European - Turkish Doner Bread Line
MAIN UNIT MACHINES COMPOSING THE MACHINE
1- KESTART DOUGH REMOVAL UNIT
2- RESTING MACHINE – WITH CONVEYOR BELT –
3- DOUGH SHAPING MACHINE
4- 1ST SERVING UNIT
5- 1ST PRESSING UNIT
6- FLAT RESTING BELT
7- 2ND SERVING UNIT (ROTATES 90 DEGREES)
8- 2ND DOUGH PRESSING UNIT
9- 3RD DOUGH PRESSING UNIT
10- 3RD SERVING (TRANSFER TO BAKING TRAYS)
PRODUCTION UP TO 180 GRAMS OF DOUGH WEIGHT
MAXIMUM 7000 PIECES/HOUR PRODUCTION CAPACITY
BREAD SIZES: SMALL DONER BREAD: 8-9cm x 22cm RECTANGULAR BREAD
KESTART DOUGH REMOVAL UNIT
The machine body and parts are made of high-quality 304-grade Chromium-Nickel CRNI stainless steel, non-rusting and non-fading, imported from Finland.
The machine can cut dough between 30-180 grams.
The machine can cut and shape up to 11,000 pieces of doner bread dough in an hour.
(Hamburger bun dough: max 10,000 pieces per hour, Sandwich bun dough: max 7,000 pieces per hour).
The “Kestart” unit has 6 belts with a length of 2300mm.
Due to using a small amount of flour during the cutting process, it creates a clean working environment.
The amount of flour added to the cut dough can be adjusted as needed.
The machine does not require continuous lubrication during the cutting process; the lubrication system is automatically adjusted.
Thanks to the pressure-free cutting of the dough, it does not damage the dough, unlike other machines (Stress-Free Dough Feature).
This machine is the main unit for all production lines, and additional units can be used with this machine to produce all types of dough.
With the cutting unit, dough can be cut into different sizes to prepare doner bread, sandwiches, hamburgers, ciabatta, tortillas, and lavash at the desired weights.
Dough Resting Machine (with Conveyor Belt)
The Dough Resting Machine consists of a total of 86 units in 6 cassettes (total dough baskets: 516 units). Of these, 70 cassettes (420 baskets) are filled and operational for sandwich, roll, and hamburger bread processing. 16 cassettes (96 baskets) remain empty and serve as a return. The machine has two discharge outlets.
For making roll bread or hamburgers, the intermediate discharge belt is activated, and the dough for these products is dropped onto the intermediate belt. This belt continues until the exit of the resting machine. For making sandwich bread or half loaves, the lower intermediate belt is deactivated. The dough directly passes through this discharge and, after circling through the resting area, reaches the final discharge belt.
Dough pieces dropping onto the 3D drop mechanism at the sandwich discharge are aligned in three rows and fed into the molding machine to create sandwich products.
When Kestart is at its minimum speed, the Dough Resting Machine operates for 6.5 minutes (6.5 minutes resting time for each batch of dough).
Part of the Dough Resting Machine’s surroundings is covered with air-void polycarbonate material. This allows for easy removal for detailed cleaning.
The dough drops onto the resting baskets according to the exit center of the 6-row belt. The Dough Resting Machine is a single-piece unit and is easy to assemble. The process of removing and attaching the baskets is straightforward.
Standard Dimensions:
Height: 2.15 cm, Length: 2.90 cm, Width: 1.10 cm
For Special High Double Resting Type: Length: 3.80 cm
Shaping (Rolling) Unit
Incoming roll dough is pre-shaped using a rotating upper belt. After pre-shaping, the dough takes its final shape on the shaping pillow. The shaping cushions can be adjusted and easily detached for cleaning. The pre-shaping belt is also used as a product flattening belt.
Length: 2.45 cm, Special Type Line: 2.45 + 19 cm = 2.26 cm.
1st Serving Unit
Dough from the first shaping unit is sent to the second intermediate resting. After approximately 8 minutes of resting, the dough is transferred to the 1st pressing unit. If the trays are not in the correct position, automatic sorting does not occur, and a warning is displayed. The number of dough pieces to be arranged in the trays can be adjusted as needed. The trays can be positioned horizontally or vertically before arranging the dough. The trays are automatically placed on the serving bed and are automatically removed after the serving process.
Length: 1.90 cm
Tray Sizes: 80 x 104 cm is the maximum size for the serving unit tray.
All tray sizes from 50×74 to 80×120 can be easily used in the serving units.
5: First Rolling Unit
In this unit, the dough is given its initial shape.
Length: 1.10 cm
6: Resting Flat Belt
From the first rolling unit, the fermented dough is spread on the resting flat belt, creating a 90-degree turn in the process.
Length: 5.10 cm
7: Second Sheeting Unit
Fermented and rested dough is simultaneously rotated 90 degrees to be sent to the second sheeting unit. For L-type lines, there is a 90-degree turn. There is no turn for straight lines. This unit does not involve automatic tray insertion or removal. Dough is transferred in this unit only for changing direction.
Length: 1.90 cm For the Straight Type European Doner Bread Line, there are 7 units in total, and this is the final serming unit.
8: Second Sheeting – Rolling Belt
Length: 1.30 cm.
The sheeting-rolling process continues to achieve the desired thickness of the product.
10: Third Dispensing (Automatic Tray Dispensing)
In this section, the dough is flattened to give the bread its final shape. Each flattening unit’s height adjustment can be customized according to the product. Length: 1.30 cm
9: Third Flattening Unit
Our machine can easily pour various types of products into trays and wooden pans of the desired size.
Thanks to the simple adjustments of our machine, it can pour onto grooved and flat trays.
The tray with the product is automatically pushed onto the pouring bed and after pouring, the full tray is automatically taken out. The pouring process does not occur unless an empty tray is inserted; the machine stops.
In case of a power outage, the machine stops, and when power is restored, it continues from where it left off.
From here, the trays are taken to the baking ovens.
Length: 1.90 cm
TOTAL PROCESS TIME: 15 – 20 MINUTES.
L Type Units Length: 22.15 cm
Flat Type Units Length: 17.65 cm
Special Type Double Resting: 23.24 cm
IMPORTANT WARNINGS!
In the Kestart machine, there is an oiling unit connected to the dough pressing system to assist. The liquid oil used here is good quality Corn Oil or specially made Kestart Liquid Oil. Other oils will definitely damage the machine and void the warranty. Preliminary work should be carried out in the customer’s workplace to create a comfortable working environment with these dimensions. The placement and operation of the machine in the workplace should be planned. The machine should be unloaded from the transport vehicle with a large forklift and then placed in the desired location inside the building using a manually controlled Transplat (at least 2.5 tons). The Loading-Unloading Instructions on the machine or packaging must be read before proceeding. The machine requires a 380 Volt power supply to operate in the workplace. During the warranty period, unauthorized intervention and the use of non-original spare parts will void the warranty.
IMPORTANCE OF KESTART OIL
It eliminates residue and stickiness in cutting devices. Using Kestart oil extends the machine’s lifespan. It reduces maintenance costs for the machine. Kestart oil contains a high amount of Oleic Acid obtained through refining. Its color is clear, colorless, or light yellow. It is not used directly for cooking. Its contact with food is not harmful to health. It is derived from Olive Oil, Hazelnut Oil, and Sunflower Oil. Research has shown that as a monounsaturated fatty acid, it reduces the risk of high blood pressure and provides protection against heart and vascular diseases by balancing cholesterol. Additionally, it has been found to reduce insulin requirements in diabetic patients and has a protective effect against certain types of cancer.