Automated pastry production: Precise, flexible and efficient
Cost-effective production of pastries calls for precise adaptation to a wide variety of shapes, fillings and dough textures. With our innovative and flexible solutions for pastry production, you can efficiently cover a wide range of products. Whether it's for artisanal operations or large-scale industrial production, RONDO is your expert partner for scalable solutions with short changeover times.
Common challenges in pastry production
Complexity of production processes
The diversity found in the pastry segment stems from the wide variety of dough textures and complex processing steps. Lamination of dough, dosing and processing of various fillings, and changeovers between different products are some of the challenges encountered in this regard.
Shortage of skilled labour
Despite the increasing level of automation, the expertise of staff remains a critical factor. Skilled personnel remain in high demand in the pastry production segment, but are hard to find. If there is a shortage of capable staff, it can be difficult to maintain the usual product quality – especially when production is running at full capacity.
Scaling pastry production
When expanding their product range, many businesses encounter space constraints. Limited space in the bakery calls for compact installations capable of producing high output volumes.
Innovative solutions for your pastry production system
Mastering product diversity with flexibility
RONDO is synonymous with versatility. With RONDO, you can produce a variety of pastries using a single machine, while benefiting from short changeover and cleaning times. As such, our make-up lines are characterised by high overall plant efficiency. At our Dough-How Centers, you can test your product ideas under real-world conditions without your production coming to a standstill.
Process reliability through intuitive operation
To help address the shortage of skilled workers, RONDO machines feature intuitive user interfaces that are easy to operate even without in-depth technical knowledge. This reduces the amount of training required when new staff join the company. What’s more, the clear user guidance system, including digital recipe management, ensures consistently high product quality.
Scalable solutions for sustainable growth
RONDO solutions offer long-term investment security because they are scalable. They range from manual dough sheeters to the fully automatic ASTec Pastry Line, designed for maximum industrial output. Regardless of the size of the business, this allows capacity and automation levels to be continuously adapted to new requirements.
The process behind industrial pastry production
Pastries are probably the most versatile category of baked goods there is. The possibilities are virtually endless when it comes to producing pastries. At RONDO, we categorise pastries according to the method of preparation. Every method of preparation involves the use of various accessories. The production process for a double-decker pastry is used here as an example of the pastry production process.
Dough preparation
Dough preparation
The base of the double-decker is made from high-quality puff pastry. The first step involves making the base dough from flour, water and salt using an industrial spiral mixer.
Dough band & lamination
Dough band & lamination
The mixed dough is formed into a continuous, uniform dough band using a dough band former. Next, butter or margarine is spread onto the dough. This can be done manually (using a dough sheeter) or automatically using a fat pump and a laminating line (e.g. MLC 4.0).
The recipe determines how many laminating runs are carried out, meaning that there could be 144 or 192 dough and fat layers, or even more than that. The process produces a laminated dough band, ready for further processing.
Length cutting
Length cutting
On a versatile cutting station, the laminated dough band is divided into several strips using a cutting roller. At the same time, a decorative pattern is cut into half of the dough strips. These form the upper part of the final product.
Filling
Filling
A filling depositor adds the desired filling, such as nut filling or jam, intermittently to the undecorated dough strips.
Sandwiching
Sandwiching
With the aid of a toboggan accessory, the decorated dough strips are guided precisely over the filled strips and set down. This is how the ‘double-decker’ structure of the pastry, from which it takes its name, is formed.
Cross cutting
Cross cutting
A guillotine cuts the double-decker products into their final shape and length with great precision and to the exact weight required.
Panning & resting
Panning & resting
Before the final step, a panning machine places the dough pieces onto a baking tray. Depending on the production process, this may be followed by a resting period to stabilise the dough structure and ensure that the pastries have a more uniform shape.
Baked or frozen
Baked or frozen
The final step involves baking the pastries in an industrial oven, before the final product is packaged and delivered to retail outlets. Alternatively, the dough pieces are delivered frozen to the point of sale and baked there.
RONDO solutions can be used to make these pastries
Superb product quality
Watch the pastry production process on our Starline 5 in this video.
Click here to request a consultation on your pastry production
Lines for producing pastries
The requirements for the production environment are just as varied as the range of pastries. While in artisanal bakeries the emphasis is often on maximum flexibility in a limited space, industrial production focuses on maximum output and automated cleaning processes (washdown). At RONDO, we help you choose the right machine to suit your capacity and shift patterns.
Artisanal pastry production
- 80 - 100 g
- 150 kg/h
Automated production of pastries
- 80 - 100 g
- 500 - 800 kg/h
Industrial pastry production
- 80 - 100 g
- > 1 t/h
- 24 h / 365 days a year
Have we piqued your interest in pastry production?
Get in touch with us. We would be happy to advise you and work with you to find the solution that best suits your needs. If you have any questions about the latest trends in pastry production, dough processing or bakery equipment for family-run bakeries, industrial bakeries or the catering industry, we are here to help.
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