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Comas, Layer Cake Production Line, 2018, 240 Cakes/h Capacity, 400mm Width, Cream Depositor

Comas, Layer Cake Production Line, 2018, 240 Cakes/h Capacity, 400mm Width, Cream Depositor

Description

  1. Overview
    1. Automatic production line for sponge cakes (in layers) filled with cream.
    2. Rectangular cakes made from sponge cake (in layers), filled with cream.
    3. Cake composition: rigid support base / sponge cake layer / syrup, cream / sponge cake layer / pressing / syrup / cream / sponge cake layer / pressing / syrup / cream, cocoa powder, granulated sugar, walnuts or hazelnuts.
    4. Capacity: 240 cakes per hour, with a width of 400.
    5. Year 2018.
    6. The Abrigo Flexcut Plus ultrasonic cutting robot is part of this line and included: 1 Fanuc 6-axis robot with 2 ultrasonic blades, 610 mm (24.0 in) cutting width. It is not a separate machine.
  2. Article 1: Belt Conveying Device
    1. 1 pc. Belt conveying device for feeding the cakes to the various work units.
    2. Stainless steel support structure, with height-adjustable support legs.
    3. Intermittent movement via an inverter-controlled motor.
    4. Set of belts, fitted with stops, for feeding the cakes.
    5. Indication of the length and position of the tray under the operating units, controlled by an encoder.
    6. Mechanical device to adjust the distance of the centering stops of the conveyor belts.
    7. Section in linear meters for the belt conveyor.
    8. Section in linear meters for the adjustable side guides.
  3. Article 2: Manual Loading Space
    1. 1 Available space on the conveyor belt, for manual loading of the sponge cake base.
  4. Article 3: Syrup Feed Tank
    1. 1 Syrup feed tank, equipped with: hopper and base made of stainless steel, mounted on wheels; sensor for minimum product level; pump for transferring the product to the syrup depositing system.
    2. 2 Pump for the syrup depositing system, driven by an inverter, complete with connection pipe.
  5. Article 4: Syrup Dosing System
    1. 1 Syrup dosing system consisting of: support frame for the spray ramp, fixed to the conveyor belt; syrup spray ramp, with spray nozzles.
  6. Article 5: Cylinder Depositor
    1. 1 Cylinder depositor, model DRT, for depositing homogeneous creams or jams, dosable at room temperature.
    2. "C"-shaped support frame for the depositing head, made of stainless steel, mounted on wheels.
    3. Electro-mechanical cam device to ensure vertical movement of the depositing head.
    4. Stainless steel depositing assembly with 2 detachable cylinders.
    5. Stainless steel hopper with 2 detachable cylinders, for transporting the product to the depositing assembly.
    6. Photocell to detect the product level in the hopper.
    7. Handle for adjusting the height of the depositing assembly.
    8. Items for product "A": Interchangeable dosing plate with adjustable opening.
  7. Article 6: Manual Operation Space
    1. 1 Available space on the conveyor belt, for manual operation.
  8. Article 7: Product Pressing System
    1. 1 Product pressing system, equipped with: support frame fixed to the conveyor belt; handle for height adjustment; support device with vertical, pneumatic movement.
    2. Items for product "A": Interchangeable pressing device.
  9. Article 8: Syrup Dosing System
    1. 1 Syrup dosing system, consisting of: support frame for the spray ramp, fixed to the conveyor belt; syrup spray ramp, with spray nozzles.
  10. Article 9: Cylinder Depositor
    1. 1 Cylinder depositor, model DRT, for depositing homogeneous creams or jams, dosable at room temperature.
    2. "C"-shaped support frame for the depositing head, made of stainless steel, mounted on wheels.
    3. Electro-mechanical cam device to ensure vertical movement of the depositing head.
    4. Stainless steel depositing assembly with 2 detachable cylinders.
    5. Stainless steel hopper with 2 detachable cylinders, for transporting the product to the depositing assembly.
    6. Photocell to detect the product level in the hopper.
    7. Handle for adjusting the height of the depositing assembly.
    8. Items for product "A": Interchangeable dosing plate with adjustable opening.
  11. Article 10: Manual Loading Space
    1. 1 Space on the conveyor belt for manual loading of the sponge cake base by the operator.
  12. Article 11: Product Pressing System
    1. 1 Product pressing system, equipped with: support frame fixed to the conveyor belt; handle for height adjustment; support device with vertical, pneumatic movement.
    2. Items for product "A": Interchangeable pressing device.
  13. Article 12: Syrup Dosing System
    1. 1 Syrup dosing system, for rectangular cakes, consisting of: support frame for the spray ramp, fixed to the conveyor belt; syrup spray ramp, with spray nozzles.
  14. Article 13: Cylinder Depositor
    1. 1 Cylinder depositor, model DRT, for depositing homogeneous creams or jams, dosable at room temperature.
    2. "C"-shaped support frame for the depositing head, made of stainless steel, mounted on wheels.
    3. Electro-mechanical cam device to ensure vertical movement of the depositing head.
    4. Stainless steel depositing assembly with 2 detachable cylinders.
    5. Stainless steel hopper with 2 detachable cylinders, for transporting the product to the depositing assembly.
    6. Photocell to detect the product level in the hopper.
    7. Handle for adjusting the height of the depositing assembly.
    8. Items for product "A": Interchangeable dosing plate with adjustable opening.
  15. Article 14: Manual Operation Space
    1. 1 Space on the conveyor for manual operation.
  16. Article 15: Fine Dust Filtering Unit
    1. 1 Fine dust filtering unit, consisting of: 4 stainless steel support legs; stainless steel hopper; detachable fine filter; internal scraper with electro-mechanical movement.
    2. Items for product "A": Product limiting mask.
  17. Article 16: Vibrating Depositor
    1. 1 Vibrating depositor for depositing dry granular products.
    2. 4 stainless steel support legs.
    3. Stainless steel product hopper.
    4. Depositing unit consisting of a vibrating base.
    5. Timer for adjusting the deposit.
    6. Potentiometer for adjusting the product quantity.
    7. Electric and control panel.
  18. Article 17: Conveyor Belt
    1. Conveyor belt to be positioned after the ULTRA-SOUND cutting device, for receiving and manually handling the pre-cut cakes.
    2. 1 FDA polyurethane conveyor belt, with: stainless steel support structure with height-adjustable legs; movement driven by an inverter-controlled motor; belt scraper with collection tray; quick-release belt device for cleaning operations; m. right-hand section of the conveyor belt.
  19. Article 18: Electrical Installation
    1. 1 Electrical installation and control panel with PLC.
  20. Cutting Robot (Abrigo Flexcut Plus, Part of This Line)
    1. Automatic ultrasonic blade cutting system.
    2. The ultrasonic blades are moved by 1 robot (6 axes) and cut the product as it is moved by a conveyor.
    3. See the specifications contained in this document for the requested details.
  21. Cutting Robot Data
    1. Possible cutting types: X - Y.
    2. Number of robots: 1.
    3. Number of blades per robot arm: 2.
    4. Standard blade dimension: Length: 305x2=610 mm (24.0 in), Maximum cutting depth: 50 mm (2.0 in).
    5. Product: Cake layer - room temperature, dim. 600x400 mm - h < 50 mm (2.0 in), placed on a plastic sheet, Guided along the side.
    6. Speed: About 1 cut/second.
    7. Series cutting: Available.
    8. Available marking: CE, CSA, UL.
    9. Standard power supply: 480 V ac, 3 phases + ground + common.
    10. Maximum load current: 27 A.
    11. Other power supply: To be evaluated on request.
    12. Compressed air supply: 4 bar minimum (1).
    13. (1) The safe use of compressed air is to cool the blade; Nl/min is the maximum flow rate allowed by each of the two installed solenoid valves; downstream of the valve there is a regulator that reduces the flow rate, and the actual flow rate will be adjusted according to various factors (room temperature, product temperature, etc.). Normally, we consider 50% of the maximum value.
  22. Standard Machine
    1. Stainless steel base frame.
    2. Safety/acoustic guards, made of an aluminum frame and Lexan panels, doors fitted with electronic interlock switches.
    3. Standard conveyor belt, with an inverter-driven motor, length 4000 mm (157.5 in), width 700 mm (27.6 in), drum diameter 100 mm (3.9 in); side guides at the infeed, sensors for product verification.
    4. 1 robot, 6 axes, payload capacity 70 kg (154 lb) (the robot frame is painted; stainless steel not available).
    5. N°2 ultrasonic systems, including generators, cables, converter, horn, blade.
    6. Pneumatic equipment with the air treatment unit and solenoid valves installed in the area, not inside the enclosure.
    7. The electrical installation includes a cabinet with a Siemens PLC and control panel. On the control panel it is possible to select: cutting dimensions; cutting speed (to optimize the cutting result for different products).
    8. Remote assistance system included via eWon router (if internet connection is available at the customer's site).
  23. Machine Work Cycle
    1. The same robot will perform both the X and Y cuts.
  24. Standards
    1. Components: Robot: Fanuc; PLC: Siemens; Pneumatics: SMC or FESTO; Induction motor: SEW.
  25. Abrigo Flexcut Plus (Part of This Line, Included)
    1. Abrigo Flexcut Plus is an automatic ultrasonic food-cutting and portioning machine.
    2. The Abrigo Flexcut Plus is an automatic ultrasonic food-cutting and portioning machine, used to divide large food products into uniform, saleable portions—particularly cakes, pastries, and other bakery products.
    3. Typical applications include: Large sheet cakes and layered cakes: cutting into individual squares, rectangles, or strips.
    4. Round cakes: dividing into wedge-shaped slices.
    5. Pastries and frozen desserts: producing clean, consistent portions.
    6. Dairy products: possible applications within Abrigo's ultrasonic cutting range, depending on the machine's configuration.
    7. How it works: Titanium blades vibrate approximately 20,000 times per second while cutting. This reduces product sticking to the blade and helps produce clean cuts with less waste—particularly useful for sticky or layered products.
    8. The "Plus" version can use up to four blades arranged in line, providing a combined cutting width of 1,200 mm (47.2 in)—about 47 inches (1,193.8 mm). Published cutting depth is 50 mm (about 2 inches) standard, or 100 mm (about 4 inches) in a special configuration. It can also cut while following products moving along the conveyor.