Chocolate countlines

Chocolate countlines are a major sector of the confectionery market. They represent a key impulse buying item. The UK market is the largest in Europe with annual sales of chocolate to reach £6.7bn. The leading manufacturers are Cadbury and Mars.

It is notable that of 8 featured products below, the average age is 63 years since introduction. The oldest is Cadbury Dairy Milk, introduced over 100 years ago. These products dominate the shelves of the UK retailers and make it difficult and expensive for newcomers to break into the market.

Baker Pacific have extensive process know-how for chocolate, biscuit, wafer, caramel…. Please check our team’s experience at our page “About”, and request further information at our “Contacts”page.

Cadbury Dairy Milk         

originally introduced in 1905, “with a glass and a half of fresh milk”, now with a wide range of flavours and fillings

DAIRY MILK

Galaxy

from Mars, also sold as “Dove” in many countries

GALAXY

 

Kit Kat

a world-wide favourite. The origin of the brand was at Rowntrees UK (now Nestle) in 1911. The Kit Kat bar was sold under the name Kit Kat Chocolate Crisp from 1937

KIT KAT

 

 Mars 

the original “work, rest and play”, first manufactured in UK in 1932, the plant in Slough UK, now produces 3 million bars a day

MARS

 

Twix

great balance of chocolate, caramel and biscuit, first produced by Mars in UK in 1967.

TWIX

Snickers

peanut favourite from Mars with annual sales exceeding USD 2.0m

SNICKERS

Bounty

exceptional coconut product from Mars, introduced in UK and Canada in 1951

Bounty

Lion bar

caramel and wafer from Rowntrees (now Nestle), popular since 1970’s

LION

Twirl

Twirl from Cadbury Ireland, introduced in the 1970’s and now with two “flake” style bars

TWIRL

Tunnocks

Tunnocks caramel wafer, “Scotland’s favourite”  – 5,000,000 are made and sold every week.

TUNNOCKS

Rocky

Rocky from Fox’s Biscuits, with thick milk chocolate

ROCKY

Kinder Bueno

From Ferrero, Italy, introduced in 1990 and now a popular world-wide product

BUENO

Cadbury Wispa

Low density chocolate for a light snack, 30% lighter than a similar volume of chocolate.

WISPA

More information from:

www.sweetretailing.co.uk

www.foodmanufacture.co.uk

www.iriworldwide.co.uk

www.ferrero-trade.co.uk

www.euromonitor.com


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Key components – burners

 

Our key components file lists over 50 key components for biscuit oven construction. These components have all been used and proven and are recommended by Baker Pacific. The file for each component provides a picture, specifications and manufacturer’s details.

  1. Bearings
  2. Burners
  3. Clamping elements, chains, sprockets…….
  4. Control handles
  5. Electrical equipment
  6. Electric cable and trunking
  7. Electric sensor and monitoring equipment
  8. Fans and Blowers
  9. Gas equipment
  10. Insulation and seals
  11. Oven bands
  12. Pneumatic equipment
  13. Painting and coatings
  14. Pressure Switches
  15. PLC equipment
  16. Motors and gearboxes
  17. Motors – DC
  18. Radiant tubes
  19. Refractory
  20. Thermocouples
  21. Temperature controllers
  22. UPS

The complete Key Components file is available for USD 85.00 and may be ordered at our Contacts page.

Our second key component file includes oven burners for Direct Gas Fired ovens and burners for Indirect Fired ovens.

SECTION 2: BURNERS

 

Eratec

MFB burners (metal-fibre burners)

Eratec 1

 

Eratec high rate infra-red ribbon burners for Direct Gas Fired Ovens

  • Direct heat transfer by radiation (without contact and air movement)
  • High radiant power density 100 – 1000KW/m2
  • Precise control and power modulation
  • Energy consumption savings compared to conventional Direct Gas Fired Burners (up to 20% saving depending on the oven and number of burners)
  • Low pollution (up to 80% less CO and NOX)
  • Safe for people and equipment (no burn back)
  • Low maintenance

 www.era-tec.fr


Flynn Burners

 Flynn 1

 

Flynn Direct Gas Fired Burner installation

 

 

 

Flynn distributor

www.flynnburner.com


 Maxon burners

Maxon

Maxon dual fuel installation

Natural Gas Low Temp Burners

OVENPAK® 400 Series

MAXON’s OVENPAK® 400 Series is the world’s most flexible and reliable industrial burner. The OVENPAK® burns most any fuel gas and requires only low pressure fuel. This natural gas burner provides clean combustion with low NOx levels while providing unmatched turndown.

OVENPAK® Gas Burners provide outstanding performance in ovens and dryers, paint finishing lines, paper and textile machines, food baking ovens, coffee roasters, grain dryers, and fume incinerators.

www.maxoncorp.com

 


Mont Selas

 

Enviro Mont™ Burner

Mont Selas in conjunction with RMR Thermal Solutions have developed an Expanded Nitmesh Tube Firing Burner (patent pending) for use in tunnel baking ovens to replace the old industry standard ribbon burner, to achieve typical gas savings up to 25% *.

  • UP TO 25% GAS SAVINGS*
  • HIGH TURN DOWN
  • EASILY RETROFITTED
  • LOW MAINTENANCE
  • EXCELLENT FLAME STABILITY

Nitmesh is a woven metal fibre and is welded over the slot in the burner tube, it is well proven technology and has excellent flame retention properties and reduces the risk of flash back.

The Expanded Nitmesh burner can be supplied in 1¼”, 1½” and 2” sizes as direct replacements for existing ribbon burners with nominal ratings from 4kW to 44kW.

Burners are designed to work on natural gas or LPG on air blast, high pressure and atmospheric pre-mix systems and will operate with an air turn down ration of up to 8:1 (dependent on flame sensing safeguard limitations).

The improved efficiency of Nitmesh comes from the extra radiant heat provided by the hot surface of the Nitmesh material which can become incandescent, as opposed to the gas flame on a ribbon burner which provides only a limited amount of radiant heat due to its low emissivity. Most of the heat from a ribbon burner is provided by natural convection heating the oven roof area above the burner which then re-radiates the heat back to the product on the conveyor. For bottom burners the base of the conveyor will be heated by natural convection plus the additional radiant heat provided by the incandescent surface of the Nitmesh.

Burners supplied in varying lengths and sizes to suit your individual requirements.

We can also offer a comprehensive site installation service, and oven profiling, following installation to further improve on the operational efficiency of the oven and reduction of your carbon emissions. For further information and site visit to determine requirements please contact our Chadderton office.

*Subject to operational conditions.

Mont Selas

www.montselas.co.uk

 

 

Weishaupt

Weishaupt

Weishaupt natural gas burner installation on an Indirect Radiant oven

 

  • Exemplary efficiency: The digital combustion management system ensures that only exactly the amount of energy is consumed that is needed at the time.
  • Excellent emission levels: Weishaupt Low NOx technology (standard for gas burners, optional for oil burners) is exemplary in reducing emissions with special mixing assemblies for intensive flue gas recirculation
  • Sophisticated technology: All W range burners work fully automatically. Powerful microprocessors continuously control and monitor the combustion process for maximum efficiency.
  • Silent operation: The transversely mounted fan draws air through a sound attenuated inlet.
  • Versatility: The W range offers oil and gas burners in five ratings from 12 kW to 570 kW.
  • Long life: More than 50 years of experience and development work have gone into Weishaupt burner technology. Only the best materials are used in manufacture

www.weishaupt.co.uk


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Key components – Bearings

Our key components file lists over 50 key components for biscuit oven construction. These components have all been used and proven and are recommended by Baker Pacific. The file for each component provides a picture, specifications and manufacturer’s details.

  1. Bearings
  2. Burners
  3. Clamping elements, chains, sprockets…….
  4. Control handles
  5. Electrical equipment
  6. Electric cable and trunking
  7. Electric sensor and monitoring equipment
  8. Fans and Blowers
  9. Gas equipment
  10. Insulation and seals
  11. Oven bands
  12. Pneumatic equipment
  13. Painting and coatings
  14. Pressure Switches
  15. PLC equipment
  16. Motors and gearboxes
  17. Motors – DC
  18. Radiant tubes
  19. Refractory
  20. Thermocouples
  21. Temperature controllers
  22. UPS

The complete Key Components file is available for USD 85.00 and may be ordered at our Contacts page.

Our first key component file is “Bearings” for high temperature applications and linear bearings for slides for the oven band tension arrangement.

                                                                  

 SECTION 1 – BEARINGS

SKF High temperature bearings for oven band support rollers

SKF bearing

Bearing assembly with SKF bearing type Y – V228 suitable for operating temperatures up to 350oC

SKF heavy duty bearing assembly for oven end drums

Delvy end SKF bearing

 

Delivery end drum SKF bearing assembly

 

Bearing housing                  SKF SNL 522-619

Bearing                                  SKF 22222EK

Adaptor sleeve                     SKF H322

Fixing ring                             SKF FRB 135/200

Seals                                      SKF TSN 522L

High Visc. Grease                SKF LGEV2

Assembly instructions         SKF 4403/III E

www.skf.com


Linear Motion Ball Rail Systems

THK caged ball LM bearings

THK 1+2

THK SHS caged ball bearing linear slide supporting the tension end drum bearing

www.thk.com


Bosch Rexroth

Bosch Rexworth

 

  Bosch Rexroth ball rail system supporting tension end drum bearing

 

 

Bosch linear rail

 

www.boschrexroth.com

 


 NSK / RPH bearings

 Download “The ABC of Bearings” and Catalogue at:

www.nsk.com

www.jp.nsk.com/services/basicknowledge/manual/abc

 

 


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Go! potato

Cracker oven

Baker Pacific oven baking crackers by infrared radiation in China


Go!potato, a very thin, well made potato cracker by Siantar Top, Indonesia. The company, founded in 1988 has become a leading and innovative maker of snacks, biscuits and noodles with revenue of IDR 1.82tn.

Packs in and outer

The cracker is flat, approximately 1.36mm thick and of even colour.

Multi bisc pic

Ingredients: wheat flour, fresh potato, sugar, vegetable shortening and oil, glucose, soya lecithin, MSG, protease, colour, tartrazine CI19140.

PT Siantar Top Tbk,

Jl. Tambak Sawah 21-23, Waru,

Sidoarjo 61258

Indonesia

Go face bite!

Supporting oven bands

Baker Pacific successfully use cast iron skid bars to support wire mesh ovens bands, (for example Z47, Z 47R and Ashworth U66-48-1718 PGLW). The skid bars are used on ovens of up to 100m length. Where the products and oven conditions are very dry, some graphite skid bars can be added to reduce friction . Skid bars are trouble free and do not require maintenance, except annual checks and cleaning.

Skid bar pic

 

 

 

 

 

 

 

 

 

Skid bar with access port before oven band installation

Cast iron skid bars are placed inside the baking chamber with a pitch of 0.8 – 1.2m. They are supported in frames and are removable for cleaning. Apart from cleaning, which is infrequent, skid bars do not require any maintenance.

The skid bars are cast from iron with a graphite content which reduces friction. The material and casting are critical to the performance and the skid bars are supplied to suitable specifications, for example International ISO/DIS 185 Grade 200 / 250. The chemical composition, casting process, shape of the mould and cooling rate are important to achieve the optimum low friction and durability of the skid bars in operation.

The surface of the skid bar has a microstructure of a pearlitic matrix with evenly spread type A graphite flakes to ASTM A247 standard with no hard particles. Maximum allowed amount of ferrite is 10%. No ledeburite is allowed. The sliding surface of the skid bar is machined after casting by removing the surface layer (1.0mm), which contains ferrite and would result in scratching of the band. The final surface should have a roughness of Rmax 3.0um

The installation of the skid bars is critical to good band tracking. The bars must be level and at right angles to the direction of band travel. Levelling is best done optically with a laser instrument.

Skid bar supports drg

 

 

 

 

 

 

 

                         Baker Pacific skid bar support with levelling adjustment and access port

Return band supports

On the return below the baking chamber, the band is supported on rollers. A proportion of these, usually one in three, may have spring loaded guide discs. These are very effective in keeping the band in its central position.

 

Return roller

 

 

 

 

 

 

 

 

 

 

 

Baker Pacific spring loaded return band support roller

Heavy mesh band supports

Heavy mesh bands are supported on rollers, which will carry heavy bands with low friction. The design of the supports and adjustment for levelling and the specification of the bearings are critical as the rollers operate at baking temperatures. If the rollers seize, they will quickly cause wear to the oven band. The ends of the rollers are therefore exposed for inspection and high temperature bearings must be used. The bearings are mounted outside the baking chamber and are insulated from the chamber.

Band support roller 2

SKF bearing

Bearing assembly with SKF bearing type Y – V228 sealed for life and suitable for operating temperatures of up to 350oC

More information may be found in our Baking Process and Engineering Manual

Scottish Shortbread

Header pic

 

 

 

 

 

 

Baker Pacific ovens bake by infrared radiation. This is the ideal heat transfer method for producing high quality products, with excellent texture and  flavour.

Scottish shortbread – rich and delicious. Traditionally made with 3 parts fine pastry flour, 2 parts butter and 1 part sugar (by weight). Petticoat tails may also have caraway seeds added. At New Year, Hogmanay in Scotland, the shortbread may be decorated with candied citrus peel and “sweetie” almonds.

Shortcake is similar, but made with vegetable oil and a leavening agent.

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