Technical analysis & Cost of Ownership assessment

The Rademaker Crusto is an industrial bread production line based on sheeting technology. Sheeting technology is chosen above the traditional bread making systems because sheeting provides various important benefits. First of all sheeting makes it possible to handle a wide variety of dough types, from ‘green’ to pre-fermented dough, all at high capacities. By using stress free dough sheeting and laminating technology, you can achieve basically any dough and bread structure desired. The dough structure that is created during mixing, kneading and preproofing remains intact, resulting in the highest quality products.

Furthermore, the line consists of a number of innovative and versatile modules on wheels that can easily be positioned in any required line order. This flexibility is key when it comes to configuring your application and managing production efficiency.

The Crusto Bread line is suitable for processing a wide range of dough types at industrial scale starting at about 500 up to 9,000 kilograms per hour (batch sizes ranging from 200 – 700 kg / liters).

The key benefits of this unit are already shown at multiple customer locations: the Crusto Bread line has proven to be extremely dough friendly for a wide range of products and dough types. Even the most fragile dough structure stays intact during the chunking and pre-sheeting process. Furthermore, the line is easy to operate and the accessibility allows fast and simple cleaning procedures.

Apart from these key benefits, the Crusto bread line also creates a very stable product flow. This is a direct result of the efficient split of the cascading chunk-process and subsequent sheeting actions, which are perfectly controlled by various sensors. Actual results in factory environment show that this stable product flow yields the best possible dough homogeneity.

TEST SET-UP

 Thorough tests in the Rademaker Technology Center (RTC) are performed in order to determine the exact positive effects of the improved dough homogeneity on the final product weight accuracy. Subsequently the resulting benefits for the Cost Of Ownership are assessed by details calculations based on actual factory circumstances. Various tests are performed with both the Crusto Bread line as well as comparisons with state-of-the-art competing lines and systems and previous generation Rademaker equipment. A broad range of different dough types was put to the test with water percentages ranging from 55% up to 85%.

Three different products were selected for the high volume tests: 80 gram square buns, 165 gram baguettes and 150 gram ciabatta. Various runs with significant numbers of products are performed in order to guarantee a statistically correct result. During these detailed and thorough tests the volume and cell structure of the final products as well as the weight accuracy before and after the baking process are examined.

 

summary of results

Comparison of volume, homogeneity and final accuracy was performed for the above mentioned product type in various different runs. Also a variety of different environmental circumstances are assessed in order to achieve the most reliable result.

Furthermore the volume and cell-structure is shown in the pictures. These pictures clearly show the fact that the structure of the dough remains fully intact due to the very dough friendly handling of the Rademaker Crusto bread line.

Effect on cost of ownership

Product accuracy can have a significant effect on the overall cost price for production. In general the cost price contribution of the so-called “give away” or product overweight is normally in the range of 20 – 30% of the total added cost of a bread sheeting & make-up line (excluding baking and packing). With the improved accuracy, the added cost of the “give away” portion of the bread sheeting & make-up line can be dramatically reduced. Cost of Ownership (CoO) calculations show that a total cost reduction of up to 15% can be achieved depending on the type of dough. From this investigation it is safe to conclude that the Rademaker Crusto Bread line is not only creating a higher quality product but can also seriously boost your profit.

Interested in the Crusto bread production line? Contact our sales team: +31 (0)345 543 543