Making the right fit
No matter what type of dough, accuracy remains a key consideration when choosing a divider. High-moisture doughs typically need to run at higher speeds, which can pose challenges in terms of accuracy.
“To achieve this, flow division needs to be simple and effective for multilane applications,” Mr. McIsaac said. “Our waterwheel technology ensures scaling accuracy that is not dependent on operators ‘dialing in’ valves or motors.”
The correlation between moisture levels and accuracy should not be overlooked.
“Dough weight accuracy generally declines the more moisture a dough contains,” noted Rich Breeswine, president and chief executive officer, Koenig Bakery Systems. The company recommends a dough yield of up to 171 for its regular piston dividers.
For even higher weight accuracy at the same speed, Mr. Breeswine said, Koenig developed its Industry Rex AW line, which has a weight accuracy of +/- 1.5% at 90% of the production output.
“This dividing and rounding system is adjustable and provides even pressure, which ensures the highest weight accuracy with all types of dough before dividing it by pistons,” he said.
Rheon also addresses weight accuracy with its V4 stress-free dividers. The system first sheets the dough and then cuts the pieces by weight that is measured via load cells located under the conveyor. This system now includes checkweighers in the belt after the cut.
“It will verify if the divider hit the target and then make adjustments as the dough sits,” Mr. Giacoio explained.
As dough rests in a bowl, trough or hopper, it changes from the time it was first mixed; therefore, the pieces might not have the same consistency as they head through makeup and further down the line.
“The machine is able to change with each piece,” he said. “The information is sent back to the PLC and those adjustments are made in an instant.”
Gemini/KB Systems also designs its dividers for weight accuracy with its inline checkweighing system, which is connected via a feedback loop.
Handtmann’s dividing technology focuses on scaling accuracy to help bakers avoid giving product away or risk shorting the customer.
“Depending on what the baker is trying to achieve for scaling accuracy, we can set up our divider to deliver the tightest weights possible,” said Cesar Zelaya, bakery sales and technology manager, Handtmann. “In cases where maintaining the dough structure is more important, and a small fluctuation in weight is acceptable, we can minimize the mechanical work on the dough. Adjustments only take a few minutes for changeovers.”
Accuracy is an area that has been well-served by innovation in recent years thanks to servo technology.
“The use of servos has made setup and repeatability of performance much easier with dividers,” said Bruce Campbell, vice-president, product technology, AMF Bakery Systems. “Servos perform the same function day in and day out, so the operator has less to worry about and can set the divider to run a particular recipe each day. The precise motion control means you get exactly the correct movement — no more, no less — which is critical in the case of dividing and controlling pressure.”
Handtmann dividers are designed with a servo-driven auger in the hopper to help guide sticky or stiff doughs into the chamber. A vacuum also creates consistent dough flow that leads to reliable scaling.
“We can regulate the speed of the auger in the hopper to optimize the feeding process and the vacuum level without stressing or degassing the dough,” Mr. Zelaya said.
To meet requirements such as scaling weights, higher throughput and dough consistency, Handtmann uses servo drives for better reliability.
“It is also easier to monitor them during production and troubleshoot for maintenance,” Mr. Zelaya added.
Servos aid in not only accuracy but also speed and precision, Mr. Sanchez said.
“This allows design engineers to fine-tune feedback controls with responsive machinery,” he said.
In order to accommodate dividing needs now and into the future, bakers must also consider versatility.
Stiffer doughs that move at lower speeds might be easier to run, but they require a versatile scaling system that can handle the range of production speeds for specific dough types. Mr. McIsaac said the Reiser Vemag system can accomplish that. Designed with double-screw technology, the Vemag divider is equipped with a fully adjustable vacuum system and hopper infeed.
“We match the system to the product and the speed of the line,” Mr. McIsaac said. “The machine is recipe-driven, and variables are changed from product to product with minimal operator intervention.”
Bakers must also consider consistency.
“Options like a top-mount dough developer are available, which reduce the size of air pockets in the dough and improves consistency,” Mr. Sanchez said. “This unit receives dough from the final mixer and feeds emulsified dough into the divider hopper.”
