Client: A Growing Commercial Bakery, Dominican Republic
Production Line: Industrial Burger Bun Production Line
Capacity: 10,000 pcs/hour
Solutions Provider: IMAR Equipment
The Client's Strategic Needs:
Meeting Contract Demands: Needed guaranteed, consistent output to fulfill a major new contract with a national restaurant chain.
Production Flexibility: Required a line capable of producing multiple bun sizes without extensive downtime for changeovers.
Optimizing Footprint: Limited factory space demanded a compact and efficient line layout.
Tropical Climate Resilience: Ensuring stable fermentation and consistent product quality in a hot and humid environment was a critical challenge.
IMAR's Adaptive Burger Buns Solution:
IMAR engineered a robust yet agile production line, prioritizing precision and quick-change capabilities to empower the client's market expansion.
- Versatile Dough Mixer: A spiral mixer chosen for its gentle, efficient mixing action, ideal for developing the uniform, soft texture required for premium burger buns.
- Divider & Rounder: Equipment with quick-change settings allows for seamless weight adjustment and shaping for different bun sizes, minimizing changeover time and waste.
- Climate-Controlled Proofer: A specially insulated proofing cabinet with precise humidity and temperature management compensates for ambient conditions, ensuring perfect rise and volume every time.
- Compact Direct-Fire Tunnel Oven: A space-saving oven with a dedicated baking surface for even browning and the signature "burger bun" top-shine, all while being highly fuel-efficient.
- Automated Cooling & Slicing: A multi-tier cooling conveyor optimizes floor space. The integrated bun slicer ensures clean, precise cuts ready for packaging.
The entire line is managed by a user-friendly PLC, allowing for recipe storage and one-touch changeovers, making it simple for operators to manage.
Embracing the Future of Manufacturing
With global bakeries rapidly shifting toward digitalized and smart manufacturing, the integrated PLC in this line represents a crucial first step in closing the automation loop. IMAR Equipment envisions future upgrades for this facility, all designed to further drive down operational costs and enhance sustainability.
Key Outcomes Delivered:
1 Secured Major Contract: The reliable output of 10,000 buns per hour enabled the client to confidently secure and fulfill their pivotal QSR partnership.
2 Enhanced Operational Agility: Quick changeover capabilities allowed the bakery to respond swiftly to varying customer orders, increasing their market responsiveness.
3 Maximized Space Utility: The compact line design fit perfectly into the existing facility, eliminating the need for a costly factory expansion.
4 Uncompromised Quality: Consistent product size, texture, and color strengthened the client's reputation as a premium supplier to the foodservice industry.
