The equipment for manufacture of pastry confectionery (confectionery pancakes)

     Manufacture and sale of equipment
     One of the lines of  Ltd "PCG «Lesnaya Skazka» activity is working out and sale of equipment for the confectionery enterprises. In 2010 the line on manufacture of pancakes has been developed and established at our enterprise. For today the line is successfully maintained, brings in stable income and shows short time of outlay recovery. As a result of successful realization of the project the decision on manufacture and sale of the given equipment outside of Ukraine was accepted.

     “Lesnaya skazka” – it is a company that was established in 1998. During the years of our existence, we have travelled all the way from a small workshop to a large confectionary undertaking. Our undertaking produces more than 80 output articles, including “chewing marsh-mellow” which is exclusive for the CIS market. At present, output of our undertaking is presented in all regions of Ukraine, 27 regions of Russia, and also in Byelorussia, Moldova, Georgia, Azerbaijan, Lithuania and Latvia. Also the company is actively occupied with production, fettling and further selling of its equipment.

     Since October 2010 our undertaking produces, at the equipment that was made by us, an exclusive product for Ukrainian market – confectionary pancake “Pancake”. During the first five months of the work we were a success to reach the maximum power of our new line, without exceeding the bounds of Ukrainian confectionary market.

     It is that exactly equipment which our company considers as an effective investment, we would like to offer to your firm.

     Type - the line to produce flour confectionery with filling

• item “Confectionary pancake”
• capability 240 kg per hour, 4800 pieces per hour
• baking time 95 -120 sec
• average weight of one article 55gr
• size Ø 70 – 90 mm
• dimensions of the main machine 9,5 x 1,9 x 1,5 m
• maximum gas consumption 15 cubes per hour

     I. PRELIMINARY ECONOMIC DESIGN IN LESS DETAILS

     Taking into consideration cost of the raw materials on the Russian market (flavor – 10.30, pasteurized egg mixture – 60.50, sugar – 30.80, fruit paste – 29.00), also salaries, energy materials cost in the RF and its delivery within the 500 km zone,  the cost price of one kilo of production, according to our recipe, will be 66.98 rubles.

     With breakeven of 22.00 rubles the outgoing price to the distributor will be 88.98 rubles.

     With distributor up charge of 25% and shop up charge of 30%, the cost for the confectionary pancake “Pancake” in the shop will be 144.59 rubles.

     Basing on experimental selling in the RF (15 kg from the one shop per month) we can state that in order to sale out the planned production capacity of the line it is necessary to cover around 8 400 shops, at the same time line payback will be 5,5 months. With line work for 55% from the planned production capacity the output make up 70 ton per month – line payback is 10 months.

     Taking into consideration additional equipment cost and premise preparation for line installation, project payback may rise to a year and a half.

     If necessary, our company is ready to prepare line installation economic ground additionally and individually, taking into consideration the readings and rates in yours particular undertaking.

     II. LINE INTEGRATION

     The line to produce flour confectionery is designed for automatic mass line production of flour confectionery with jam, paste, fruit paste filling. The technological process includes articles baking, their filling and sandwich forming operations.
The line consists of baking machine and sandwich-machine.

     The baking machine bakes the articles automatically when periodically putting dough doses on the heated stoving surface of the copper plates.

     Transfer conveyor transfers the pastry to the sandwich-machine, where the special device coats one of the product with filling, covers it with the second product, levels the top and the bottom pieces and forms the sandwich.

     1. The backing machine.

     The backing conveyor is equipped with the copper furnace plates which are heated by the means of top and bottom gas infrared radiant burners (IRB).

     The temperature of the stoving plates surface is measured with temperature sensor and is automatically kept up within the preset limits by the gas feed valve adjustment. Baking time range: 95 – 120 seconds. Preset temperatures range: 180 - 210°C.

     Dough depositor is situated above baking conveyor. It is equipped with funnel from the stainless steel. For preventing from dough overheating the funnel has 2 layers construction and is connected to the external system of water cooling. The depositor is equipped with the independent electrical drive.

     Dough is loaded by portions to the depositor funnel manually or automatically.

     Dough level is controlled by sight.

     Dough is portioned on the furnace plates. Dough portion is previously regulated to the required article extend manually, in the range from 15 to 30 gr. Portion weight deviation: not more than 2,5%. All the details of the depositor that have contact with products are made from the stainless steel. On the work completion the machine is easily disassembled in order to be cleaned and washed without any special tools. In order to transfer the machine to the washing zone the line is equipped with special truck.

     Baking machine heating system consists of bottom and top gas burners. Heating system is equipped with automation, adjustment and security blocks. Work of the heating system is agreed with the arranged combustion products outlet system during:

• Gas pressure before burners increasing or decreasing
• Flame extinction in the burners
• Indicator actuation of the gassed premise
• Voltage absence in the control unit
• Fault in the control unit.

     Turning-over device turns over the products for baking on both sides automatically.

     The release with the air stream push releases the pastry from the baking machine conveyor to the transmission conveyor. The products come to the conveyor on the reverse side.

     Transmission conveyor transfers the pastry that has been removed from the baking machine plates by the release to the inverter. The conveyor has an independent drive, stainless steel construction and plastic heat-resistant belt that is 1250mm width.

     Roller brush automatically removes the stuck, burnt dough from the furnace plates. The brush rotates constantly and cleans the furnace plates at the section of their return motion. Brush motor works independently.

     Oil spray unit is fixed on the frame of the baking machine. The oil with the help of the compressed air is sprayed on the furnace plates. The quantity of the sprayed oil is adjusted by time slice of the oil spray (coating) specification.

     Oil puller device is actuated from the independent motor. Oil puller device is designed for proportional oil distribution on the furnace plates’ surface in order to create thin and uniform oil layer for the guarantee of high-quality pastry and their secure separation from the plates.

     2. Sandwich-machine

     Inverter is designed for preliminary products positioning execution before their supply to the sandwich-machine.

     From the transmission conveyor belt the products come to the inverter conveyer belts.

     In the following device the leveled products are rearranged automatically in two rows for 6 pieces. Then the rows move to the sandwich-machine.

     Filling depositor with the stainless steel funnel is installed over the sandwich-machine conveyor which operates independently. The depositor provides the coating on the baked products of the preset size of the filling. The depositor can work with jam, pasta, cream, condensed milk. Dose adjustment is carried out manually. The size of particles (granules) in the filling should not exceed 5x5mm. Dose range: from 10 to 20gr. Dose weight deviation: approximately +/- 1,2% (depending on the kind of the filling). The machine is filled with portions manually or in the other way. Filling level is controlled visually. The machine is easily disassembled in order to be cleaned and washed without any special tools.

     Thermal punch unit provides products surface marking with the given pattern or drawing. It is driven with the pneumocylinder and is heated by electrical ten.

     Then the products come through conveyor to the sandwich-forming unit which sequentially through the row with the help of the vacuum take lifts the raw of the products that are lying the right side up and  put them on the corresponding rows of the products with the filling.

     Product edge sealing device. Dimensions of the top and bottom of the pressure pad are given previously according to the dimensions of the product. Top pressure pad is stationary and the bottom pressure pad is lifted by the pneumocylinder. Each unit is removable and changeable.

     Then ready produce are given to the cooling system conveyor (or on the packing to the interim boxes that are designed for cooling) and packing conveyor which are not the part of the proposed line.

     III. DELIVERY TIME: 6 months after receiving the prepayment and adjusting of all technical details of the order.

     IV. NOTES

     The things listed below should be provided by You at the time of the supervision installation work beginning:
     - All engineering work with the building: coloring, isolation, lighting, heating, ventilation, climate system, etc.
     - Natural gas supply for equipment connecting up: gas pressure to the heating system 2 – 3 kPa.
     - Electricity supply to the place of equipment power cabinets’ installation: voltage 380V, frequency 50Hz, power consumption 7,5kWt.
     - Water supply for depositor cooling: water temperature 10-15°C, water extent for cooling 200 liters per hour.
     - Compressed air supply for equipment connecting up: compressed air consumption – 1,5 m3 per minute, the compressed air must be dry, cleansed, without any oil granules, with minimal pressure 8 bar.
     - Binding for gas feeding and gas outlet, electric power, compressed air, cool water, sewage system and condensate, and also equipment that is necessary for adjustment, management and safety measures validity, for example: gas pressure adjuster, electrical voltage stabilizers when voltage is fluttering +/-5%, water-softening and water preparation devices.
     - Electric wiring including installation material for connecting different parts of the line (between electric boards, terminal boxes etc.).

• Blowdown ventilations for arranged combustible gas and reek outlet together with necessary ventilators.
• Auxiliary personnel dedication ( 1 installation specialist, 1 electrical engineer), mates.
• Raw materials supply for official test carrying out.

     V. GUARANTEE: during 12 months period from the moment of commissioning, but no longer than 13 months from the date of delivery.
     Wearing parts are out of the guarantee.
     Guarantee for purchased componentry – according to the passports of the goods.

     VI. TECHNOLOGY. We are ready to provide technological help (formulation, technological process, technologist training, raw materials selection etc.), marketing researches of this product selling, provide help in picking up optional equipment for confectionary pancakes production, in personnel training (technologist, line operator).
     Technologist’s work cost per one working day is 265 Euro.

     VII. OPTIONAL EQUIPMENT

     On customer’s request for additional cost the line could be additionally equipped with: automatic dough delivery block, cooling system, parting gases forced outlet system, compressor with air cleansing system, packing system, eggs slaughter, raw materials screening.
 

Yours faithfully Vadim Litovchenko
Tel. +380661397178
Manager PCG “Lesnaya skazka” Ltd.Ukraine, Kharkiv