Fully automatic production of bread and rolls

OSCAR (“0” – Stress Calibrating Adjustable Rollers)
In a manner of speaking, the heart of the system is the RONDO bread dough-sheet pre-former OSCAR. The dough sheet pre-former patented by RONDO meets the required high standards with regard to gentle discharge of pre-leavened, highly hydrated doughs. As the OSCAR touches the dough as little as possible during forming of the dough sheet and the properties of the gluten structure are not changed, it guarantees the highest quality of the products.

Its main features are:

• Two hexagonal rollers that carefully draw the dough out of the small hopper and feed it to the two finely grooved rollers.
• Two flour dusters that apply flour to the rollers to prevent the dough from sticking
• Two pressing paddles that set the dough sheet to the desired width using oscillating movements
• A satellite head with 10 freely rotating upper rollers and, unique on the market, with two lower rollers. Thanks to the two lower rollers integrated in the system, two-stage rolling of the dough sheet is achieved before the traverse roller. This reduces the rolling force and preserves the gluten structure.

Cross roller
The cross roller is used primarily to set the dough width, whereby a side effect is that the dough tension is additionally reduced. It is important here that the cross roller leaves no traces on the dough sheet. For this reason, the RONDO cross roller has a very large chamfer on the feed side. The large diameter helps improve the degree of shaping.

Calibrating unit
To get the dough sheet to the desired final thickness, the dough sheet runs through one calibrating unit or two calibrating units.

• Diameter or the rollers: 220 mm
• Roller gap: 0.5 – 20 mm
• The dough thickness can be set using the handwinding wheel of the modern control system.
• Maximum degree of shaping: 2:1

Slitting and spreading
Calibration is followed by the shaping and designing of the product itself. Slitting cutters cut the dough sheet into strips and these are then fed on the downstream separation belt to the guillotine. The separation belts are very easy to set and setting requires no tools. Templates ensure the correct position of the separation belts in the event of product changes.

Guillotine
The guillotine is used to cut the products to the desired length. Guillotines made by RONDO are travelling guillotines and can also be used with different stamps with round, oval and other shapes. As required, different cutting technologies can be used to stamp tapered baguettes or also round baguettes in the guillotine. The high-performance industrial guillotines achieve stroke rates of significantly higher than 120 strokes per minute.

Seeding unit
Everyone knows how popular and healthy wholemeal seed rolls are. The RONDO seeding system can be used to apply seeds to the top and bottom of rolls, depending on the size. Water is applied to the surfaces so that the seeds adhere. As an option, RONDO offers an automatic seed return to the hopper. The entire system is mounted on wheels, which means it is very easy to integrate into the line or move away.

Moulding system for baguettes and sandwiches
If you want to produce long-moulded types of bread such as baguettes, hot dog rolls or rolled bread, you use the RONDO long-moulding system. Interchangeable moulding plates enable a wide variety of shapes to be produced in the long-moulding system, for example tapered baguettes or round baguettes. The long-moulding system is moveable and can easily be replaced by the seeding unit or an intermediate conveyor belt.

Panning
Depending on the product, whether rectangular ciabattas or moulded baguettes, various panning systems are used. The classical drawing-off tables are used above all for cut or stamped products. For baguettes or other rolled products, accurately positioned panning is important. This panning system is integrated in the long-moulding system; it places the products accurately in recessed baking trays.