Bread & Buns Production

Bread & Buns Production Process

1. Mixing & Feeding Dough

After mixing, the dough goes through hopper-shaped feeders. The hoppers are often lined on the inside with belt material. The mixture is then transferred to various shaping processes.

Belt Specifications Required

When dough is conveyed to different stages in the process, food grade belts with good grip and release properties are a must. Patterned belts can also be advisable depending on the conveying angle. Small end radii facilitate release of the dough at the end of the conveyor.

Our Solution

Forbo Movement Systems offers both conventional fabric-based and homogenous belt for these conveying tasks. They deliver the properties required for conveying foodstuffs and good grip and release of the dough.

Features, Functions, Benefits

Thanks to various coatings, such as PU and polyolefin, these belts offer a high standard of hygiene and lots of patterns to ensure excellent grip and release properties. They are easy to clean and MHLW, EU and FDA compliant. Belt edge sealing (Smartseal) can also be applied. A special belt design (Frayfree) minimizes fraying of unsealed belt edges.

Other Information

If required, splices can also be made while the belts are on the conveyors. We offer various splicing methods and tools for fabric-based and homogenous belts.

Downloads

You can find detailed information on the relevant products in the following brochures: Siegling Belting – Food, ref. no. 269, Fullsan Flat – Lower Cleaning Costs, Better Hygiene ref. no. 197 and Siegling Transilon Conveyor and Processing Belts, ref. no. 224.

Siegling Belting Food
Ref.-No. 269 | PDF | EN
Siegling Transilon Product range
Ref.-No. 224 | PDF | EN
Fullsan Flat – Lower Cleaning Costs, Better Hygiene
Ref.-No. 197 | PDF | EN

2A. Forming Buns

Once the dough has been portioned, there are various ways of creating the shape required. To create buns, pieces of dough are usually rounded. Shaped pieces of dough are conveyed for fermentation and optionally for sprinkling with water.

Belt Specifications Required

Good grip and release properties, superb positioning accuracy and suitability for foodstuffs in general are the top priorities for these processes. Forming belts must be good at rounding, the spreading belts used need to be troughable, elastic and have very good release properties, even when very little flour is applied. Due to the exceptional ambient conditions (approx. 40°C, high humidity), mold-resistant belts are required during the fermentation process.

Our Solution

Forbo Movement Systems offers numerous fabric-based, elastic, and homogenous belts, as well as plastic modular ones, for these conveying and processing tasks. They provide the properties necessary for conveying foodstuffs, good grip and the technical specifications for forming, conveying and fermenting.

Features, Functions, Benefits

Hard-wearing, two-ply urethane belts, which can be coated with cotton, are used for rounding. As spreading belts, elastic urethane ones are the hygienic alternative to conventional cotton belts. During fermentation, both TPU belts with and without fabric inlay and plastic modular belts (in spiral towers) are used. Belt edge sealing (Smartseal) can be applied to many of the belts. A special belt design (Frayfree) minimizes fraying of unsealed belt edges. These belts’ good release properties minimize the need for flour as a release agent. They are easy to clean and EU and FDA compliant.

Other Information

Neat splices leave virtually no traces on the bottom of the products. If required, splices can also be made while the belts are on the conveyors. We offer various splicing methods and tools for fabric-based, elastic, and homogenous belts.

Downloads

You can find detailed information on the relevant products in the following brochures: Siegling Belting – Food, ref. no. 269, Fullsan Flat – Lower Cleaning Costs, Better Hygiene ref. no. 197, Siegling Transilon Conveyor and Processing Belts, ref. no. 224 and Siegling Prolink Plastic Modular Belts, ref. no. 800.

Siegling Belting Food
Ref.-No. 269 | PDF | EN
Fullsan Flat – Lower Cleaning Costs, Better Hygiene
Ref.-No. 197 | PDF | EN
Siegling Transilon Product range
Ref.-No. 224 | PDF | EN
Siegling Prolink Plastic Modular Belts
Ref.-No. 800 | PDF | EN

2B. Forming Bread

After the dough has been portioned, belts moving in opposing directions give loaves their shape by rounding/forming them. Some of the pieces of dough are then placed in pans.

Belt Specifications Required

To round/shape the dough, food-safe belts with relatively high belt tension are required. Even when very little flour is used, they must offer very good release properties. Small end radii facilitate transfer of the pieces of dough to subsequent belt sections.

Our Solution

Forbo Movement Systems offers numerous fabric-based, elastic, and homogenous belts for these conveying and processing tasks. These provide the properties necessary for conveying foodstuffs, good grip and the technical specifications for the forming process.

Features, Functions, Benefits

The belts used are FDA/EU approved and can come with belt edge sealing (Smartseal). A special belt design (Frayfree) minimizes fraying of unsealed belt edges. The wear-resistant belt coatings have enhanced surfaces. They are perfect for the forming process due to their good grip and release properties. Many of the belts are ideal for knife edges.

Siegling Belting Food
Ref.-No. 269 | PDF | EN
Fullsan Flat – Lower Cleaning Costs, Better Hygiene
Ref.-No. 197 | PDF | EN
Siegling Transilon Product Range
Ref.-No. 224 | PDF | EN

3. Proofing

Before they’re baked, finished pieces of dough are left to prove. As these process takes quite a lot of time, slow, cascading conveyors or spiral towers are used. Discontinuous processes without conveyor belts are also used.

Belt Specifications Required

Due to the exceptional ambient conditions (approx. 40°C, high humidity), the risk of mold growing increases during proofing. Alongside the need for food-grade belts with good grip and release properties, mold resistance is the key requirement at this stage of production.

Our Solution

Forbo Movement Systems offers numerous fabric-based, homogenous belts and plastic modular ones for these conveying and processing tasks. The belts combine the requisite properties for foodstuffs and the grip with the requirements of the proofing process.

Features, Functions, Benefits

For cascading conveyors, fabric-based belts (Transilon) with belt edge sealing (Fullseal), as well as homogenous TPU belts (Fullsan), provide the protection from mold growth required. Plastic modular belts with large open areas (Prolink, series 9/18) are used in spiral towers. All belt types are easy to clean and EU and FDA compliant.

Other Information

High-quality splices leave virtually no traces on the bottom of the products, which are easy to remove. If necessary, splices can also be made while the belts are on the conveyors. We offer various splicing methods and tools for fabric-based, elastic and homogenous belts.

Downloads

You can find detailed information on the relevant products in the following brochures: Siegling Belting – Food, ref. no. 269, Fullsan Flat – Lower Cleaning Costs, Better Hygiene ref. no. 197, Siegling Transilon Conveyor and Processing Belts, ref. no. 224 and Siegling Prolink Plastic Modular Belts, ref. no. 800.

Siegling Belting Food
Ref.-No. 269 | PDF | EN
Fullsan Flat – Lower Cleaning Costs, Better Hygiene
Ref.-No. 197 | PDF | EN
Siegling Transilon Product range
Ref.-No. 224 | PDF | EN
Siegling Prolink Plastic Modular Belts
Ref.-No. 800 | PDF | EN

4. Oven

The finished dough pieces are conveyed through the oven and baked during the oven cycle. While still hot, they are transferred from the oven belt to the out-feed belt and sent on for further processing.

Buns transferred to the out-feed belt for further processing

Belt Specifications Required

The in-feed and out-feed belts must be able to withstand high temperatures for short periods of time and have good release properties. Small end radii are required to transfer the products. The belts must be suitable for use with foodstuffs.

Our Solution

Metal mesh or grid belts, not supplied by Forbo Movement Systems, are used in the oven. Fabric-based conveyor belts (Siegling Transilon) or plastic modular belts (Siegling Prolink), which are resistant to the oven’s radiant heat, are ideal options as in-feed and out-feed belts. These are food-grade belts and can be used over small end radii.

Features, Functions, Benefits

For this application, fabric-based belts (Siegling Transilon) are usually made endless with a 60° Z-splice. This type of splice means that the belt tracks exceptionally smoothly over knife edges. Mechanical fasteners can also be applied. Belt edge sealing can be added too if a very high standard of hygiene is required. In addition to offering hygienic surfaces through and through, plastic modular belts (Siegling Prolink) also come with small end radii. All belt types are available with patterns that provide good release properties, are easy to clean and EU and FDA compliant.

Other Information

High-quality splices leave virtually no traces on the bottom of the products, which are easy to remove. If necessary, splices can also be made while the belts are on the conveyors. No special tools are needed for Siegling Prolink plastic modular belts. We offer various splicing methods and tools for fabric-based and homogenous belts.

Downloads

You can find detailed information on the relevant products in the following brochures: Siegling Belting – Food, ref. no. 269, Fullsan Flat – Lower Cleaning Costs, Better Hygiene ref. no. 197, Siegling Transilon Conveyor and Processing Belts, ref. no. 224 and Siegling Prolink Plastic Modular Belts, ref. no. 800.

Siegling Belting Food
Ref.-No. 269 | PDF | EN
Fullsan Flat – Lower Cleaning Costs, Better Hygiene
Ref.-No. 197 | PDF | EN
Siegling Transilon Product range
Ref.-No. 224 | PDF | EN
Siegling Prolink Plastic Modular Belts
Ref.-No. 800 | PDF | EN

5. De-panning

When pieces of dough are baked in pans, they have to be tipped out when they emerge from the oven. In automated processes, this step is carried out by a vacuum belt above the conveyor. Suction cups on the belt attach themselves to the loaves and lift them out of the pan. At the end of the vacuum belt, the shaped loaves are placed on the next belt.

Belt Specifications Required

Despite relatively big vacuum openings, the belts must be capable of withstanding the tensile load from the loaves hanging off them. The discharge belt must have an open area so that the loaves can cool down well. Food-grade belts are also required.

Our Solution

Fabric-based conveyor belts (Siegling Transilon) are used as vacuum belts. Plastic modular belts (Siegling Prolink) with a large open area act as discharge belts that cool products down.

Features, Functions, Benefits

Customized perforations are added to the fabric-based belts that have the appropriate tensile force (Siegling Transilon). Tailor-made suction cups can be clipped into the perforations. For onward conveying, plastic modular belts (Siegling Prolink) with open areas of 57% are ideal for cooling the loaves down quickly and in a controlled manner. All belt types are easy to clean and EU and FDA compliant.

Other Information

High-quality splices leave virtually no traces on the bottom of the products, which are easy to remove. If necessary, splices can also be made while the belts are on the conveyors. No special tools are needed for Siegling Prolink plastic modular belts. We offer various splicing methods and tools for fabric-based and homogenous belts.

Downloads

You can find detailed information on the relevant products in the following brochures: Siegling Belting – Food, ref. no. 269, Fullsan Flat – Lower Cleaning Costs, Better Hygiene ref. no. 197, Siegling Transilon Conveyor and Processing Belts, ref. no. 224 and Siegling Prolink Plastic Modular Belts, ref. no. 800.

Siegling Belting Food
Ref.-No. 269 | PDF | EN
Fullsan Flat – Lower Cleaning Costs, Better Hygiene
Ref.-No. 197 | PDF | EN
Siegling Transilon Conveyor and Processing belts Product range
Ref.-No. 224 | PDF | EN
Siegling Prolink Plastic Modular Belts
Ref.-No. 800 | PDF | EN

6. Cooling Section

Before they are put into piles and packaged, the baked goods cool down on the cooling section and the surfaces dry. Curved conveyors are often added to the relatively long cooling sections.

Belt Specifications Required

The belts must be suitable for use with foodstuffs. They need to have relatively heat- and abrasion-resistant surfaces and be able to cope with curved applications.

Our Solution

Both fabric-based conveyor belts (Siegling Transilon) and plastic modular belts (Siegling Prolink) with heat-resistant surfaces can be used as cooling belts. Each is available as curved belts and suitable for use with foodstuffs.

Features, Functions, Benefits

All Transilon belts for cooling applications are easy to clean, EU and FDA compliant and can come with belt edge sealing (Smartseal). Curved belts with fabric tension members have enhanced fabric designs (e.g. are longitudinally and laterally soft). They are made of several segments, resulting in a good distribution of force in the belt. Plastic modular belts (Siegling Prolink) are also suitable for straight and curved sections. Belt types with a large open area enhance cooling processes in the baked goods and are also ideal for use in very low temperatures.

Other Information

High-quality splices leave virtually no traces on the bottom of the products, which are easy to remove. If required, splices can also be made while the belts are on the conveyors. No special tools are needed for Prolink plastic modular belts. We offer various splicing methods and tools for fabric-based belts.

Downloads

You can find detailed information on the relevant products in the following brochures: Siegling Belting – Food, ref. no. 269, Fullsan Flat – Lower Cleaning Costs, Better Hygiene ref. no. 197, Siegling Transilon Conveyor and Processing Belts, ref. no. 224 and Siegling Prolink Plastic Modular Belts, ref. no. 800.

Siegling Belting Food
Ref.-No. 269 | PDF | EN
Fullsan Flat – Lower Cleaning Costs, Better Hygiene
Ref.-No. 197 | PDF | EN
Siegling Transilon Conveyor and Processing Belts
Ref.-No. 224 | PDF | EN
Siegling Prolink Plastic Modular Belts
Ref.-No. 800 | PDF | EN

7. Detection and Packaging

7. Detection and Packaging Processes

A range of methods is used to detect whether foreign bodies are present in the products. These detection processes can be integrated at various points in the production process. The products are weighed and packaged to prepare them for sale. The products are usually packaged in bags or trays and then wrapped. Depending on the machinery and the product, the products are then labelled, wrapped and/or repackaged and deep frozen if necessary.

Belt Specifications Required

The belts need to be suitable for use with foodstuffs and easy to clean. Specific belt characteristics are also required, such as uniform thickness during the weighing process, good grip in order to position the product precisely and good release properties during the labelling process. In the case of metal detectors and X-ray equipment, the requirements depend on the application. In deep-frozen sections, the belt must not become brittle at temperatures down to -40°C.

Our Solution

Forbo Movement Systems’ portfolio stands apart for its exceptional quality and wide selection of types. The ranges offer numerous special belt types geared to particular tasks and comply fully with the requirements of your HACCP concept.

Features, Functions, Benefits

Special surface characteristics make the portioning and wrapping process easier and more reliable. Special finishes for weigher belts provide extremely precise splices of the same thickness. Antistatic or non-antistatic belts are available for metal detectors, depending on requirements. To ensure safe x-raying, belts with a high friction coefficient are used on the top face so that the equipment’s safety curtain can pass through without the products on the conveyor belt slipping. The food-grade Prolink series, made of polyoxymethylene (POM) or polyethylene (PE), offer exceptionally long service lives when products need to be deep frozen.

Other Information

If required, all belt types can be spliced on the conveyor itself. No special tools are needed for Prolink plastic modular belts. We offer various splicing methods and tools for fabric-based and homogenous belts.

Downloads

You can find detailed information on the relevant products in the following brochures: Siegling Belting – Food, ref. no. 269, Fullsan Flat – Lower Cleaning Costs, Better Hygiene ref. no. 197, Siegling Transilon Conveyor and Processing Belts, ref. no. 224 and Siegling Prolink Plastic Modular Belts, ref. no. 800.

Siegling Belting Food
Ref.-No. 269 | PDF | EN
Fullsan Flat – Lower Cleaning Costs, Better Hygiene
Ref.-No. 197 | PDF | EN
Siegling Transilon Conveyor and Processing Belts
Ref.-No. 224 | PDF | EN
Siegling Prolink Plastic Modular Belts
Ref.-No. 800 | PDF | EN

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Bread & Buns Production