Fully automatic dough band production
The quality of laminated puff pastry and Danish pastry dough products depends heavily on the laminating technology that is used. Factors such as the degree of shaping, design of the fat pump, satellite heads and traverse rollers as well as the number of calibrating units deployed are of decisive significance here.
As a general principle, it can be said: the less energy applied to the dough sheet during the laminating process, the better the quality of the dough sheet and thus of the final product. RONDO has taken account of this fact to a great extent in the design of its industrial laminating lines and configured the individual components in such a way that the energy applied is kept to a minimum.
Industrial dough band formers
Different doughs require different dough sheet pre-formers. This is why the corresponding dough sheet pre-formers are used depending on whether a classical base dough for puff pastry or soft yeast doughs are involved.
Three-roll dough band former
The RONDO triple-roller dough sheet pre-former is used for firmer doughs such as the classical yeast-free base dough for puff pastries.
It features:
- Large roller diameter
- Two grooved and one ground roller
- Individually adjustable upper and lower roller gap
- Separately driven upper and lower rollers
OSCAR (“0” – Stress Calibrating Adjustable Rollers)
The RONDO dough sheet pre-former OSCAR is used for soft yeast, Danish or croissant doughs. This is a system patented by RONDO that discharges the dough extremely gently. The main focus here is on avoiding a negative influence on the gluten structure during discharge.
The main features of this machine 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, a unique feature, with two lower rollers (RONDO patent).
Fat pump
The fat pump is a key element of the laminating line. RONDO makes sure that a system is used in which the fat is heated a little as possible during the entire discharge process. The blocks of fat are fed continuously by means of a pneumatic cylinder to the mono pump. This presses the fat through a tube to the fat dispenser, where the fat is applied to the dough sheet that is running underneath according to the set fat thickness. The generous dimensions and the combination of pneumatic cylinder and mono pump result in only very low fat warming.
Satellite head with one or two lower rollers
Depending on the position (first section or second and third section) within the laminating line, RONDO uses satellite systems with one lower roller or two lower rollers. Compared to those of other manufacturers, RONDO satellite heads have the largest outer diameter. This results in a uniquely flat approach angle during the rolling process, which means less energy is applied to the dough. After formation of the layers (second section), RONDO uses the satellite head with two lower rollers (RONDO patent). This rolling technique delivers the gentlest dough reduction on the market. The technology is the core element of the industrial system, guaranteeing faultless laminating and thus very high quality of the finished products.
Folding device
The folding device is used to form between four and twelve clean layers. Depending on what you want and on the dough conveying process, RONDO can offer various folding systems.
- Vertical folding device, suitable for most types of dough
- Vertical folding device with integrated guiding conveyor belts, used above all for soft doughs.
- Folding with drawing-off table. Before drawing-off, the dough sheet is cut with a guillotine and the dough pieces created in this way are placed one on top of the other with the drawing-off table.
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 a number of calibrating units. Depending on the desired product quality, but above all in the case of high belt speeds, between one and three calibrating units are used.
ModularityThe RONDO laminating line can be set up in a wide variety of variants. Depending on the type of production and the given space available, a large number of solutions are possible, for example the classical U-shaped or L-shaped laminating line. Other designs are the Z shape, laminating in a line or the orbital version in which blocks are deposited by hand.
