Pfalzgraf Konditorei produces baked goods for the food service sector in one of the most modern factories in Europe. An Ishida multihead weigher is responsible for the precise dosing of the fruit toppings. And at the end of the line, a checkweigher and an X-ray inspection system from the same manufacturer ensure compliance with the high quality standards.
In May 2015, a major fire destroyed the entire plant of the Pfalzgraf confectionery and the medium-sized company was on the brink of collapse. It took an enormous effort to rebuild the company within just nine months. Reconstruction of the company realised.
Today, Konditorei Pfalzgraf has regained its place on the market and is once again supplying high-quality cakes and gateaux to professional users. The comeback has been supported by high-performance production machines and adherence to the proven high quality standards. The technology from packaging machine manufacturer Ishida has made a valuable contribution.
Highly adhesive fruit as a challenge
Pfalzgraf Konditorei, for example, benefits from a CCW-M 106 multihead weigher, which is used for dosing the fruit toppings on cakes and pastries. Ishida developed the linear, semi-automatic scale especially for Strongly adhesive fresh products and smaller production batches.
The functional principle: An operator distributes the fruit fed on the conveyor belt evenly into the feed chutes to the weighing trays and can carry out a visual inspection of the fruit at the same time. Special scrapers on the plastic trays prevent product adhesion.
After weighing, the fruit portions are filled directly onto the tarts and cakes using a lowering funnel. The variable filling units have been specially adapted to the respective product requirements and the shapes of the baked goods (round or rectangular).
Overcrowding used to be
Pfalzgraf Konditorei processes a wide range of products with the multi-head weigher in two-shift operation. Raspberries, strawberries, wild berries and mandarins as well as fruit mixes are added to the baked goods. The filling weights are between 240 and 2,500 grams at a maximum speed of 16 cycles/minute. In view of the high-priced fruit, however, the Accuracy as a decisive criterion.
According to Production Manager Stephan Koller, the new scales have significantly increased productivity: „The volumetric dosing system we used to use gave us 20 to 30 grams of fruit too much on each product. No more overcrowding.“ The Ishida machine is therefore an extremely economical solution for the baked goods manufacturer, and amortisation was achieved in a short time.
Another advantage Koller cites is the very Product-friendly working method of the plant, which prevents damage to the sensitive fruit as far as possible.
[infotext icon]The Pfalzgraf Konditorei GmbH is based in the climatic health resort of Pfalzgrafenweiler in the northern Black Forest. Founded in 1985, the family-run company employs 150 people and is a market leader for high-quality confectionery in the European out-of-home market. Daily sales total around 20,000 frozen cakes and tarts in 70 different flavours[/infotext].The processing of wet fruit requires frequent basic cleaning measures, and the multihead weigher is well suited for this. Stephan Koller characterises the watertight machine as „extremely hygiene-friendly“. The scales can be dismantled down to the housing without the use of tools. The product-carrying trays and channels are placed in the dishwasher, the base body is washed with spray water.
The right weight for sure
Ishida technology comes into play again at the end of the production line. A DACS-G checkweigher checks the already packaged cakes and tarts for compliance with legal requirements. Production manager Stephan Koller reports in this context that the authorities are satisfied with the results of the Weight test of the product packaging are very satisfied.
The DACS-G checkweigher not only offers maximum precision with high performance, but also Great flexibility thanks to the large weighing range. You can switch between two settings at the touch of a button, so that a very wide range of products can be checked with one checkweigher.
The unique DFL (Dislocating Force Limiter) function automatically disconnects the weighing sensor from the weighing belt in the event of external interference. The checkweigher then resumes operation immediately.
X-ray inspection system guarantees foreign object detection
Pfalzgraf Konditorei is committed to the strictest quality guidelines and guarantees its customers the highest quality standards. Free of foreign bodies. A metal detector was not an option for the baked goods manufacturer. Not only were metal contaminants to be excluded, but also a wide range of other foreign bodies. Consequently, an Ishida IX-GA 4075 X-ray inspection system marks the end of the production line. Even at high speed, the system reliably detects foreign bodies as small as one millimetre in diameter. For example, the pies and cakes could contain small granite stones that have got into the product with the fruit. The X-ray inspection system also identifies contaminants made of metal, glass and plastic.
To check for foreign objects, the machine measures the Density of cakes and tarts. An X-ray beam is passed through the baked goods and photodiodes record the incoming rays. Depending on the level of X-rays received, the diodes send a signal to convert them into a greyscale image. If inclusions are present with a greater density than the product, they appear as dark spots on the image. Cavities and cracks are lighter in colour as more X-ray light penetrates them.
More precision with every test procedure
The patented technology of the Ishida X-ray inspection system is based on a Software with a learning genetic algorithm. By analysing image data over several generations, the device achieves a very high level of accuracy. „This allowed us to customise the system for the specific properties of our products,“ says Stephan Koller. „A more precise protocol for the calibration can then be created with each test procedure.“ For calibration, it is sufficient to scan a test object two to three times. Data logging serves as proof of proper production processes and also provides information for process optimisation.
The employees at Pfalzgraf Konditorei were quickly familiarised with the largely maintenance-free X-ray inspection system. After an automatic setup, the easy-to-operate machine is ready for use within 90 seconds. Fine adjustments can then be made during ongoing production. Up to 100 programmable presettings enable a quick product changeover.
