SOLLICH-CHOCOTEC bar production line - STEPHAN, for PROTEIN BARS, consisting of:
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Location:Bad Salzuflen, Germany
or
Description
1. Systems for the production of base masses for bar manufacturing.
The product base is prepared using a HILTON PROCESS SOLUTIONS sugar pre-dissolving system and enters the CHOCOTECH Type Autograv cooking machine via a 150-liter glucose tank to produce the base syrup. The agitator mounted in the cooking machine generates shear forces that ensure a lump-free and homogeneous dispersion.
In a CHOCOTECH Type Turbowhip-300 pressure aeration machine, built in 2017 with an output of approx. 300 kg per hour, an aerated mass (e.g., egg white) is produced and discharged into a pressurized vessel together with the vacuum-treated base mass. Due to the overpressure, both masses can be mixed into a fine-pored bar mass. This process ensures the "aeration" of the mass to make it light & fluffy.
For an additional component mass, a CHOCOTECH Type Carastar 180/400 universal batch cooker, built in 2010, is available for cooking various masses such as caramel, binders, jelly, fillings, sugar solutions, etc. The cooking chamber is designed for approx. 300 liters of slurry and up to 130°Celsius at an operating pressure of 10 bar. After the cooking process, the mass is discharged into the intermediate buffer tank mounted below. While the slurry batch is being processed in the tank, the next batch is already being weighed, mixed, and cooked in the cooking vessel, creating a continuous workflow.
A dry dosing system above the STEPHAN mixer was used to add protein powder and flavor, with a direct connection to the mixer located below.
In a STEPHAN Type Combicut TC-300 universal mixer (built in 2013) with a double-walled process vessel, dry ingredients can be mixed with liquid components while being cooled or heated. Here, temperatures of up to approx. 95°Celsius can be reached. Additionally, four nozzles in the vessel can inject direct steam straight into the product, enabling rapid heat treatment. A large slide valve opening allows for barrier-free feeding of different raw materials. The drive shaft mounted in the process vessel is equipped with three double-cutting blades.
The total capacity of approx. 300 liters allows for batches of approx. 200 liters and, depending on the product, can achieve a total output of approx. 1,000 kg per hour.
2. Bar forming with various combinations of base masses.
A SOLLICH Type FKL-S 50 water chiller from the year of manufacture 2010 is available for the mass forming machines as well as the subsequent coating process.
The base masses are formed, cooled, and cut in the SOLLICH Type Conbar-400 forming line.
The SOLLICH Type WEB-400-G roller former (built in 2010) is equipped with two cooled rollers and forms the mass into a product slab, which is then leveled with a Type SAW-400 calibrating roller (built in 2010) and subsequently marked from above with a Type SAP-400 embossing roller (built in 2017). Following this, granules or nuts can be distributed onto the mass slab using two available mobile Type SWS-420 vibratory sprinklers (built in 2017) in a C-frame. The subsequent Type ANDR calibrating machine ensures a uniform slab height.
Next, a caramel mass is applied by a second roller former with one roller and transferred directly into a Type KK-ET-420 cooling tunnel. The 10-meter cooling track with water cooling at the bottom cools and stabilizes the mass slab. A Type SSC-400-SG longitudinal cutting machine with a spreading belt and a Type BT-620 guillotine cuts the desired bar shape from the slab.
Several spreading belts (built in 2017) are available in different widths:
28, 31, 34, 42 mm
3. Bar enrobing with Mass supply and storage:
A SPIRAX SARCO Type EasyHeat steam system is available to supply the machines with hot water.
For the coating, 10 x stainless steel agitator tanks with a capacity of 500 to 2,000 kg are provided, equipped with metal separators (Eclipse Magnetics) and corresponding mass pumps. All agitator tanks are equipped with melting coils for optional melting of masses.
4 x 1000 kg tanks (of which 3 x Chocotech with their own hot water circuit)
4 x 2000 kg tanks, built in 2018
2 x 500 kg tanks
All melting coils and the remaining tanks are supplied by the SPIRAX steam system.
SOLLICH Type Turbo TT-600-D disc tempering machine, with Allen Bradley control system.
The first enrobing of the bars then takes place with a CHOCOTECH Type UZM-S-620 enrobing machine, built in 2004 with a working width of approx. 620 mm.
In between, there is an ET-TB-620 fabric belt table, built in 2010, on which a SOLLICH Type SL-400 longitudinal cutter, built in 2017, is mounted for the longitudinal cutting of the bars.
The second coating is performed with a SOLLICH Type TEM-620 enrobing machine, built in 2011.
A RUSSELL Type Finex-Separator vibrating sieve made of stainless steel is also mounted here. The sieve serves to actively filter the enrobing machine in order to remove impurities or pieces from the system.
This is followed by a SOLLICH Type ET-TB fabric belt table with a working width of approx. 620 mm, built in 2010, for a Type Decormatic DC-4-620 decorator, built in 2017, with a built-in nozzle pipe and an SPN-500 mass pump. The decorator is supplied by a Type MT-100-Turbo mini-tempering machine, built in 2017.
In addition, a Type BT-620 bottom cooling table, built in 2010.
Final cooling takes place in the SOLLICH Type Glossmaster KK-S-620 air cooling tunnel, built in 2005, with a working width of approx. 620 mm and a cooling track of approx. 12 meters.
The hoods are in 1-meter polyurethane sections.
4. Packaging of the bars.
A single-row aligner with a turning station and a timing belt aligns the bars perfectly and feeds them to the FUJI flow wrap machine. The shuttle, bypass, connecting belt (joint), turning belt, and turning round belt (polycord) are controlled via a central control system in the switch cabinet located directly next to the line.
The bars are fed into a horizontal flow wrap packaging machine via speed-controlled feeding and packed into flow packs by a FUJI Type FW-3400, built in 2016.
The output is between 30 and 300 pieces per minute, depending on the product size.
The machine features a splicer for automatic film changes.
A belt conveys the bars to a manual packing station (length approx. 8 meters) where the bars are placed into a cardboard box by hand.
The box is transported further via a conveyor belt to the SONTEX shrink packaging system.
The packaging is completed with a SONTEX shrink packaging system with a shrink tunnel, checked with a check-weigher, and finally placed onto a pallet manually.
Output: approx. 180 bars / min (up to 1,000,000 bars per week in a three-shift operation)
The output depends on the mass and product and is not a binding specification.
Space requirement: Current layout approx. 50 meters length x 20 meters width
The product base is prepared using a HILTON PROCESS SOLUTIONS sugar pre-dissolving system and enters the CHOCOTECH Type Autograv cooking machine via a 150-liter glucose tank to produce the base syrup. The agitator mounted in the cooking machine generates shear forces that ensure a lump-free and homogeneous dispersion.
In a CHOCOTECH Type Turbowhip-300 pressure aeration machine, built in 2017 with an output of approx. 300 kg per hour, an aerated mass (e.g., egg white) is produced and discharged into a pressurized vessel together with the vacuum-treated base mass. Due to the overpressure, both masses can be mixed into a fine-pored bar mass. This process ensures the "aeration" of the mass to make it light & fluffy.
For an additional component mass, a CHOCOTECH Type Carastar 180/400 universal batch cooker, built in 2010, is available for cooking various masses such as caramel, binders, jelly, fillings, sugar solutions, etc. The cooking chamber is designed for approx. 300 liters of slurry and up to 130°Celsius at an operating pressure of 10 bar. After the cooking process, the mass is discharged into the intermediate buffer tank mounted below. While the slurry batch is being processed in the tank, the next batch is already being weighed, mixed, and cooked in the cooking vessel, creating a continuous workflow.
A dry dosing system above the STEPHAN mixer was used to add protein powder and flavor, with a direct connection to the mixer located below.
In a STEPHAN Type Combicut TC-300 universal mixer (built in 2013) with a double-walled process vessel, dry ingredients can be mixed with liquid components while being cooled or heated. Here, temperatures of up to approx. 95°Celsius can be reached. Additionally, four nozzles in the vessel can inject direct steam straight into the product, enabling rapid heat treatment. A large slide valve opening allows for barrier-free feeding of different raw materials. The drive shaft mounted in the process vessel is equipped with three double-cutting blades.
The total capacity of approx. 300 liters allows for batches of approx. 200 liters and, depending on the product, can achieve a total output of approx. 1,000 kg per hour.
2. Bar forming with various combinations of base masses.
A SOLLICH Type FKL-S 50 water chiller from the year of manufacture 2010 is available for the mass forming machines as well as the subsequent coating process.
The base masses are formed, cooled, and cut in the SOLLICH Type Conbar-400 forming line.
The SOLLICH Type WEB-400-G roller former (built in 2010) is equipped with two cooled rollers and forms the mass into a product slab, which is then leveled with a Type SAW-400 calibrating roller (built in 2010) and subsequently marked from above with a Type SAP-400 embossing roller (built in 2017). Following this, granules or nuts can be distributed onto the mass slab using two available mobile Type SWS-420 vibratory sprinklers (built in 2017) in a C-frame. The subsequent Type ANDR calibrating machine ensures a uniform slab height.
Next, a caramel mass is applied by a second roller former with one roller and transferred directly into a Type KK-ET-420 cooling tunnel. The 10-meter cooling track with water cooling at the bottom cools and stabilizes the mass slab. A Type SSC-400-SG longitudinal cutting machine with a spreading belt and a Type BT-620 guillotine cuts the desired bar shape from the slab.
Several spreading belts (built in 2017) are available in different widths:
28, 31, 34, 42 mm
3. Bar enrobing with Mass supply and storage:
A SPIRAX SARCO Type EasyHeat steam system is available to supply the machines with hot water.
For the coating, 10 x stainless steel agitator tanks with a capacity of 500 to 2,000 kg are provided, equipped with metal separators (Eclipse Magnetics) and corresponding mass pumps. All agitator tanks are equipped with melting coils for optional melting of masses.
4 x 1000 kg tanks (of which 3 x Chocotech with their own hot water circuit)
4 x 2000 kg tanks, built in 2018
2 x 500 kg tanks
All melting coils and the remaining tanks are supplied by the SPIRAX steam system.
SOLLICH Type Turbo TT-600-D disc tempering machine, with Allen Bradley control system.
The first enrobing of the bars then takes place with a CHOCOTECH Type UZM-S-620 enrobing machine, built in 2004 with a working width of approx. 620 mm.
In between, there is an ET-TB-620 fabric belt table, built in 2010, on which a SOLLICH Type SL-400 longitudinal cutter, built in 2017, is mounted for the longitudinal cutting of the bars.
The second coating is performed with a SOLLICH Type TEM-620 enrobing machine, built in 2011.
A RUSSELL Type Finex-Separator vibrating sieve made of stainless steel is also mounted here. The sieve serves to actively filter the enrobing machine in order to remove impurities or pieces from the system.
This is followed by a SOLLICH Type ET-TB fabric belt table with a working width of approx. 620 mm, built in 2010, for a Type Decormatic DC-4-620 decorator, built in 2017, with a built-in nozzle pipe and an SPN-500 mass pump. The decorator is supplied by a Type MT-100-Turbo mini-tempering machine, built in 2017.
In addition, a Type BT-620 bottom cooling table, built in 2010.
Final cooling takes place in the SOLLICH Type Glossmaster KK-S-620 air cooling tunnel, built in 2005, with a working width of approx. 620 mm and a cooling track of approx. 12 meters.
The hoods are in 1-meter polyurethane sections.
4. Packaging of the bars.
A single-row aligner with a turning station and a timing belt aligns the bars perfectly and feeds them to the FUJI flow wrap machine. The shuttle, bypass, connecting belt (joint), turning belt, and turning round belt (polycord) are controlled via a central control system in the switch cabinet located directly next to the line.
The bars are fed into a horizontal flow wrap packaging machine via speed-controlled feeding and packed into flow packs by a FUJI Type FW-3400, built in 2016.
The output is between 30 and 300 pieces per minute, depending on the product size.
The machine features a splicer for automatic film changes.
A belt conveys the bars to a manual packing station (length approx. 8 meters) where the bars are placed into a cardboard box by hand.
The box is transported further via a conveyor belt to the SONTEX shrink packaging system.
The packaging is completed with a SONTEX shrink packaging system with a shrink tunnel, checked with a check-weigher, and finally placed onto a pallet manually.
Output: approx. 180 bars / min (up to 1,000,000 bars per week in a three-shift operation)
The output depends on the mass and product and is not a binding specification.
Space requirement: Current layout approx. 50 meters length x 20 meters width
Specifications
| Manufacturer | Sollich, Chocotech |
| Year | 2005 |
| Condition | Used |
| Stock Number | G13476 |