Mega 52 OP/AL System


Application

For the automation of proofing and loading in the production of thin crust pizza. The OP/AL is composed of an Overhead Proofer (OP) and patented Automatic Loader (AL) plus one press.


Capacity

Single Mega 52 with One Touch Control
  • 36 Balls to 6 1/2″ up to 3200 dz/hour (requires 2 TWS dividers)
  • 25 Balls to 8 1/2” up to 2250 dz/Hour
  • 16 Balls to 10 1/2″ up to 1440 dz/Hour
  • 9   Balls to 14″ up to 810 dz/Hour

Construction

  • OP: All stainless steel mainframe, exterior doors and shafts. Stainless steel sprockets trays, chains and miscellaneous hardware.

Standard Features

  • Precision timing gate interfaces divider and OP to assure consistent loading
  • All continuously guided roller chains
  • Concealed utility ducts for air, electrical and water service
  • Interface hardware for AL
  • Patented third station heated discharge platen for superior product roundness and release for smooth transfer
  • One Touch system control

Options

  • Cool air input to proofer configured with steam and humidity system and auto temperature control
  • Clean-in-place system
  • Vault style insulated and hinged proofer door and double wall insulated top
  • CE or CSA Conforming
  • Press Camera / Auto Sizing System
  • Automatic steam/dryer and humidity control
  • First and second tier cooling conveyor jam free air system
  • Remote viewing panel for Inspection System
  • Stack transfer
  • Press Puck removal
  • Compression SYS for small diameter product

Auto Loader One Touch Control System

The One Touch Control allows the operator to recall a recipe saved for all the following parameters:

    • Divider timing
    • All zones of press temperature control
    • Press pressing time
    • Press belt delay time
    • Oven dwell time
    • Oven belt temperatures
    • Cooler infeed belt speed (if separate)
    • Main cooling conveyor speed
    • Cooler discharge belt speed (if separate)
    • Proofer cycle rate
    • Auto loader program
    • Proofer humidity set point
    • Proofer heat set point
    • Clean-in-place system
    • Counter stacker row counts

Mega 52 Vacuum Head Press

Standard Features

  • Patented quick-change Teflon coated pressing skin with product specific shims are changeable in less than 2 minutes
  • 52″ wide x 52″ long platen is hydraulically actuated
  • Accurate, electronic, dual direct drive, dual drive Teflon belt rollers (both rollers are driven), belt-indexing system. System features repeatable digital speed control to allow easy timing with OP/AL system.
  • Magnetically Encoded Belt with connecting pin facilitates belt removal and replacement
  • Auto Tracking system eliminates need for repeated adjustment of Teflon belt
  • Main conveyor design and air assist prevents cripples at discharge roller
  • Patented continuous platen cover reel system allows the operator to index a new platen cover into position within (1) minute
  • Teflon “Belt Saver”

Touch Screen Control

  • Multi-zone temperature control system assures superior platen temperature control
  • Touch Screen interface displays all error messages and prompts operation data input
  • Temperature controls include faulty heater message via PLC
  • Multi-zone temperature control system assures superior platen temperature control
  • Touch Screen interface displays all error messages and prompts operation data input

Construction

  • 1-1/4″ Vacuum shimming platen with dual 2″ platens
  • 18 heaters top and bottom (36 total) plus heated discharge platen
  • All high strength cast steel structural press components.
  • Patented heated discharge platen
  • All cast A frame, top and bottom H frames as well as “frog”

Micro Blower Premix Oven (optional with convective tunnel oven)

  • Independent premix blowers with infrared eye surface temperature thermostatic control per tier for optimal bake
  • All stainless steel main frame, double insulated doors and hood
  • First tier air turnaround, second tier optional
  • Free standing UL approved control panel with color Touchscreen and One Touch interface
  • Electronic ignition
  • Unique retractive plastic mesh discharge eliminates waste from entering cooling as well as downstream packaging
  • Plastic belt with patented rope transfer with retract feature

Lawrence Positive Positioning Cooling Conveyor

  • Patented positive positioning turnarounds preserves orientation without increasing maintenance.
  • All sanitary wash down frame design eliminates standing water or debris collection
  • Double end drive with poly chain belt drive for low maintenance and quiet operation or independent Lenze drives

OP/AL Option

Lawrence Accuview Vision Inspection System sorts and rejects for the following criteria:

    • Diameters
    • Flat edges
    • Holes
    • Overlaps
    • Toast points (baked marks)
    • Sorts up to 8 lanes and 200 tortillas/minute per lane

System includes:

  • Touch screen operator interface
  • Rugged industrial PC
  • LED illumination for uniform view of product and low cost of operation
  • Color camera with high definition and air purge to prevent lens contamination
  • Pneumatic reject bar with food grade air filters
  • Easy cleaning plastic conveyor belting

Press Camera Option

  • Used where producers demand greater control of size due to changing dough conditions for Legend 42 and Mega 52 lines
  • Normally integrated with Lawrence Proofing system
  • HMI display screen
  • Full info display for actual and target diameter
  • Digital chart recorder shows actual and target set point deviation graphed over time

Small Product Pressure Control System for Small Diameter Product Option

  • Assures superior control of hydraulic pressure when there is a low resistance present and near zero pressure is still too much
  • Allows the operator control of oven pressing force when the diameter for a given loader plate is smaller than the normal diameter run on that pre-press program

Pizza Docker Option

  • Used to perforate the surface of product after forming but before baking
  • Equal to 90% of full line production speed 
  • All stainless-steel frame and docker roller FDA approved rubber belt
  • Easy adjustment belt tension
  • Docker depth control
  • Stainless-steel mesh discharge