Replicating traditional methods of preparing buns, bagels and rolls on an industrial scale is a task with an extensive list of challenges, to achieve high-volume, consistent results. Flexibility and innovation joined in dedicated production lines help provide the answers for endless product variations.
Over-night fermentation, the perfect round shape, a crusty, shiny appearance or topped with sesame seeds – the most prized characteristics of buns, bagels, or rolls can quickly become the challenges in industrial manufacturing, either in the case of traditional products and processes or when introducing new, hybrid product innovations. New and updated technology solutions also provide the best answers to all challenges for the processes involved, and help improve overall efficiency. Notable examples we looked into include Koenig’s new generation of roll lines – the KGV Plus, and the latest addition, KGV EC that was just launched at iba.CONNECTING EXPERTS mid-March.
Koenig: the very latest in roll lines
The new KGV EC has taken cleaning and accessibility of this technology range one step further, with features incorporated in what is now one of the most powerful lines built by Koenig. Its default configuration includes a choice of 26 products,
König: The KGV-EC line
+ Various working widths
+ 50 to 65 strokes/min, depending on the product
+ 46,800 pieces per hour in 1,200mm working width and 12-row operation
+ Configurable pre-proofer with, for example, 750 usable swings at 50 strokes/min (proofing time of 15 minutes) or at 60 strokes/min (proofing time of 12.5 minutes).
The KGV plus line, the predecessor in this family, features the highest performance for a Koenig bun line. Also, the line can process doughs with chunks (chocolate, nuts, etc.), which extruder lines often cannot handle, adds the specialist. KGV plus bun line offers an hourly output of approx. 60,000 pieces in 12-row operation; it was awarded with the ASB Innovation Award 2019 and with the iba Award 2018. It consists of the new T-Rex AW high-performance dough divider and rounder, pre-proofer, forming station and an innovative belt stamping station for bagel and donut production, the company details. With specially designed rounding ledges, the T-Rex AW achieves an output of 100 strokes/min. for gentle and smooth dough piece rounding. For this high performance, the line has a relatively small footprint.
For efficiency optimization, “The entire process needs to be coordinated for high-performance lines to guarantee consistent quality. For such high volumes, dough mixing is particularly important and must be timed precisely. Whether customers use continuous mixing systems or stand-alone mixers, the batch production must be coordinated with processing on the make-up line,” explains Staufer.
