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Brief Introduction
Full-automatic 39-model Gas Wafer Production Line
Full-automatic wafer production line is
designed and manufactured according to the facts of domestic
biscuit manufacturing industry and absorbing the most
well-known wafer production lines of many overseas
manufactories, which features reliable performance, compact
structure, small occupation, high yield, lower energy
consumption, convenient maintenance, simple operation and
non-environmental pollution.
Equipments composing
full-automatic gas wafer production line:
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1?/span>Gas
tunnel baking machine |
one set |
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2?/span>JP—connecting
machine |
one set |
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3?/span>LP—cooling
machine |
one set |
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4?/span>TW—cream
spreading machine |
one set |
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5?/span>S?/span>
wafer conveyor |
one set |
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6?/span>J—cutting
machine |
one set |
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7?/span>D—pulping
machine |
one set |
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8?/span>WG—cream
mixer |
one set |
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9?/span>F—smashing
machine |
one set |
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10?/span>cold
cabinet |
one set |
For the deployment of the production line,
please refer the plane and stereo configuration diagram of
full-automatic wafer production line.
As the most important equipment of
full-automatic wafer production line, tunnel gas baking
machine has extraordinarily outstanding performances with
the main characters as follows: 1. Unanimous heat colors of
wafer block. Thanks to the scientific selection of heating
components, superior material selection for baking plate and
reasonable die carrier structure, the heat colors of the
center and periphery of the wafer block having been baked
are unanimous. 2. High rate of certified products with
finished product rate of not less than 98%. Because of
uniform heating and unanimous heat colors, the demoulding
rate of biscuit is high with improving rate of certified
products accordingly. 3. Small cubage. As a result of
reasonable layout, the body length of the baking oven is
only 2/3 of the same type of product, which saves space
greatly.
Main technical parameters of
SH—R39 model full-automatic
gas wafer production line
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Model |
Main technical parameters
|
|
Gas baking machine |
Quantity of template: 39 model
Size of template: 470mm×325mm
Adjusting range of wafer block
thickness: 2.5mm-3.2mm
Demoulding method: automatic
demoulding
Adjusting range of temperature:
normal temperature to 180?/font>
Temperature error: 1?/span>
External dimensions (L×W×H):
8.5m×1.56m×2.4m
Others:?/span>
Equipped with 10.4 inch color touch screen made
in Taiwan;
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can display and control the setting temperature and
actual temperature on the touch screen;
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can display and control the display, adjustment and
setting of the running speed of template, control of
each motor of baking machine and mixture status.
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1. Productivity: about 3000Kg or so /h (39
model)
2. Production capacity: daily output of R39
model wafer production machine is 2 tons. The material ratio
between wafer block and sandwich is 1:1.
3. Parameters of whole production line:
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Electric power consumption of whole production line: About
25KW (380V, 50HZ)
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Compressed air: About 0.9 M3/MIN
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Gas consumption (liquid gas): 15?/span>/H
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Nature gas consumption: 20M3?0M3/H
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Size of wafer: 460mm×320mm
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Effective cutting size of wafer block: 455mm×315mm
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Baking time of wafer block: 90 seconds
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External dimensions of whole line: 19m×2m×2.4m (L×W×H)
4. Gross weight: about 17 T
5. It is Ok for only 4 workers to operate one
production line.
6. Debugging personnel: one person
7. One 40?/span>container
and one 20?/span>container
package are required for R-39 model wafer production line.
This company can also manufacture
special-form wafer production line equipments, such as big
grid, steamed twisted roll and animal etc., according to the
consumer’s demands.
The whole production line is deployed in
line according to production process flow and is configured
with a site with length of 18m and width of 8m according to
39 model (material and finished product packaging exclude
150m2)
Material selection of the production line
meets with the demands of food hygiene and all bought in
components are imported or products from well-known
factories and meet with the national standard.?/font>
Each part of the completed machine runs in
balance and reliably with coordinative and continuous motion
and sensitive and reliable electric controlled and air
controlled system.
The production line is controlled by unit
machine. The system composed of programmable logic
controller (PLC), the main control component, adopts
imported product of gas baking machine.
The oven body is full metal structure with
perfect heat preservation performance and is beautiful and
elegant. Observation windows are set for each heating area
to facilitate the inspection of production. The burner is
redesigned and adopts state of art energy-saving burning
technology to improve the heat efficiency greatly. The
temperature in the oven is uniform with perfect heating
quality and low-cost of heating source expense and thus the
service life of the equipment is prolonged.
This equipment is the most important one of
the wafer production line, which consists of 39 pairs of
baking plate, change-speed frequency modulation motor,
reductor drive device, mixture injection system, gas heating
system and gas leakage alarming device of baking plate,
conveying and connecting device of baking machine.
When the baking machine runs normally, the
baking plate opens at the time of running to the outside of
die sinking track, mixture injects to baking plate uniformly
through a raw of small holes on nozzle. The upper and lower
baking plates open and close and are locked automatically.
The mixture will be dried to white with faint yellow wafer
block under the effect of high temperature.
Operating instruction:
Must inspect the completed machine and
confirm all systems are normal before starting up the baking
machine formally.
Firstly run biscuit template after starting
up exhaust fan and air blower, secondly, ignite. It will
automatically ignite after pressing ignition button and the
fir size can be adjusted through turning the button on the
operation panel.
When turning off the machine, it shall turn
off the ignition button firstly. The exhaust fan and air
blower can only be turned off after 20 minutes.
The speed adjustment of baking plate in
baking machine is realized through frequency converter to
change frequency. The baking speed of the baking plate is
one circle per 85-90 seconds. The running speed of the
baking plate is to be modified by the help of the adjustment
button on the operation panel.
The adjustment baking template’s heating
temperature is realized through adjusting the flame size.
When there is change in water content of flour adhesive and
the running speed of baking plate changes, the flame size
shall be adjusted.
Automatic detection of coal gas and alarming
devices are set for the baking machine, which adopt imported
components to ensure sensitive detection and timely actions.
If the coal gas quantity in the baking machine is detected
over the safety value, the system will alarm and cut off gas
valve immediately.
The ration between the gas and the air in the
baking machine is preciously calculated by the engineer to
ensure the full burning of gas. On one hand, it can save
energy; on the other hand, it can ensure no carbon deposit
jams the burner. Before entering into burning mixture, the
air will through air filtration and will be delivered to mix
by the blower fan after removing dust particle, which is
also a measure to prevent solid matters from jamming burner.
Suggest equipping hand-held infrared
thermometer along with the machine to detect the temperature
at each point of template at any moment to facilitate
adjustment and controlling.
Demoulding of wafer block is perfect. Color
of wafer block is unanimous. The thickness of wafer block is
between 2.5 and 3.2MM, which is adjustable. The thickness
deviance of wafer block is ±0.20mm. This machine can product
23-26 wafer blocks per minute.
Introduction to equipments
and materials making up of electric wafer production
machine:
1. Tunnel baking machine
The hinge-with-bolt tunnel baking machine,
which is outstanding in function, can make the mixture and
baking process done automatically. It’s the most important
wafer-manufacturing machine.
1. The demanding primary
materials are mentioned as follows:
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Material name |
Notes |
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Material name |
Notes |
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1 |
Frame |
Materials with international
standard |
2 |
Track |
Cold drawn steel of No. 45# |
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3 |
Template and die carrier |
Jianmen |
4 |
Electrical machine |
SEW of Germany |
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5 |
Oven door and top cover adopt
imported 304 stainless steel with thickness
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6 |
Heat preservation cotton |
Imported material |
7 |
Oven electric appliance converter |
Panasonic of Japan |
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8 |
Frequency modification device of
completion of mixture |
Panasonic of Japan |
9 |
Switch of distributing box |
Schneider of Germany |
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10 |
Switch of completion of mixture |
Taiwan |
11 |
Clutch |
Hefei |
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12 |
Touching screen |
Mitsubishi of Japan |
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2.
The demanding burning materials are shown as follows:
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Item |
Product name |
Specification |
Notes |
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1 |
Sphere valve |
1-1/2" |
Jinshi of Italy |
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2 |
Vertical filter |
1" |
Singer of America |
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3 |
Pressure reducing valve |
S301 1-1/2" |
Fisher of American |
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4 |
Micro-manometer |
0-1000mmAQ |
Japan |
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5 |
Micro-manometer |
0-2000mmAQ |
Citizen of Japan |
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6 |
Pressure switch |
C6097A |
Honeywell |
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7 |
Electric magnet valve |
1-1/2?VE4040A |
Honeywell |
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8 |
Sphere valve |
1/2" |
Jinshi of Italy |
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9 |
Pressure-free valve |
3/8?KZ-10 |
Fisher of American |
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10 |
Sphere valve |
1/4" |
Jinshi of Italy |
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11 |
Electric magnet valve |
1/4" |
Honeywell |
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12 |
Ignition needle and ignition
stick |
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13 |
Mixture tube |
VM-15 |
Shoel of Japan |
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14 |
Sphere valve |
3/4" |
Shoel of Japan |
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15 |
Igniter |
KP-772 |
Chengyu of Taiwan |
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16 |
Sphere valve |
1" |
Jinshi of Italy |
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17 |
Electric magnet-valve |
1?VE4025A |
Honeywell |
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18 |
Pressure-free valve |
1?A25Z-2 |
Honeywell |
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19 |
Manual butterfly valve
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BVM-65 |
Shoel of Japan |
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20 |
Automatic butterfly valve
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BVC-65 |
Shoel of Japan |
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21 |
Gear motor |
M7284A |
Honeywell |
1. Electronic thermal tunnel baking machine
The hinge-with-bolt tunnel baking machine
which is outstanding in function, can make the mixture and
baking process done automatically. It’s the most important
wafer-manufacturing machine.
The demanding primary materials are shown
as follows:
|
|
Material name |
Notes |
|
Material name |
Notes |
|
1 |
Frame |
Material with international
standard |
2 |
Track |
Cold drawn steel of No. 45# |
|
3 |
Template and die carrier |
Jiangmen |
4 |
Electrical machine |
Jiangsheng of Jiangmen |
|
5 |
Oven door and top cover adopt
imported 304 stainless steel with thickness of
1.2mm |
|
6 |
Heat preservation cotton |
Imported material |
7 |
Oven electric appliance converter |
Panasonic of Japan |
|
8 |
Mixture making converter |
Panasonic of Japan |
9 |
Switch of distributing box |
Schneider of Germany |
|
10 |
Mixture making switch |
Taiwan |
11 |
Clutch |
Hefei |
2. Bonding machine
This machine is mainly used to convey the
wafer block baked in baking oven to cooling machine.
Materials: the machine frame is made of
steel with international standard and the cover adopts
imported 304 stainless steel plate with thickness of 1.2mm.
Decelerating machine (SEW of Germany),
Electrical machine power: 380V 250W
3. Cooling machine
The machine runs slowly to cool down and
convey the wafer block.
Materials: The machine frame is made of
steel with international standard and the cover adopts
imported 304 stainless steel plate with thickness of 1.2mm
andΦ6
stainless raw material.
4. Cream spreading machine
The cream is applied, laid up and
laminated automatically and regularly before the wafer block
is sent to the conveying belt.
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Material name |
Notes |
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Material name |
Notes |
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1 |
Frame |
Material with international
standard |
2 |
The cover adopts imported 304
stainless steel plate with thickness
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3 |
Convey belt |
Italy |
4 |
Continuously
variable transmission |
Xingguang of Foshan |
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5 |
Converter |
Panasonic of Japan |
6 |
Process controller |
Siemens of Germany |
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7 |
Photoelectric switch |
Taiwan |
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Main technical parameters?/font>
Drive electrical machine for cream
spreading roller: JWB-×0.75-40DII
Drive electrical machine for convey belt
and wafer block pressing roller: JWB-×0.75-40DII
Drive electrical machine for to-and-fro
laminating machinery: Y802-4 0.75KW
Power of thermoelectric tube for cream
spreading roller and cream mixing roller: 220V 0.3KW×2
5. Biscuit-transporting machine
The machine conveys the wafer block to
the cutting machine.
Materials: the machine frame is made of
steel with international standard and the cover adopts
imported 304 stainless steel plate with thickness of 1.2mm
and imported orange belt.
Electrical machine (SEW of Germany)
Electrical machine power: 380V 0.55
6. Cutting Machine
The machine is equipped with to-and-fro
conveying belt and it can cut the wafer block to all sizes.
Materials: the machine frame is made of
steel with international standard and the cover adopts
imported 304 stainless steel plate with thickness of 1.2mm
and imported orange belt.
Procedure controller (Siemens of
Germany), Proximity switch (Taiwan)
Electrical machine (SEW of Germany),
Electrical machine power: 380 0.75W N=1400r/min
Decelerating machine type: I=24:1
7. Wafer better mixer
The machine is the mixing system, the
first technology processing equipment in wafer
manufacturing. It adopts the separate delivery and automatic
circulation system.
Material: the machine frame is made of
steel with international standard and the cover adopts
imported 304 stainless steel plate with thickness of 1.2mm
Twin mixing barrels made of imported 304
stainless steel plate with thickness of 3mm, Mixture pump
(Guangzhou)
Electrical appliance switch (Schneider of
Germany), Electrical machine (SEW of Germany)
Main technical parameters?/font>
Mixture quantity per time: 60kg/flour
25kg
Power consumption: main electrical
machine 380V 3KW 2900r/min
Model: Y100L2-4-V1
Mixture pump electrical machine: 380V
0.75kw
8. Cream mixer
The machine mixes the sugar, butter and
other matters abundantly according to the technology
prescription.
Materials: the machine frame is made of
steel with international standard and the cover adopts
imported 304 stainless steel plate with thickness
Cream barrel adopts imported 304
stainless steel plate with thickness of 3mm
Electrical machine (SEW of Germany),
Decelerating machine (SEW of Germany)
Electrical machine power: 380V 5.5KW
9. Wafer smashing machine
This machine is a kind of supplementary
equipment and utilized for waste recycling.
Material: the machine frame is made of
steel with international standard, and adopts imported 304
stainless steel plate with thickness of 3mm
Electrical machine (SEW of Germany),
Electrical machine power: 380V Y112-4 4KW 50H2
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