Product Overview
A fully automated, modular production line engineered for continuous lamination of high-yield pastry products. It delivers precise fat-to-dough ratios, uniform multi-layer structural development, and high-speed portioning for industrial bakeries and large-scale food manufacturers.
Specification
|
Model |
Dimensions |
Voltage / Power |
|
PC-3000 |
L 13500 × W 1900 × H 1800 mm |
380V / 35KW |
Product Features
Precision Servo Lamination: Servo-controlled gauging rollers maintain a thickness tolerance within +/- 0.2mm, preventing friction-induced tearing and ensuring uniform flakiness.
High-Speed Cutting: Mechanical or ultrasonic modules execute clean separation with an accuracy of +/- 0.5mm, reducing trimming waste to under 2%.
Digital Formulation: HMI touchscreen stores up to 100 recipes, allowing rapid digital switching of layers (4 to 144 layers) and cutting dimensions in under 30 minutes.
Hygienic Design: Open-frame SUS304 or SUS316 stainless steel construction eliminates bacterial harboring zones and permits 360-degree high-pressure washdown.
Full Automation: Synchronized conveying, sheeting, laminating, depositing, and cutting operations maximize OEE and eliminate manual cross-contamination.
Smart Control: Built on Siemens or Allen-Bradley PLC platforms with real-time sensor monitoring, automated tension control, and predictive maintenance alerts.
Applications
High-volume commercial production of:
- Puff Pastry & Palmier Pastries
- Danish Pastries (Filled & Unfilled)
- Croissants (Straight, Bent, & Mini)
- Frozen Laminated Dough Sheets
- Savory Filled Turnovers & Meat Pastries
Operational Efficiency & Compliance
Global Standards: Fully compliant with FDA guidelines and EHEDG sanitary principles; equipped with food-grade PU belts.
Toolless Maintenance: Quick-release scrapers and tension mechanisms accelerate daily sanitation routines.
Premium Components: Critical parts sourced globally from Siemens, Schneider, Festo, SMC, and SEW-Eurodrive for easy local replacement.
Factory Connectivity: Standard Profinet, Modbus TCP, and OPC UA interfaces enable direct integration with localized MES or ERP systems.
Quality Control & Logistics
Precision Manufacturing: Dynamic balance calibration of CNC-machined gauging rollers and multi-axis servo synchronization under simulated loads.
Factory Acceptance Test (FAT): Mandatory 48-hour continuous trial run using the customer's specific recipe, verified via live video before dispatch.
Export Packing: Vacuum-sealed moisture barrier film inside heavy-duty, ISPM 15 heat-treated wooden cases with internal steel framing.
Global Commissioning: Field engineers available worldwide for physical installation, fine-tuning, and operator training.
Factory & Hard-Power Focused
Timeline & Footprint:
Established in 2013, expanding into a 12,000 square meters manufacturing base strategically situated in Foshan's high-tech industrial center.
Human Resources:
A robust workforce of 400+ employees, including a dedicated engineering division led by national senior baking machinery experts.
Compliance & Intellectual Property:
Operating under strict EU CE Certification standards, supported by multiple proprietary utility and design patents.
Global Reach & Client Base:
Empowering over 3,000 global customers with reliable export capabilities across Europe, Southeast Asia, Northeast Asia, and international markets.
FAQ
Q: How does the system handle highly elastic or high-gluten dough profiles without shrinkage after cutting?
A: The production line incorporates multi-stage progressive reduction satellite rollers rather than a single heavy reduction step. This gradual sheeting method, combined with integrated stress-relief conveyor loops before the cutting station, completely relaxes the internal gluten network of the dough, ensuring the final cut shapes remain dimensionally stable without shrinking during continuous baking or freezing.
Q: What is the typical service life of your mechanical and ultrasonic cutting blades, and how is wear managed?
A: Our standard hardened alloy mechanical blades are rated for 8,000 to 12,000 operating hours depending on dough density and inclusion types. For high-speed lines utilizing ultrasonic cutters, titanium alloy horn components operate under automated frequency matching to eliminate edge wear. All cutting modules feature a slide-out cartridge design, allowing complete blade block replacement in less than 10 minutes.
Q: Can the lamination system handle non-dairy fats, low-melting-point plant-based margarine, or liquid inclusions?
A: Yes. The fat extrusion pump can be fitted with individual heating and cooling zones that regulate fat viscosity in real time. For delicate plant-based fats with low melting thresholds, we can integrate cross-flow air knives directly over the sheeting tables to stabilize the fat sheet surface before it enters the first folding station.
Q: How does the electrical cabinet handle hot, humid washdown environments without risking component failure?
A: The primary electrical enclosure is built to IP65 ingress protection standards and is completely separated from the mechanical washdown zones. It is equipped with a closed-loop air-to-air heat exchanger or a dedicated cabinet air conditioner, which prevents condensation buildup and isolates sensitive microelectronics from ambient flour dust and chemical cleaning agents.
Q: What are the exact structural flooring and utility supply requirements for installing this system?
A: The floor must be a reinforced concrete slab with a minimum thickness of 200mm and a level tolerance of within +/- 2mm per meter to support the continuous weight distribution. Your facility must supply a stabilized compressed air source delivering a minimum of 0.6 to 0.8 MPa at a continuous volume flow rate dictated by the line width, alongside standard industrial drainage access point configurations beneath the main washdown zones.
Q: How do you protect the fine mirror finishes of the gauging rollers against salt corrosion during sea transit?
A: All precision-ground gauging rollers undergo a specialized industrial degreasing process, followed by the application of a peelable, heavy-duty anti-corrosion polymer coat. The entire assembly is then packed with multi-point active desiccant canisters within a heavy-gauge VCI (Vapor Corrosion Inhibitor) vacuum barrier bag, protecting the metallurgy against salt-spray degradation for up to 180 days of marine transit.
Q: Can the automated line run continuously across multiple shifts, and what are the scheduled lubrication requirements?
A: The line is designed for continuous 24/7 industrial operational cycles. Critical heavy-load bearings and drive chains are piped into a centralized, automated lubrication system that distributes food-grade lubricants at pre-programmed run-time intervals via the PLC, eliminating manual maintenance stops and lowering scheduled servicing intervals to once every quarter.
