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Maker - Product Challenge

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Changemakers

Whether it is marmalade or pizza, sauce or hummus, chocolate or fruit puree, most food products undergo a cooking step during their production process. Cooking is nothing more than applying heat to food, but there are different methods to do it. For instance, baking, frying, and roasting involve cooking food without using water, unlike boiling or steaming. Industrial cookers such as vacuum and pressure cookers, industrial fryers, industrial ovens, and industrial roasters focus on specialized applications that meet the different needs of the food industry by helping producers achieve a homogeneous cooking process.

Cooking

“A party without cake is just a meeting.” America's beloved chef, Julia Child, couldn't have been more right. Nowadays, cakes are a blaze of colors and flavors and it's amazing to think that it only takes a few basic ingredients and steps to make them. Mix fat, flour, eggs, sugar, water and salt to make the batter. After baking and cooling it, let your imagination run wild when it comes to toppings, fillings, and decorations.

Cakes

<span style="font-weight: 400;">Bringing together a wide range of process machinery to develop a production line for sponge-based products like swiss rolls, layer cakes and family cakes is complex and expensive. Complete “turnkey” production systems with complete automation offer a time and money saving solution to small through to large scale bakery production environments.</span>


<h2>Turnkey multi product lines for sponge-based baking</h2>
<span style="font-weight: 400;">Tonelli has a hard-earned worldwide reputation for bakery and confectionery machinery. They have used their class-leading experience to bring to develop complete, fully automated production lines that allow new sponge-based products to be brought to market more quickly and efficiently than has previously been possible.</span>

<span style="font-weight: 400;">Tonelli production lines provide a turnkey solution to the entire baking process, including ingredients mixing (and production of batters and creams), depositing, rolling, layering, cutting and more.</span>

<span style="font-weight: 400;">A wide variety of final packing options can be made available to allow the complete automation of every part of the production process.</span>

<span style="font-weight: 400;">All components and process stations are completely integrated and designed to offer the most efficient production path possible for your given product requirements.</span>

<span style="font-weight: 400;">Production volumes can be from as low as 250 kg per hour up to 1,600 kg per hour, allowing you to choose the optimum performance for your production needs.</span>

<span style="font-weight: 400;">The highest quality of components and construction methods is used throughout, to ensure a production line that is reliable, efficient and easy to clean and maintain.</span>

Line for sponge cakes production

<span style="font-weight: 400;">The production of creams, sauces, ragouts, ready-to-bake, and similar products require combinations of mixing, heating and cooling, necessitating several pieces of equipment. By combining temperature treatments and mixing processes in one machine, cost can be reduced and efficiency increased, all while maintaining excellent product quality.</span>


<h2>Combined mixing and thermal treatment system for a wide range of products</h2>
<span style="font-weight: 400;">Tonelli has used it’s well-known industry experience to bring together cutting-edge mixing and thermal treatment processes in one unit - the Tonelli CombiTherMix.</span>

<span style="font-weight: 400;">The CombiTherMix features a centrifugal homogenizer that offers 3 different types of rotating impeller, allowing you to achieve the optimal results for your product.</span>

<span style="font-weight: 400;">Integral scrapers and interchangeable mixing tools make this a fully flexible machine able to handle recipes from delicate sauces to hearty ragouts, or robust pâtés.</span>

<span style="font-weight: 400;">The CombiTherMix features a host of cooking options including saturated steam, food-grade steam injection, and hard vacuum treatments. For cooling and freezing it has the facility to use pumped iced water or liquid nitrogen. All are available in the same single unit, saving you money over having multiple production equipment.</span>

<span style="font-weight: 400;">Featuring an aseptic discharge valve for hygiene, the CombiTherMix is constructed of stainless steel for easy cleaning and hygienic practice. </span>

Temperature-treatment mixer for bakery &amp; gastronomy

Sugar powder is a key ingredient in a wide range of bakery, confectionery, and patisserie products. For small-scale producers buying ready-milled Powdered sugar adds additional expense and storage requirements to your production line. A dedicated in-house small-scale sugar mill for grinding your own icing sugar can reduce ingredients costs and increase efficiency, allowing you to produce only the quantity you need.


<h2>Robust and high-quality sugar mill designed specifically for small-batch production environments</h2>
The MIA Food Tech Sugar Mill has been designed specifically for small-scale producers to make their own icing sugar from granulated sugar. The Sugar Mill offers high-quality milling and top-end components with a size of only  1000mm x 450mm x 1200mm.

As well as all sugar-contacting parts being made of stainless steel for sanitary purposes, the entire assembly is also manufactured from stainless steel. As well as making cleaning of the external parts easier, this ensures maximum robustness of construction and a long lifespan.

Simple to operate with only On and Off controls, the Sugar Mill is designed to work either in a stop/start fashion or to be operated for longer periods. When operating continuously, the Sugar Mill can process up to 35kg of granulated sugar per hour.

Granulated sugar is introduced manually into the upper hopper, which is highly polished to reduce friction to a minimum and ensure all the sugar passes smoothly to the milling blades. The output bin has an easy-open stainless steel lid, ensuring sugar dust is kept contained within the bin to improve the working environments around the machine.

Weighing only 150kg and fitted with high-quality wheels, the machine can be moved easily, allowing it to be stored away from the production area when not in use. The height of the input funnel has been specifically designed to make hand-loading comfortable for operators, and the wide opening reduces the risk of spillage and wastage.

Small sugar mill for entry level production

Donuts quite simply need decorations. The added value through unique and visually appealing decorations provide a taste for the eyes and the mouth. And so, if you are looking for a sophisticated unit that is capable of just that, you are at the right place.


<h2>Multi-nozzle donuts decoration with full customization</h2>
The SDL (Stationary Depositor Large) from Foodjet is a stationary, high-speed donut decorator that can work with individually controlled FJ28 nozzle jets, making this system a suitable option for mass donut decoration. It is available in deposition widths ranging from 600-1600mm.

Furthermore, with nozzle sizes ranging between 400-1500 micron, the unit can accurately dispense between 50-750L/hour of foodstuffs. Decoration can be made in a range of different fully customizable patterns with accuracy better than 0.5 mm, allowing for unique and attractive new decoration designs. Unique vision system ensures that the design is perfectly printed in the donut without any spilling. The pump unit can hold up to 70L of liquid foodstuff at a time, making this system ideal for mass production. Furthermore, the unit is very low maintenance as there are no moving parts that can get worn out or damaged over time.

High speed decorator for donuts

It is not uncommon for ice-cream decorator units to become faulty and produce a visually disappointing product. In order to keep customers happy, you need to find a solution that can live up to the promise.


<h2>Decorating extruded ice cream with chocolate</h2>
The Mobile Depositor Small (MDS) unit from Foodjet can easily work with up to 4 depositor FJ28 heads with nozzle sizes ranging between 400-1500 micron and depositing width of up to 600mm with accuracy better than 0.5mm. Due to the functional properties of the FJ28, the MDS can safely and accurately decorate the ice-cream basing on design and shape of the product.

The IP67 design frame promotes very minimal cable visibility that requires an insignificant amount of maintenance and cleaning attention, making this particular unit a great addition to any business. Moreover, the unit’s integrated vision camera ensures minimum waste when decorating the ice-cream.

With flow rates between 50-750L per hour, such a unit is ideal for ice-cream manufacturers who are looking for a single solution that can effectively decorate ice-cream of different texture, flavors, and shapes.

Chocolate decorator for extruded ice-cream

Filling or decorating biscuits was always a difficult task. Sometimes biscuits are not perfectly aligned, and the filling ends up not being straight, sometimes there is too little filling, sometimes too much. All these problems together lead to a not-perfect product. Having an automatic decorating system would bring the product up to customers’ expectations.


<h2>Precise filling jam in biscuits on high speed</h2>
A depositing solution like the SDL (Stationary Depositor Large) from Foodjet is fully capable of fulfilling the task. Together with the 70L liquid stuffing tank, the FJ28 depositor head and its nozzle sizes ranging between 400-1500 micron, it has the ability to process a large number of cookies or biscuits and dose the decoration with a precision better than 0.5mm

Furthermore, the SDL is integrated with an illuminated vision camera hood on the entry side in order to maximize productivity by ensuring that every biscuit is precisely filled while minimizing the waste of foodstuff.

High speed decorator for filled biscuits

In the past, there were not many ways to make waffles or wafers colorful, tasty, and attractive to the customer, however, with the advancement in technology, that no longer is the case. With an automated &amp; programmable solution, you have the complete freedom to decorate your products in designs that suit your requirements and brand characteristics.


<h2>Accurately decorate waffles with high speed</h2>
Available in 600, 800, 1000, 1200, 1400, 1600mm depositing widths, together with the FJ28 and the Pump Unit Large (PUL), the Stationary Depositor Large (SDL) by Foodjet is a simple and effective solution for the mass decoration of waffles and wafers. The FJ28 depositor head is capable of spreading foodstuff through the individually controlled nozzle-jets with accuracy better than 0.5mm. Together with the FJ28, the PUL can effectively distribute between 50-750L of liquid foodstuff per hour, making this unit the perfect partner for fulfilling bigger capacities.

Unique Foodjet Designer Studio allows to design droplet-patterns for depositor's heads. In combination with an in-built vision system in ensures perfect decorated waffles with no waste.

High speed waffle decorator

Only a few things are as attractive as a gorgeously glazed doughnut. Even when customers are not in the mood, that beautiful sheen will invite them to take a bite. To achieve this appearance, the two doughnut types, cake and yeast doughnuts, can use the help of appropriate doughnut making equipment.

Doughnuts

Making ice cream is all about mixing and homogenizing. First you need to blend, pasteurize and standardize your mixture. Then store it in tanks and freeze and aerate the mix until it reached the right consistency. Now you can add fruits, cookies and other solids if you like. In the final step the mix goes through an air blast hardening machine and it's ready to store and ship.

Ice cream

Biscuits are confectionery products that contain mostly flour, which you mix and bake with other ingredients as sweet or savory snacks. Biscuit production involves four primary processes: mixing, forming, baking, and cooling. For you to perform these processes, you need basic biscuit processing equipment, including mixers, molders/cutters, and ovens.

Biscuits

FoodJet is a Dutch company with a 40-year-old tradition of engineering. The company manufactures machines for the bakery and confectionery industry and specializes in high-precision depositing machines, specifically designed for liquid foodstuffs.

Customers are used to seeing pretty cupcakes with topping and fruits on top. A cupcake without anything is simply boring and will stay on the store shelf till the expiration date. At the same time, big topping can make hands dirty, and that is very inconvenient. So, the question is - how to put filling on top so precisely that there is not a single drop that can end up on hands?
<h2>Industrially produced vs Hand-made cupcakes</h2>
There are generally two types of cupcakes in the world: hand made and industrially made cupcakes. You can find handmade ones in home bakeries, coffee shops, and restaurants. As they are made by a cook one by one, customers do not expect them to be perfect and identical. Every difference only proves that the product was actually made by hand. But industrially made bakery products that are sold in the store face totally different customers’ expectations. Every drop of chocolate in the wrong place will be a sign of a low quality. This is where <a href="https://making.com/products/chocolate">professional chocolate making equipment</a>, and other similar machinery can help those on an industrial or commercial scale.
<h2>Technology for perfect filling.</h2>
<a href="https://www.foodjet.com/cup-cake-chocolate-surface-filling">Surface printing technology</a> can help to prevent this kind of problems. The industrial vision system in combination with droplet-patterns for depositor's heads ensures depositing a perfect circle on the cupcake surface will make customers happy. One of the main advantages of this printing technology is software flexibility that allows not only to create perfect cupcakes but also to fill cookies, waffles, or even pizzas.

Chocolate surface filling for cup cakes

Food

Bakery production includes foods usually made from flour such as bread, biscuits, and cakes. Depending on the baked good you want to make, flour can be mixed with water or other ingredients producing a paste called dough or batter. The dough is then baked in the oven using dry heat. During baking, heat is transferred from the air to the dough, first on the surface and then in the center. Moisture and liquids escape through evaporation.

Bakery

You can’t buy happiness, but you can buy chocolate; that’s basically the same thing. We were not surprised to discover that chocolate - to be specific, cocoa beans – was so valuable that it was used as a currency in Mayan times. When making chocolate, cocoa beans need to be dried, fermented, and roasted before using chocolate making equipment to turn them into your favorite chocolate product.

Chocolate

Our food chain starts in the soil, growing crops and livestock. But between the fields and the stores, there is a line of industrial food processing equipment. Processes may be as minimalistic as cleaning fruit and as complex as homogenizing milk alternatives made from pressed legumes. In each case, processing technology is an important link in the food production chain.

During the Middle Ages, sugar sweets were a delicacy only for the rich due to the high cost of sugar. Thankfully, the discovery that sugar could be extracted from sugar beets made sweets affordable for everyone. The sweet category is broad, covering chocolates, chewing gums, sugar candies, and candied/glazed products with sugar. To make these confections, sugar manufacturing equipment needs to cover different steps within the production line such as sugar dissolution, syrup cooking and cooling.

Sweets

To produce multiple sponge cake varieties and keep up with the changing industry trends, a production line requires versatility. The line must be ready to produce new products without having to go through a time-consuming format changeover. A unit that can switch formats in minutes is ideal to save time and speed up your production.
<h2>Switch between cakes through different cutting and roller configurations</h2>
The TT Italy Sponge Cake Production Line uses a turbo mixer to prepare the batter and cream materials. A roller depositor then dispenses a layer of batter on the oven belt. The line can prepare decorations before everything moves into the baking area.
After moving through the baking and cooling sections, the cakes will reach a workbench section where a longitudinal cutter and syrup dosing unit work. A filling dispenser is also suitable for filled goods.
A transversal cutter will create the proper cuts measured for your use. An ultrasonic cutter can also work with items with heavy cream content, preventing the squeezing of filling while cutting, ensuring end product uniformity and desired looks.

Sponge cake production line

Exposed baked goods can develop bacteria from the circulating air in an area if left in the open for long. Goods that do not spend enough time cooling off may also warp and leak their contents if handled too soon. A suitable approach to handling the cooling process and moving the items forward is necessary for a successful preparation process.

<h2>Prevent bacteria, humidity, and external threats using active UV treatment</h2>
The TT Italy Sponge Cake Cooling Tunnel is an alternative to a traditional cooling conveyor. The tunnel has a small indoor space for cooling the product. The indoor environment ensures the right conditions for cooling the cakes, plus it keeps the humidity level in check.
Besides the above, the indoor environment also prevents outside bacteria from entering the cakes. The active UV treatment inside the tunnel cleans the air and provides an accurate space for cooking purposes. The design is different from cooling spirals, as it supports the proper alignment of all items. The design ensures the products stay in their proper location, allowing for an easier and safer approach to adding a filling or other topping.

Sponge cake cooling tunnel

Cookies

TT Italy is an Italian manufacturer of solutions for the bakery industry. Offering tailor-made equipment, the company offers both complete lines and single units. Different types of sponge cakes, cupcakes, or celebration cakes are TT Italy's expertise.

If your sponge cake didn't turn out as fluffy as you wanted, don't worry...the first guy who invented it, didn't do a good job either. His cake was much more like a cracker. But in his defense, it was 1615. These days everyone knows that to make a fluffy cake, batter temperature matters. But how can you control it when you have to produce hundreds of uniform, soft sponge cakes a day?

<h2>What does batter temperature have to do with gluten development?</h2>
Let me answer you: everything. When <a href="https://making.com/batter">making batter</a> for your sponge cake, the room temperature must be kept constant and must not exceed 24 °C. If it’s a scorching day or the ovens inside your plant are on, the temperature can easily rise up to 30°C. As a result, batter and fat become more watery and when water appears, wait for it, gluten develops. Flour contains two proteins, glutenin and gliadin, which bond together when water is added. This forms an elastic network of proteins called gluten that makes the batter sticky. If there is too much of it, your fluffy sponge cake will become chewy and get a bread-like texture. It is also hard to deposit the sponge cake layers evenly, between 4-5 mm each, if the batter is too viscous.
<h2>A closed mixing system to control your batter temperature</h2>
After premixing, sponge cake batter is often prepared in open planetary mixers. Change-overs and combining different mixers together make it difficult to control temperature and achieve batter uniformity. As Natalija Pepeljugoska, Food Technologist at TT Italy, explains, in this case a closed mixing solution that avoids exposing the batter to the outside temperature can be recommended. Industrial-scale cake manufacturers use their Turbo Mixer starting from a capacity of 400kg of batter per hour. It has an integrated cooling system to make sure the temperature stays between 18-24 °C for perfect batter quality. By injecting controlled air or nitrogen instead of oxygen into the closed vessel, the risk of anaerobic micro growth is reduced.

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https://www.youtube.com/watch?v=QMznf7B5ZHc&amp;t=19s

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Gluten morgen… Temperature control in your sponge cake production

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