Step moulding lines

Step moulding lines are ideal for production of wide range of moulded chocolate products, from plain chocolate bars and tablets, through products with ingredients, various recipes of filled products and combinations of chocolate and biscuits.

In technical terms these lines work with loose moulds, which are during step mode transported through individual sections, during which individual technologic operations are executed. Essentially they are fully automatic loop lines. They are ideal for production of wide spectrum of moulded chocolate products, from plain chocolate bars and tablets, through products with ingredients, various kinds of filled products and combinations of chocolate and biscuit. Each section of line is designed and manufactured from modules, which allows for individual approach to needs and requirements of customers. In addition it’s also possible to extend the line by individual sections and modules in the future, and thus to enlarge range of manufactured products or increase of production capacity.

Standard width of mould ranges from 275 mm to 1200 mm and maximum operation speed ranges from 12 moulds per minute to even 30 moulds per minute. Line may also be adjusted to already existing set or sets of moulds given by customer.

Production line usually consists of small loop and large loop. Small loop serves for production of basic spectrum of plain chocolate products and chocolate with ingredients. Large loop is designed for production of filled products with or without various ingredients such as whole hazelnuts, cherries, crushed ingredients or biscuits. Project can be realized also in two stages by future installation of large loop to small loop, which allows for saving acquisition investments and adjusting range of delivery to current needs of customer.

Step moulding lines
  • Step moulding lines
  • Step moulding lines
  • Step moulding lines
  • Step moulding lines
  • Step moulding lines
  • Step moulding lines
  • Step moulding lines
  • Step moulding lines
  • Step moulding lines
  • Step moulding lines
  • Step moulding lines
  • Step moulding lines
  • Step moulding lines
  • Step moulding lines
  • Step moulding lines
  • Step moulding lines
  • Step moulding lines
  • Step moulding lines
  • Step moulding lines
  • Step moulding lines
  • Step moulding lines
  • Step moulding lines

Small loop is composed out of these basic sections:

Station of automatic identification of undemoulded moulds

  • Electromechanical system for identification of undemoulded products in each mould
  • Reliable functionality independent from colour, cleanness of moulds and other possible not suitable operating conditions
  • Signal for the following removal of undemoulded mould automatically and clean mould insertion

Station of automatic mould removing

  • Automatic removing and stacking of moulds in two modes – removing of identified undemoulded moulds or collection of whole set of moulds during change-over on the line

Station of automatic mould insertion

  • Automatic insertion of moulds into each empty position on conveyor from stack of moulds

Tempering section

  • Tempering of moulds to required temperature by transition of moulds through usually two independently controlled tempering zones
  • Designed residential time allows to work with air of its operational temperature, which prevents risk of overheating of moulds when line stops
  • As standard it uses to be designed with walkway for comfortable transition of operators into inner area of moulding line

Infrared heater

  • It serves mainly for melting of possible chocolate or cream residuals on top surface of the moulds for their following cleaning by cleaning roller
  • Heaters intensity regulation, automatic switch off the heaters and change of their position in case of line stopping
  • Metallic heating spirals are guarantee of food safety

Cleaning roller

  • Settable turns of the roller and its automatic shut down and lift it up over the mould in case of line stopping
  • Stainless steel roller tempered by water from its own water system

Mass depositor

  • Depositing piston head designed according to request for dosing of either plain chocolate masses or chocolate masses with inclusions
  • Movements of pistons, movements of inner rotary rollers / “subers” / and other mechanical parts driven by individual servo drives with possibility to comfortably set parameters, individual recipes and its saving

Vibrating section

  • Vibrating section consists from several vibrating stations with possibility to set eccentricity and frequency for each station individually
  • Horizontal vibrators and vertical vibrators are combined depending on sorts of used masses
  • Noise insulating covering of hygienic design

Cooling section

  • Its design enables setting of required cooling profile depending on the recipe
  • Temperature of the air and airflow are independently controlled and settable in each cooling zone

Twister

  • Number of twisting positions and configurable twisting angle ensure required release of products in mould’s cavities prior to demoulding

Demoulding section

  • It allows demoulding of products standardly either directly onto conveyor belt or onto trays
  • Individual demoulding positions are independently adjustable and controlled in order to reach effective demoulding of products created in various geometrical shapes and sizes
  • Option of demoulding into countermoulds or directly into blisters

Large loop additionally contains:

Shell-forming station

  • Combination of high speed shell-forming heads driven by servo drives for effective chocolate shells creation
  • Excessive chocolate mass is in standard production collected into removable collecting vessels and automatically pumped away
  • Effective double wiping of moulds after shell-forming

Cooling tunnel for shells

  • Individual cooling section of horizontal design
  • Equipped with two mould turning devices, option to choose „U“ or „V“ shape of shell

Shell cooling section

  • Independently controlled and regulated section for shell cooling of vertical design

Filling depositor

  • Depositing piston head dedicated for dosing fillings / creams / fat based and water based, which may be either plain or with inclusions
  • Movements of pistons, movements of inner rotary rollers / “subers” / and other mechanical parts driven by individual servo drives with possibility to comfortably set parameters, individual recipes and its saving

Vibrating section

  • Vibrating section consists from several vibrating stations with possibility to set eccentricity and frequency for each station individually
  • Horizontal vibrators and vertical vibrators are combined depending on sorts of used masses
  • Noise insulating covering of hygienic design

Filling cooling section

  • Cooling of filling to required temperature by transition of moulds through usually two independently controlled cooling zones
  • As standard it uses to be designed with walkway for comfortable transition of operators into inner area of moulding line

Bottoming section

  • Pre-heating by infrared heaters
  • Classical depositing piston head equipped with servo drives
  • Vibrating section
  • Wiping / scrapping / station with two-phase wiping and collection of wiped excessive mass into collection vessel
  • Vibrating section

Optional supplementary equipment for moulding lines:

Weighing cells

  • Automatic weight control of dosed chocolate, formed chocolate shells, dosed filling or finished product
  • Regular weight control after set time interval or control of each mould / limited by performance of line /

Mould removing station for off-line weighing

  • Serves for safe removal of always just one mould from line’s conveyor, based on order of staff

Whole hazelnuts depositor

  • Simple and highly effective system for dosing of whole hazelnuts into particular positions in mould’s alveoli

Cherries depositor

  • Simple and highly effective system for dosing of cherries from spirit into particular places in mould’s alveoli

Crushed ingredients, crisps, crocanut depositor

  • Dosing devices designed for dosage of specified volume of ingredients into particular places in mould’s alveoli
  • Design is specific according to kind of ingredients: crushed nuts, crocanut, crisps, mixtures of crushed ingredients

Biscuit feeder

  • Several variations of design for biscuit feeding system according to biscuit shape and size usually into chocolate or cream

Pressing device

  • Device with exchangeable pressing head and changeable height dedicated for pressing of whole hazelnuts, cherries or biscuits into chocolate or fillings

Inclusions dosing and mixing

  • Ideal for feeding of one or more kinds of inclusions at the same time and their transportation into mixing scroll
  • Continual mixing with chocolate mass or cream
  • Feeding of mixture into mass depositor

Tray dispenser

  • Depositing of one tray on top of mould for following demoulding of products onto trays

System of frames and blisters

  • System of feeding and transportation blisters for automatic demoulding of products directly into blisters

Whole production process is controlled by computer. Interface between line and staff is presented by several control panels. Central operating panel with 17inch monitor is standard and with user-friendly screen for complete control over machines and technology of whole line, and additional control panels each with 10 inch screen for higher comfort of control, too.

Following as standard:

  • excellent visualisation
  • short-term and long-term saving of measured values in individual sections of the line
  • shift registers
  • identification of defective states
  • remote service via internet
  • and many more