CUSTOMISED FLEXIBLE SOLUTIONS
Jostec offers complete production line solutions tailored for the needs of the customer. From starting with the rolling of the dough to finishing with the loading and handling of the baking trays. Our equipment is suited for diversified handling and treatment of doughs, from trendy, gluten-free thin bread doughs to traditional yeast doughs. We offer solutions for forming the dough, decoration and fermentation and the handling of the baking trays. We will design and build a production line that fits the needs and demands of the customer. We aim to expand capacity and optimise the bakery premises by designing a bespoke line for efficient prodution in collaboration with our customer requirements.
ROLLING UNITS
MAKE-UP TABLE
PANNING UNIT
Single way loading system, which fills the trays or a transversal cross conveyor. Fills the tray in a single motion, for example, after the roll moulding machine. It is possible to adjust the conveyor speed, the filling distance and the filling delay. The standard equipment offers a filling distance of, at most 700 mm and a conveyor belt width of 650 mm.
TRAY HANDLING UNIT
Handling of trays after the production line. Lifting of trays from the trolley, covering the tray with parchment paper – the products are transferred to the tray – filling of the baking surface and automatic transfer. Capacity up to 800 trays/h. Suitable to a limited extent for baguette trays and moulds.
COOLING SPIRAL
Roll-out sheeter for short and wet doughs
Thickness of the dough sheet 1 – 5 mm. The width can be varied within 300 – 600 mm. No additional calibration.
Suitable for example for crispbread and gluten free pizza.
Treatment of the dough sheet, for example seeding, pricking, cutting etc.
Homogenizer as option for mixing rest dough and fresh dough and eliminating air bubbles.
| SPECIFICATIONS | |
|---|---|
| Dough thickness: | from 1 to 5 mm |
| Dough width: | 600 mm (unless specified) |
| Suitable for: | e.g.: crisp bread & gluten-free dough |
| Mobile: | semi |
| Interface: | switchboard or controlled by line |
| Calibration: | manual |
| Material: | stainless steel |
Roll-out sheeting line for gluten free and dry doughs
A multi-step, roll-out sheeter for thin dough sheets.
Feeding unit and two calibration sheeters.
Sprinkles flour both on the surface and under the bottom.
Minimum thickness of the dough sheet around 1 mm, depending on the dough type and the needs.
Standard width of the dough sheet 600 mm, other dimensions on request.
Standard output speed around 2 – 7 metres/min.
Rolls out for example crispbread and laminated doughs for pies and pastry. Suitable also for handling of gluten free doughs.
| SPECIFICATIONS | |
|---|---|
| Suitable for e.g.: | crispbread, pie, crunchy pie, gluten-free dough |
| Smallest thickness: | 1 mm |
| Dough width: | 600 mm (unless specified) |
| Calibration: | manual |
| Material: | stainless steel |
Roll-out sheeting line for yeast doughs.
An efficient and gentle production line for yeast and other gluten containing doughs. Suitable for example for buns and rolls.
The feeding unit gently forms a thick initial band to save the rising capacity of the dough.
A short period of rest followed by satellite roll-out sheeting, traverse roll out and calibration.
When necessary two calibration phases as in the illustration.
Sprinkles flour both on the surface and under the bottom.
Minimum thickness of the dough sheet around 2-3 mm, depending on the doughs and the calibration.
Standard width of the dough sheet 600 mm, other dimensions on request.
Standard output speed around 2 – 7 metres/min.
| SPECIFICATIONS | |
|---|---|
| Smallest dough thickness: | 2-3 mm |
| Unspecified width: | 600 mm standard |
| Output speed: | 2-7 m/min |
| Suitable for e.g.: | yeast dough, gluten dough |
| Material: | stainless steel |
Roll-out sheeting line for wet and tough gluten doughs
A multi-phase and step roll-out sheeter treats the dough gently and in an optimal manner.
The dough is divided in the first phase and the parts are put into a line. After pre-sheeting the dough will be moulded by a satellite sheeter. Thereafter traverse sheeting and two calibrations.
Amount of treatments according to needs. Also, the number of flour sprinklings is optimized. Plastic, removable sheets and oil lubrication can be added to the bowl.
Thickness of the dough sheet is 2 – 15 mm. Nominal width 600 mm.
Suitable for example for ciabatta doughs or other doughs demanding gentle treatment
| SPECIFICATIONS | |
|---|---|
| Dough thickness: | 2-15 mm |
| Dough width: | 600 mm |
| Suitable (especially) for: | ciabatta & sensitive dough |
| Calibration: | manual |
| Material: | stainless steel |
Make up table
The versatile make up table is adapted for many various needs. Suitable for brushing, prickling, cutting into shapes or strips, removal of scrap dough, sprinkling of the edge, filling with jam, folding of the strip band, rolling, decorative cutting and transverse cutting. The production line length can be designed from 2-12 m.
A wide range of accessories at your disposal. The cutting-edge selection enables decorative cutting of the products. The table can be delivered as free standing or as a part of the production line.
Standard height of the table is 900 mm and the conveyor width is 650 mm. Other dimensions are also available.
| SPECIFICATIONS | |
|---|---|
| Line length: | 2-12 m (depending on needs) |
| Belt width: | 650 mm |
| Table height: | 900 mm standard |
| Mobile: | no (unless specified) |
| Material: | stainless steel |
DECO Surface decoration unit
A unit to be installed after the production line, including:
- water sprinkling
- egg brushing
- glazing (with additive)
- seeding
- cheese spreading
Water sprinkling with water mist. Egg brushing with a plate brush. Recycling of surplus seeding as an option as illustrated. Seeding can be directed precisely towards the product rows. Length of the equipment 1,5 metres or more, depending on the number of pockets. Standard width 600 mm. Connected to the production line, controlled from the operating desk of the line.
The conveyors are made either as belts or as grates. The conveyor is divided into sections, which prevents mixing of materials.
The machine is equipped with lockable wheels. Transport to the cleaning room is easy.
| SPECIFICATIONS | |
|---|---|
| Fixed width: | 600 mm |
| Conveyor: | Rod network belt (steel), plastic net, belt |
| Mobile: | Yes |
| Length: | 1,5 m + |
Tray filling unit
A solution for one-way filling needs, for example after a roll machine or when the tray can be moved.
The photo shows an adjustable tray rack. The tray can be filled longitudinally or crosswise.
Filling can be adjusted according to belt speed, filling distance and delay.
Filling distance 200 - 700 mm with standard equipment.
The belt width is 650 mm with standard equipment.
Several different dimensions are available on request.
Transmission of the belt via a toothed belt, which makes filling silent and gentle. The open design enables easy daily cleaning and maintenance when needed.
The filling unit can be connected to the production line or it can operate independently. (Control unit not shown in the picture).
The length of the equipment depends on the height difference between the feeding unit and the filling level and the inclination angle of the belt.
| SPECIFICATIONS | |
|---|---|
| Panning travel distance: | 200-700 mm (standard) |
| Belt width: | 650 mm (standard) |
| Tray positioning: | multidirectional |
| Material: | stainless steel |
Filling Unit
For two-way filling.
Fills the tray in both longitudinal and traverse direction.
The filling unit makes it possible to fill the tray optimally and without touching the products by hand.
The line can be left or right hand orientated.
Standard belt width is 650 mm and the maximal filling distance is 700 mm.
The synchronous conveyor included in the equipment is equipped with lockable wheels, which makes it easy to uncouple for cleaning. Connections with quick couplings. The synchronous conveyor transports the products on a grate.
Belt drive via a toothed belt, which makes the filling silent and gentle.
The open design enables easy daily cleaning and maintenance when needed.
The filling unit can be connected to the production line or it can operate independently.
(Control unit without touch control in the photo.)
The length of the equipment depends on the height difference between the feeding unit and the filling level and the inclination angle of the belt.
| SPECIFICATIONS | |
|---|---|
| Panning travel distance: | 200-700 mm (both ways) |
| Belt width: | 650 mm (standard) |
| Tray positioning: | multidirectional |
| Material: | stainless steel |
| Line configuration: | left/right |
Pulling tray filling unit
A filling unit for industrial production, aimed for transport of the products to the prover or directly to the oven.
Optional standard belt widths (B) 400 and 650 mm. Wider belts on request. Maximal width 1,5 metres.
Pulling distances (A) from 1 metre up to 4 metres.
Fills the boards of the prover or the tunnel prover or directly to the oven on the grate conveyor as in the picture. The filling method can be chosen according to the product row, the product group or the total width.
Photo cell control.
Filling levels (H1) and spaces (H2) and orientation of the line are selectable.
The filling unit includes a rising filling tip and automatic control of the belt.
(The control unit is missing from the photo.)
| SPECIFICATIONS | |
|---|---|
| Belt width: | 400 or 650 mm (standard) |
| Material: | stainless steel |
| Dist. A: | 1-4 m |
| Control panel | |
Tray handling
Replaces heavy and boring work operations.
The raw dough pieces are transferred from the production line to the filling unit (1), which arranges a convenient filling batch.
The baking trays from the tray lift (2), where the tray trolley is delivered. Automatic lifting of the trays to the conveyor (4).
In the photo a parchment paper feeder (3), which feeds paper onto the trays before filling the products on the trays.
Conveyor with 9 pockets.
It is possible to add an automatic surface filling device after the conveyor and an attached transfer unit.
Capacity with paper feeder around 350 - 400 trays/h, otherwise more than 500 trays/h.
The dimensions of the illustrations are based on tray size 450 x 600 mm and a standard filling unit with 650 mm belts and 700 mm filling distance.
The whole equipment is connected to the same control panel with touch control logic.
| SPECIFICATIONS | |
|---|---|
| Capacity: | 500+ (standard), 350 (approx. with papering) |
| Tray measures: | from 450x600 mm |
| Product setting on trays after papering | |
| Tray lifting: | automatic from trolley |
| Rack loading & transferring: | automatic |
| Paper from roll: | width depends on tray, cutting length adjustable |
Paper feeding unit for the production line
A paper feeding unit to be placed after the production line.
Operational principle:
- The raw dough pieces coming from the production line are addressed to the conveyor of the paper feeder.
- The paper is released from the roll (1) as a continuous band.
- The paper is cut by a guillotine (2) to a defined length between the product rows.
- The paper is held towards the belt by vacuum (3).
- The products will be transported on the cut paper to the next belt for further treatment.
The width of the paper roll is 300 – 800 mm. The maximal standard diameter of the roll is around 700 mm.
The minimum height of the line is determined by the paper roll placed under the conveyor
| SPECIFICATIONS | |
|---|---|
| Papering without trays | |
| Paper roll width: | 300-800 mm |
| Max. roll diameter: | 700 mm |
| Cut length: | adjustable |
| Material: | stainless steel |
Paper feeding unit for a closed tray or peel board line.
Will feed paper onto the empty tray simultaneously as the tray is transported out through the corner.
The products are placed on the tray immediately after paper feeding.
The capacity depends on i.e. the tray dimensions, for example 350 trays per hour.
The baking paper is released from the roll (1), cut and placed onto the tray.
Length (L) of the tray, for example 800 - 2000 mm. Width of the tray/paper for example 400 - 800 mm.
In one single 700 mm paper roll there is more than 7 km paper. The paper used for this purpose is generally silicone covered on both sides (41 g/m2).
| SPECIFICATIONS | |
|---|---|
| Tray length: | 800-2000 mm |
| Tray width (paper): | 400-800 mm |
| Roll: | 700 mm (gives est. 7 km) |
| Paper: | generally siliconized (41 g / m2) |
The ultra-hygienic Promax spirals are easy to clean and maintain as well as offering a good overall economy due to their construction. They are also very quiet when in use. The spirals do not contain an inner drum which frees up floor space in the production facilities. Such space can be used for other purposes such as cooling. Quick and easy assembly significantly shortens the overall startup time.
