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ingredient storage room handles flour, which is sifted at receipt and as it moves to the mixer’s holding tank. The company installed three stations of 2,000- and 3,200-lb above-mixer use hoppers; one set is in use now, with two in place for the future. The brew system sits in one corner of the main production flour. The fermentation operation produces 3,600 lb of 40%-flour brew per hour. The mixture goes through a 10-minute blending stage, followed by 25 minutes in one of three fermentation tanks. The brew then passes through a heat exchanger that reduces its 95°F temperature to 36°F before it enters the cold hold tank. The brew system can easily hold brew for 36 hours over a weekend for the next startup day. DOUGH TO OVEN. “The fully automated dough mixer requires automatic feed,” Mr. Mitchell said. A Shick IntelliBatch ingredient management and batch execution software manages the inventory of ingredients and their flow to the mixers. Bulk and minor ingredient transfer into the AMF 3,200-lb fully automated horizontal mixer when signaled by the computer-integrated batching system, but micro ingredients are manually portioned at a station in front of the mixer. After being placed into a weigh-up bucket, they are dumped by hand into the mixer bowl. Dough discharged from the mixer is pumped to a vertical conveyor leading to an overhead horizontal conveyor. The belt dribbles the dough into the AMF SBD 8-across rotary bun divider. (The whole-wheat Angus bun, an oversized item, was being made during Baking & Snack’s visit run 6-across.) “We recently changed the divider’s rounding bars to Teflon-coated aluminum from the original UHMW [ultrahigh-molecular-weight polyethylene],” Mr. Kozloski said. The new bars release dough balls without sticking. Rounded dough pieces fall down the zigzag board of the AMF Accupan bun makeup system. After a short intermediate proofing period, the dough pieces drop to the system’s sheeter to be flattened and deposited in waiting bun pans that index forward to accept each row of dough pieces. A Larramore flour reclaim system with filter manages the dusting flour. When making Angus buns, the dough pieces pass under a herringbone-patterned roller that imprints them to give the desired braided appearance. Filled bun pans encounter a Burford orbital shaker that oscillates the pan in the horizontal plane to properly seat dough pieces.

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Baking&Snack - March 2011

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