ASTec Croissant Line
RONDO is one of the global leaders in laminating technology and bundles this comprehensive expertise in the ASTec Croissant Line. The line processes laminated dough with high precision and to the highest hygiene standards, consistently preserving the sensitive fat layers. From classic butter croissants to filled specialities, the line delivers consistent product quality with maximum efficiency.
Does the ASTec Croissant Line suit your business?
ASTec Croissant Line is designed for industrial bakeries that want to combine high production volumes with strict hygiene standards. If you value gentle dough processing to guarantee the characteristic layering of your croissants, this line offers the right technological basis. Its modular design and multi-shift operation make it suitable for companies that want to scale their capacities and minimise cleaning times at the same time.
Up to 150,000 croissants
per hour
The ASTec Croissant Line is designed for maximum industrial output. Thanks to the precise circular cutting roller and the precise synchronisation of the curling units, it processes every product with consistent shape accuracy, even with this quantity.
30 % time saving
during cleaning
The ASTec hygiene concept massively reduces manual labour. Thanks to open profiles, the absence of horizontal surfaces and easy accessibility, you save almost a third of the time per cleaning cycle, which directly increases the effective production time of your system. In addition, the user interface guides you step by step through the cleaning process.
Fastest
product changeovers
Flexibility is of crucial importance in modern production. The sophisticated design and recipe management of the new 22-inch HMI enables a complete product changeover in just a few steps. Thanks to ASTec Process Control, speeds and thickness are automatically adjusted to the new product. The HMI guides the operator through the settings for the new product.
Innovative, modular, efficient
RONDO Croissant System
Experience the unique functional principle of the highly efficient and modular RONDO Croissant System in the 3D video. Double your production capacity and reduce your operating costs at the same time.
Strengths of the ASTec Croissant Line
Gentle lamination - distinctive layering
- Maintaining the dough structure
- Uniform dough band
- Temperature stability
In croissant production, the quality of the lamination as well as resting and cooling phases are crucial. The ASTec Croissant Line processes the dough band in such a way that the fine layers of dough and fat are precisely preserved. This contributes to a fluffy texture and the desired volume of the end product after baking.
Maximum flexibility for filled products
- Precise filling depositor
- High modularity for a wide range of curled products
- Ease of maintenance
ASTec Croissant Line adapts to your requirements. The high level of flexibility enables process-reliable production of a wide range of curled croissant variants. By integrating a high-performance filling depositor, you can produce complex specialities with precise dosing - whether sweet or savoury. The sophisticated design not only ensures fast changeover between different products, but also guarantees maximum ease of maintenance and durability in continuous industrial use.
High-performance curling unit for perfect end products
- Individual curling pressure
- Varied shapes
- Process-stable depositing
The curling process has a decisive influence on the appearance of the croissant. Thanks to its precise adjustment options, the ASTec Croissant Line enables the production of a wide variety of croissant types - from the classic, straight curled shape to the traditionally bended croissant using an integrated bending unit. The mechanical stability of the units ensures that the shaping remains stable even at high speeds.
Precise cutting and positioning
- Exact cutting edges
- Reliable turning
- Easy format changeover
The cutting unit works with high repeat accuracy to ensure identical dimensions of the dough pieces. This reduces rejects and rework to a minimum. The integrated turning unit positions the triangles precisely for the curling process, which forms the basis for uniform baking results and optimised volume of the croissants.
High process reliability thanks to automated belt management
- Synchronised belt speeds
- Controlled dough tension
- Minimised mechanical stress
ASTec Croissant Line uses an intelligent control system that perfectly coordinates all conveyor belts. This drastically reduces dough band cracks and deformations. You receive an absolutely uniform end product and avoid unplanned line stops, which massively increases the overall effectiveness of your system (OEE).
Durability and ease of maintenance
- Low-wear components
- Fast and easy component replacement
- Preventive maintenance support
In high-performance production, downtime is the biggest cost factor. The design of the ASTec lines is based on robust mechanics for continuous use. The easy access to all maintenance-relevant parts reduces technical downtimes to a minimum. You benefit from low total operating costs (total cost of ownership) and an investment that will reliably deliver maximum output rates for many years to come.
Ideal for these baked goods
Our industrial croissant line is ideal for the production of croissants in all designs and regional variations - whether filled or unfilled, straight, bended or individually shaped. Your creativity starts here!
How can we help you?
The industrial croissant production process on the ASTec Croissant Line
Dough band forming
Dough band forming
Depending on the recipe and the desired dough structure, the dough band is formed by a standard extruder (for classic doughs) or by the MIDOS system (for particularly soft doughs or doughs with a high water content). The aim is to achieve an absolutely tension-free and homogeneous dough band.
Learn more about MIDOSCooling (optional)
Cooling (optional)
The cooling chamber can be installed in the laminating or sheeting process to ensure perfect layering and improve the flavour and aroma of the end products.
Fat pump
Fat pump
Continuous supply of fat (margarine or butter) by means of a fat pump. The patented RONDO laminating process ensures that the fat layers are precisely incorporated between the dough layers and do not soak into the dough.
Gentle dough thickness reduction
Gentle dough thickness reduction
A satellite head is used to bring the dough-fat package to the desired final thickness. The large diameter of the satellite head prevents the layer structure from tearing or the fat from being pressed into the dough.
Lamination
Lamination
This is the centrepiece of our technology. The desired number of dough and fat layers (e.g. 24, 36 or more) is created by precise folding. Various folding technologies are used to create the desired end product: fan folding as a cost-efficient and simple solution or Cut and Stack for maximum uniformity.
Cross roller and calibration
Cross roller and calibration
The cross roller ensures the exact band width and relaxes the dough in the cross direction for maximum dimensional accuracy. The subsequent calibrating unit guarantees a constant thickness across the entire width - the basis for high weight accuracy and minimised losses.
Cutting and separating
Cutting and separating
The dough band is cut into longitudinal strips and then into shapes such as triangles. Immediately afterwards, it is mechanically separated and turned to ensure that the dough pieces are uniformly aligned for further processing and do not stick together at the edges.
Filling (optional)
Filling (optional)
The RONDO filling depositor works with the highest filling quantity precision and guarantees a clean application of the filling. By consistently avoiding an undesirable smearing effect, the edges of the dough remain absolutely clean. This not only optimises hygiene, but also ensures that the products are perfectly sealed.
Curling and bending
Curling and bending
The precise curnling unit curls the croissants into the desired shape, while a bending unit optionally bends them into the desired shape. The ASTec Croissant Line can curl up to 150,000 pieces per hour - with a guaranteed consistent appearance and maximum repeat accuracy for every product variant.
Finishing and further processing
Finishing and further processing
After curling, the croissants are finalised for the market. They are then placed on trays or freezer belts in a line pattern. The ASTec Croissant Line supports all strategies: from green frozen and pre-proofed to part-baked or fully baked products. Thanks to this precise control, the pastry volume remains untouched until the final step and you remain flexible for all market trends.
Inspiration & insights
Get an up-to-date insight into the world of RONDO: with success stories, customer portraits and product news.
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 Croissant Line
| Capacity | 1'000 - 3'000 kg/h |
| Recommended operating time | 24 h / 365 days |
| Available line widths | 700 mm, 900 mm, 1,200 mm |
Our innovative dough band former
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.
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Get in touch with us. We will be happy to advise you on which solution suits your needs.
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