ASTec Pastry Line
ASTec Pastry Line combines RONDO's leading laminating technology with a modular design that enables the production of an almost unlimited variety of pastries. From classic puff pastry to modern trend products, this line offers the technical precision required for consistently high quality on an industrial scale.
Does the ASTec Pastry Line suit your business?
ASTec Pastry Line is the right choice for industrial companies looking for a multifunctional solution. It is ideal if you want to produce not just a standard product, but a variety of shapes, sizes and fillings on a single system. Whether classic doughs or gluten-free baked goods - the design of the line is tailored to the special requirements of laminated doughs with their dough-fat layers and guarantees a smooth process.
Maximum
Product range diversity
Thanks to the modular design and a wide range of accessories such as rollers, stamping dies, dusters and decorative elements, you can expand your range at any time without having to invest in a completely new line.
30 % less
cleaning effort
The consistent ASTec hygiene design with open profiles and minimised horizontal surfaces drastically reduces the cleaning effort and increases system availability.
Rapid changeover
of the products
Accessories can be exchanged quickly and easily. The automatic detection of accessories saves valuable set-up time so that the production of product variants can start immediately and highly efficiently.
Strengths of the ASTec Pastry Line
Assortment flexibility thanks to modular design
- Fast adaptation to market trends
- Easy integration of accessories
- Minimised changeover times
The modular design and a wide range of accessories enable the production of classic puff pastries through to complex filled baked goods. This ensures your investment in the long term, as you can respond to new consumer requirements at any time.
Artisanal quality on an industrial scale
- Stress-free dough band reduction
- Structure retention
- First-class volume and texture
Despite high industrial production capacities, the ASTec Pastry Line treats the dough band as gently as in artisan production. By using satellite heads, the dough is gently reduced in many small steps. The result is an undamaged dough structure with a characteristic, airy flaking.
Process reliability and weight accuracy
- Continuous monitoring of the material flow
- Servo drive technology for precise control
- Minimum tolerances
The combination of state-of-the-art sensor technology and ASTec Process Control enables you to achieve exceptional process stability. The intelligent automatic system recognises irregularities and independently adjusts the speed to the dough conditions. This not only significantly reduces the reject rate, but also ensures a reliable calculation basis and absolutely homogeneous product quality, even with unskilled personnel.
Increased efficiency due to reduced cleaning effort
- Hygienic design
- Up to 30 % less cleaning time
- Higher system availability
The Advanced Sanitary Technology Concept (ASTec) is directly integrated into the mechanical structure of the line. No dead spaces and a design that consistently avoids dirt deposits enable radically shorter cleaning times. The resulting time gain flows directly back into your productive time, which noticeably increases overall equipment effectiveness (OEE) and reduces ongoing operating costs.
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Mastering complex recipes and speciality products
- Laminating expertise
- Gluten-free competence
- Development of niche products
Our comprehensive expertise (Dough-how) in dough behaviour allows us to process even sensitive laminated doughs reliably. Whether classic puff pastry or the growing market for gluten-free specialities - the ASTec Pastry Line is designed to ensure consistent quality even with sensitive recipes. This allows you to serve specialised market niches with industrial precision.
Technological edge thanks to RONDO Dough-how
- Close cooperation with product development
- Faster time-to-market
- Individual training
With RONDO, you are opting for more than just a machine: together with your product development team, we realise new products or adapt existing recipes. Our master bakers also support you in optimising your processes directly at the machine on your premises or in one of our Dough-how Centres. Thanks to this collaboration, products can be realised faster. It also ensures that your system is optimally matched to your raw materials and quality requirements right from day one.
Ideal for these baked goods
ASTec Pastry Line is the perfect choice for all filled and unfilled pastry variations - from classic Danish pastries and puff pastry pieces to savoury snacks and gluten-free specialities.
How can we help you?
Production process of the ASTec Pastry Line
Dough band forming
Dough band forming
Once the dough has been produced, an endless dough band is created. Using a standard extruder or the MIDOS system, the dough band is formed without tension. This is crucial for controlling the viscosity of the dough - especially for demanding recipes such as gluten-free doughs.
Fat pump and laminating
Fat pump and laminating
For laminated pastries, a precise layer of fat (butter or margarine) is applied to the dough band using a fat pump and then folded into the dough. Next, the dough and fat are layered to the desired number of layers. In the first station, RONDO usually uses efficient fan folding. For the highest industrial demands on uniform layering, we integrate Cut and Stack to guarantee absolutely even layer distribution right up to the edges of the belt.
Gradual dough thickness reduction
Gradual dough thickness reduction
The layered laminated dough blocks are gently rolled out by satellite heads in many small steps to form an even dough band. In contrast to conventional rollers, the layered structure is not squashed, resulting in a beautifully laminated end product.
Cross roller and calibration
Cross roller and calibration
The cross roller sheets the dough band to the required working width. The final calibratior ensures a homogeneous dough thickness across the entire band width - the basic prerequisite for minimising weight tolerances.
Cutting, stamping and separating
Cutting, stamping and separating
The dough band is divided into strips by longitudinal cutting rollers and, if necessary, formed into specific shapes (e.g. circles or squares) using stamping tools. Mechanical separation ensures that the dough pieces are precisely positioned and separated for the subsequent steps.
Filling (optional)
Filling (optional)
The precise filling depositors apply fillings (creams, chunks, savoury fillings) with pinpoint accuracy. The RONDO technology prevents a smearing effect, which means that the edges of the dough remain clean and close perfectly when subsequently folded.
Folding, forming and rolling up
Folding, forming and rolling up
The process step is designed for versatility. Thanks to the modular design, a wide variety of pastry variants can be produced - from rolling into snails, double-decker products, folding or even cutting in complicated decorative elements. This flexibility allows you to reliably reproduce a wide range of make-up processes on a single system and agilely switch your production to new variants or complex product designs at any time.
Finishing and depositing
Finishing and depositing
In the final step, the products are finished by spraying (e.g. egg glaze) or seeding (seeds, granulated sugar). The dough pieces are then placed on trays or freezer belts in an exact line pattern, ready for proofing, baking or shock freezing.
Dough-how Services: Process optimisation and technological support
In our Dough-how Centres, we offer you the opportunity to test your recipes under real conditions and develop them to market maturity. Our Dough-how experts support you directly on site with process optimisation and individual training on the system. The goal: consistently high baked goods quality, maximum dough band utilisation and resource-saving production. From the kneading process to baking, every step is analysed in order to sustainably increase efficiency.
ASTec: The standard for future-proof hygiene
The Advanced Sanitary Technology concept (ASTec) from RONDO is the answer to the constantly increasing requirements for industrial food safety and offers you decisive technological progress. Depending on the production environment, the system is available in two specialised versions: ASTec Dry (D) for efficient dry cleaning and ASTec Wet (W) for processes that require intensive wet cleaning. Both versions are consistently constructed according to hygienic design guidelines to prevent dirt deposits and minimise downtimes.
Technical data
Astec Pastry Line
| Capacity | 1'000 - 3'500 kg/h |
| Recommended operating time | 24 h / 365 days |
| Available line widths | 700 mm, 900 mm, 1,200 mm, 1,500 mm |
ASTec Process Control: The intelligence behind your productivity
In a market environment where precision and speed are the key to success, ASTec Process Control (APC) is redefining the control of industrial lines. As the intelligent heart of your production, APC integrates state-of-the-art sensor technology and real-time analyses to guarantee absolutely stable and high-performance production - around the clock.
Have we aroused your interest?
Get in touch with us. We will be happy to advise you on which solution suits your needs.
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