ASTec Donut Line
Donuts are a global trend product with enormous potential for creative variations. ASTec Donut Line from RONDO combines industrial performance with the flexibility required for modern bakery product ranges. Thanks to the innovative dough band technology, donuts can be produced in many different shapes.
Does the ASTec Donut Line suit your business?
ASTec Donut Line is the ideal solution for industrial producers who prioritise maximum versatility and sustainability in the production of deep-fried pastry. It is perfect for companies that need to achieve high output rates of up to 2,000 kg per hour and at the same time want to utilise their raw materials completely. Thanks to the ability to return the dough net without any loss of quality, a wide variety of shapes such as hearts, squares or long johns can be produced on the same line while conserving resources.
Up to 2,000 kg
Output quantity
ASTec Donut Line is designed for maximum industrial performance. With working widths of up to 1,200 mm, you can achieve an impressive capacity that reduces your unit costs while guaranteeing consistent product quality.
100 % raw material efficiency
through dough return
The ASTec Donut Line produces no waste thanks to the controlled recycling of dough offcuts. Every square centrimetre of dough band is completely transformed into high-quality products, which not only protects the environment but also directly improves your margins.
Boundless
Variety of shapes
The sheeting process allows you to create a wide variety of shapes of deep-fried pastries. Whether classic donuts, jelly donuts or creative trend biscuits - you utilise the full potential for a wide, attractive range.
30,000 donuts per hour
ASTec Donut Line
With the ASTec Donut Line, you can produce delicious, high-quality donuts: industrially, with maximum efficiency and in all varieties and sizes.
Strengths of the ASTec Donut Line
Sustainability through complete dough utilisation
- Zero waste - complete recycling
- Maximum utilisation of raw materials
- Reduction of material costs
ASTec Donut Line is optimised to consistently avoid dough losses. After the donuts have been stamped, the leftover dough is recycled and gives the dough more flavour or can be reused for another donut shape. This enables production without dough waste and increases the efficiency of your entire line.
Sheeting process for more options
- High yield of end products
- Texture that stays soft for longer
- Processing of doughs with high hydration
RONDO relies on gentle dough band forming with the MIDOS system and the sheeting process for donut production. This enables the processing of softer doughs with a higher water content, which results in a more moist crumb and longer freshness. The dough structure remains so stable that the donuts show excellent rise in the simmer.
Process stability instead of manual reworking
- Exact dough band thickness across the entire width
- Shape stability thanks to precise stamping
- Constant weight
Irregular weights and shapes lead to problems in automated packaging systems. ASTec technology ensures that every donut has exactly the same thickness and geometry across the entire belt width. This guarantees you a stable process without expensive downtime or manual sorting.
Modular system for maximum variety
- Production of many shapes and sizes
- Fast response to seasonal trends
- Easy and quick change of stamping dies
Strictly designed lines often prevent the rapid introduction of new products. The modular system of the ASTec Donut Line enables quick die changes, allowing you to make full use of the dough band, for example by using Donut Holes or realising new trend shapes without major conversion.
Reduction of downtimes through optimised cleaning
- Hygienic design against dirt accumulation
- Short cleaning cycles
- Compliance with strict hygiene guidelines
Long cleaning intervals and microbiological risks are a major burden for industrial operations. The Advanced Sanitary Technology Concept (ASTec) is designed to reduce cleaning times by up to 30%. The system is designed in such a way that dirt does not stick in the first place, which massively increases your system availability.
Reproducible quality regardless of the shortage of skilled labour
- Intelligent control
- Process parameters can be called up at the touch of a button
- Constant results even with changing operating personnel
Deviations in product quality due to different operators are a risk. The ASTec Donut Line stores all relevant parameters digitally. This ensures one hundred per cent reproducibility and ensures that your donuts always achieve the accustomed top quality.
Ideal for these bakery products
ASTec Donut Line is the ultimate solution for producers who want to produce a wide range of deep-fried pastries without wasting material. Thanks to the specialised sheeting technology and efficient dough band processing, the system is ideal for producing a wide variety of shapes and textures.
How can we help you?
Dough band forming
Dough band forming
Using an extruder or the MIDOS system, the dough is formed into a homogeneous, tension-free dough band. This is gently sheeted to the desired final thickness using a satellite head, cross roller and calibrators. This process preserves the gluten structure in the dough, which is crucial for the subsequent fluffiness of the donut.
Stamping
Stamping
The desired shape is cut into the dough band using special stamping dies. This guarantees clean cut edges and an identical look for each individual product.
Residue-free dough utilisation
Residue-free dough utilisation
The remaining dough net is lifted off after stamping and returned. This means there is no waste and the dough can be applied without residue. This saves money and guarantees sustainable production.
Panning
Panning
The dough pieces are precisely aligned and placed on proofing trays. This guarantees that the donuts have optimum space to develop for the next steps.
Proofing and deep-frying
Proofing and deep-frying
In the proofing chamber, the donuts rest for approx. 40-50 minutes at 30-35 °C on swing trays. This is where the dough develops its full volume and the desired fluffy texture. They are then deep-fried at approx. 180-190 °C. Each side remains in the fat bath for around 50-60 seconds, creating the typical colouring and characteristic white edges.
Finishing and packaging
Finishing and packaging
After cooling, the donuts undergo the final production step. Depending on the variant, a filling is injected, they are glazed or decorated with toppings. Finally, depending on the requirements, a blast freezing process is carried out for quality assurance before the donuts are finally packaged.
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 Donut Line
| Capacity | 1'000 - 2'000 kg/h |
| Recommended operating time | 24 h / 365 days |
| Available line widths | 700 mm, 900 mm, 1,200 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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