PLC Controlled Automatic Simit Production Line
General Features
All machine faults are displayed on the screen in both images and text for notification.
The overall adjustment of the machine is done on a PLC controlled touch screen.
The working components and belts of the machine can be easily removed and replaced.
The machine is easy to clean.
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. Tava Serme unit is optional.
THERE IS NO AUTOMATIC SERME UNIT IN THIS LINE.
1- KESTART – DOUGH CUTTING SECTION
The body of the machine is made of food-grade 304 Chrome Nickel. CRNI stainless steel.
The machine is six-piston and cuts 6 doughs in each stroke.
Dough between 30 -180 grams can be cut in the machine. It cuts and rounds an average of 11,000 doughs per hour.
Minimal flour is used during cutting, creating a clean working environment.
The amount of flour given to the dough can be adjusted.
The machine does not require continuous oil (food-grade oil) during the cutting process.
Due to the low pressure applied to the dough, it does not cause deformation during cutting.
2- RESTING
In the interim resting machine, 6 doughs from the cutting machine are placed into the tins and rested. After resting, the dough is transferred to the processing section, with the dough divided into three.
There are 86 sets of 6-dough transport cassettes in resting. There are a total of 516 dough baskets.
These baskets are made of food-grade compliant, removable, and washable polymer material.
Out of these, 70 sets of 6-cassette (420 basket) work full, and 16 sets of 6 (96 basket) are empty return trays.
The trays are made of polymer filaments.
The minimum resting time is 3 minutes.
There are transfer belts under the resting trays.
When resting is not used, these belts are used for the direct passage of the dough coming from cutting.
3- SHAPING UNIT
Doughs take on the initial shape of the product here.
In the shaping unit, simit doughs are turned into threads and transferred to the processing belt.
Sandwich doughs also take their final shape on the processing belt.
Roll and Hamburger doughs are transferred for resting without processing on the belt.
4- ROLLING-INDENTATION UNIT
Doughs from Kestart are brought here for initial shaping.
The dough takes its shape by rolling and creating indentations on it.
Indentations are made on the dough for filling pastries.
5- PROCESSING BELT
- This belt consists of two belts stacked on top of each other.
- The lower belt can be manufactured between 2 to 6 meters according to the need.
- The lower belt is an empty belt with worktables.
Manual labor for simit and pastry dough from previous sections is done on these tables. - The final shaped products are placed on the upper conveyor belt.
The upper conveyor belt is generally used for simit production. - Simit tying process is performed on this belt and transferred to the syruping section.
- Both belts are made of white PVC and are extremely easy to clean. Wet cleaning process can be applied.
- The entire chassis of the belt is made of non-corrosive and non-staining CRNI Stanless Steel from Finland.
6- SYRUPING UNIT
- The syruping process of simits coming from the upper conveyor belt is done in this section.
- The system consists of a syrup cascade and two fans.
- The circulation of the syrup is maintained by a lob pump. This pump does not froth the syrup and does not lose its properties.
- Simit come from the conveyor belt and are transported on a wire belt under the syrup cascade. Under the syrup cascade, there is an overflow section. The dripping syrup here wets the bottom of the simit.
- Syruped simits pass onto a second wire belt. An additional blowing fan on this belt helps drain excess syrup from the upper surface of the simit.
- As simits from the second belt transition to the third belt, they flip over. On this belt, excess syrup from the bottom of the simit is drained.
- This ensures minimal consumption of syrup and improves the appearance of the simits.
- All bearings and components of the syruping machine are made of stainless steel and are corrosion-resistant.
- Seal gaskets prevent the syrup from leaking out of the machine.
7- SESAME TRAY
This unit used in simit production is entirely made of stainless steel.
It consists of a circular tray that rotates around a single axis.
Simit from the syruping unit falls into this tray, and a staff member mixes them with sesame. It mechanically arranges them onto the baking tray.
IMPORTANT NOTICES!
- 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 can damage the machine and void the warranty.
- The customer should prepare a comfortable working environment of these dimensions at their workplace. The placement of the machine at the workplace should be planned. The machine is unloaded from the transport vehicle using a large forklift, and then manually controlled using a Transplat (minimum 2.5 tons) to place it in 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 be available at the workplace.
- Unauthorized intervention and the use of non-original spare parts during the warranty period will void the warranty.
Importance of Kestart Oil
- Eliminates residues and stickiness in cutting mechanisms.
- Extends the machine’s lifespan.
- Reduces machine maintenance costs.
- Kestart oil contains a high percentage of highly-refined 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 derived from olive oil, hazelnut oil, and sunflower oil.
- Research has shown that Kestart oil reduces the risk of high blood pressure, balances cholesterol, and provides protection against cardiovascular diseases. Additionally, it reduces insulin requirements in diabetes patients and has a protective effect against certain types of cancer.