The totally automated Genesis incorporates a water heater/chiller unit, water meter, mixer, dough divider, bread moulder, roll rounder and intermediate prover, together with two on board computers that control the whole system. A new software package has now been introduced that is even more user friendly than when the Genesis was introduced to the market place two years ago. Regularly used programmes can be saved and then recalled to the touch screen in an instant. The secondary computer can be used to programme-in 'one off' recipes and has a comprehensive self-diagnostic and monitoring system.
Occupying a footprint of just 3.4 x 1.8 metres the Genesis will produce long and round rolls, French sticks and oven bottom and tin bread effortlessly and consistently.
At the heart of the Genesis is a unique combined mixer and divider. The 80-kg spiral mixer operates with a divider designed to enter the bowl and divide the dough one portion at a time from inside the mixer bowl.
What has resulted from this fundamental re-think of dough dividing technology is not only a smaller, genuine one-person bread plant that is really easy to operate, but also a far superior system when compared with traditional bread plant technology.
The Genesis divides with supreme accuracy; operates on a greater range of dough types and does not require time-consuming daily dismantling for cleaning as the plant is also equipped with a computer controlled self-cleaning cycle. Operators no longer have to cut and lift dough out of the mixer bowl, as is required with traditional bread plants. This gives the potential for greatly reduced incidence of repetitive strain injury (RSI), and because the system is totally enclosed, airborne amylase and flour dust is also minimised. This all helps to make bakeries a cleaner and safer environment in which to work.
In operation the dough is divided and the dough pieces for loaves and French sticks are then passed into the intermediate prover, or further divided for bread rolls before being routed into the intermediate prover. After a twelve-minute intermediate proof time, loaves, French sticks, baguettes and long rolls are processed through the primary moulder. Round rolls are diverted into the rounder for rolls of 38 grams up to 140 grams. Daily output through the Genesis System will produce as much as one tonne of finished product in 8 hours with just one operator. Output examples per hour are approximately - 1600 x 50 gram rolls; 1400 x 85 gram rolls; 400 x 340 gram baguettes and 250 x 900 gram loaves.
Before commencing production the operator selects the product mix to be produced from the on-board computer. The touch screen panel automatically calculates the amount of flour, water and other ingredients that are required. After they have been added (and checked in by the computer), mixing can commence. The computer's touch screen will also show the number of tins and trays that are required for this dough mix. The operator has plenty of time to prepare the correct number of tins and trays for the completed mix. The only manual settings on the Genesis system are for the pressure board and sheeting gap and loaf side guides.
The Genesis does not have to be constantly manned. Once production parameters have been set and the mixer has been loaded the Genesis will operate automatically and the operator can attend to other tasks in the bakery. The machine will stop and wait when dough pieces reach the end of the prover and will not start the moulding process until the operator is ready and a 'start' button on the main panel has been pressed.
Issued by Jeff Bownds, Marketing Manager. 05/04
MONO's revolutionary Genesis Bakery System eliminates hours of monotonous, hard work for the small to medium sized bakery business. All the operator has to do is to load the required ingredients into the mixer bowl; select the parameters for up to eight consecutive products which are displayed on a large, integral, touch screen panel and the bread plant does the rest.