpack 2014

Plant control innovations, and developments that enhance three key components of the confectionery cooking process, will be introduced by Baker Perkins at Interpack (Hall 04 / C21).

Cooking developments on show at Interpack

Plant control innovations, and developments that enhance three key components of the confectionery cooking process, will be introduced by Baker Perkins at Interpack (Hall 04 / C21). These upgrades cover the Autofeed ingredient weighing and mixing system; Microfilm™ cooker; and Colour and Flavour Addition (CFA) system.

Upgraded monitoring and control technology means that the entire confectionery production line, from ingredient mixing to depositor discharge, is now fully integrated and automated. Additional sensors and actuators in conjunction with the latest hardware and software help to reduce set up times and improve efficiency. Operators can control the entire line from a single HMI that includes full process visualisation, recipe management, calibration and alarm handling.

Autofeed

The Autofeed system automatically weighs and mixes dry and liquid confectionery ingredients into a homogeneous slurry. Separate vessels with associated pump, valves and pipework have been consolidated into a single skid-mounted system that requires less floor space and reduces installation time. The system is contained in a one-piece stainless steel frame with good access for cleaning with hygienic components and materials used throughout.

Microfilm™ Cooker

The hygiene, energy efficiency and ease of maintenance of the swept thin-film Microfilm™ cooker have been improved while retaining all the quality and consistency benefits of the Microfilm™ cooking process. The machine on show at Interpack will feature a twin outlet for feeding depositors with two hoppers, and an integrated pressure dissolving process that reduces energy and water consumption. Other energy saving features include an indirect condenser to minimise cooling water consumption, and systems to recover energy from flash steam and flash vapour.

The Microfilm™ is used to cook a complete range of sugar, high-sugar and sugar-free confectionery products. The cooking process is extremely rapid and delivers consistent high quality on every product. Hard candies, cream candies and high milk candies are easily handled with excellent control of moisture and, where required, caramelisation. The capability includes soft confectionery such as toffee, caramel, gums, jellies and fruit pastes.

Colour and Flavour Addition System

The Colour and Flavour Addition system mixes accurately metered quantities of colours and flavours into the cooked syrup, between the Microfilm™ and depositor. Accurate metering improves consistency and reduces costs. By incorporating them into the hot syrup at the last minute it minimises the loss of expensive flavours, particularly volatiles, through evaporation and flash-off. It also allows colours and flavours to be changed rapidly ‘on the run’, eliminating the time and ingredient cost of starting and stopping the cooking system.

The new design enables installations to be individually tailored for each customer. Systems are configured for the exact number of recipes the customer uses with heating, recirculation and mixing options available to hold the ingredients in optimum conditions. The system is fully integrated with the line control system and self-draining to speed up cleaning at the end of each run.

All the new systems are modular and enable optional features to be added within the standard framework to maintain the small footprint. Peristaltic pumps are used on all the new systems as they are intrinsically hygienic, offer a wide range of adjustment and can be easily integrated into the line control system.

The control system includes a washout programme for the Autofeed and Microfilm™. Hot water is flushed through the system for a predetermined period to remove product build up and residue.

Source: Baker Perkins