Case Study: Doughnut Line

Client and Challenge

One of the large-volume doughnut manufacturers was updating its production line to add a fryer to a downstream glazing/packing operation.

They required a 8.1m conveyor that was capable of:

• Move hot, delicate doughnuts without deformation or sticking.
• Cooling the hot doughnuts
• Keep a steady distance and position to fit the receiving machine.
• Combine with other control and safety systems.
• Enhance high food hygiene and wash-down standards with minimal interruption.

The current system relies on shorter, partial conveyors and manual operations, leading to micro-stoppages, product flow variability, and sanitation issues.

VCSP Solution

Based on experience with custom food-grade conveying systems, VCSP developed a stainless-steel belt conveyor with motors and an open-wire-mesh belt to convey doughnuts. The important features of the design were:

• Stainless-steel frame, 8.1m long, which has been designed to fit the height and footprint of both machines.
• An open area; a food-grade wire-mesh belt, chosen for its lack of a cover, drainage, and contact with the product, suitable for oil-fried baked goods.
• Belts driven by a motor, which can be adjusted to keep up with upstream and downstream equipment and adjust throughput to balance.
• Open profile hygienically constructed materials with limited horizontal surfaces and easy-access guards to provide wet cleaning and inspection.
• Programmable power and control interface to enable the conveyor to come in and out and interlock with the remainder of the line.

Implementation and Integration

VCSP collaborated with the bakery’s engineering team to survey the existing line, verify interfaces, and install within an allocated maintenance window. Steps included:

• Measurement and three-dimensional modelling of the transfer route between the fryer and the subsequent processing machine.
• Fabrication of the conveyor using food-grade stainless steel, supports, belt, side guides and drip control.
• Test-run in the factory to demonstrate that the belt tracks, the performance and speed range of the motor prior to delivery.
• Installation on location, line alignment, and electrical connection to the customer’s existing safety and control system.
• Commissioning live product, adjusting the belt speed and position of the guide to ensure the protection of the doughnut shape and surface finish.

Results For The Bakery

Following commissioning, the bakery reported significant operational and quality gains. Although the specific numbers will depend on the shift, the line improvements included:

• More uniform, continuous flow of products among machines, with little or no minor stoppage and manual inputting.
• Light treatment of doughnuts, where the number of damaged or misshapen products is less likely to reach the glazing and packing stages.
• The open wire-mesh structure and hygienic stainless-steel construction, which is easily washed and inspected, facilitate quicker, easier cleaning.
• Cooling the doughnuts for the next production stage
• Better utilisation of the line, since the 8.1m conveyor is now a reliable connector between two important pieces of equipment, helping ensure the target throughput is maintained.

Why The Bakery Chose VCSP

VCSP was chosen by the bakery because it has a background in the food industry, custom-made stainless-steel fabrication and a history of providing hygienic conveying systems. The capability of VCSP to design, produce and assemble a customised 8.1m doughnut line, including motors, wire-mesh belt and controls, provided the client with a scalable, future-proof solution that will enable continued production growth.