Compressed air-free spraying system for high product quality and reproducibility in the baking process

Precise spraying for fine pastries: By using an individual technotrans spraying system, Confiserie Mellinia, a subsidiary of Coppenrath Feingebäck, improves its product quality and saves energy and resources.

Precision and reliability along the entire process chain play a key role in the production of pastries. This also applies to the application of water, which ensures a pleasantly soft consistency in gingerbread, for example. Confiserie Mellinia invested in a tailor-made technotrans spraying system to optimize this process and thus improve the product quality and, in particular, the reproducibility. Thanks to the precise, compressed air and mist-free water application, Mellinia, a subsidiary of Coppenrath Feingebäck, saves around 30 percent water and prevents unwanted deposits in the production environment. The fully mobile design of the technotrans solution with pivoting spray bars also makes cleaning and maintenance considerably easier.

The family bakery Coppenrath Feingebäck GmbH, based in Groß Hesepe, has been producing high-quality products for almost 200 years, which are now available in more than 60 countries around the world. For the company, now run by Andreas Coppenrath in the sixth generation, quality and the environmentally conscious and energy-efficient production of its products are of particular importance. For this reason, the baked goods manufacturer continuously invests in optimizing its systems and processes. This claim applies not only to the main plant, but also to the Coppenrath subsidiary Confiserie Mellinia GmbH in Großröhrsdorf. When the traditional bakery near Dresden was looking for a new spraying system for its largest baking line, it found the ideal partner in technotrans, who designed an application-specific solution.


"As one of the few German manufacturers, we at Mellinia produce gluten-free gingerbread with a lot of manual work and care. To give the gingerbread its characteristically soft consistency, it is moistened with water after backing to absorb the necassary moisture," explains Michael Reher, Product Development at Coppenrath Feingebäck. However, the use of an existing spraying system with two-substance nozzles led to fluctuations in quality due to inconsistent water application. In addition, it generated an undisrable water mist in the production envirronment, which resulted in condensation and water loss. "Our requirements for the new spraying system were therfore clearly definded: a continuous, uniform and mist-free application of water in stable quantities as well as high level of reproducibility," says Reher. 

Application-specific design as a mobile system

In order to meet these requirements, technotrans developed a customized spraying system based on the spray.xact food series in close cooperation with Coppenrath Feingebäck. This was preceded by extensive laboratory tests at the technotrans headquarters in Sassenberg, where Coppenrath was able to gain an impression of the precise water application. "The result convinced us. In a direct comparison with the competition, technotrans was the only supplier that was able to fully meet our requirements," emphasizes Reher. Due to the spatial conditions in the production facility, Coppenrath also deliberately opted for a mobile system in order to have more flexibility. The technotrans solution is used on the manufacturer's largest baking line, which produces seasonal products such as gluten-free gingerbread in addition to year-round baked goods. A corresponding sensor recognizes the freshly baked products and then starts the spraying process.


The system has two spray bars set one behind the other with a spray width of 1,000 millimetres in order to apply the required amount of liquid evenly using pre-moistening and main moistening. The spray bars are equipped with compressed air-free, high-frequency valves that prevent mist formation and produce a precise, homogeneous spray pattern. This saves resources, as the system completely dispenses with compressed air and only uses minimal amounts of water. Coppenrath Feingebäck is impressed by the high level of precision: "We are now able to set the exact amount of moisture via the system's control panel - we believe this is unique on the market," says Reher. The water tank is also equipped with a fill level sensor and provides precise information about the level of the medium at all times. It is filled via a central supply or manually during production so that there is no downtime. All of the material used in the technotrans spray system is certified food-safe.


Optimum accessibility for cleaning and maintenance

A special feature of the fully mobile spraying system is its maintenance and cleaning-friendly design. Hary Kosciesza, Business Development Manager at technotrans, explains the advantages of the design: "The system can be moved as a whole and the spray bars are located on a pivoting frame, which makes it easy to change position - for example, to clean the entire system in a separate washroom." The control panel is equipped with a splash guard, all edges on the tank are rounded and the entire system is designed to be watertight. In addition, the spray valves can be completely dismantled, for example for maintenance or to clean them completely in an ultrasonic bath. The software has a special rinsing program that allows cleaning agent to flow through a circulation line - the valves are rinsed free at the same time.


With regard to the cooperation with technotrans and the satisfactory results after the commissioning, Coppenrath Feingebäck draws a positive conclusion and emphasizes the comprehensive quality of the consulting services. "The professionalism and the constructive exchange with the service department were very good. technotrans responded specifically to our needs and integrated its spraying system perfectly into our existing systems," emphasizes Reher. The user's satisfaction is reflected in the expansion of the cooperation: Coppenrath Feingebäck has already ordered two more spraying systems for the application of a vegetable release agent. Additional systems, for example for spraying products with egg, are also under discussion.


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