Bakes and Controls Moisture for Bakery Products

The Baking Tunnel Ovens from GEA Bakery, combining expertise from GEA Comas and GEA Imaforni, are engineered to deliver unmatched baking precision. These ovens excel in accommodating an array of bakery products, from artisan bread and French baguettes to cookies and pastries. Employing modular technology, they enable precise temperature and humidity regulation within each zone, optimizing baking quality and consistency. These ovens support continuous and high-speed automated operations, ensuring production lines maintain a steady pace and quality output.

Available in gas, electric, and hybrid models, the ovens are designed for seamless integration into existing bakery systems. Gas ovens use the Venturi principle for precise combustion control with real-time adjustments via an intuitive interface. The electric models offer zero CO2 emissions, making them eco-friendly with significant energy conversion efficiency. Hybrid ovens combine multiple heating methods, ideal for varied product profiles like crackers and biscuits, enhancing moisture control and color consistency.

With capacities scalable to meet industrial demands, these ovens handle extensive throughput while ensuring minimal maintenance needs and integration with automation systems. Enhanced by advanced simulation tools for custom configurations, GEA Bakery provides engineering support to tailor solutions to specific process requirements, reinforcing its commitment to sustainable and efficient bakery production solutions.

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Cuts and Shapes Dough into Diverse Snack Products

The Rotary Cutting Station, designed by Thomas L. Green, provides a solution for industrial bakeries aiming to precision-cut and shape dough into an array of snack products such as pretzel bites and shortbread cookies. The equipment utilizes a continuous rotary die assembly to press dough against high-precision engraved die rolls, effectively forming consistent shapes. Equipped with an integrated conveyor system, it synchronizes seamlessly within production lines, including upstream mixers and downstream ovens. Capable of handling various dough thicknesses, it supports customization with multiple die rolls for complex shapes. The station includes features for efficient scrap removal, recycling off-cuts back into the dough handling system. Built within Reading Bakery Systems’ SafeShield Program, it ensures safety and hygiene with interlocked guard mechanisms and easy-clean access. Comprehensive automation is achieved through PLC control, promoting synchronized speed adjustments for optimal product quality and throughput efficiency, making it a robust choice for snack manufacturers and food production companies.

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Extrudes and Fills Diverse Snack and Bakery Products

The Filled Stick Extruder from Reading Bakery Systems is engineered to streamline the production of diverse snack and bakery items. It excels in creating filled snack sticks by utilizing low-pressure extrusion and precision co-extrusion of both dough and a soft filling. This system accommodates applications such as snack and bakery production and co-extruded pet treats. It features customizable die and compression heads for seamless product changeovers.

With an output capacity tailored to suit your line requirements, its modular design allows integration with existing systems, enhancing production line efficiency. The extruder’s control systems are fully PLC-automated, offering real-time monitoring and precise flow control, while optional temperature management supports sensitive dough consistency.

Constructed with easy-to-clean materials and designed for tool-free disassembly, the system supports stringent sanitation standards. Available configurations include 1 to 6 extrusion units, making it adaptable to various production scales. Additionally, Reading Bakery Systems provides ongoing engineering support and customization options to fit specific production needs.

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Processes Dough into Consistent Fried Snack Shapes

The Fried Snack Extruder from Reading Pretzel, part of Reading Bakery Systems, is designed for snack food manufacturers and bakery businesses looking for a reliable solution in producing varied fried snack items. This extruder stands out due to its flexibility in processing applications such as potato rings and ethnic noodles with precision cut using a high-speed bandcutter capable of up to 275 cuts per minute. The equipment manages up to 3,000 pounds of dough per hour, ensuring high throughput for continuous production.

The extruder integrates seamlessly into production lines thanks to its advanced automation, featuring a touchscreen control interface for easy regulation of dough flow and cutting speeds. Its jacketed extrusion housings enable precise temperature control, enhancing product consistency and quality. Reading Bakery Systems’ SafeShield Program ensures operator safety with automatic controls and simple, tool-free disassembly, supporting easy sanitation. Designed for durability and efficiency, the Fried Snack Extruder offers custom die and compression heads for quick product changeovers and is adaptable for multiple food industry needs. Additionally, its construction permits effortless cleaning without production downtime, promoting operational efficiency and compliance with food safety standards.

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Produces Consistent Frozen Dough and Bakery Products

The Thomas L. Green GenesisPRO Series Frozen Dough Machine is designed to enhance flexibility and control in high-speed frozen dough production lines. It uses precise recipe-driven linear servomotors to optimize wire positioning, stroke length, and product drop, ensuring consistent weight and accuracy, up to 300 cuts per minute. This equipment is ideal for producing a variety of bakery products, including frozen cookie dough, co-extruded and encapsulated cookies, granola bars, and shortbread biscuits.

Integrated pneumatic feeding and separation systems streamline operation and maintain product quality with minimal operator interaction. The system’s design, adhering to SafeShield standards, features removable components for effortless sanitation and maintenance, reducing parts count by 50% compared to traditional systems. Fully PLC-controlled, the GenesisPRO offers seamless integration with existing dough handling systems, supporting automated processes with touchscreen interfaces for easy recipe adjustments. Custom wirecut and die assemblies accommodate diverse product needs, making it a versatile solution for industrial bakeries aiming for efficiency and high quality.

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Reduces Dough to Uniform Thickness

The Thomas L. Green Gauging Station from Reading Bakery Systems excels in precise dough sheet reduction, ensuring uniform thickness for crucial products like saltine crackers, thin crust pizzas, and butter cookies. Utilizing a 3:1 reduction ratio via hardened rolls, it maintains dough consistency through advanced control systems that automatically adjust roll gaps. Designed for high-speed, continuous operations, it seamlessly integrates into production lines, optimizing dough flow and density. With adjustable roll gaps and integration-ready discharge conveyors, this system is perfect for bakeries and snack manufacturers. Built to Reading Bakery Systems’ SafeShield standards, it ensures safety and sanitation, featuring interlocked guards and easy-clean conveyors.

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Extrudes and Shapes High-Pressure Snack Products

The High Pressure Snack and Bakery Extruder from Reading Bakery Systems offers reliable and versatile solutions for snack food and bakery producers. This equipment allows continuous mixing, cooking, and extruding, forming diverse products like cheese puffs and pet food kibble. Its flexible design supports quick changeover of screws and dies, accommodating various product shapes and textures. With integrated PLC-controlled systems, it aligns seamlessly with production lines, optimizing throughput and ensuring high-speed, automated operations. The extruder features automatic controls, enhancing safety and sanitation while minimizing operator exposure. Constructed with durable materials, it ensures adherence to food safety standards and easy cleaning, backed by customization options to meet specific production requirements.

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Provides Flexible Heat Transfer for Baking and Drying

The SMART Oven Zone from Reading Bakery Systems is engineered for industrial bakeries and food processing companies that require adaptable baking solutions. It stands out by offering configurable heat transfer modes, using both radiant and convection heat for optimal product quality. This oven can handle a variety of applications including snacks, pretzels, crackers, cookies, biscuits, granola, and pet food, allowing seamless integration into diverse production lines. It facilitates a flexible baking and drying process with its modular design, permitting rapid adjustments to the baking profile suited for your specific end-products like cheese-flavored crackers or ginger biscuits.

The oven’s capacity is bolstered by its fully automated operation, powered by a feedback-based control system for continuous recipe-based adjustments. It incorporates advanced control systems designed in-house for precision and efficiency, offering real-time monitoring through feedback loops. Available in both gas and electric models, it offers energy efficiency and sustainability, with options to convert existing gas ovens to electric. Constructed under the SafeShield Program, the oven is designed for operator safety, quick sanitation, and food safety compliance. It includes large access doors for easy maintenance, active flame and temperature monitoring, and optional fire suppression systems, ensuring robust safety standards.

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Controls Baking Heat and Airflow Independently

The Electric Baking Zones from Reading Bakery Systems offer a comprehensive solution for industrial baking where conversion from traditional gas systems is necessary. Employing a penthouse design with independent top and bottom temperature control, this equipment ensures precise air distribution and consistent baking results. Suited for applications ranging from snacks like pretzels and cheese puffs to biscuits and granola bars, it supports high-volume production with modular sections for seamless integration into existing lines. The zones can be adjusted for various product types and are designed for energy efficiency, reducing operational carbon footprints. Automated and equipped with a feedback-based control system, the Electric Baking Zones consistently monitor conditions to ensure optimum performance. Built under the SafeShield Program, they prioritize safety and sanitation, featuring robust cleaning access and optional fire suppression systems. This equipment is ideal for bakery manufacturers and snack producers seeking to enhance their production processes with environmentally-friendly technology.

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Balances Heat and Controls Humidity for Baking

The Emithermic XE Oven Zone from Reading Bakery Systems offers a versatile solution for precision baking and drying in the food production industry. Utilizing a combination of Thermatec high radiant panels and electric radiant elements, this oven eliminates the need for gas burners, delivering balanced heat and ensuring optimal flavor and texture in products such as biscuits, crackers, and snacks. It includes a humidity-controlled product zone for enhanced baking control and integrates easily into existing production lines with its modular design. With throughput customizable to meet the demands of commercial bakeries and snack manufacturers, the Emithermic XE Oven Zone supports continuous and automatic operations. The electric components reduce downtime associated with traditional gas burner maintenance, while the energy-efficient design helps in cost savings. Built for safety and sanitation, it complies with food industry standards, offering easy cleaning access and explosion prevention features.

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