Rademaker BV

Hygienic Design in Industrial Bakery Equipment
Rademaker bakery solutions are exceeding the standard

Manufacturers of bakery and food equipment are multi-taskers. They must meet increasingly stringent legal standards, guarantee operator safety and deal with the increasing awareness of consumers with regard to healthy living. For instance food safety regulations often require very specific adaptations in equipment design.

Material choices are limited, therefore, combinations of disparate obstacles such as such as surface roughness and the requirement for regular cleaning, often results in a compromise being made in other important aspects such as system safety, durability and cost-price. In addition, there is the never ceasing economic pressure to increase production and reduce costs. Balancing these competing agendas is critical to the success of industrial bakeries. With Rademaker at your side, you can rest assured that you will be provided with hygienic solutions that are state-of-the-art and that will allow you to face the future with confidence.

Food safety; it's self-evident
Food safety has always been paramount, never more so than in today's world where news of recalls or related illnesses circle the globe instantaneously. The resulting pressure on food manufacturers also trickles down to their equipment suppliers to pay extra attention to hygienic design. For Rademaker, however, this is nothing new. Hygienic design is and has always been at the core of innovative bakery solutions provided by the leading manufacturer of industrial bakery production lines. At Rademaker, hygienic design and food safety come naturally.

As food safety cannot be compromised, Rademaker offers a cross-functional approach in which hygienic design, sanitation, quality, maintenance and operations are engaged to optimize the production process. To arrive at the best possible solution, Rademaker's dedicated, highly skilled and experienced professionals employ the latest engineering technology. In the 1980s, Rademaker first incorporated hygienic design in its Pielines and it has been over 25 years since the Dutch company first received USDA approval for equipment installed in meat plants. This experience led Rademaker to design the Sigma Laminator and Sheeting line in the 1990s: the first ever top-to-bottom D4W (Design for Washdown) line. Today, Rademaker Pizza-topping, Bread, Pastry and Croissant production lines are also among the most sanitary of production lines on the market.

The Rademaker Sigma® Design
Rademaker's Sigma® design represents a combination of internally developed guidelines. It is targets the highest level of hygiene in combination with the highest operator safety whilst maintaining a perfect process technology and best possible functionality and efficiency. Therefore, this design is identified with the name Sigma® representing the sum of everything that is required for high-end industrial bakery production.

More importantly the hygienically designed parts of the Sigma® guidelines are directly derived from various high-end requirements for hygiene & cleanability such as the GMA standard and EHEDG recommendations. With excellent machine surface finishing, tilted upper surfaces, rounded frames, food approved blue plastic parts and the absence of hinges and bolts, the Sigma® equipment will meet the highest industrial expectations for hygiene.

Apart from unmatched product quality and practically zero risk for contamination, the overall combination of the above improvements has resulted in an extremely low cleaning time, very high levels of uptime and significantly reduced maintenance. Furthermore, this new highend Rademaker design is fully designed and approved for wet cleaning (D4W) which has already been introduced into the industry by Rademaker three decades ago.

The essentials
Food safety and operator safety are an essential combination and central to the Sigma® design.

Rademaker aims to incorporate a higher level of hygiene resulting from a total elimination of recesses, cavities and dead corners. Coverings with openings further enhance the direct view of the process and enable the end user to see all possible contamination present in the machine.

Cableways are positioned above the line but not over the product zone to prevent cross contamination. As there are always differences of opinion regarding cableways, there are solutions for fully closed cableways, as well as those with conduit and wire mesh cable trays.

Another important hygienic improvement in the latest
Sigma® design is the use of lifetime-lubricated bearings throughout the direct product zone. This results in a zero risk for lubrication contamination. Outside and away from the direct food zone, sealed bearings are used which can be lubricated during or after production. In addition to this, direct-drive and gear-motors are also positioned outside the product zone as well as bearings filled with H1 lubricants. This required a major effort for Rademaker's Research & Development and Engineering department.

Material selection & use
The latest generation Sigma® design is set-up around compatible materials only. This approach is based on the use of food-grade materials and food-contact parts certified in conformity with FDA and REGULATIONS (EC) n°1935/2004, (EC) n° 10/2011 and (EC) n° 2023/2006 (GMP).

Obviously, this results in the application of all stainless steel covers and cableways but also fully stainless steel electrical cabinets. Whilst smooth surfaces help reduce spore development, every section of the equipment is applied with the required surface roughness in order to provide the best balance between the necessary hygienic level and the overall production cost.

As for food contact parts, these are all constructed with approved materials of which the plastics are manufactured in blue for good recognition. Full certification & traceability is guaranteed and completely integrated in the ERP systems that Rademaker included in their manufacturing process.

As a dedicated manufacturer of industrial bakery equipment there is a constant drive towards further improvement of materials especially with regards to key wear-parts and delicate parts in the product zone, there is a strong and continuous improvement program together with various material suppliers.

Cleanability
Apart from a perfectly optimized hygienic set-up, cleaning and maintenance is a key aspect of the overall design approach.

Enabling fast and easy cleaning requires detailed attention for aspects such as quick-release transport belts and detachable transport belt scrapers. In addition, the application of lightweight tooling and make-up units is key to enabling easy cleaning.

A cleaning modus is programmed into the machine PLC resulting in minimal time loss that maximizes line efficiency. In addition, plenty of room for cleaning is created underneath each part of the equipment. During cleaning itself, easily accessible, wet-cleanable equipment and systems provide cleaning efficiency: industrial bakeries will need less water, less energy and fewer chemicals to obtain the required result. Mobile sanitary critical units (e.g. egg yolk sprayers and depositors) are suitable for separate cleaning in a washroom increasing line availability, therefore, enabling continuous production. All covers are tilted at an angle to allow water to drain easily thus avoiding contamination of the product zone resulting in reduced drying times after cleaning.

Summary
Although many people consider hygienic design as an expensive obligation, the Sigma® design proves the opposite. Proper application of all hygienic requirements not only enables the end-user to live up to the regulations, it also results in a highly cost-efficient operation.

Enabling fast and effective cleaning with a minimum usage of water and chemicals reduces downtime by removing the necessity to stop the system for lubrication. Together with optimized design for faster drying, all these improvements deliver a combination of the highest possible hygiene and lowest possible running cost.

In the end, this approach makes the Rademaker Sigma® design not only a benchmark for hygienic equipment design but also the world standard with regards to the lowest cost of ownership!

Website: www.rademaker.com

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