Every baker knows that dough density changes from the time it is dropped out of a mixer to the time it arrives at the divider. That is very significant when trying to measure and divide portions by volume. Ram and shear or pocket-type dividers adjust scaling by increasing or decreasing the volume of each portioning chamber. If dough density was consistent, the same size pocket would always produce the same size dough piece.
The extrusion-type dividers, with or without a metering pump, force dough through an orifice at a given flow rate. A cutoff mechanism passes through the dough stream at a desired interval, cutting a dough piece that is the inner diameter of the orifice with a length that is dictated by how often a cut is made. For example, 1" in diameter and 2" long.
Two factors contribute to scaling errors in this scenario. The first is the same as the pocket-type divider. The geometry of your portioning chamber or tube is irrelevant and the same size dough piece will almost never weigh the same. Second is the inability to keep the dough flow rate out of the cutoff orifice consistent without overworking the dough and creating heat, which contributes to changing the dough density and characteristics.
The Vision Validator is a completely integrated quality inspection and rejection system which monitors the weight, height, and color of baked bread loaves approaching the packaging area at rates of 200 pieces per minute. This system utilizes a high-precision, in-motion weighing system that incorporates non-proprietary, high-speed height and color components. Every baked loaf is inspected prior to slicing. If any criteria fall outside an acceptable range, the loaves can be rejected into a module.
The system can be adapted to any conveyor layout that precedes the wrap area, including decline and incline sections. The system provides real-time graphs for each loaf inspection to identify negative process trends. All of the inspection results are written to a text file for analysis using your preferred SPC software or our CheckManager quality analysis software. Additional inspections, such as topping coverage and disbursement, split-top verification, dimensions, and roll-over identification, can be added at any time with each inspection module. The Vision Validator inspection system is perfect for satisfying customers with the most demanding quality requirements.
Batch Manager Software
The Batch Manager Software installed on the supervisor computer allows for supervisory editing and the creating of formulas and ingredient tables. The scheduling function allows the supervisor to determine the order of formulas to be run for a production period, along with the number of batches for each formula and any partial formulas that are required. The production schedule is downloaded to the MB scaling stations to begin production.