Kurt Makina, Pilot Chocolate Making Line, 6-Unit Laboratory Scale
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Description
Overview
Laboratory-scale computer-controlled chocolate and cream production line.
This laboratory pilot line for chocolate is composed of the following 6 units: mixer for chocolate dough, two roll pre-refiner for chocolate dough, five roll refiner for chocolate dough, chocolate conche, storage agitator for chocolate dough, and chocolate tempering unit.
Laboratory Mixer For Chocolate Dough (Type Mix20)
Mixer volume: 30 liter.
Mixing capacity: 20 kg per batch.
Mixing time: 5 to 10 minutes.
Electronics control: Siemens PLC.
Working power: 0.75 kW, 50 Hz.
Double jacketed.
Heater and temperature controlled.
One shaft mixing mechanism.
The raw materials are mixed at a suitable heat.
PLC based temperature control of the heating water and the mixed product.
Thanks to high efficient double-jacketed water sections, mixing operation is achieved within 5 to 10 minutes.
Full consistency is obtained.
With electronic control system, the shaft of the mixer can rotate clockwise or counter-clockwise.
In accordance with the program, the shaft rotates with the optimum rpm.
In due course, it stops automatically.
Voltage: 380-440 V.
Frequency: 50 Hz.
Control unit voltage: AC 220 V.
Dimensions (LxWxH): 905 mm x 580 mm x 1055 mm.
Laboratory Two-Roll Pre-Refiner For Chocolate (Type R200)
Capacity: approximately 50 kg/h (120-200 microns) depending on the recipe.
R200 consists of: frame, rolls, drive, transmission, hydraulic system, roll cooling, scraper, control cabinet, and inspection doors on both sides of the machine.
All parts that come in contact with the product are made of stainless steel, except the roll surfaces.
Feeding section: easily moved out for cleaning rolls; automatically comes in tight contact to scrape the edges of the working area with the hydraulic system when the pre-refining process starts.
Processing section: two rolls, with the following specifications: roll diameter: 200 mm; working width: 220 mm.
The rolls are made of centrifugally, double-layered special alloy cast iron.
Rolls are mounted in roller bearing with grease lubrication.
Grease lubrication pipes are centrally localized for easy operation, central greasing.
Special helical gear wheels are in enclosed boxes with forced oil lubrication for transmission.
Driving section: the helical gear wheels are at the right side of the frame.
It is driven with high performance V belts directly on the second roll, whereby the V belt pulley is installed in the machine.
Hydraulic units and the roll cooling system are located on a block at the left side of the frame.
Gears are force lubricated with oil pump.
Overall specification: W: 1065 mm, H: 1730 mm, L: 1250 mm.
Working specification: ambient temp: 24-36 °C; motor power: 3 kW.
Electrical data: voltage: 380-440 V; frequency: 50 Hz; control unit voltage: AC 220 V.
Electronic controls: Siemens PLC.
Hydraulic system: the hydraulic pressures for each side of the rolls are adjusted by turning the knobs to the desired values indicated at the gauges.
Discharge section: scraper blade scrapes automatically without any damage on the rolls.
The width of the knife is 30 mm.
Scraper blade material: special alloy spring steel.
Two roll refiner for chocolate is designed with latest technology.
2-roll refiner can be used as pre-refiner before five roll refiner or stand alone refiner with multiple refining process.
The crushing of chocolate ingredients between the two grinding rolls makes it possible to use crystal sugar instead of powder sugar.
In this way it is possible to eliminate the humidity in chocolate.
Pre-refiner reduces the prepared mix from 6000-1000 µ to 120-200 µ grain thickness.
It forms a very well texture with molecules of raw material and fat.
Also this process improves the adhesive capability of the chocolate dough to the 5-roll refiner rolls.
It reduces the duration of the conching period.
Pre-refiner refines the product with a compact hydrostatic pressure system.
Capacity is 10 to 60 kg/h.
Laboratory 5-Roll Refiner For Chocolate (Type R200L)
Capacity: approximately 50 kg/h (18-25 microns) depending on the recipe.
Consists of generally: frame, rolls, drive, transmission, hydraulic system, roll cooling, scraper, control cabinet, inspection doors on both sides of the machine, stainless steel feeding hopper, and stainless steel discharge chute with an observing window.
All parts that come in contact with the product are made of stainless steel, except the roll surfaces.
Feeding section: easy move out for the rolls cleaning.
5-roll refiner has soft start system.
The machine can stop and start again even when the rolls are under pressure.
Automatically comes in tight contact to scrape the edges of the working area with the hydraulic system when the pre-refining process starts.
Processing section: five rolls; roll diameter: 200 mm; working width: 200 mm; dynamic balance is 750 rpm.
The 1st and the 2nd rolls are the feeding rolls group.
From the 3rd to 5th rolls are grinding rolls group.
The rolls are made of centrifugally, double-layered special alloy cast iron.
Rolls are mounted in roller bearing with grease lubrication.
Grease lubrication pipes are centrally localized for easy operation, central greasing.
Special helical gear wheels are in enclosed boxes with forced oil lubrication for transmission.
Cooling system: automatic water heat sensors; solenoid valves in the cooling water cycle to allow the automatic on and off.
Cooling water circulation system contains PLC controlled solenoid valves that allow automatic water flow for each roll.
In case of pressure drop or no water, the rolls are released from pressure and the system stops automatically.
Digital thermo controllers for the rolls sense the water temperature very accurately.
Cooling water flows through the water lance sprinkler into the roll and comes in contact with all the inner surfaces at an even temperature at the same time.
Water lance is equipped with thermometer and pressure gauge.
Thermo sensor PT100.
The roll cooling system is located on a block at the right hand side of the frame.
Driving section: the helical gear wheels are at the left side of the frame.
It is driven with a high performance V belts directly on the fifth roll, whereby the V belt pulley is installed on the machine.
Gears are force lubricated with oil pump.
Hydraulic system: the hydraulic pressures for left and right side of the feeding and grinding rolls group are adjusted by turning the knobs to the desired values that are indicated at the gauges.
Measurements of installation and dismantling area: A (width) 920, B (length) 1315, C (height) 1730.
Refining capacity of the laboratory 5-roll refiner depends on the following factors: thickness of the powdered sugar and cacao; ingredients of the cacao liquor (fat content); thickness of the desired refined product; temperatures of the rollers; previous processing (mixing, etc.) of the product before fed into.
Electronic control section: the control unit is a PLC touch-screen practically reaches as it is on the faces of the machine.
Environmental temperature: 24 to 36 °C.
Main motor protection type: IP 54.
Power of the main motor.
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