Toast Bread Production Lines
Royal Kaak tin bread and toast lines are an integrated production solution built for high output, process stability and consistent products. Every piece of equipment on the line works together to keep the flow uninterrupted and under control, from dough handling through baking to the pan return.
Each line is engineered specifically around the target capacity, the product recipe, the pan size and the plant layout. The modular structure gives the best answer to what you need today, while leaving room for future capacity increases and a wider product range.
- Capacity
- 2,000 – 12,000 products per hour
- Engineering
- specific to the product and the plant layout
- Operation
- few operators needed
- A highly automated line design that keeps production efficient with a minimum of operators
- Controlled process parameters for repeatable quality, consistent weight and an even product structure
- Pans made and specially coated by Kaak, so that products release from them cleanly and under control after baking
- Automatic strap changeover and storage on lines where different straps are used for different products and pan types
- Line components running in sync with one another, for stable, uninterrupted production at high capacity
- A modular system architecture, so it can be supplied as a complete line, as individual machines or as spare parts
The six stages of the line
From mixing to packing. At every stage the technology is chosen for your product and your capacity.
Silos, dosing and the MDD mixer
Baking starts with the right raw materials. These vary more and more, and ingredients are becoming increasingly sustainable, ecological and organic. Kaak silos and dosing systems give control over every ingredient and over the process.
- Ingredients are dosed straight from the silos into the MDD mixer
- MDD: Mechanical Dough Developer
- As raw materials vary more, control matters more
- Mixer
- MDD, Mechanical Dough Developer
- Feeding
- silos and dosing system
Classic make-up or a sheeting line
After mixing there are two routes. Classic make-up: divider, rounder, proofer and moulder. The alternative is a sheeting line, designed to handle pre-risen, high-hydration dough more gently and without stress.
- Classic: divider, rounder, intermediate proofer, moulder
- Sheeting line: stress-free handling for pre-risen, high-hydration dough
- Which technology is right depends on your product and the capacity you need
- Option
- classic make-up or sheeting line
- Sheeting line
- high-hydration dough
Pans, straps and final proofing
After make-up the line deposits the dough pieces into pans and straps and places them in one of the proofers.
- For toast bread the straps are automatically fitted with a lid as they come out of the proofers
- Other tin bread types can be decorated with seeds before they go into the oven
- Depositing into pans is part of the line, not a separate operation
- Toast
- automatic lidding
- Tin bread
- seeding option
Thermal oil or cyclothermic oven
Kaak has all baking methods available in-house. Which oven is right depends on your product and the capacity you need. Tin bread and toast are baked in thermal oil or cyclothermic ovens.
- Thermal oil oven: voluminous, stable product with an even crust colour
- Cyclothermic oven: even baking at the sides, even in a wide oven
- The oven is planned together with the rest of the line
- Oven
- thermal oil or cyclothermic
- Choice
- by product and capacity
Depanner and delidding
After baking the line carries the pans to the depanner, where the products are removed from the straps. Because Kaak produces and coats the pans and straps in-house, a clean release is guaranteed.
- Pans and straps are made and coated by Kaak
- On a toast line an automatic delidder sits between the oven and the depanner
- The suction depanner lifts the product without crushing it
- Pans
- made and coated by Kaak
- Toast line
- automatic delidder
Spiral cooling and crate handling
Baked product is cooled in the spiral cooling system, or in a multi-step or multi-deck cooler. Empty pans return through the strap cooling tunnel to the starting point and take on new dough.
- Spiral cooling, or a multi-step or multi-deck cooler
- Empty pans return through the strap cooling tunnel
- If a different product needs different straps, the straps storage changes them over automatically
- Cooled product is carried to the packing department
- The handling equipment puts the right product in the right crate for the right shop
- Cooling
- spiral · multi-step · multi-deck
- Pan return
- strap cooling tunnel
- Straps storage
- automatic changeover
Tell us whether you will produce toast or tin bread and the capacity you want, and we will lay the line out for it.