PLC Controlled Automatic Simit and Poğaça Production Line
General Features
All machine faults are displayed on the screen as images and indicated with text.
The overall adjustment of the machine is done on the PLC controlled touch screen.
The working components and belts of the machine can be easily disassembled and assembled.
The machine is easily cleanable.
The machine has a complete assembly and disassembly feature.
Our machine is the only one in Turkey for dough cutting.
The line consists of 7 units. The Tray Placement unit is optional.
AUTOMATIC TRAY PLACEMENT UNIT IS NOT AVAILABLE IN THIS LINE.
1- DOUGH CUTTING SECTION
The body of the machine is made of food-safe 304 Chrome Nickel. CRNI stainless steel.
The machine has six pistons and cuts 6 pieces of dough in each stroke.
Dough weighing between 30 – 180 grams can be cut on the machine. It cuts and rounds approximately 11,000 pieces of dough per hour.
Minimal flour is used in cutting, creating a clean working environment.
The amount of flour given to the dough can be adjusted.
The machine does not require constant oil (food-grade oil) during the cutting process.
Due to minimal pressure applied to the dough, it does not cause deformation.
2- RESTING
Dough from the cutting machine is taken in sets of 6 to the intermediate resting machine. After resting, the dough is lowered to 3 and transferred to the processing section.
There are 86 sets of 6-piece dough transport cassettes in the resting section. A total of 516 dough baskets are available.
These baskets are made of food code-compliant, removable, and washable polymer material.
Out of these, 70 sets of 6-cassette (420 baskets) are filled and operational, and 16 sets of 6-cassette (96 baskets) are empty and for return.
The cassettes are made of polymer files.
The minimum resting time is 3 minutes.
There are transition belts under the resting cassettes.
When resting is not used, these belts are used to directly transfer dough from cutting.
3- SHAPING UNIT
Here, the dough takes its initial shape for the intended product.
In the shaping unit, simit dough is turned into a cord shape and taken to the processing belt.
Sandwich dough also takes its final shape on the processing belt.
Roll and hamburger dough are transferred to the processing belt without further shaping.
4- ROLLING & MARKING UNIT
The dough from the dough cutting section is brought here for initial shaping.
The dough is initially rolled and shaped using rolling and marking rolls.
A marking is made on the dough here for filling the poğaça.
5- PROCESSING BELT
This belt consists of two stacked belts.
The lower belt can be manufactured between 2 to 6 meters as needed.
The lower belt is an empty belt with working tables.
Manual work for shaping simit and poğaça dough from previous sections is done on these tables.
The products that have taken their final shape are placed on the upper transport belt.
The upper transport belt is mainly used in simit production.
Simit tying process is done on this belt, and they are transferred to the syruping section.
Both belts are made of white PVC and are extremely easy to clean. Wet cleaning can be performed.
The entire chassis of the belt is made of stainless steel and does not tarnish, CRNI Stainless Steel made from Finland.
6- SYRUPING UNIT
- The syruping process of the simits coming from the upper conveyor belt is carried out in this section.
- The system consists of a syrup waterfall and two fans.
- The circulation of the syrup is maintained by a single lob pump. This pump does not create foam in the syrup and does not alter its properties.
- The simits come from the conveyor belt and are transported on a wire belt under the syrup waterfall. Under the syrup waterfall, there is an overflow section. The dripping syrup from here moistens the bottom of the simits.
- Simit’s that have been syruped move to a second wire belt. An additional blowing fan on this belt helps drain excess syrup from the upper surface of the simit.
- As the simits from the second belt transition to the third belt, they flip over. On this belt, excess syrup on the bottom side of the simit is drained.
- This process ensures minimal consumption of syrup and enhances the appearance of the simits.
- All bearings and components of the syruping machine are made of stainless steel and are resistant to rust.
- Sealing gaskets prevent syrup from leaking outside the machine.
7- SESAME SEED DISPENSING TRAY
- This unit used in simit production is entirely made of stainless steel.
- It consists of a round tray that rotates around a single axis.
- Simit’s coming from the syruping unit fall into this tray, and a staff member mixes them with sesame seeds.
- It mechanically arranges them in the baking tray for baking.
IMPORTANT WARNINGS!
The dough pressing system in the cutting machine is aided by an automated oiling unit. The liquid oil used here is good quality Corn Oil or specially made Kestart Liquid Oil. Using other oils may cause damage to the machine and void the warranty.
The customer must prepare a comfortable working environment of these dimensions in their workplace. The placement of the machine in the workplace should be planned. The machine is unloaded from the transport vehicle using a large forklift and then manually directed using a hand-operated Transplat (at least 2.5-ton capacity) to the desired location inside the building. No action should be taken without reading the Loading-Unloading Instructions written on the machine or its packaging. The machine requires a 380 Volt power supply to operate in the workplace.
Unauthorized intervention and the use of non-original spare parts during the warranty period will void the warranty.
The Importance of Kestart Oil
- Eliminates residue and stickiness in the cutting apparatus.
- Extends the machine’s lifespan.
- Reduces maintenance costs for the machine.
- Kestart oil contains a high proportion of highly purified Oleic Acid. It has a clear, colorless or light yellow color. It is not used directly in cooking but its contact with food is not harmful. It is extracted from Olive Oil, Hazelnut Oil, and Sunflower Oil.
- Research has shown that Kestart oil reduces the risk of high blood pressure by balancing cholesterol, providing protection against heart and vascular diseases. Additionally, it reduces the insulin needs of diabetic patients and has a protective effect against certain types of cancers.