Standard gas-heated wafer production line

APPENDIX 1

EQUIPMENT TECHNICAL SPECIFICATIONS

1. DJ Liquid Batter Mixer

Designed to prepare batter for wafer sheets. After mixing, the batter is pumped into an intermediate tank and supplied to the oven by pump as required.

• The mixer and holding tank are integrated into one unit; flour loading per batch: 25 kg.

• The paddle mixing assembly is easy to clean; 25 kg of flour is mixed with water and other ingredients to produce 65 kg of batter in approximately 3 minutes.

• The mixing tank is made of SUS304 stainless steel.

• Welded carbon-steel frame with heat-resistant silver coating.

• SEW motor; SKF bearings (Sweden); Schneider AC contactors; batter feed pump from a well-known Chinese brand.

Dimensions: 1720 × 1100 × 1000 mm. Total power: 4.5 kW, including a 3 kW mixer motor and two 0.75 kW pumps.

2. SWT-51 Gas-Fired Wafer Baking Oven

The main unit of the line. Gas heats the baking plates. An automated system distributes batter across the plates and ensures uniform baking of wafer sheets.

• Welded carbon-steel frame with heat-resistant silver coating.

• Plate holders are made of high-strength QT500 ductile iron; baking plates are made of special heat-resistant cast iron. The plate surfaces may have a hard-chrome coating.

• Outer oven cladding is SUS201 stainless steel; internal insulation panels reduce radiant heat.

• Triangular burners with plum-blossom-shaped nozzles; gas components manufactured in Italy and Japan.

• Drive with automatic tensioning; touchscreen displays operating status and parameters.

• Components: SEW motor, SMC pneumatics, SKF VA201 and SKF Explorer bearings, Schneider contactors and circuit breakers; Siemens S7-200 or Mitsubishi FX-1N controller; Danfoss or Panasonic frequency inverter; Siemens Smart Line 1000 or Hakko touchscreen; Sick photoelectric sensor; Optex SD-105 proximity sensor.

Main specifications: gas heating; 51 pairs of baking plates; standard plate size 470 × 325 mm. Total power stated in the technical description: 30 kW; main drive 2.2 kW, blower 2.2 kW, batter feed pump 0.75 kW; 380 V, 50 Hz. Gas consumption for a 55 g sheet and a 470 × 325 mm plate: 58 m³/h. Output: approximately 26 sheets/min (51 plates in 2 minutes). Sheet size: 464 × 321 × 2.5 mm. Oven dimensions according to the technical appendix: 10550 × 1700 × 2260 mm; weight: 16 t.

3. JP-5 Wafer Sheet Receiving Machine

Receives hot wafer sheets from the oven, removes residue and transfers them to the cooler. Gentle transfer reduces the risk of sheet damage. Food-contact parts are made of SUS304 stainless steel and food-grade polyurethane belt.

SUS201 frame; silver-painted carbon-steel supports. The five-point receiving wheel rotates opposite to the oven drive wheel at the same speed. Three rows of brushes remove crumbs. SEW motor; TR/SKF bearings. Dimensions: 2300 × 700 × 850 mm; power: 0.37 kW.

4. LPM4 Walk-Through Wafer Sheet Cooler (Fan Type)

Provides natural cooling of the sheets and reduces thermal stresses that could cause breakage during further processing. The walk-through design allows personnel to pass underneath the equipment.

SUS201 frame; separate drive motor; PLC control with photoelectric monitoring and automatic indexed movement. Product-contact parts are SUS304. SEW motor; TR bearings. Dimensions according to the technical appendix: 2280 × 720 × 2730 mm; power: 0.37 kW; effective capacity: 60 sheets; stainless-steel 12A double-pitch chain; spacing between sheets: 76 mm.

5. SP4 Wafer Sheet Collector

Automatically collects acceptable wafer sheets coming from the oven if the cream spreading machine or cooling tower experiences a temporary malfunction. The sheets can be returned to production after the fault is resolved. Detection and collection of chipped sheets are provided, as well as sheet blocking in the event of a cream spreader malfunction.

Stainless-steel frame; painted carbon-steel supports. Product-contact parts are SUS304 and food-grade PU belt. Dimensions: 2000 × 700 × 760 mm; power: 0.18 kW; SEW motor.

6. TC4 Cream Spreading Machine

Applies cream evenly to pre-cooled wafer sheets, forms wafer blocks with a specified number of layers and lightly presses them. The number of layers is adjustable (3, 4 or 5), as is the cream layer thickness. Automatic temperature control is provided for the dosing roller.

• Modular cream spreading head for easy disassembly and cleaning; rotating layer-stacking mechanism; two-roll press.

• Feed/spreading belt: 5 mm thick rubber belt; pressing is performed by a pneumatic cylinder.

• Separate electrical cabinet, PLC control and touchscreen; the standard version has no hot-air unit.

• Sheet blocking and discharge are provided when the machine stops.

SEW motor, SMC pneumatics, TR bearings, Schneider contactors; Siemens S7-200 or Mitsubishi FX-1N controller; Danfoss or Panasonic inverter; Smart Line 700 or Hakko touchscreen; Sick and Optex SD-105 sensors.

Dimensions: 3000 × 1200 × 1300 mm. Total power: 2.62 kW; motors for the spreading belt, roller, stacking and pressing: 0.75, 0.75, 0.37 and 0.75 kW respectively. Heating is specified as 1.5 kW; rollers: 0.5 kW × 2; hoppers: 0.25 kW × 2. Number of layers: 3–5.

7. LF Vertical Cooling Tower

Cools cream-filled wafer blocks so that the cream sets and the blocks can be cut cleanly and packaged. Cooling time depends on the product; estimated at 15–25 minutes. Products are placed on holders and moved by an indexing conveyor.

Stainless-steel housing; product-contact parts are SUS304; cooling fan installed separately. SEW motor; TR bearings; Schneider contactors; Mitsubishi FX-1N PLC; Panasonic inverter; Hakko touchscreen; Sick and Optex SD-105 sensors. Dimensions: 3130 × 1200 × 3600 mm. Power: 1.11 kW (0.75 kW main motor, two 0.18 kW conveyor motors). Incoming cold-air temperature: 10–13 °C; relative humidity: 55%.

7.1. Refrigeration System / Cold-Air Blower

Designed to cool and dehumidify the cold air. R22 Freon is used as the refrigerant.

Copeland compressors (USA); digital microprocessor temperature controller; protection against overload, high/low pressure, startup problems and shutdown; Schneider electrical components; housing panels with polyurethane insulation. Dimensions: 2200 × 1100 × 1800 mm. Compressors: 4 hp × 1 and 3 hp × 2. Centrifugal fan: 1.5 kW, 380 V, 50 Hz. Temperature range: 5–8 °C; control accuracy: ±1 °C; one evaporator and one condenser.

8. QSS Wafer Block Conveyor

Transports wafer blocks to the cutting machine. Stainless-steel construction; food-grade belts, chain drive with tensioning device and support strips beneath the belt to prevent wafers from falling or breaking. Product-contact parts: SUS304 and food-grade PU belt. SEW motor, TR bearings, SMC pneumatics, Schneider contactors.

Dimensions: 1500 × 700 × 780–1100 mm; weight: 80 kg; power: 0.18 kW. Designed for operation with the JDX4 cutting machine.

9. JDX4 Cutting Machine

Cuts cream-filled wafer blocks. The number of layers is selected according to requirements; piece dimensions are changed by replacing the blades/blade assembly. Reciprocating chain drive; trimmings are collected automatically. Blade cutting provides a clean cut with minimal damage to the block. A connecting holder and transparent safety guards that open and close quickly are provided.

Carbon-steel frame with SUS304 cladding; all food-contact parts are SUS304. SEW motor; TR bearings; Schneider contactors. Dimensions: 1620 × 2300 × 1240 mm; weight: 400 kg; power: 0.75 kW; maximum cutting speed: 9 blocks/min; cutting-edge thickness: 0.3 mm.

10. WG Horizontal Cream Mixer

Stainless-steel mixer for cream preparation. Two mixing elements rotate in opposite directions. Cream is discharged using a tilting mechanism. Mixing time depends on the cream formulation.

Capacity: 250 L; double insulated jacket made of SUS304; blades of 2Cr13/SUS304 stainless steel; carbon-steel frame with SUS304 cladding. Each batch uses 30 kg of solid palm fat and 40 kg of powdered sugar. SEW motor, TR bearings, Schneider contactors. Dimensions: 1840 × 850 × 1350 mm; weight: 1000 kg; total power: 5.05 kW (mixer 4.5 kW, tilting mechanism 0.55 kW); mixing speeds: 1400 and 700 rpm.

11. F Wafer Trimmings Crusher

Crushes trimmings produced during cutting for reuse and waste reduction. Crushed material may be added to the cream according to the recipe. SUS304 housing; 3 kW SEW drive motor. Wafer baking waste is approximately 2%.

APPENDIX 2. ACCEPTANCE CRITERIA

• The equipment must comply with the Russian standard.

• The proportion of acceptable wafer sheets at the collector output is up to 98%; criteria: clear pattern, adequate filling and uniform baking.

• Deviation in the weight of applied cream on the wafer block conveyor: ±3%.

• For a 50 g wafer sheet and five sheets with four cream layers, estimated output is: cream-to-wafer ratio 1.25:1 — 1.96 t/24 h; 1.35:1 — 2.05 t/24 h; 1.5:1 — 2.18 t/24 h.

• The line must run smoothly and provide continuous production; each unit is checked against the line technical specifications.

• Stainless-steel sheet thickness: 1.2 mm.

• Circuit breakers and contactors: Schneider; intermediate relays: Omron or Schneider.

• The oven, cream spreading machine, cooling tower and cutting machine have audible and visual alarms.

• The cream spreading and cutting machines have safety guards; the cream mixer and crusher have protective covers.