Belts for the Bakery industry

EN
Belts for the Bakery industry
Belting solutions for:
• Bread & bun processing
• Biscuit production
• Pastry processing
Within the food industry Ammeraal
Beltech has been setting the standard
for many years with its consistent
product quality and market specific
hygiene features.
Quality and improved hygiene standards
are magic phrases in the food processing and can only be guaranteed by using
totally hygienic production processes,
short cycles and fault free logistics.
In all industries and especially the bakery
industry we have the application knowhow and product range to be the perfect
partner for original equipment manufacturers whilst providing a comprehensive
network to meet end-user demand.
Contents
Introduction 2
Typical process lines
Bread & bun 3 – 4
Biscuit 5 – 6
Pastry 7 – 8
Our product portfolio
Process and conveyor belts Modular belts 9 – 10
11 – 12
More of our products 13
At your service 14
Rely upon innovation, quality and our service
Ammeraal Beltech continues to prove
its commitment to a combination of
quality and innovation through the
ongoing introduction of new materials,
accessories and hygiene concepts for
the food industry.
Process and conveyor belts are developed and produced in various locations
throughout the world by the most modern techniques, based on expert knowledge and on thorough understanding
of the application environment.
Forming, moulding, proving, cutting –
these are just some of many baking
processes. These processes require
very special belt characteristics. In the
Ammeraal Beltech range we have many
profiled belts and surface materials to
meet all baking applications.
A wide range of belts with excellent
resistance to oils and fats, superb release
characteristics, increased flexibility and
for use with high or low temperature,
is available to meet even the most stringent international standards of hygiene,
both for direct contact as well as for
packed product conveying.
The product’s feature:
• Excellent release properties
• Suitable for knife edge transfers
• High temperature possible
• Meets FDA requirements
The unique and complete product
portfolio of Ammeraal Beltech, includes
also Modular belts, Endless woven belts,
seamless coated Engineered and Timing
belts, and provides the best technical
and efficient belting solution for biscuit,
bread & bun, and pastry processing.
Typical process line for Bread & Bun
Specific belt requirements for:
Pre-processing:
• Handling of very sticky and
wet dough
• Good release and high grip
for moulding
• Oil and fat resistant
• Resistant to shrinkage and to
belt edge fray
• Easy to clean
• Resistant against pollution
Cooling, finishing and packaging:
• High thermal conductivity
• High or low temperature resistant
• Resistant to cutting
• Metal detector suitable
E
D
B
C
A
mixing
oven
I
A Dough divider
When mixing is complete dough
is divided into equal pieces
E Moulder
Pieces of dough are shaped and moulded
by shaping belts running at different speed
I Depanner
Bread is removed from the pans to
support the cooling process
B Check weigher
The weight of each piece of dough is
very important to ensure that the finished
product complies with regulations
F Panner
Dough pieces are placed in a tin
J (Spiral) cooling system
Cooling is done under controlled
conditions to ensure correct temperature,
humidity and time in (spiral) cooling tunnels
C Conical rounder
This kneads and shapes each piece of
dough to maintain product consistency
D Pre-prover
Dough pieces are allowed to recover in a
linear or spiral conveyor, the first or intermediate proving stage
G Final prover
Dough rises in strictly controlled temperature and humidity conditions
H Oven infeed belt
Dough is transported to the oven where
steel belts are running
K Cutter
Bread is sliced if needed, wrapped
and transported to the final packaging
area or freezer
L Metal detector
This is used to ensure that no foreign bodies have contaminated the product
oven
H
G
F
distribution
L
K
J
J
Other applications not shown:
• Spreader
• Seeder
• Lid handling
• Freezer
• Tray handling
• Packaging machine
Typical process line for Biscuit
Specific belt requirements for:
Pre-processing
• Handling of dry and oily dough
• A combination of adhesion and
release properties for consistent
running
• Highly oil and fat resistant
• Resistant to shrinkage and to
belt edge fray
• Resistant to cutting
• Suitable for knife edges
Cooling and secondary processing
• High thermal conductivity
• High temperature resistant
• Easy to clean
• Flexible belt construction for curves
Finishing and packaging
• Metal detector suitable
• High grip
• High running speed
• Accumulation possible
oven
F
mixing
E
D
C
B
A
mixing
A Dough feeder
When mixing is complete dough is either
fed into the laminator or directly into the
rotary moulder
B Laminator
Produces a continuous sheet or cut sheets
of dough with gauge rollers
C Gauge rolls
The layered dough is processed through
gauge rolls before the rotary cutter
D Rotary cutter
Creates the final biscuit shapes by a cutter
roller
E Scrap return
Dough is taken away and returned to the
hopper for re-use
F Cooling system
Biscuits are cooled on long belts or in
(spiral) tunnels. Open area Modular belts
are used for faster cooling
G Enrober
Applies jam or chocolate on the biscuits.
This needs to be very accurate. Another
cooling system follows the enrober
H Rotary moulder
Alternative way of biscuit production
by means of a moulding drum shaping
the biscuit. Biscuits are extracted from
the drum by belt suction
G
finishing,
packaging, and
distribution
oven
oven
H
Other applications not shown:
• (auto) stacker
• freezer
• packaging machine
Typical process line for Pastry
Specific belt requirements for:
Pre-processing
• Handling of very sticky and
fat dough
• Resistant to cutting and forming
• Very good oil and fat resistant
• Resistant to shrinkage and to
belt edge fray
• Suitable for knife edges
Cooling and finishing
• High thermal conductivity
• High or low temperature resistant
• Flexible belt construction for curves
• Metal detector suitable
Packaging
• High grip
• High running speed
• Accumulation possible
D
C
B
A
mixing
A Dough sheeter, curling device,
and cross roller
When pre-mixing is complete the dough
is rolled out to an endless sheet before
it runs through the curling device and
cross roller
B Gauge roller
Through gauging of dough the laminator
guarantees a specific thickness
C Folding station
The pastry dough is folded in a zigzag
pattern for a second folding stage and
final sheeting
D Make-up line
• Circular cutters cut the dough in any •
•
required width
A variety of fillings is applied with
depositors and the pastry is folded
and curled
Guillotines with cutting knifes are
cutting the pastry before going to
the oven
oven
second
folding,
lamination, and
resting
tunnel
Other applications not shown:
• Resting tunnel to restore the balance between fat and dough layers before
final sheeting
• Croissant line with cutters, depositor and final moulders
• Pizza line with cutters and automati-
cally topping
Hygienic Process and Conveyor belts
for handling of bakery goods
Fabric based plied belting
Ammeraal Beltech supplies belting for
every facet of the baking process from
dough feed right up to packaging.
Besides a standard range of process
and conveyor belts Ammeraal Beltech
is also able to provide belts for specific
bakery processes like:
Designed to handle even the most
difficult dough handling applications,
our coatings are engineered for machine dry, wet, and oily doughs, and
employ fabrics with dimensional stability and flexibility for the best possible
performance.
•
•
•
•
Depanner belts with suction cup retainer system
Cooling belts with excellent heat transfer properties
Bagel forming machine belts
Spliceable rotary moulder belts
Fast becoming the food industry standard, Ropanyl PU belting is hard-wearing, fat resistant, non-toxic, has high
dimensional stability and is easy to
install.
For wet processing of foodstuff, Nonex
PVC coated belting gives excellent service across a wide variety of applications.
Overview
Belt type
Main features
Customer benefits
Fabric belts
Cotton/polyester surfaces
• Excellent non-stick properties
• Very good release of dough
• Different combinations of yarn material possible • Long belt life
• Good abrasion resistance
• Reduced cleaning time
• Impregnation possible
Nonex belts
PVC coated
• Good resistance to oils and fats
• Easy to clean non-migrating surface
• A wide range of profiles available
• Cost efficient solution
• Less downtime of your production line
Ropanyl belts
PU coated
• Very good resistance to oils and fats
• Cut and impact resistant
• High temperature resistance
• Longitudinally flexible belt construction
• Non-fray and non-shrink constructions available
• Good release properties
• Small pulley diameters
• Reduced risk of product contamination
• Lower running costs
• Less downtime of your production line
Peflex belts
PE coated
• Excellent wear and impact resistance
• Good oil and fat resistance
• Suitable for higher temperatures
• Cold resistant
• Less polution due to excellent release
• Less cleaning costs
• Good belt performance
Nitrile belts
Rubber coated
• Excellent wear and impact resistance
• Good oil and fat resistance
• Suitable for higher temperatures
• Cost effective in dough applications
• Less downtime of your production line
Silam belts
Silicone coated
• Excellent resistance to oils and fat
• High friction top cover
• High temperature resistance
• Solution for dough applications
Note: Fabric, Nonex, Ropanyl, Peflex, Nitrile, and Silam are trade names of Ammeraal Beltech. The same coating materials can also be
applied on our Endless woven fabric belts
10
Hygiene concepts
To make sure your production is able
to meet the demand of freshness
quality we offer our special hygiene
concepts for the swift and convenient
processing of the foodstuff:
• Amseal edge protection
• AntiMicrobial concept
• Range of Blue belts
• KleenEdge belt construction
• Hygienic Footless flights
Belt fabrication
Ammeraal Beltech belts can be made
endless by means of various splicing
methods. Semi-finished products are
customized to exact requirements by
using computer aided design techniques at local sites. This means that
new and innovative solutions can be
developed quickly and cost-effectively.
Our high-frequency
welded hygienic
Footless flight can
be fed over smaller
drum diameters
and cleaned thoroughly, very easily
and quickly.
Belts with AntiMicrobial additives to
assist in reducing
the number of microbes as food contact surfaces.
Our Amseal belt protection completely
seals the belt edges on all sides with
thermoplastic strip to protect against
external influences and circumstances.
Belts can be fitted with accessories
such as carriers, ropes and corrugated
sidewalls, made endless and finally
engineered with holes and grooves.
Accessories are applied for tracking
the belt, and to increase or ensure the
conveying capacity.
The colouring of
the Blue belts
makes it much
easier to identify
product contamination and impurities
can be spotted
much faster.
Our curve belts
ensure a smooth
transport of
products.
A special KleenEdge construction is
designed in such a way that the high
strength reinforcement fabric is held
securely in a tough non-cracking
thermoplastic polyurethane sandwich.
The KleenEdge constructions stop fibre
pullout contamination and stop belt
shrinkage.
Our superior design limits bacteria
penetration and compliance with
HACCP and your food safety standard
takes place as a matter of course.
Belt are executed with a variety of cover
surfaces to achieve lower friction, good
release properties or to make the belt
suitable for inclined conveying.
11
Modular belts for efficient handling
of dough and finished products
Modular belting
Ammeraal Beltech sets new standards
in bakery industry with modular belting
technology. The unique belt design
maintains the highest hygiene standards. The All-in-One series of modular
belts is the perfect solution for combining straight and inclined belts in one
smooth continuous operating conveyor.
Where positioning is important a
modular belt with
positive drive is the
best solution
Modular belts are offering outstanding
advantages:
• Easy to clean surface and sprockets
• No tracking problems due to
positive drive
• Easy repair and easy replacement resulting in low maintenance costs
• Different food grade materials with easy release properties available in many colours e.g. food blue
• Various open area belts for efficient cooling and easy cleaning
• Accessories such as dividers,
side plates, and high friction inserts are available
Our Modular belts
in Acetal material
with smooth hard
surfaces can be
used for accumulation and pushing
off sideways
In case of panhandling we offer
heat resistant
Modular belts with
very low noise
level compared to
flat top steel belts
Overview
Belt type
Main properties
Benefits / application indication
SM60500
1/2” Straight belt
• Flush top / 30% open area
• 50% contact area
• suitable for 20 mm nose bar
• excellent release characteristics
• smooth performance
TT60500
1/2” Straight belt
• Solid top non stick A18-profile
• contact area <10%
• small nose bar suitable
• metal detectable material
• excellent release characteristics
• ideal belt for dough transport from divider
to prover
S61000
1” Radius belt
• Flush top / 43% open area
• 35% contact area
• belt for proofing and freezing
• general transport
• straight and radius transport in one belt
CT61000
1” Radius belt
• Curved top / 43% open area
• 15% contact area
• belt for proofing and freezing
IS61500
1.5” Radius belt
• Flush top / 38% open area
• 43% contact area
• belt for pan handling
• straight and radius transport in one belt
PR62000
2” Spiral belt
• Flush top / 52% open area
• 17% contact area
• also available in small product execution
(PR62000SPS)
• belt for cooling and freezing
12
Spiral modular belts
The same design that has proven to be
successful in standard radius applications is also the best solution for many
spiral systems. Today we are worldleader in plastic belts on spirals, having
more installations in proving, drying,
cooling, chilling and freezing applications than any other manufacturer.
Stainless steel belts
are often replaced
by a Modular belt,
which is stronger, has a lower
weight, and no
wear debris.
Over the years we replaced a lot of
steel belts based on the following
advantages of Modular belts:
• 100% plastic parts eliminate product contamination from wear debris as caused by steel spiral belts
• Meet USDA specifications for
cleanability, available in FDA plastics for direct food contact
• Non-stick surface reduces and/or eliminates frost, ice and other environmental build-up
• Less power consumption due to
lower belt weight and lower friction
• High speeds possible, up to 2 m/s
• No lubrication required
Our Spiral belts are
able to handle 7200
bread loafs of 800
gr. each per hour
in cooling applications.
Our All-in-One series and Spiral Pro
belts with a collapsing factor varying
from 1.35 up to 2.2 offers a right belt
for every spiral applation in bakeries.
Our Curved Top 1’’
radius belt with
easy release and
non-stick properties is a solution
for proofing and
freezing croissants.
In circumstances where an open belt
construction is essential for the process, modular belting technology with low
sanitation costs and low maintenance is
the perfect solution for especially spiral
applications in the food industry.
On-site support
Our technical spiral experts will come
to you to review all aspects of the
belt’s operation from system design
to start-up or changes necessary to
replace a steel belt. Either Ammeraal
Beltech oversees the installation of
your new spiral belt or you complete
the installation yourself, we will be
there to ensure that it runs exactly as
intended.
13
More of our products
Endless woven fabric belting
Ammeraal Beltech’s in-house weaving
and coating facilities make it possible
to offer a wide range of endless coated
and uncoated fabric construction, using
numerous natural and synthetic yarns
such as cotton, flax, polyamide, polyester and aramid.
There are many applications where standard process or conveyor belts cannot
be used. Where extreme temperature
resistance is needed, our heat resistant
seamless belts are the perfect choice.
Our custom-made endless woven
AmDough belts give the right answer
to the strict requirements of rotary
moulder and rotary cutter applications
with different kind of dough and knife
edges.
Also endless woven belts with additional coatings such as Nonex, Ropanyl
and Silam are available for applications
where a splice is not allowed or cannot
be admitted. We offer tailor-made solutions with many profile surfaces to give
the right answer to the strict requirements of dough handling.
Unique product portfolio
Ammeraal Beltech offers a complete
range of quality Rapplon power transmission belts made on state-of-the-art
production equipment.
Whenever your process demands accurate synchronization of time or distance
Timing belts of Ammeraal Beltech are
the ideal solution.
With a range of Engineered belts we are
able to offer solutions varying from very
hard and solid to extremely soft cellular
top cover material for different applications in packaging areas.
Equipment and tooling
With the new Maestro splicing equipment Ammeraal Beltech companies and
distributors are able to make consistent,
reliable, hygienic splices in process and
conveyor belting:
• Less shrinkage of fingers, providing extremely flat splices without rims
• Stronger splices which do not crack or open to prevent bacteria growth
• Smooth, simple and slim design
allowing easy cleaning and easy
handling
• No water or forced air cooling
necessary: no influence on food
production environment
• Quick-splice cycle results in less
production downtime
14
At your service
Facts & figures
Ammeraal Beltech is an international
company with affiliates in 25 countries.
Our products are available globally via
a network of distributors and service
centres in more than 150 countries.
We have 7 primary production plants
which manufacture rolls of process
conveyor belting. Our network of over
80 service centres employing more than
1,600 highly qualified employees are located in close proximity to our customers and provide tailor made solutions
often combined with a 24/7 service.
Innovation
Within our purpose-built R&D centres we are continuously optimising
and improving our products to satisfy
constantly changing demands, such
as higher speeds and temperatures,
increased cleanability and durability, and
more stringent international standards
of hygiene and safety.
Because Ammeraal Beltech manages
every aspect of the belting quality – from
the fabric to the final fabrication – we
are confident that we are able to develop
the belt that meets your future needs.
Service network
We understand the importance of keeping your business running and know
how costly and disruptive downtime can
be. That’s why we offer a service network worldwide, that is available round
the clock at local level.
We ensure that there is an Ammeraal
Beltech branch near you, so the support
you receive will be fast and convenient.
Technical support
With the on-site support of Ammeraal
Beltech’s experienced team of Sales
Engineers, nothing is left to a chance
and ensures valuable support and your
complete satisfaction. Our product
specialists have the technical proficiency
to develop a belt for most difficult
operating conditions in any industry.
A sound combination of a global network, market segment knowledge and
product management is the basis for
our innovative and service-orientated
organisation.
Your global contact
International Head Office:
Ammeraal Beltech Holding B.V.
Handelsstraat 1
P.O. Box 38
1700 AA Heerhugowaard
The Netherlands
Austria
T +43 1 2929372
F +43 1 2928906
[email protected]
Hungary
T +36 234 275 10
F +36 234 275 11
[email protected]
Sweden
T +46 44 43015
F +46 44 43349
[email protected]
Belgium
T +32 2 466 0300
F +32 2 466 4272
[email protected]
Italy
T +39 051 660 60 06
F +39 051 660 60 16
[email protected]
Switzerland
T +41 55 2253 535
F +41 55 2253 636
[email protected]
Brazil
T +55 11 4655 1244
F +55 11 4655 1099
[email protected]
Luxembourg
T +352 26 48 38 56
F +352 26 48 38 57
[email protected]
Thailand
T +66 2 902 2604-13
F +66 2 902 0422
[email protected]
Canada
T +1 905 890 1311
F +1 905 890 3660
[email protected]
Malaysia
T +60 3 806 188 49
F +60 3 806 189 35
[email protected]
United Kingdom
T +44 1992 500550
F +44 1992 553010
[email protected]
Chile
T +56 266 96975
F +56 266 96709
[email protected]
Netherlands
T +31 72 57 51212
F +31 72 57 43364
[email protected]
United States
T +1 847 673 6720
F +1 847 673 6373
[email protected]
China
T +86 21 6534 4690
F +86 21 6548 0430
[email protected]
Portugal
T +351 22 947 94 40
F +351 22 941 30 81
[email protected]
Czech Republic
T +420 56 7330 056
F +420 56 7330 637
[email protected]
Singapore
T +65 62739767
F +65 62735490
[email protected]
Finland
T +358 3 278 4400
F +358 3 273 1400
[email protected]
Slovakia
T +421 2 55648541-2
F +421 2 55648543
[email protected]
France
T +33 3 20 90 36 00
F +33 3 20 32 29 17
[email protected]
South Korea
T +82 31 448 3613-7
F +82 31 448 3618
[email protected]
Germany
T +49 4152 937-0
F +49 4152 77695
[email protected]
Spain
T +34 93 718 3305
F +34 93 718 6273
[email protected]
Reference: 45.0 EN Date 09/2006
T +31 72 5751212
F +31 72 5716455
[email protected]
www.ammeraalbeltech.com