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As well as in the biscuit and cracker sector, Imaforni also plays a leading role in the design and supply of complete turn-key lines for the production of layer cakes, Swiss rolls, mini Swiss rolls or muffin-like products. Despite the fact that sponge-type products and muffins can be considered as similar products from a marketing point of view, the processes involved in manufacturing them are completely different. The top professional quality of Imaforni is a guarantee of performance and of the highest standards of production also in these sectors.
The ingredients, stored in tanks and silos, are blended together in a suitable mixer for approximately 90 seconds; the batter is stored in an intermediate tank and then pumped through a turboemulsifier which incorporates large quantities of air. A second pump transfers the emulsion to the hopper of a specially designed depositor, which continuously deposits a layer of batter directly onto the oven band.
Sugar sprinklers and/or decorators can be used for the production of more sophisticated products.
By means of a specially designed device, the oven band is uniformly greased to make sure the baked product can be detached properly. The baking phase is crucial for correct and uniform development of the sponge and normally takes about 6-7 minutes.
After baking, the sponge can be cooled either on an in-line overhead conveyor or on a cooling conveyor placed below the oven in order to save space.
The sheet of sponge then enters the decorating section, where a number of devices cut the product longitudinally, inject alcohol and/or cream (if required). The product can be rolled up manually, or automatically where high production rates are required or where labour costs are high.
The sponge product can then be coated with chocolate and cooled before being sent to the packaging section, which may occur in two steps: individual wrapping of each product, followed by multipacking of a set number of products.
The ingredients are normally weighed and loaded into the mixer automatically. The cycle usually takes around 10 minutes and is concluded when the batter is transferred to an intermediate tank which feeds the hopper of the depositor.
The batter is normally deposited in small paper boxes which are automatically loaded onto metal frames by a pneumatic system prior to the depositor.
The depositor may be made with a double head to produce two-colour products. For the production of more sophisticated products, it is also possible to position two depositors one after the other.
The task of the oven is to transform the liquid material into a tasty, edible, appealing food; consistent temperature and uniform baking are essential factors for obtaining the desired lift and quality.
After a set period of cooling, the products are demoulded by a vacuum device from the metal frames, which then return to the depositing stage.
Savoiardi are one of the most traditional Italian-style biscuits and are known the world over. They recipe is very rich as it is based on eggs, while the texture is fairly open. They are widely used in Italian homes for the preparation of the famous “Tirami sù” traditional Italian dessert. In our country, every mother knows how to prepare this cake for her children and family!
In other countries, Savoiardi are known as “Boudoir biscuits” and “Ladyfingers”.
Imaforni can be considered as the leader in this process technology for we have 30 years’ experience in the supply of the biggest and most fully automated production lines throughout the world.
Lines for the production of ladyfingers can be supplied with a capacity of 400/800 up to 1200 kg/hour.
The ingredients, stored in suitable tanks and silos, are blended together in a vertical mixer; the batter is stored in an intermediate tank and then pumped through an aerator and fed to the hopper of a specially designed depositor. The batter is deposited in metal tins and then coated with icing sugar. The excess sugar is then recovered and recirculated, during which time the batter rests and settles, which is very important for its further development.
Correct baking is crucial if one is to obtain a high quality product. The oven generally consists of three zones: the first is very important for the development of the desired texture of the product, where it is essential that a constant and uniform temperature of around 210 ºC is reached within the baking chamber. The second zone is where the real baking process takes place. The last zone is used for gentle baking to stabilize the overall condition of the product.
After leaving the oven, the product is gently detached from the tins by a specially designed device, then cooled at room temperature and automatically demoulded and conveyed to wrapping and packing.
The tins, on the way back to the depositing stage, are brushed, greased, flour dusted and the excess of flour is removed by a vacuum system, in order to provide perfectly clean tins ready to receive the batter.
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