Client: A Leading Industrial Bakery in Vietnam
Production Line: Fully Automatic Butter Buns Production Line
Capacity: 30,000 pcs/hour
Solutions Provider: IMAR Equipment
The Client's Core Challenges:
Capacity Ceiling: Existing machinery was incapable of meeting surging market demand, creating an urgent need to break the 30,000 pieces per hour barrier.
Rising Energy Costs: With escalating energy prices in Vietnam, the client had a critical requirement for a production line with superior energy-saving performance.
Labor Dependency and Inconsistent Quality: Reliance on manual processes led to variations in weight, shaping, and proofing of the butter bread, compromising brand consistency.
Stringent Hygiene Demands: Maintaining strict hygiene standards in Vietnam's high-humidity climate presented an ongoing challenge.
IMAR Equipment's Butter Buns Solution:
- IMAR's engineering team conducted an in-depth analysis of the client's pain points and designed a comprehensive, efficient, and energy-conscious production line. The solution featured:
- High-Speed Double-Arm Mixer: Specifically engineered for rich butter-based dough, ensuring optimal gluten development and uniform butter distribution for superior dough elasticity.
- High-Precision Dough Divider and Rounder: Guaranteed exact weight control, establishing a foundation for standardization and reducing raw material costs.
- Intelligent Proofing System: Utilizing PLC-controlled temperature and humidity, optimized for the local climate, to ensure every batch of butter bread proofs perfectly with consistent volume and internal texture.
- Energy-Efficient Tunnel Oven: Incorporated advanced insulation and heat-recirculation technology to minimize thermal loss. A unique heating profile delivers the ideal golden color and fluffy texture for each loaf.
- Efficient Cooling Conveyor: Rapidly and uniformly reduces bread temperature, locking in moisture for optimal slicing and packaging.
- Fully Automatic Slicing and Packaging System: Enabled a completely touch-free process from oven to final package, maximizing hygiene and minimizing labor.
The entire line is synchronized by a central PLC system, allowing for seamless module integration and real-time monitoring. This modular batch control is key to delivering consistent output and simplified, data-driven energy management.
Key Outcomes and Value Delivered:
Production Breakthrough: Successfully achieved the target output of 30,000 pieces per hour, increasing the client's production capacity by over 20% and enabling rapid market expansion.
Substantial Cost Reduction: Full automation cut labor costs by over 15%, while the energy-optimized tunnel oven improved thermal efficiency by approximately 25%, drastically reducing per-unit energy consumption.
Enhanced Quality and Hygiene: Product consistency and hygiene compliance reached new heights, strengthening brand reputation with end-consumers who praised the bread's superior taste and appearance.
Streamlined Operation and Maintenance: The user-friendly HMI and modular design simplified both equipment maintenance and operator training.
