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Flexco - Partners in Productivity

Back to Industrial Baking

Dry and Wet Ingredient Storage Mixing Live Bottom Hopper Dough Elevator/Sandwich Conveyor Dough Transport/Divider Feed Belt Dough Sheeter/Divider Gauging Rollers Rotary Dough Slitter/Cutter Scrap Release/Take-Away Conveyor Weigh Scale Guillotine Cutter Rounder Final Sheeter Dough Moulder Panning Spiral Proofer Oven Cooling Spiral Depanning Empty Pan Transport Conveyor Pan Washing Metal Detector Slicing Bagging Toting Tote Stacking Shipping

1. Dry and Wet Ingredient storage

Dry and wet ingredients are stored in a contained area or room to keep dust confined to that area. The silos deliver the dry ingredients directly to the mixers via a piped system that utilizes vacuum or air pressure to transport the ingredients directly to the mixers. Oil, water, and other liquid ingredients are piped directly into the mixers via a series of computer-regulated pumps. The amount of each liquid is carefully controlled per the needs of each specific recipe.

2. Mixing

The mixing of ingredients sets the chemical process side of baking in motion. Industrial mixers can be horizontal or vertical stand style mixers. Large industrial mixers are capable of mixing 1,000 lb. (450 kg) to 2,000 lb. (900 kg) of dough. Secondary ingredients such as rye seeds and rye flour are often added to the mixer manually.

3. live bottom hopper

In some bread baking operations, the mixers will dump the bread dough directly into a dough hopper. Some dough hoppers have a screw system that “pumps” the dough into a vertical pinch/sandwich conveyor, also called a dough elevator conveyor. Other dough hoppers will have “take-away” conveyor belt that delivers slabs of dough portioned by cutters built into the live bottom hopper to the vertical pinch conveyor.

ISSUES

  • Endless Splice Failure
  • Dough carryback
  • Belt mistracking

SOLUTIONS

High quality splices made quickly are key in industrial baking operations. The Novitool® Aero® Splice Press is the best and fastest endless splicing press available. There can be up to 2500 lbs. of dough in the hopper when full. Live-bottom dough hoppers require a strong endless splice free of pin holes.

The Novitool® Pun M™ Mobile Finger Punch can be used at the conveyor site and does not require electrical power. This can speed up the processing time of the splice, thus reducing conveyor downtime.

The FGP Food Grade Primary Cleaner can be installed on the return side of the belt at the first bend pulley, past the nose bar to tackle carryback. Removing the potential carryback dough promotes better overall belt tracking reducing one of the larger pain points.

A squarely-cut belt end is very important to achieving a perfect finger splice that tracks well. The Laser Belt Square offers a quick and accurate way to locate a perfect belt cut reference line, every time.

The 845LD Belt Cutter offers a quick, safe, and accurate way to make a perfectly straight cut belt in a single pass. A straight cut is important in achieving a finger punch that is square to the belt edges.

4. Dough Elevator/Sandwich conveyor

Dough elevators are used to carry the dough vertically up to a transport conveyor that feeds the dough divider. The use of dough elevators has eliminated the need for dough trough lifts commonly found in many older industrial bakeries. Dough elevators typically utilize monolithic belting, but some may utilize traditional urethane plied belting. The dough elevator is made up of two conveyors with belts running in opposite directions that are “sandwiched” together.

ISSUES

  • Spillage and carryback
  • Poor splice quality

SOLUTIONS

Carryback and dough release can be a big problem with dough elevator conveyors. Installing an FGP Food Grade Primary Cleaner on the top belt can help to release the dough chunk, allowing it to properly transfer. Placing an FGP on the lower belt can reduce carryback and provide production gains as the scraped dough will drop onto the transport conveyor.

Quick and efficient, the Novitool® Aero® Splice Press offers superior finished splice quality in the quickest time possible. The quality of the finished splice helps to ensure long splice life with dough elevator systems that utilize traditional plied belting. Since the dough is generally concentrated in the center section of the sandwiched elevator conveyor belts, stress is increased in the center area of the splice. A superior endless splice is required.

The Novitool® Amigo™ Splice Press is quick, accurate, and safe. The butt splice created by the Amigo is superior, and the “no ouch” aspect of the heating element means that monolithic belts utilizing longitudinal cords can be spliced with little worry of cord material poking through the top or bottom surfaces of the belt.

The 845LD Belt Cutter offers a quick, safe, and accurate way to make a perfect cut in a single pass.

All great splices begin with a perfectly squared belt end. The Laser Belt Square offers a quick and accurate way to locate a perfect belt cut reference line, every time.

5. Dough Transport/Divider feed belt

Dough transport and divider feed conveyors are used to transport dough to pre-sheeters and dividers, or other dough transport conveyors.

ISSUES

  • Dough sticks to belt
  • Plied belt endless splice failure
  • Monolithic belt splice failure
  • Belt mistracking

SOLUTIONS

Carryback and dough release can be a big problem with dough elevator conveyors. Installing an FGP Food Grade Primary Cleaner on the top belt can help to release the dough chunk, allowing it to properly transfer. Placing an FGP on the lower belt can reduce carryback and provide production gains as the scraped dough will drop onto the transport conveyor.

Quick and efficient, the Novitool® Aero® Splice Press offers superior finished splice quality in the quickest time possible. The quality of the finished splice helps to ensure long splice life with dough elevator systems that utilize traditional plied belting. The quality of the finished splice helps to ensure long splice life with dough transport belts that utilize traditional plied belting.

The Novitool® Pun M™ Mobile Finger Punch can be used at the conveyor site and does not require electrical power. This can speed up the processing time of the splice, thus reducing conveyor downtime.

The Novitool® Amigo™ Splice Press is quick, accurate, and safe, offering a superior butt splice. The “no touch” aspect of the heating element means that monolithic belts utilizing longitudinal cords can be spliced with little worry of cord material poking through the top or bottom surfaces of the belt.

Alligator® Spiral Lace offers the lowest profile mechanical splice option. And it is a completely non-metallic fastener. A great solution for premade replacement belts offering a hinged splice that is quick to install, keeping critical downtime to a minimum. Available in both food grade white and food grade blue options, it is a great option for all industrial baking facilities.

All great splices begin with a perfectly squared belt end. The Laser Belt Square offers a quick and accurate way to locate a perfect belt cut reference line, every time.

The 845LD Belt Cutter is a quick, safe, and accurate way to make a perfect cut in a single pass.

6. dough sheeter/divider

A dough sheeter or divider is positioned here. The type of bread determines whether it is a sheeter or divider.

The dough divider’s primary function is to cut the dough into precise portion sizes, according to the weight/size of the bread product being produced. Dough sheeters are designed to press the lump of dough into flat sheets. Sheeting provides consistency in the quality of the bread product produced.

ISSUES

  • Finger splice failure
  • Monolithic splice failure
  • Integrated lamination belts time consuming to change/replace
  • Dough sticks to smooth rollers

SOLUTIONS

High quality, long lasting splices are key for dough gauging, which is why the Novitool® Aero® Splice Press is perfect for the job. Popped fingers can catch on the dough, causing the dough to tear, as well as creating a potential contamination issue. And splicing speed is always important in industrial baking operations.

The Novitool® Pun M™ Mobile Finger Punch can be used at the conveyor site and does not require electrical power. This can speed up the processing time of the splice, thus reducing conveyor downtime.

The Novitool® Amigo™ Splice Press creates a consistent butt splice with no air bubbles or imperfections. The pre-heat option makes it possible to create a great splice in even the most humid of environments. And the actual splicing process is fast and efficient, allowing for the lamination belts to be up and running as quickly as possible.

The Alligator® Spiral Lace Fastening System offers the lowest profile mechanical splice option and is a completely non-metallic fastener. It is also a great solution for pre-made replacement belts offering a hinged splice that is quick to install, keeping critical downtime to a minimum. Available in both food grade white and food grade blue options, it is a great option for all industrial baking facilities. Ideal for most industrial baking applications, including metal detection belts.

The FGP Food Grade Primary Cleaner can be installed against the first bend pulley after the nose roller/bar on the return side of the belt. This will remove excess dough that sticks to the belt and will deposit it into a tray or onto a scrap take-away conveyor.

The Alligator® Spiral Lace Fastening System offers the lowest profile mechanical splice option and is a completely non-metallic fastener. It is also a great solution for pre-made replacement belts offering a hinged splice that is quick to install, keeping critical downtime to a minimum. Available in both food grade white and food grade blue options, it is a great option for all industrial baking facilities. Ideal for most industrial baking applications, including metal detection belts.

All great splices begin with a perfectly squared belt end. The Laser Belt Square offers a quick and accurate way to locate a perfect belt cut reference line, every time. A squarely-cut belt end is very important to achieving a perfect finger splice that tracks well.

The 845LD Belt Cutter offers a quick, safe, and accurate way to make a perfectly straight cut in a single pass. A straight cut is important in achieving a finger punch that is square to the belt edges.

7. gauging rollers

Gauging rollers are used to gently bring the dough down to the final processing thickness. It is common to find a series of two or more gauging rollers installed on a dough processing line. The operator will utilize only the gauging rollers necessary for the dough being produced. Other gauging rollers on the line will simply be adjusted upwards so to not make contact with the dough if not needed.

ISSUES

  • Dough sticks to rollers

SOLUTIONS

The FGP Food Grade Primary Cleaner can be installed upside down on roller to release dough from the roller.

High quality, long lasting splices are key for dough gauging. Popped fingers can catch on the dough, causing the dough to tear, as well as creating a potential contamination issue. The Novitool® Aero® Splice Press produces the smoothest, most consistent finger splices that meet strict sanitary guidelines.

8. RotARY DOUGH SLITTER/CUTTER

Rotary dough slitters/cutters are to trim dough slabs down to the correct width.

ISSUES

  • Endless splice damage or failure
  • Dough build up on conveyor belt

SOLUTIONS

Dough slitters are set up so that the rotary or stantionary blades are positioned just above the belt. A raised splice may interfere with the slitting process. The Novitool® Aero® Splice Press produces the smoothest, most consistent finger splices that meet strict sanitary guidelines.

The Novitool® Pun M™ Mobile Finger Punch can be used at the conveyor site and does not require electrical power. This can speed up the processing time of the splice, thus reducing conveyor downtime.

In rotary dough cutting applications, it is important that the belt remain clean and free of carryback in order to ensure the quality of the dough cutting. Dough that is stuck to the belt can produce carryback, causing the sheeted dough to tear or stick during the cutting/trimming Installing an FGP Food Grade Primary Cleaner will eliminate build up, ensuring quality product

9. Scrap release/take-away conveyor

Bread products can have integrated scrap recovery systems. In all cases the scrap recovered is circulated back up to the first part of the dough handling process, including the dough hopper feeding the first sheeter, the hopper feeding the dough divider, or the hopper feeding a dough extruder forming cookies/biscuits.

ISSUES

  • Dough sticks to conveyor belt
  • Belt mistracking
  • Finger splice failure

SOLUTIONS

The scraped material from an FGP Food Grade Primary Cleaner can be removed from the belt and deposited into a catch pan that is emptied regularly.

All great splices begin with a perfectly squared belt end. The Laser Belt Square offers a quick and accurate way to locate a perfect belt cut reference line, every time. A squarely-cut belt end is very important to achieving a perfect finger splice that tracks well.

The 845LD Belt Cutter offers a quick, safe, and accurate way to make a perfectly straight cut in a single pass. A straight cut is important in achieving a finger punch that is square to the belt edges.

High quality, long lasting splices are key for dough gauging. Popped fingers can catch on the dough, causing the dough to tear, as well as creating a potential contamination issue. And splicing speed is always important in industrial baking operations. The Novitool® Aero® Splice Press ideal for this step of the process. The Aero® Press creates the lowest profile, flattest splice in the industry.

The Novitool® Pun M™ Mobile Finger Punch can be used at the conveyor site and does not require electrical power. This can speed up the processing time of the splice, thus reducing conveyor downtime.

10. weigh scale

The weigh scale conveyor is critical in controlling the size of the loaf. Weigh scale measurements are incorporated into the length that the dough will be cut to in the guillotine cutter.

ISSUES

  • Endless splice failure

SOLUTIONS

Consistent splices are required for dough weigh scales. The Novitool® Aero® Splice Press produces the smoothest, most consistent finger splices that meet strict sanitary guidelines.

The Novitool® Pun M™ Mobile Finger Punch can be used at the conveyor site and does not require electrical power. This can speed up the processing time of the splice, thus reducing conveyor downtime.

11. Guillotine cutter

Once the dough goes through the rotary slitter, it is cut to a final dimension according to the desired weight of the product. The guillotine cutter works in direct conjunction with the weigh scale and an interface that the line operator can control. The guillotine cutter’s primary purpose is to cut the dough into sections that match the requirements for the weight of the final baked bread product.

ISSUES

  • Endless splice failure
  • Belt mistracking

SOLUTIONS

The Novitool® Aero® Splice Press offers consistency in splice height and quality unmatched in the industry. The unique design of the heat platens allows for a very uniform finished splice without the typical “sink” in the splice found with other splicing presses. This is of particular importance in the handling of dough after the scale has weighed the dough. Keeping the dough consistent through the cutting process is key. An uneven splice or a finger that is beginning to lift could pull dough away from the cut slab and throw the final weight off.

The Novitool® Pun M™ Mobile Finger Punch can be used at the conveyor site and does not require electrical power. This can speed up the processing time of the splice, thus reducing conveyor downtime.

12. Rounder

With some bread processes, the dough is delivered to an initial dough rolling station. With certain breads and buns, the initial rolling can take place directly after the dough divider. The rounding of the divided dough is created by a set of concave rails with light grooves that grab the upper edge of the dough as the belt conveys/rolls the dough through the rail. The rail can be tapered to give the rolled dough ball an egg shape.

ISSUES

  • Dough carryback
  • Endless splice failure
  • Melt mistracking

 

SOLUTIONS

The rounding application really depends on the amount of additional flour added to the dough just prior to entering the rounding rails. When not enough flour is used, the dough ball becomes very sticky, leaving dough on the rails and on the belt. It is very important that this dough be removed from the belt so that the buildup does not compound the issue. The FGP Food Grade Primary Cleaner can often be installed at the first bend pulley below the nose roller/nose bar. The constant tension provided by the internal torsion spring allows the FGP to continue cleaning when the dough becomes more or less sticky due to changes in environmental conditions.

High quality, long lasting splices are key for dough rolling/rounding. Popped fingers can catch on the dough, causing the dough to tear, as well as creating a potential contamination issue. Quick splicing speed and consistent, quality splices make the Novitool® Aero® Splice Press the ideal splicing tool for this process.

The Novitool® Pun M™ Mobile Finger Punch can be used at the conveyor site and does not require electrical power. This can speed up the processing time of the splice, thus reducing conveyor downtime.

All great splices begin with a perfectly squared belt end. The Laser Belt Square offers a quick and accurate way to locate a perfect belt cut reference line, every time. A square cut belt end is very important to achieving a perfect finger splice that tracks well.

The 845LD Belt Cutter offers a quick, safe, and accurate way to make a perfectly straight cut in a single pass. A straight cut is important in achieving a finger punch that is square to the belt edges.

13. final sheeter

Final sheeting is used with some bread dough processes. The final sheeter flattens the rolled dough down to the desired thickness required for the moulding process that follows.

ISSUES

  • Dough sticks to the conveyor belt and sheeting rollers
  • Endless splice failure
  • Belt mistracking

SOLUTIONS

It is very common to see metal or UHMW scraper blades installed to scrape the buildup off the smooth rollers found in a sheeter. The FGP Food Grade Primary Cleaner can be installed upside down to scrape the upper roller. The incorporated tensioning system can keep constant tension against the roller, ensuring the best cleaning efficiency possible. An FGP may also be placed on the conveyor belt that is transporting the dough through the moulding process. The FGP can be installed to scrape the belt as it transitions around the first return bend roller. Eliminating carryback issues will extend belt splice life and overall belt life.

High quality, long lasting splices are key for dough moulding conveyor belts. Popped fingers can catch on the dough, causing the dough to not roll properly. Popped fingers can also create a contamination issue as well as a catastrophic belt tear. Consistent, sanitary splices make the Novitool® Aero® Splice Press the ideal splicing tool for this process.

The Novitool® Pun M™ Mobile Finger Punch can be used at the conveyor site and does not require electrical power. This can speed up the processing time of the splice, thus reducing conveyor downtime.

All great splices begin with a perfectly squared belt end. The Laser Belt Square offers a quick and accurate way to locate a perfect belt cut reference line, every time. A square cut belt end is very important to achieving a perfect finger splice that tracks well.

The 845LD Belt Cutter offers a quick, safe, and accurate way to make a perfectly straight cut in a single pass. A straight cut is important in achieving a finger punch that is square to the belt edges.

14. dough moulder

The dough moulder’s purpose is to roll the dough in a cylinder shape and to “seal” the dough ends prior to the panning process. The sealing of the dough allows the bread to bake as a single loaf and to not “break apart” or split uncontrollably when baked.

ISSUES

  • Dough sticks to the conveyor belt and sheeting rollers
  • Endless splice failure
  • Dough carryback
  • Belt mistracking

SOLUTIONS

The FGP Food Grade Primary Cleaner can be installed on the conveyor belt that is transporting the dough through the moulding process. The best position in which to install the FGP is in the area where the belt transitions around the first return bend roller. Dough build up on return rollers can create uneven tension along the belt width. This can cause tracking issues and can reduce the life of endless splices. Eliminating carryback issues will extend belt splice life and overall belt life.

High quality, long lasting splices are key for dough moulding conveyor belts. Popped fingers can catch on the dough, causing the dough to not roll properly. Popped fingers can also create a contamination issue as well as a catastrophic belt tear. Consistent, sanitary splices make the Novitool® Aero® Splice Press the ideal splicing tool for this process.

The Novitool® Pun M™ Mobile Finger Punch can be used at the conveyor site and does not require electrical power. This can speed up the processing time of the splice, thus reducing conveyor downtime.

All great splices begin with a perfectly squared belt end. The Laser Belt Square offers a quick and accurate way to locate a perfect belt cut reference line, every time. A square cut belt end is very important to achieving a perfect finger splice that tracks well.

The 845LD Belt Cutter offers a quick, safe, and accurate way to make a perfectly straight cut in a single pass. A straight cut is important in achieving a finger punch that is square to the belt edges.

15. panning

Panning of the bread dough happens prior to the product entering the proofer. For buns and rolls, the panning may take place after the proofing operation. Bread panners automatically place the prepared dough into the pans.

ISSUES

  • Dough sticks to belt
  • Mechanical splice failure
  • Finger splice failure

SOLUTIONS

It is very common for UHMW scraper blades to be installed to scrape the buildup off the conveyor belt delivering the dough to the panner. On occasion, there are scraper blades installed to scrape buildup off dough shaping rollers incorporated into the panning process. The FGP Food Grade Primary Cleaner is engineered specifically for use in food and baking operations.

The Clipper® Roller Lacer® and Roller Lacer® Gold Class™ allow the mechanics to install Clipper®/Anker® Wire Hooks and G Series™ fasteners on wide belts often found in industrial baking operations. The added features of the Roller Lacer Gold Class allow for a 35% reduction in fastener installation, which means the conveyor can be back up and running in a shorter amount of time.

The staggered leg design and flat stamped stainless steel make the Clipper®/Anker® G Series™ Belt Fastening System a perfect option for panning conveyors. The low profile of the fastener will reduce the wear potential as well. It can also reduce noise during the panning process.

Laser Belt Square. All great splices begin with a perfectly squared belt end. The Laser Belt Square offers a quick and accurate way to locate a perfect belt cut reference line, every time. A square cut belt end is very important to achieving a perfect finger splice that tracks well.

The 845LD Belt Cutter offers a quick, safe, and accurate way to make a perfectly straight cut in a single pass. A straight cut is important in achieving a finger punch that is square to the belt edges.

High quality, long lasting splices are a requirement for dough panning conveyors. When PVC belting is used endless spices may be preferred to reduce pan to splice impact that can be found with mechanical splices and the Novitool® Aero® Splice Press is ideal for panning belts.

The Novitool® Pun M™ Mobile Finger Punch can be used at the conveyor site and does not require electrical power. This can speed up the processing time of the splice, thus reducing conveyor downtime.

The Alligator® Spiral Lace Fastening System offers the lowest profile mechanical splice option and is a completely non-metallic fastener. It is a great solution for pre-made replacement belts, offering a hinged splice that is quick to install, keeping critical downtime to a minimum. Available in both food grade white and food grade blue options, it is a great option for all industrial baking facilities.

16. spiral proofer

Bread loaf proofers at large baking facilities are designed in a large spiral configuration. The loaf pans slowly move up and then back down the spiral. For small buns, the proofing takes place in a small proofing box that carries the dough balls up and down a series of buckets very similar to tiny bucket elevators feeding onto each other.

17. Oven

The ovens used in large industrial bread product bakeries often look like an enclosed “room”. The product goes into the oven that contains either a large spiral conveyor, 5 ft (1.5 m) to 10 ft (3 m) in diameter, or a series of decks that move the baking product up and down through the oven in a vertical fashion. Oven temperatures and times vary depending on the product being baked. Humidity is often added for the baking of bread products. Some smaller products like buns or rolls may be baked at a higher temperature for a shorter period of time.

18. cooling spiral

Baked bread products must go through a cooling process in order to be packaged with the correct amount of heat-induced humidity. A little humidity present in bagging softens the crust a bit, making it easier to eat. Cooling spiral conveyors are more commonly found in large bread product baking facilities. The cooling spirals can be up to 10 feet in diameter with modular belts that are 60” or more in width. The cooling spiral slowly brings the bread product up the spiral giving it time to cool before depanning or loaf transport to cutting and packaging.

19. depanning

Depanning is the operation of removing the baked bread product from the baking pans used in the baking process. In large industrial baking facilities, the depanning of baked product is often automated.

ISSUES

  • Mechanical splice failure
  • Belt and splice damage from pans

SOLUTIONS

The depanning transfer conveyors are short conveyors that see a lot of cycles around the pulleys. It is not uncommon for the baking pans to slam into the belt, causing damage to the splice over time. The Alligator® Staple Fastening System is strong, impact and abrasion resistant, and quick/easy to install. When the neoprene rubber impression cover belt is properly skived, the Alligator Staple is protected by the impression cover that remains. And the fastener’s large, stable offset loops make the splice quick and easy to join together when installing the belt on a conveyor.

The Alligator® Staple RSTK-4 Kit includes everything necessary to install the product in a convenient tool box. This allows for quick repairs to belts at the conveyor or in the shop and quick installation of RS into new belts.

When baking pan impact is a concern, installing the Clipper®/Anker® Wire Hook Fastening System beneath the top ply in a hybrid or hidden splice can greatly increase splice life

The Clipper® Roller Lacer® and Roller Lacer® Gold Class™ allow mechanics to install Clipper®/Anker® Wire Hooks and G Series™ fasteners on wide belts often found in industrial baking operations. The added features of the Roller Lacer Gold Class allow for a 35% reduction in fastener installation, which means the conveyor can be back up and running in a shorter amount of time.

High quality, long lasting splices are key for depanning take-away belts. PVC thermoplastic belts are commonly used for the upper belt containing vacuum cups. The PVC has good heat resistance, as well as oil and fat resistance. These belts are made endless with a finger splice, which makes the Novitool® Aero® Splice Press a good choice for consistent, quality splicing during this process.

The Novitool® Pun M™ Mobile Finger Punch can be used at the conveyor site and does not require electrical power. This can speed up the processing time of the splice, thus reducing conveyor downtime.

The Alligator® Spiral Lace Fastening System offers the lowest profile mechanical splice option and is a completely non-metallic fastener. It is a great solution for pre-made replacement belts, offering a hinged splice that is quick to install, keeping critical downtime to a minimum. Available in both food grade white and food grade blue options, it is a great option for all industrial baking facilities.

All great splices begin with a perfectly squared belt end. The Laser Belt Square offers a quick and accurate way to locate a perfect belt cut reference line, every time. A square cut belt end is very important to achieving a perfect finger splice that tracks well.

The 845LD Belt Cutter offers a quick, safe, and accurate way to make a perfectly straight cut in a single pass. A straight cut is important in achieving a finger punch that is square to the belt edges.

20. empty pan transport conveyor

After the bread loaves are removed from the pans, the empty pans are transported to the pan washing machine. Table top chain and modular belting are used in this process.

21. Pan Washing

Pans are washed and dried through an in-line automated pan washing system. The cleaned pans are transported to an accumulation area where they are then fed back into the bread loaf panning process.

22. Metal Detector

Metal detectors are generally set up just prior to packaging after the bread product has been in contact with any metal production/processing parts. Metal detectors in industrial baking are often set up to detect a 1mm “bb” size piece of metal.

ISSUE

  • Finger splice failures

SOLUTIONS

High quality splices at a consistent thickness/density are key for metal detector conveyor belts. The consistency of the splice thickness and density to that of the rest of the belt helps to eliminate false positives or other detection errors. The Novitool® Aero® Splice Press has a unique platen design that incorporates the outer cooling zones to keep the platens level with the belt surface without sinking into the belt, creating an indentation, like other presses do.

The Novitool® Pun M™ Mobile Finger Punch can be used at the conveyor site and does not require electrical power. This can speed up the processing time of the splice, thus reducing conveyor downtime.

The Alligator® Spiral Lace Fastening System offers the lowest profile mechanical splice option and is a completely non-metallic fastener. It is a great solution for pre-made replacement belts offering a hinged splice that is quick to install, keeping critical downtime to a minimum. Available in both food grade white and food grade blue options, it is a great option for all industrial baking facilities, especially those with metal detectors.

23. slicing

Today’s inline industrial slicers use a series of band-type blades set at the spacing required to create even slices with the bread being produced. This type of slicer is quite common, with some units capable of slicing up to 100 loaves of bread per minute. In high volume bread operations running 24/7, a complete set of blades may be changed out once per week or sooner.

ISSUES

  • Modular belt failure
  • Finger splice failure

SOLUTIONS

High quality splices made quickly are key in industrial baking operations. If the bread slicing station goes down, the whole production line may be shut down. The high quality finished splice of the Novitool® Aero® Splice Press ensures the longest-lasting splice possible.

The Novitool® Pun M™ Mobile Finger Punch can be used at the conveyor site and does not require electrical power. This can speed up the processing time of the splice, thus reducing conveyor downtime.

The 845LD Belt Cutter offers a quick, safe, and accurate way to make a perfectly straight cut in a single pass. A straight cut is important in achieving a finger punch that is square to the belt edges.

All great splices begin with a perfectly squared belt end. The Laser Belt Square offers a quick and accurate way to locate a perfect belt cut reference line, every time. A square cut belt end is very important to achieving a perfect finger splice that tracks well.

24. bagging

Bagging operations can be a bottleneck area in many high production industrial baking facilities. If bagging goes down, it can have a trickle back effect, eventually causing the whole production line to stop until the bagging equipment is repaired.

ISSUE

  • Plied/PVC Urethane splice failure

SOLUTION

Some bagging machines incorporate narrow bands of plied belting to transport the loaf through the bagging system. There can be six or eight of the narrow bands feeding into the bagger. The Novitool® Aero® 325 Splice Press is the perfect solution for splicing these narrow belts.

25. Toting

Packaged bread loaves are automatically loaded into the totes via an automated loading system. When the tote has 10 or 12 loaves loaded in, it is automatically transported through the outbound conveyor system where it will be automatically stacked.

ISSUE

  • Mechanical splice failure

SOLUTIONS

When tote impact is a concern, installing the Clipper® Stainless Steel Unibar® Wire Hook Fastening System in a hybrid or hidden splice below the top ply can greatly increase splice life.

The Clipper® Roller Lacer® and Roller Lacer® Gold Class allow mechanics to install Clipper® Wire Hooks and G Series™ fasteners on wide belts often found in industrial baking operations. The added features of the Roller Lacer Gold Class allow for a 35% reduction in fastener installation, which means the conveyor can be back up and running in a shorter amount of time.

The Clipper® Wire Hook and G Series™ Belt Fastening System are the best choice for mechanically fastening live roller drive belts. The low profile of these fasteners helps to keep noise levels to a minimum. The speed of installation is critical in breakdown situations. Clipper mechanical belt fasteners are a great choice for a quick repair, even on endless belts.

High quality splices made quickly are key in industrial baking operations. The Novitool® Aero® Splice Press is the best and fastest endless splicing press available. Conveyor uptime is critical in all areas of the industrial baking operation, all the way through the packaging operation.

The Novitool® Pun M™ Mobile Finger Punch can be used at the conveyor site and does not require electrical power. This can speed up the processing time of the splice, thus reducing conveyor downtime.

The Alligator® Spiral Lace Fastening System offers the lowest profile mechanical splice option, and is a completely non-metallic fastener. It is a great solution for pre-made replacement belts, offering a hinged splice that is quick to install, keeping critical downtime to a minimum. Available in both food grade white and food grade blue options, it is a great option for all industrial baking facilities.

All great splices begin with a perfectly squared belt end. The Laser Belt Square offers a quick and accurate way to locate a perfect belt cut reference line, every time. A square cut belt end is very important to achieving a perfect finger splice that tracks well.

The 845LD Belt Cutter offers a quick, safe, and accurate way to make a perfectly straight cut in a single pass. A straight cut is important in achieving a finger punch that is square to the belt edges.

26. Tote stacking

Automated stacking of totes or racking of bread racks into rolling racks is utilized at most large industrial baking facilities. The system automatically stacks the totes to the desired number and then transports the stack down a live roller conveyor or modular belted conveyor where the stack is manually removed by a worker.

ISSUES

  • Endless splice failure
  • Mechanical fastener failure

SOLUTIONS

Clipper® Wire Hook and G Series™ Belt Fastening Systems are the best choice for mechanically fastening live roller drive belts. The low profile of these fasteners helps to keep noise levels to a minimum and the speed of installation is critical in breakdown situations. Clipper mechanical belt fasteners are a great choice for a quick repair, even on endless belts.

Clipper® G Series™ Clipper® Roller Lacer® and Roller Lacer® Gold Class™ allow mechanics to install Wire Hooks and G Series™ fasteners on wide belts often found in industrial baking operations. The added features of the Roller Lacer Gold Class allow for a 35% reduction in fastener installation, which means the conveyor can be back up and running in a shorter amount of time.

High quality splices made quickly are key in industrial baking operations. The Novitool® Aero® Splice Press is the best and fastest endless splicing press available. Conveyor uptime is critical in all areas of the industrial baking operation, all the way through the packaging operation. When a live roller drive belt needs to be replaced using an endless splice, the Aero Press is the only answer.

The Novitool® Pun M™ Mobile Finger Punch can be used at the conveyor site and does not require electrical power. This can speed up the processing time of the splice, thus reducing conveyor downtime.

All great splices begin with a perfectly squared belt end. The Laser Belt Square offers a quick and accurate way to locate a perfect belt cut reference line, every time. A square cut belt end is very important to achieving a perfect finger splice that tracks well.

The 845LD Belt Cutter offers a quick, safe, and accurate way to make a perfectly straight cut in a single pass. A straight cut is important in achieving a finger punch that is square to the belt edges.

27. shipping

The most common shipping method for bread products is tractor trailers. Industrial bakeries owned by grocery chains will have dedicated tractor trailers assigned to deliver the baked products to a central distribution warehouse. From there, the bread products will be placed on tractor trailers to deliver the product to the grocery stores served by the distribution center warehouse.