Breadcrumb Machines

Why Breadcrumbs?

“The market for ready to eat meals in the five largest European countries - the UK, Germany, France, Italy and Spain - increased 5%

between 2006 and 2007 to reach approximately 8.4 billions euros. Sales of RTE meals are forecast for a further 18% growth and will

reach 9.9 billion euros by 2011.”- researchbuy.com

• Food industry - it is growing fast and having problems in finding good breadcrumb suppliers.

• Animal feed industry – most of animal food has a high percentage of breadcrumbs.

• Final consumer – supermarkets and other points of sales.

101 uses for breadcrumbs!• For breading fish, meat and vegetables.

• As a binding or thickening agent for soups and sauces.

• For adding to paste-dough based products. (Croquettes, köfte, stuffing, scotch eggs, nuggets, Christmas puddings, etc).

• Breadcrumbs can be soaked and adding back into the dough. In certain types of bread it can help with hydration in the production process.

• For adding to delicatessen products as a way of improving texture and increasing water retention: (sausage meat, sliced processed meat, etc.)

• As animal feed: (fish, birds, other animals).

• Footprint as small as 2 x 4.5 metres• Crumbs par-baked, surplus or unsold bread• Can be integrated into crust removing unit• Sealed and hygienic unit• Plants from 150-5000 kilos per hour• Optimised for energy efficiency

CARACTERISTICS OF THE LINE

Mode of operation (compact plant)

• Our unique MTV shedder mill consists of a two stage system of revolving blades that cut the bread into small pieces.

– Designed without crevices to eliminate danger of fermentation.

• The reduced bread is transferred by fluidised air conveyor system.

– This can be any length so the plant can be situated away from the bread source.

• Surplus air is removed by means of a cyclone separator.

• The crumbed bread is heated in a constantly revolving chamber. The chamber’s internal cellular structure ensures product is uniformly distributed to increase the surface area of the product and to balance the cylinder. Those particles with higher moisture content remain in the dryer for a longer period of time.

– resulting in constant level of moisture in the final product and avoiding over-dry or toasted particles.

• Located behind the dryer is a combustion chamber whose burner produces and maintains the BTU’s required for the system.•

– which is in turn based on the humidity in the product.

Mode of operation (cont…)

• The crumb now passes through our vertical axis aspirated MTM crumber mill with smooth internal surfaces and cyclonic separation of product from air.

- Incorporates easily interchangeable internal sieve.

• This feeds into the plansifter grading machine which automatically filters the desirable breadcrumb size and separates the dust from the crumb.

- Dust produced 0.5%. Fines 15% (125-200 microns).

• Breadcrumbs pass to silo via pneumatic conveyer.

Mode of operation (cont…)

MillFeeder

Plansichter

Hot air generator

Cutter / Mill

Dryer Silo

Compressed air unit

Production Flowchart

Performance Specifications

Bread Humidity Chart (Compact PR-350 Kg/h RDP) PRODUCT: White Bread Standard B Return B

Bread types Partially baked Standard Bread Standard Bread

Input Capacity (Kg/h): 250 350 470

Process: Continuous Continuous Continuous

Apparent Density: (Tm/m) 0,28 0,29 0,32

Initial Humidity (%): 36 30 25

Final Humidity (%): 8 8 10

Heating Fluid: Air (max. 350ºC.) Air (max. 350ºC.) Air (max.300ºC.)

Water to evaporate: (Kg/h) 76 78 78

Bread Crumb Production: (Kg/h)

174 272 392

Approx. Consumption: Therms/h

68 (270000 BTU) 67 (265860 BTU) 67 (265000 BTU)

Chart demonstrates how the system performs based on the removal of humidity throughout the process:

Performance Specifications

Bread Humidity Chart (PR-500 kg/h RDP) PRODUCT: White Bread Standard B Return B

Bread types Partially baked Standard Bread Standard Bread

Input Capacity (Kg/h): 420 500 600

Process: Continuous Continuous Continuous

Apparent Density: (Tm/m) 0,28 0,29 0,32

Initial Humidity (%): 37 30 25

Final Humidity (%): 8 8 10

Heating Fluid: Air (max. 350ºC.) Air (max. 350ºC.) Air (max.300ºC.)

Water to evaporate: (Kg/h) 120 119 100

Bread Crumb Production: (Kg/h)

297 380 500

Approx. Consumption: Therms/h

110 102 89

Chart demonstrates how the system performs based on the removal of humidity throughout the process:

Performance Specifications

Bread Humidity Chart (PR-1000 kg/h RDP) PRODUCT: White Bread Standard B Return B

Bread types Partially baked Standard Bread Standard Bread

Input Capacity (Kg/h): 770 1000 1200

Process: Continuous Continuous Continuous

Apparent Density: (Tm/m) 0,28 0,29 0,32

Initial Humidity (%): 37 30 25

Final Humidity (%): 8 8 10

Heating Fluid: Air (max. 350ºC.) Air (max. 350ºC.) Air (max.300ºC.)

Water to evaporate: (Kg/h) 243 240 200

Bread Crumb Production: (Kg/h)

527 760 1000

Approx. Consumption: Therms/h

212 204 180

Chart demonstrates how the system performs based on the removal of humidity throughout the process:

Performance Specifications

Bread Humidity Chart (PR-2000 kg/h RDP) PRODUCT: White Bread Standard B Return B

Bread types Partially baked Standard Bread Standard Bread

Input Capacity (Kg/h): 1500 2000 2300

Process: Continuous Continuous Continuous

Apparent Density: (Tm/m) 0,28 0,29 0,32

Initial Humidity (%): 37 30 25

Final Humidity (%): 8 8 10

Heating Fluid: Air (max. 350ºC.) Air (max. 350ºC.) Air (max.300ºC.)

Water to evaporate: (Kg/h) 473 478 383

Bread Crumb Production: (Kg/h)

1027 1522 1917

Approx. Consumption: Therms/h

440 410 380

Chart demonstrates how the system performs based on the removal of humidity throughout the process:

MOLINO TROCEADOR

MOLINO

GENERADOR DE CALOR

CICLONSILO

TROMMEL-SECADOR

TRANSPORTE NEUMATICO

PLANSICHTER

PLANTA COMPACTA PAN RALLADO PR-250

PR 2000

Dedicated bread crumb line (Panalca)

2005PANALCA-2, Alcala de H., Madrid 1600kg/hDIATOSTA, Aveiro, Portugal 350kg/hRUIPAN, Fuenlabrada, Madrid 3000kg/hLUCENA, Malaga, Spain 350kg/h

2006GALLO, Cordoba, Spain 1600kg/hPANRICO, Tenerife, Spain 1000kg/hARTADI, Zumaia, Spain 1500kg/hIn process, New Jersey, United States 350kg/h

Latest breadcrumb installations by Serton

Why Serton Enginy?

• 80% installed capacity in Spain is Serton • 30 years of experience• Flexible, low cost base• Design and build• Long history of repeat orders from est. clients

Serton Enginy, S.L.Travessera de Les Corts, 164 / 08028 Barcelona

tel: (+34) 933 300 250 Fax (+34) 933 300 754 /

www.sertonenginy.com / export@sertonenginy.com