Exclusive: DLG Analyzes Versatile Turnkey Production Lines

Working with turnkey lines is essential for the industrial manufacturing of baked goods. Versatility is a key feature, as the equipment lines must support the production of different ranges of baked goods, and formulation updates.

Changing the product running on the line is a challenge regarding hygiene standards, the product standard and the consistency of the recipe itself, especially if it includes allergenic substances, Simone Schiller (pictured), managing director at DLG-Competence Center Food, explains in an interview with us (Deutsche Landwirtschafts-Gesellschaft – German Agricultural Society).

Schiller underlines an important, core aspect impacting the design of turnkey lines for bakeries: very quick and rigorous cleaning must be possible. Furthermore, hygiene is the biggest challenge for this type of equipment. The biggest challenges are hygienic design, and data evaluation and documentation, according to Schiller. The cleaning and maintenance protocols must be very clear.

Another big challenge is to save time during retooling and cleaning, she explains; however, changing the product manufactured on a processing line always includes a risk of mistakes.

In terms of networking processes and their specific equipment, for an optimal configuration, it is very important to have interfaces between the process, sensory equipment and the control of sensory equipment. “This allows predictive maintenance, which is one way to increase effectiveness of a process line,” DLG’s director highlights.

From the manufacturer’s perspective, one of the most common requirements is the connectivity between new and existing parts of production lines.

This means monitoring and synchronizing processes, which is when the use of sensors is an opportunity. “For successful synchronization, producers need very smart software, which usually means a tailor-made solution,” Schiller adds.

On the other hand, to optimize energy consumption, it is necessary to analyze individual production processes and take prompt action to make improvements or even replace old machinery.

As far as further technology innovation is concerned, the major direction for technology development in the long run is digitization, Schiller says. This will have as a result a reduction in the number of employees.

“This is desirable as employees can be a source of hygiene problems, and it is also becoming more difficult to find suitable staff. Other external influences that will drive technological development include new legislation and upcoming standards, for example on traceability and authenticity, and changing consumer demands,” Schiller concludes.

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