Maintaining stable fermentation conditions for microbial activity

The balance between lactic acid bacteria and yeast cultures determines the acidity profile, aroma compounds and functional properties of sourdough. To stabilise this process, Agriflex fermentation systems use temperature-controlled stainless steel tanks combined with controlled agitation. The mixing system keeps the sourdough homogeneous throughout the fermentation cycle while scraper geometries prevent sedimentation or crust formation on the tank walls. Maintaining uniform temperature and hydration conditions allows microbial activity to develop under stable and repeatable conditions.

Automated sourdough handling integrated into dough production lines

The fermentation units are designed to operate as part of an automated ingredient handling and dough preparation system. Sensors continuously monitor fermentation temperature and process timing, while controlled mixing maintains homogeneous sourdough properties during long fermentation cycles. Once the desired fermentation stage is reached, the sourdough can be automatically discharged and dosed into industrial mixers. This controlled process allows bakeries to maintain consistent sourdough characteristics while integrating fermentation into high-capacity bread production environments.

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Fluidised Air Cooling and Dehumidification for Powdered Ingredients

In many industrial bakeries, flour is stored in silos or handling systems where temperature and humidity vary depending on climate and storage duration. These variations can affect dough hydration, fermentation kinetics and mixer performance. Agriflex addresses this challenge with a two-stage cooling process. First, ambient air is cooled and dehumidified through a tubular heat exchanger connected to a refrigeration circuit. The treated air is then separated from condensate in a vertical treatment unit, producing cold, dry process air that can be used for ingredient conditioning.

Inline Ingredient Cooling Through a Spiral Heat Exchange Circuit

The cooled air is introduced into a pneumatic conveying circuit where the ingredient passes through a spiral stainless-steel pipe immersed in a cooling exchanger. This configuration maximises heat transfer surface area while maintaining continuous ingredient flow. Sensors and probes monitor the temperature in real time, allowing the system to stabilise ingredient temperature automatically before dosing to the mixer. Depending on process conditions, the system can reduce ingredient temperature by more than 30°C while maintaining homogeneous thermal conditions and avoiding thermal stress on the flour. Because the process operates in a closed circuit, no ice or external cooling agents are required, ensuring recipe integrity and hygienic handling of raw materials.

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Grinds Sugar into Consistent Icing Powder

The Bauermeister UCOM Sugar Grinding Mills are engineered for precision and efficiency in food processing. These mills feature explosion-resistant construction compliant with Atex 2014/34/EU regulations, ensuring safety in sugar processing facilities. They are specifically designed to produce icing sugar with fineness up to 90%

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Fills, Seals, and Packs Diverse Products

The VFFS Packaging Machine from Syntegon revolutionizes packaging with its versatile design for both the food and pharmaceutical industries. It excels in filling, sealing, and packing various products such as bread rolls, cornflakes, and espresso pods. Utilizing continuous and high-speed operation, it seamlessly integrates into existing production lines, enhancing efficiency. The machine supports multiple bag styles, including Doy Zip and stick packs, and boasts an easy-to-use HMI for rapid changeovers and minimal downtime. Built with robust servo technology, it ensures energy efficiency and precision, helping manufacturers meet stringent hygiene and industry standards. Custom engineering options and maintenance services are available to match specific operational needs.

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Automates Product Handling and Packaging Processes

The Syntegon Robotic Pick and Place Platform (RPP) offers a game-changing solution for diverse industries seeking to advance their packaging operations. This modular platform excels in automating product handling and placement with precision and efficiency.

Using integrated delta robots, the RPP system provides seamless product loading into trays or cartons, capable of achieving up to 140 picks per minute per robot, optimizing high-speed environments. Its design supports applications across pharmaceuticals, bakery products, confectionery, dairy, and more, enhancing operations from ampoules to chocolate bars.

With its compact footprint, the RPP is PLC-controlled, supporting remote monitoring and smart interface integration for scalable capacity adjustments. Its construction in stainless steel offers superior hygienic operations and compliance with rigorous industry standards, including IP65 protection for wash-down scenarios. The platform’s vision-guided inspection technologies ensure tight quality control, identifying and removing any defective products in the process.

Syntegon’s RPP system includes quick-change end-of-arm tooling for format flexibility, supporting gentle and safe product handling while reducing contamination risks. It simplifies cleaning with its open-channel, self-draining design, paired with optional CIP systems. Custom configurations and engineering support are available to tailor the platform to your specific production demands, ensuring streamlined integration into existing production lines.

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Packs, Seals, and Wraps Varied Products Efficiently

The Pack 102, Pack 403, and Sigpack HML from Syntegon are versatile horizontal flow wrappers that revolutionize packaging across multiple industries. These machines efficiently pack, seal, and wrap products like chocolate, croissants, detergent pods, and blister packs through seamless integration into your production line. With an automatic, high-speed operation capable of processing both entry-level and complex applications, these systems handle a diverse range of materials including solids, powders, and frozen goods.

The flow wrappers incorporate a horizontal form-fill-seal process, ensuring tight, reliable seals through heat, cold, or ultrasonic technologies. Syntegon’s equipment boasts throughput capacities from startup-friendly speeds to high-output levels of up to 1,500 packages per minute. They facilitate eco-friendly transitions with options for recyclable mono-materials and paper-based solutions.

Designed for easy integration, they offer synchronized system operations with a uniform control platform for enhanced product flow. Syntegon provides customization and engineering support, allowing tailored solutions to meet specific packaging requirements, ensuring optimal operational efficiency, and supporting your production goals. These wrappers meet stringent hygiene standards, with easy-to-clean components, making them suitable for food and pharmaceutical production environments.

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Automates Case Packing for Varied Product Formats

The Elematic series from Syntegon offers versatile case packers engineered for the pharmaceutical and food industries. Capable of handling a broad spectrum of product formats—from ampoules and syringes to snacks and confectionery—these machines provide seamless automation and integration into existing lines. With wraparound, sideload, and topload options, the Elematic case packers accommodate continuous and high-speed operations, ensuring both flexibility and efficiency. Their PLC-controlled systems and optional automated format changeovers optimize throughput while reducing downtime. The machines are designed to work with various packaging materials, including recycled and alternative fibers, meeting sustainability goals. Compliance with industry standards ensures these packers are suitable for stringent operational environments. Maintenance is straightforward, aided by ergonomic design and toolless changeovers, keeping operations smooth and scalable.

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Seals and Secures Diverse Product Packaging

The CBS-D-750 series and Doboy range from Syntegon represent versatile bag sealing solutions tailored for medical, food, and non-food industries. These machines excel with their reliable sealing capabilities, addressing critical packaging demands for end-products like sterile syringes and packaged meals. They employ continuous and manual sealing processes, achieving up to 30 meters per minute throughput, and handle diverse packaging forms such as pouches and cartons.

A PLC-controlled system enables seamless integration into automation lines, with models accommodating varying operation speeds and product sizes. The designs prioritize energy efficiency and ease of maintenance, with options like pinch-top and glue sealing, catering to specific material needs. Built with robust materials, these machines maintain high performance across a spectrum of applications, ensuring compliance with relevant industry standards, including GMP requirements for pharmaceutical products. Custom engineering support and flexible configurations are available to meet unique production challenges.

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Forms, Loads, and Closes Cartons Efficiently

The Kliklok ACE from Syntegon is an integrated cartoning system designed to meet the demands of high-speed, flexible packaging across a variety of industries. Distinguished by its ability to perform forming, loading, and closing in one seamless sequence, it enhances productivity while minimizing downtime. With its advanced automation, the Kliklok ACE accommodates a broad spectrum of products from pharmaceuticals to frozen foods, including blister packs, protein bars, and chocolate chip cookies. The system features high-capacity throughput, capable of handling continuous operations at varying speeds. Syntegon’s cartoning equipment offers compatibility with both solid and packaged products, ensuring precise alignment and gentle handling. The PLC-controlled interface enables straightforward integration into existing lines and provides remote-monitoring capabilities for enhanced oversight. Constructed with durable materials, the Kliklok ACE is designed for easy maintenance and delivers energy efficiency, reducing operational costs while maintaining performance. Compliance with industry standards ensures reliable operation for pharmaceutical and food production environments. Moreover, customization options are available to tailor the system to specific production needs.

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