Production line for tagliatelle and lasagna with packaging
The line described here allows the production of tagliatelle laid in bags and trays, as well as lasagna sheets laid into trays.
Mixing Unit
Double tank mixing system to mix two flours of different colors, complete with:
- semolina dosage system with continuous flow control and check through a volumetric screw and load cells;
- liquid dosing (water and egg) with the Andrews Hauser system to ensure very high precision;
- high-efficiency centrifugal pre-mixer with reel rotation adjustment not to overheat the product;
- mixing tank with hygienic-sanitary design suitable for the final mixing of the dough. The tank does not have sharp edges to prevent the persistence of residues difficult to clean;
- mixing shaft equipped with adjustable shovels fixed to the shaft through a conical connection;
- the internal part of the tank has a mirror finish to reduce the friction of the dough;
- the external part of the tank has a satin finish
the whole group is positioned on a terrace entirely made of thick stainless steel; handrails and footboards guarantee the safety of the working staff; the decking, made of 3+2 non-slip knurled stainless steel, allows you to move in complete safety; the access staircase is also stainless and equipped with non-slip steps.
The production line can work with both single and double color laminated sheets or, alternatively, with drawn sheets with a total vacuum system, using the machines described below.
Dual-color automatic sheeter
Patented machine for producing dual-color dough sheets.
a deflector allows the dough to be canalized and divided into strips whose width may vary down to a minimum of 8 mm. During lamination, the sheet is joined together thus becoming one sole body with very high consistency.
The deflector can be changed in a few minutes thus modifying the width of the produced strips: the sheet is colored not only on one side but on both of them; independent motors allow to compact the sheet in the desired way by increasing or decreasing the pressure inside the sheeter.
Single color dough sheet can be produced as well for manufacturing traditional pasta, the continuous control of the dough sheet loop being ensured through a photocell with a high-resolution laser reader; the production speed can be adjusted via the control panel and the operator interface.
Extruder with total vacuum system
Machine for the production of laminated pasta sheet with 1000 mm width, provided with a total vacuum system to avoid streaks forming into the sheet in the presence of air.
Through a sealing capsule, the dough tank is maintained under vacuum; the compression screw is designed to ensure proper processing and to have a constant loading pressure; the channel is made of stainless steel with bronze jacket, to have pasta flow properly and uniformly inside the channel; the cooling system works with glycol water at controlled temperature; the continuous control of the loop takes place through a photocell with a high-resolution laser reader; the adjustment of production speed takes place through the control panel and operator interface.
Lamination system with double pass and automatic thickness control
Double pass calibrator for the lamination of the sheet with automatic thickness control;
through a complex detection system, the machine’s management system detects the exact thickness of the output sheet; then, after comparing it with the set values, it continuously performs micro-adjustments to ensure a very regular thickness to have a regularity of the weighed product in the tray or the bag, thus avoiding manufacturing waste.
Thickness can be set via operator interface; the tension of the sheet between the first and the second lamination unit is managed by a laser photocell managed by PLC; it is also possible to set the desired length of the loop.
Pasteurization area
The steam pasteurizer to eliminate the bacterial load is built with a structure made of AISI 304 stainless steel. Instead, all parts coming into contact with steam are made of AISI 316 stainless steel to avoid corrosion and oxidation;
the thermal treatment is made with a combined system of spraying ramps and radiant plates (Facchini patent). The spraying ramps reach the product and bring it to the required temperature; the radiant plates make a double action in their turn, keeping the pasteurizing chamber at a stable temperature avoiding any waste of energy (to maintain the room temperature with expanded steam, you need more than twice the amount) and moving the steam coming from the spraying ramps to the product because the plates’ temperature, being higher, moves an air arrow onto the product;
the double insulation of the sealing cap allows to save a considerable amount of energy and dramatically reduces condensation (and related drips) inside the cap. Through special doors, you can insert and remove “data logger” treatment verification instruments with no waste of energy.
Another innovation on the line is the new system for the control of the steam stamp whose pressure is reduced and whose temperature is adjusted to enter the chamber in conditions of complete saturation and with an excellent degree of thermal exchange. The thermal plant, wholly made of AISI 316 stainless steel, equipped with valves, controllers and modulating valves (also made of AISI 316 stainless steel), ensure, in conjunction with the filter installed on the input, a perfect distribution of micro-filtered steam to avoid any possible contamination of the product.
All machine parameters are managed by PLC and may be set through the operator interface; temperature adjustments, treatment times and steam quality can be set without stopping the machine; the remote control allows to intervene even at a distance, thus significantly cutting the costs of intervention; the simplicity of the user interface simplifies any adjustment.
Pre-dryer in tiers with micro-filtered air
The pre-dryer in tiers ensures the drying of the product, reducing a part of humidity absorbed during the pasteurization treatment.
The treatment tiers are managed independently and controlled by a PLC; the new batteries for the heating without fins are very easy to clean; the sanitizing system with direct steam installed on them ensures a perfect and quick sanitation of the machine; fans mounted on mobile supports, with flag-like openings, are easily sanitizable; the IP 67 washable motors may be washed with high-pressure systems; the washing ramps placed above and below belts operate at high pressure, completely washing the belt and removing any type of residue; the UTA unit for air treatment, placed at the entrance of the machine, allows to work with practically pure air and with precise temperatures; the closing panels, wholly made of a thick layer of stainless steel and duly insulated, joined to seals with dedicated profile, avoid useless wastes of energy; the design of the machine was conceived to have the best possible sanitation.
Cooler in tiers with micro-filtered air
The cooler in tiers guarantees a perfect cooling of the product, bringing it to the desired temperature. Treatment tiers are independently managed and controlled by PLC; the new cooling batteries without fins are very easy to clean; the sanitizing system with direct steam that is mounted on them ensures perfect and easy sanitation of the machine; fans mounted on mobile supports with flag-like openings are easily sanitizable; the washable motors with IP 67 standard can be washed with high-pressure systems; the washing ramps placed above and below the belts operate at high pressure, completely washing the belt and removing any type of residue; the UTA unit for air treatment, placed at the entrance of the machine, allows to work with practically pure air and with precise temperatures; the closing panels, wholly made of a thick layer of stainless steel and duly insulated, joined to seals with dedicated profile, avoid useless wastes of energy; the design of the machine was conceived to have the best possible sanitation.
Vertical system for the accumulation of the sheet
Studied to avoid the stopping of the line during the replacement of the reel of film on the packaging machine, the system of vertical accumulation starts working by creating the time that is necessary for the change: the control system slows down the production line bringing it to 50% of its production capacity.
Cutting unit for the production of tagliatelle in trays
The pasta sheet is brought to the required height through an elevator belt; the sheet enters the cutting unit and is first vertically cut through two cutting rollers of big diameter, then is vertically cut by a helical blade; the proper length and, subsequently, the proper and precise weight of the cut is determined by the control system that manages the tension of the sheet and the cutting length.
Unit for the cutting and packing in trays
The unit for the cutting and packaging in trays ensures an optimum production of tagliatelle and lasagne directly put into the packing tray. This modern system allows to choose how the tray should be filled, either in a single or double layer, or in a double layer with the product forming a kind of “c” inside the tray, or in a triple layer with the product forming a kind of “s” inside the tray. A sophisticated management system controlling both the tension of the sheet and the length of the cut determines the precision in packing and weighing operations.
Unit for the management of the line
The line for the production, treatment, and portioning of pasta either in bags and in trays is completely managed through an integrated Siemens PLC high-performance control system coupled with the operator panel that greatly simplifies the production. All parameters may be varied during production, giving great flexibility to the system. All kneading parameters like for example humidity, kneading time, sheet thickness, and pasteurization time may be varied. The most performing part of the system surely is the one concerning the trays’ filling area: during production, all parameters that can optimize production can be varied, like, for example, the choice of cutting length to have trays of uniform weight.