Krupuk – Indonesian crackers

Krupuk or Kerupuk crackers are widely consumed in Indonesia as a snack or accompaniment to main dishes. They are also enjoyed in Malaysia.

Krupuk ingredients are tapioca starch from the cassava root, prawns (udang), or fish (ikan), seafood, vegetable (sayur), onion (bawang) and water. The ingredients are mixed to form a dough, rolled out, steamed and sliced. They are sun-dried to remove the moisture. The krupuk are fried at home in a wok with very hot oil. They expand in few seconds into a light crispy cracker.

Krupuk 2
Krupuk 3
Krupuk 5
Krupuk 6
Krupuk 1
Krupuk 7
Krupuk 8
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Oven band cleaning

Wire mesh oven band cleaning

Oven band cleaning is critical to the quality of the biscuit and the oven performance. We strongly recommend a band cleaner which operates all the time during baking, ensuring that there is no build-up of carbon, which is difficult to remove.

The Baker Pacific oven band cleaner consists of two independent driven wire brushes for cleaning both sides of the band. The unit is designed for a continuous, gentle cleaning action to maintain the band in good condition.  The top wire brush, driven by a fixed speed motor gearbox cleans the inside of the oven band. The lower wire brush unit cleans the outside of the oven band. It is mounted on a trolley for removal to the side of the oven. Guide rails are provided for the trolley with stops and locking handle. The brush is raised or lowered to the working position by a lever and the brush pressure is adjustable.

Band cleaner

Baker Pacific oven band cleaner manufactured in China

Maintaining a clean band is important, particularly when baking products with sugar toppings, and preventing contamination is vital. When baking products with toppings a good system of recovery for surplus toppings is essential to prevent toppings dropping on the oven band. A long wire-mesh panning conveyor is recommended with a level transfer of the dough pieces to the oven band.  The panning web should an open mesh band (enrober wire-mesh) and be around 2 – 3m long. The end transfer roller or nosepiece is of small diameter to allow a level transfer of dough pieces to the oven band.

For wire mesh bands which have become dirty, some hard carbon deposits may be removed by heating the band to 400oC, when the hard carbon deposits will break and can be removed by the brushes. It is important that the band is heated evenly and only sufficient temperature to carbonise the debris is used. Uneven or excess heating will distort the band.

Soft deposits may removed by steam cleaning with an industrial cleaning fluid. Suitable drainage is required. After cleaning, the band should be dried and oil (soybean oil / coconut oil) applied to prevent rusting.

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Heat Recovery System

The Heat Recovery System (HRS) uses the waste heat from the burner flues. This may be used to heat one or two final zones of the oven. These zones would not require burners, giving a saving in capital and running costs.

A proportion of the hot gases in the burner flues are diverted to an HRS collection pipe which runs along the top of the oven. Hot gases are collected from each zone with a burner. The hot gases are drawn along the collection pipe by a fan and blown into radiant ducts in the final oven zone.

Heat recovery main pic

Baker Pacific Indirect Radiant Oven with Heat Recovery System

 

 The burner flue is connected to the HRS collection pipe and the flow of hot gases is controlled by dampers.   One damper controls the exhaust flue and one damper controls the connecting pipe from the burner flue to the collection pipe. These dampers are set by the commissioning engineer to allow sufficient quantity of heat for the final zone(s) of the oven.

The HRS zone is constructed with radiant ducts above and below the oven band. The hot gases recovered from the burner flues are fed by the fan to the ducts. The fan is located on top of the oven at the end of the collection pipe.

The Heat Recovery System saves capital and running costs. By using recovered heat from the system shown, the fuel cost was reduced by 15%.

Details of the design and construction of the Heat Recovery System, with airflow calculations are included in the Baking Process and Engineering Manual available from Baker Pacific. For further details, please request at our Contacts page.

 

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Classic British biscuits

“Biscuits – the first and best convenience food”

The British love a biscuit with a hot drink! Sales reached GBP 2.2 billion (USD 3.5 bn) in 2010 and are forecast to reach GBP 2.6 billion (USD 4.2bn) by 2015. Favourites now are half coated biscuits, Chocolate Digestives, followed by chocolate chip cookies, cream biscuits, such as Custard Creams, wholemeal biscuits and tea biscuits. Biscuits have long been part of the British diet, forming an important nutritional food for travellers for centuries. By the end of the 16th century Royal Nayy sailors had a ration of 1 pound (450gms) of biscuits and 1 gallon (4.5 litres) of beer per day. Biscuits remain the nation’s favourite snack.

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High performance fans

Pictures and information from: Baker Pacific Baking Process and Engineering Manual

 Direct Gas Fired Ovens

DGF 1

 

Baker Pacific Direct Gas Fired Oven

Extraction

Moisture from the dough pieces may be extracted from the baking chamber in each zone. The wet air in the baking chamber is drawn into a series of cross ducts at the top of the baking chamber. This wet air then enters the extraction duct running along the top of the baking chamber to the extraction fan entry. The wet air is exhausted through a vertical flue (chimney) to atmosphere. The amount of air extracted in each zone is controlled by a damper, which may be manually adjusted or by a motorized valve controlled by PLC.

DGF extr fan 1-2

 

 

 

 

 

 

 

Combustion air

In each zone the air is fed to the air header pipes from an air blower mounted on top of the oven. The air is drawn from the bakery. The air pressure for the burner system is controlled by motorized valves which are regulated by the automatic temperature control system or by a variable speed inverter drive for the fan.

Moro fan

 

 

 

 

 

 

Moro combustion air fan

Indirect Radiant Ovens

IR oven pic

 

 

 

 Circulating fan

The fan is located next to the burner (on the right in the picture above). The fan draws the hot gases through the system, distribution ducts, radiant tubes, headers and return ducts.

Circ fan 1Halifax fan 18P Multi-vane Forward Curved fan

Volume:          170 cm /minute

Pressure:         50 mm / 30 mm WG

Impeller speed: 845 / 731 rpm

 

 

 

 

 

 

Extraction and turbulence

In each zone a duct above the band extracts the moist air to the extraction fan. From the fan the wet air enters a duct at the side of the oven where it may be directed to the turbulence duct or to the flue to atmosphere. The system is controlled by dampers.

IR extr fanHalifax 15P Multi-vane Forward Curved fan

Volume:            114 cm /minute

Pressure:          70 mm WG

Impeller speed: 1129 rpm

 

 

 

 

 

Oven end extraction hoods

Oven end hood - bi furcated fan

Halifax bi-furcated fan on an oven end hood

The fan extracts hot air from the open end of the baking chamber and exhausts it to atmosphere.

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Halifax fans may be purchased from Halifax UK, or from their factory in Shenzhen, China

http.www.halifax-fan.co.uk                      http.www.moro.it

For more information please request at our Contacts page

 

 

 

Low density chocolate

Processing chocolate to give a textured, low density product has a long history. The products have a light bite and mouth-feel and have up to 30% lower density – saves chocolate and saves calories!

By applying vacuum to a tempered chocolate and then cooling it to set the chocolate, a low density chocolate is produced. The production requires very accurate process settings and correct conditions throughout processing. The product may have a milk chocolate shell with a low density centre or flavoured and coloured centres such as orange, peppermint, coffee and strawberry.

Aeros

 

Another low density chocolate can be made by adding compressed air to tempered chocolate at a particular rate and temperature in a high speed mixer. This process gives a 30% reduction in weight

Wispas

 

Contact us for more process information

Measuring baking profiles

In order to monitor actual baking temperatures, a thermal data logger is used. These units are slim and will pass through the oven carried on the oven band.

ThermaPro pic

 

 

 

        ThermaPro Data Logger

 

 

Data loggers are available with multi channels, usually 6-8 for biscuit oven applications. Each channel has a thermocouple sensor which is attached to a bar spanning the width of the oven band. In this way the baking temperature is monitored and recorded at multiple positions across the width of the oven.

Data loggers such as the TCK2000, which is made in China, monitor and record baking temperatures. A TCK system comprises the following: the data logger or profiler unit with 3 up to 9 channels within an insulated box, thermocouples with high temperature connections, all accessories, and software to run on a PC. This unit is a convenient way to monitor oven performance, detect problem areas in the oven which may cause poor structure, colour, moisture level, etc.

 

TCK 1-2

 

 

         TCK 9 channel data logger to monitor and record baking temperatures

 

 

Our main baking control in most ovens (direct gas fired, indirect radiant and convection ovens) is by temperature. We set zone temperatures to match the required baking profile and control the heat input from the burners to maintain the set baking temperatures. Monitoring the baking temperatures through the oven and across the width of the oven band is therefore a valuable guide to the performance of the oven and a good starting point for trouble shooting problems such as uneven colour, moisture content…..

More sophisticated data loggers, such as ThermaPro, pictured above, monitor and record heat flux, which indicates heat transfer by radiation, conduction and convection.

For for information and enquiries please request at Contact page   

 

Filled cookies

Oven pictures

 

Baker Pacific Indirect Radiant Oven

Radiant heat transfer ensures good structure, texture and maintains colour and flavour in the cookie fillings