Rondo Doge novelties at IBA 2006
Rondostar 4000
The new Rondostar 4000, that is presented at this year’s IBA for the first time, represents on one hand the vast experience of Rondo Doge in manufacturing microprocessor controlled dough sheeters, and on the other hand the striving of its engineers to continue to develop more robust, faster, cleaning- and userfriendly machines.
The new PLC control is a significant feature for the userfriendliness of the Rondostar 4000. The machines has a colour touch screen with large, meaningful and easily understandable symbols. For easy programming and easy handling, the layout of the machine is visualised on the screen. The operator is guided step by step through the menu.
Independently of the operator’s language, everybody can use it right from the start without special instructions. One of the reasons is the existence of 4 pre-set and memorised standard programs for booking and sheeting.
Rondostar 4000 has a memory capacity of 100 programs. These can either be parameterised with the 9 fixed and proven reduction curves, or, for a very special dough, the operator can teach-in his specific and individual reduction steps. Also the manual mode has been simplified. For little jobs in-between, like producing a round pizza base, the baker can go to manual, and on the display appears a list with reduction steps. He simply taps on the desired steps and the machines performs the sheeting operation accurately. With the Rondostar, all known sheeting jobs can be carried out quickly and precisely. A second sheeter is superfluous.
For markets, where very short or specially thin dough has to be processed, variable belt speed is optionally available.
For security reason, the programs can saved on data storage medium. A modem is also available on request.
Smart-Feeder (Dough band pre-former)
The Smart-Feeder is a world novelty launched by Rondo Doge at IBA.
Weight differences in the final products are a well-known problem in the production of Ciabatta, the popular Italian special bread with up to 80% hydration and a very long bulk fermentation, or, in other words, a very moist, soft and sticky dough. Now, if the dough, before going into the actual dough band former (e.g. Smartline), is fed through the new Smart-Feeder, where a homogenous, thick dough band is formed, we achieve a 30% better weight accuracy. The final dough band is more regular in thickness and width, reducing also the scrap by up to 20%.
One of the unique features of the Smart-Feeder is its capability to process not only soft but also firm dough. The thickness can be selected between 20 to 40 mm, allowing versatile applications. The dough and cell structure remains intact , as the dough is only pre-formed.
No need to mention that when designing the machine, special attention has been paid to cleaning and hygiene. The Smart-Feeder is made of stainless steel. For easy access to the feed rollers, the hopper can be tilted. The two flour feeding belts can be taken off without tools.
Due to the staff saving that can be made with the Smart- Feeder, the return on investment is less than two years. It is a very profitable solution.
New generation of make-up lines
With Polyline and Starline, Rondo Doge is introducing a newly developed generation of make-up lines. Numerous clever and for the customer useful ideas and solutions are incorporated.
The range consists of models from 3,8 m to 17 m in length.
A special feature of the lines are their modularity. They can be produced to the customers’ requirements and available space.
The running direction can be chosen: from left to right or right to left. There, the lines can be perfectly integrated into existing work-flows.
The machine tables are made of stainless steel and have extremely robust 45° bent double fold profiles with smooth surfaces and practically no visible screws. The benefit is a long life span and excellent hygiene. Underneath the tables there are large shelves to store e.g. the accessories.
For a safe transfer of even the smallest products onto the subsequent machines, Polyline and Starline are equipped with a small radius belt catch. Quick belt releases for fast and easy cleaning are standard with Rondo Doge since many years.
To avoid sticking of the dough bands in the folding ploughs, inclined infeed sections with inferior belt dusting are available.
For an economic later extension of the lines, interfaces for machines upstream and downstream are already prepared.
Polyline
This is a make-up line for smaller to medium bakeries. From standard modules, a suitable line for each customer can be composed. This is modularity at the highest level.
For the Polyline a new PLC control has been developed.
For each product, the speed of the line and the parameters of the guillotine, the filling depositor as well as of the other driven accessories are keyed in and saved in one of the 99 programs.
Therefore, all the functions for each product are reproducible.
The quality of the final product is consistent, independently of who is working with the Polyline. The large control panel with highly resistant, washable membrane keyboard has easily understandable and meaningful symbols. The handling of the machine is therefore very simple and independent of languages.
According to the products and the fillings, the customer can choose between three different filling depositors.
The mechanical guillotine is movable along practically the whole length of the line, allowing to produce a large variety of different products.
Motors and plugs are covered and the cables are protected in a duct.
Starline
Starline is designed for industrial use and offers a number of additional advantages.
It has a cable duct mounted above the line, outside the contamination area. It is completely closed and provides cleanliness. Accessories can be plugged in different positions, allowing to produce various products with one and the same line, without the need a second machine.
The position of the control board can be chosen. It is equipped with a colour touch screen. Each program features the layout of the machine and the programmed functions and parameters. This facilitates the programming and the handling of the line.
The programs can be given a name. The operator finds the adequate program easily and mix-ups are avoided. Also on the Starline, all the functions for each product are reproducible.
Two different guillotines are available: either the pneumatic guillotine or the mechanical one with travelling sledge for high speed production. With this type of guillotine, even running at maximum speed, uniform products are guaranteed.
Industrial installations
Industrial Pizza line:
A highlight on the Rondo Doge stand is the demonstration of the Pizza line. We are presenting a demonstration line with a special IBA configuration.
We are producing pizzas with a high rim free of filling. A special feature of the line configuration is that it has an intermediate resting belt, on which the dough relaxes, with the effect that after stamping practically no shrinking is noticeable. The line is equipped with a topping station from Comas. The pizza bases are topped with tomato sauce and cheese. In order to be able to show the visitors the whole process, for space reasons, the cheese distributor is placed directly after the tomato topping, and not, as in real production lines, after the oven. The cheese is distributed in such a way that the rim remains clean.
Spira for filled and unfilled bent croissant
With the Spira, filled as well as unfilled croissant can be produced. The machine is equipped with a newly developed curling unit. This new component allows to produce with the Spira unfilled croissant at maximum speed. Working on six rows, the output is up to 18'000 filled and up to 36'000 unfilled croissant. It is the first combined machine on the market with such a high output. Another remarkable feature is the fast and easy product changeover.
Integrated into the line is a bending module. After curling, the croissant are picked and bent. Then they are held for a short moment so that the bending is maintained. At the end of the process, the croissant are deposited with the tip in the correct position.
Topline, the industiral make-up line with high speed guillotine
For the production of snails, butterflies and similar products in highest numbers, Rondo Doge has developed a high speed guillotine that can work at up to 300 strokes a minute. For IBA, this guillotine is integrated into the Topline make-up line. At the exhibition we are demonstrating the production of snails at maximum speed.
