The sifted flour is poured into an industrial mixer. Temperature-controlled water is piped into the mixer. This mixture is called "gluten" and gives bread its elasticity. A pre-measured amount of yeast is added. The growth of the yeast produces gas bubbles, which leaven the bread. Depending on the type of bread to be made, other ingredients are also poured into the mixer. After the dough has fermented, it is loaded into a divider that cut the dough into pre-determined weights. A conveyer belt then moves the pieces of dough to a molding machine. The molding machine shapes the dough into balls and drops them onto a layered conveyer belt that is enclosed in a warm, humid cabinet called a "prover." The dough moves slowly through the prover so that it may "rest," and so that the gas reproduction may progress. When the dough emerges from the prover, it is conveyed to a second molding machine which re-shapes the dough into loaves and drops them into pans. The pans travel to another prover that is set at a high temperature and with a high level of humidity. Here the dough regains the elasticity lost during fermentation and the resting period. From the prover, the pans enter a tunnel oven. The temperature and speed are carefully calculated so that when the loaves emerge from the tunnel, they are completely baked and partially cooled.
Application: Flour is stored in silos before being transferred into the production process.
Challenges: Knowing the amount of stored flour is critical for the production flow, since without it production will be interrupted or stopped altogether On time ordering of the right quantities will prevent overflows as well as wasted production time. Flour tends to stick to the silo walls, creating build-ups and rat holes, early detection will ease maintenance, reduce maintenance cost and allow optimal use of the silo content. Different types of flour cannot be mixed together in some cases, and knowing the actual volumes of stored flours can be crucial to the quality of the final product. Rosemount's 3D Solids Scanner provides accurate real-time measurements of the volume of the different types of flour stored in separate silos, taking into account such build-ups and rat holes. The 3D Solids Scanner's visualization tool allows the end-user to see the allocation of material inside the silos in real time, facilitating the scheduling of any required maintenance and cleaning before damage is caused to the product or unexpected interruptions of the baking process occur.
Application: Sugar is stored in silos before being added to the mixture.
Challenges: Sugar and sugar dust tend to accumulate, creating build ups and rat holes, so understanding actual material content continuously becomes very difficult. The materials' sticky nature challenges level measuring systems which need to operate even if sugar sticks to the antenna or other system parts. Rosemount's 3D Solids Scanner is capable of working in this harsh environment. The 3D Solids Scanner's 3D visualization tool provides a real time 3D display of the sugar's distribution inside the silos, including these build-ups, facilitating timely maintenance and reducing interruptions risks to the delivery schedule and the associated losses of time and money.