The Kaak DrieM sheeting lines are designed to optimize every step of the process for large-volume dough production. The newest update to the sheeting system can now enable easy access to the portioner for thorough, convenient cleaning and maintenance.
In Dutch, ‘drie’ means three. True to its name, Kaak’s DrieM technology development started in 2008 with a team of three – where ‘M’ stands for ‘musketeers’. Since 2021, it became Kaak Dough Technology and consists of about 180 people. Also in line with the initial technology concept, the awarded DrieM sheeting lines, focus on the craftsmanship of the process and artisanal products. Today, DrieM lines can be found in bakeries all over the world, as they are designed to produce a wide variety of bread shapes, from fine to very open structures.
With a space-saving design, the layout and philosophy of the DrieM sheeting line are perfected for bread and pizza production to ensure that the dough remains stress-free throughout the process, so that no tension or shrinkage occurs. Complete process visibility was also a design specification. The high-capacity line enables complete control over the production process, thanks to easily adjustable parameters that ensure a consistent flow of the dough. This design makes the line excel at sheeting from low to highly-hydrated doughs as well as dough with fruit inclusions, for example. With softer doughs, however, come higher cleaning requirements, since they will stick easier to surfaces. To accommodate cleaning procedures, the DrieM line has an open design and a special cleaning mode integrated in the HMI, among other features.
Kaak Dough Technology
Kaak Dough Technology has been a part of the Royal Kaak family for 30 years, following the acquisition of Benier in 1991 – a specialist with over 125 years of experience in the production of dough-handling machines. In 2021, Benier was renamed to Kaak Dough Technology to reflect the group’s new, consolidated brand image.
Kaak Dough Technology develops dough preparation systems such as Benier mixers, rounders, blenders, finishers, dividers, proofers and DrieM sheeting lines.
The Kaak Technology Center is also located in the same building as Kaak Dough Technology in Nieuwkuijk. The Kaak Technology Center includes all Kaak equipment, such as a high-speed mixer and Benier make-up systems for dividing, rounding, molding and intermediate proofing, as well as the DrieM sheeting lines – with more to be added soon. The Center is home to the complete collection of technology developed by all Kaak Group companies, including several types of ovens.
Cleaning made easy
In their work with bakeries, the Kaak specialists observed some challenges with cleaning sheeting lines, feedback they brought to the drawing board and helped design a new technology update that particularly targets one of the most difficult points to clean: the dough hopper and chunker system. Since it is placed high up above the sheeting line, it is harder to access for thorough cleaning and maintenance. Kaak researched ways to improve access and make it easier for people to clean the equipment. The solution the Dutch specialist perfected and is now launching is an ‘Easy Access Portioner’, which, as its name describes, enables faster and easier access to the portioner, without having to resort to any manual effort. Rens van Heesch, Product Sales Manager, Royal Kaak, explains why an automated solution made the most sense: “When parts are manually dismantled from production lines in industrial bakeries, there is always the risk that some are overlooked when placed back onto the line after cleaning, or they can get damaged, resulting in significant time loss. It takes longer to resume production if the reassembly is not carried out correctly. Besides, time is saved for the sanitation process itself and production can resume faster afterwards.”
The Easy Access Portioner eliminates these issues, and the need to have many people assigned to lengthy cleaning tasks – another aspect the designers incorporated, taking into consideration staff shortages in addition to process convenience. To accomplish this, the designers mounted the portioner on a frame, creating a tailor-made lift.
For any maintenance and cleaning operation, the operator only needs to press and hold a button, and the hopper and chunker will automatically slide down the support system where it is hoisted, from above the line where it is positioned while running, to a vertical position parallel to the line, with slow, controlled movement. The space is calculated for comfortable access all around the portioning system when it is lowered. “This is a very good alternative for cleaning, because it makes the hopper and the chunker knives easily accessible from either side of the hopper, for thorough sanitation,” the specialist explains. The operator can easily go around the system, while it is vertically aligned and safely locked in place at shoulder height, for ergonomical and comfortable access from each side.
Additionally, the tilting movement improves accessibility for cleaning, not only for the hopper and chunker, but also for the underlying infeed of the sheeting line, which further enhances hygiene standards, reduces cleaning time, and lowers cleaning costs.
The space required on the side of the sheeting line for the support structure and the portioner, calculating ample room to go around the hopper when brought down, is around 2 sqm (21.5 sq ft), so the line’s overall footprint remains compact. Automating the portioner movement for easy access ensures downtime is minimized.
For maintenance, the chunker knives can be taken off for repairs/replacement in case of any damage, but they do not need to be removed for cleaning.
Automated movement
The conveying system moving the portioner up and down is essential to this automated solution. Although they handle the heavy load of the hopper and chunker, the timing belts that support the controlled movement match, at least, the lifespan of other timing belts normally used in a production line. They can even outlast them, since the tilting mechanism has a limited speed and low acceleration/deceleration speed sequences.
Moreover, “The number of tilting/releasing cycles of the Easy Access Portioner is quite small compared to other timing belt applications,” the specialist notes.
For guaranteed safety, the motorized tilting system keeps all the components mechanically and electrically connected to the line, the specialist underlines. Sensors are in place to control the movement of the hopper, the mechanical stop when lowered, and the correct alignment when brought up to start operating. “It’s very important that the dough chunks are released from the portioner in the middle of the sheeting line. This is why we have a detection sensor checking the alignment and giving the system the green light to run,” van Heesch explains.
Rens van Heesch, Product Sales Manager, Royal Kaak
While improving access, hygiene standards, cleaning speed and safety, this elevator system also eliminates the need for staff training, and the risks involved in climbing to reach the equipment. During commissioning, Kaak provides training on how to clean the machine, as well as service. Cleaning routines depend on the dough’s characteristics – the more liquid the dough, the more frequently it should be scheduled.
While cleaning processes may vary according to the cleaning materials chosen and their usage instructions, as well as water use, the entire DrieM sheeting line can be washed down with water. “This all is, of course, according to the CE standards in Europe, to which we have some additional mechanical safeguards implemented as well, for the Easy Access Portioner,” van Heesch highlights.
The entire DrieM sheeting line can be washed down with water
Officially launched at the end of November 2024, the first Easy Access Portioner has already been installed and recently started running in bakeries, and more companies have already placed their orders for the automated hopper and chunker. It is suitable for industrial operations, meaning sheeting lines with production volumes ranging from 1,000 kg to 12,000 kg per hour. The solution comes with new sheeting lines and it can also be retrofitted onto existing DrieM lines by replacing the current dough portioner with the new system – taking into consideration the floor space for the frame and access around it. “We will set up a plan on how we can disassemble and install the new equipment together with
the customer, on a case-by-case basis,” the specialist says.
DrieM sheeting line factsheet
+ Single-operator production line, through automation features
+ Complete process visibility for the operator
+ Capacities from 1,000 kg to 10,000 kg per hour. Higher capacities are possible for custom setups.
+ Industrial solutions available for bread and pizza production
+ Stress-free dough processing by eliminating falling heights for the dough sheet
+ Processing doughs with liquid ingredients percentage up to 92%
+ Provides several options for make-up processes for all types of products
+ Modular standard design, which can be custom-made and can be expanded at a later time
+ Unique cross-controller design
+ Optimizing dough sheet by minimizing rework and level measurement
And, speaking of new developments, the Kaak Technology Center is soon having new equipment installed, for an even wider range of bread and pizza production lines. More information soon!
