KOMA. Dough conditioning Recovery. Storage Blast freezing and cooling systems. KOMA refrigeration techniques

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1 Dough conditioning Recovery KOMA Storage Blast freezing and cooling systems Storage technique SunRiser Blast freezing RackCommander Combined coldrooms Controls KOMA refrigeration techniques

2 Introduction KOMA refrigeration technique we are committed to our name. A powerful refrigeration technique, the appropriate room climate for every product, state-of-the-art air flow systems according to the KOMA- TLR-formula, variable sizes, components from leading manufacturers as well as the fact, that every system is developed and supplied on the basis of the best possible quality. Our optimal control and regulation of the fundamental conditions temperature, air and relative air humidity ensures well-balanced cooling and dough conditioning climates. This is the constant aim of our in-house design team. Refrigeration technique according to the high demands of the STEK-standard, controls and topquality insulation panels are all manufactured in our own factories. We also keep to these principles when it comes to installation and service. KOMA employs its own trained field service staff who use KOMA approved spares. The world nowadays is online and so are we. Installations can be monitored with faults being reported to the monitoring departement and processed immediately, 24 hours a day, 365 days a year. Further information can be found on the following pages. Are you looking for something special? Do you have an exact idea of what the temperature curve of your dough refrigeration and conditioning system should look like? Our new SunRiser will control and implement your specification one hundred per cent. Please feel free to call us, we will be happy to discuss your requirements. On the following pages we present our product range. If there are questions and should you require further information, please contact a member of our sales team as detailed on the back of this brochure. POWERFUL REFRIGERATION TECHNIQUE ALL COMPONENTS FROM ONE SOURCE Modern production plants for insulation panels, control engineering and refrigerationtechnical components in Roermond, NL CONTENTS Storage technique Page 3 Dough Deep-Freeze Storage Systems, Storage Rooms for packed goods, (-18 C / -28 C) Resource Cold Rooms, cream climate rooms, cold storage rooms (+2 C / +8 C) Dough refrigeration and conditioning Pages 4-5 SunRiser CDS (-20 C /+40 C) Recovery Slow Recovery (-20 C / +20 C) Blast freezing Page 6 Industrial Blast Freezer (IBF) with ceiling evaporator (-18 C / -38 C) Blizzard (KTT) with stand evaporator (-18 C / -38 C) Transport system Page 7 Automatic Rack Transport System (RackCommander) Combined cold room Pages 8-9 Several rooms with different temperature ranges combined to one unit. Controls Page 10 SunRiser Touch-screen Controls MonoCell Computer Controls for storage rooms and blast freezers TeleGuard Page 11 TeleGuard remote monitoring KRASS software for data recording and analysis References Page 12 KOMA Partners are convinced 2

3 Storage Technique Storage solutions for packed and unpacked goods, baked and partly baked products, fresh dough portions, cream products everything is possible. Room construction: All of our insulation rooms are manufactured in our own panel plant. The insulation is made of high-pressure, CFC free polyurethane foam of sandwich construction and incorporate a conical locking mechanism to give high insulation values. Deep freezing rooms are made from 12 cm panels, cold storage rooms from 8 cm panels. KOMA installations can be easily upgraded or moved at any time. The standard white panels have a 30 cm stainless steel strip around the outside. External stainless steel is available as an option. Doors are available as hinged or sliding (electrical option available) from 80 x 200 cm to 120 x 200 cm. Inside picture of deep freezing room with detached system ceiling and removable pressure wall for product sensitive air flow. DEEP FREEZING ROOMS, COLD STORAGE ROOMS Floor: Deep freeze rooms have a 3mm galvanised steel sheet on top of the insulated panel. Cold storage rooms have no floor Refrigeration technique: Modern, semi-hermetic reciprocating compressors Large capacity evaporator and condenser surfaces CFC-free refrigerant R-404A Options: Separated condensers Low noise condensers NRE noise reduction enclosure Plate heat exchanger Glycol-re-cooling Customized KOMA evaporator Dimensions: Standard models are delivered in modular dimensions of 30 cm, variable sizes are also possible, height 240 cm or 270 cm (internal). Safety door handle inside, door sealing made of foam rubber. Modern MonoCell Computer Controls capable of remote monitoring. 3

4 SunRiser fully automatic dough conditioning system SUNRISER PROGRAMMED SUCCESS Evaporator technique exclusively designed for KOMA with many fin bars and an integrated stainless steel condensate tub ensure ideal evaporator surfaces and avoids quick icing up. Cooling fans are equally arranged along the complete length of the pressure wall and ensure maximal consistancy. Humidification via an interior evaporation principle allows for equal fermentation results and energy saving. With the new SunRiser controls the programming is all in your hands and you are able to customize the temperature curve according to your exact requirements. The adjustable temperature range between 20 C and +40 C allows for miscellaneous variants of dough conditioning. Dough conditioning and refrigeration of the best quality with new controls. The quality of the products coming out of a CDS-SunRiser has its reasons. The construction of the room and the technical components are decisive in achieving the superb quality. Along with the KOMA-typical construction of the room 8 cm PU insulation, stainless steel interior, floor formed to a 3 mm stainless steel base tub, stainless steel pressure wall (removable without tools) the following criteria should be noticed in particular: Evaporators arranged along the complete length of the chamber provide an equal distribution of the cold air. Specific, divided evaporators along the complete length of the device. The cooler fans are separated from the evaporator for optimal constancy (special coating) KOMA provers with SunRiser controls and sliding doors. 4 Removable pressure walls for optimal air flow.

5 Recovery Systems RECOVERY / SLOW RECOVERY THE GENTLE COLD KOMA Recovery systems combine everything a modern and competitive bakery requires. Long defrosting and fermentation periods along with humidification provide for a stable product. KOMA Recovery allows for baking performances by program sequences over long periods, as variable as the requirements and demands for each of your branches. Ample evaporator surfaces, air flow led over the channel detached system ceiling and the stainless steel pressure wall, the brand new SunRiser computer controls, active humidification according to the evaporation principle and perfectly chosen cooling performance make for shine, lively cracks in crust, colour, a crispy crust, a finely splintered crust, vivid pore structure as well as aroma and taste the unique characteristics of KOMA Recovery products that will delight your customers. Thanks to sufficient cooling capacity, gentle air flow and the fact that the evaporator can be defrosted when required, every Recovery device may also be used as a dough deep freezing room. CoolDown +25 C +15 C +5 C 0 C -5 C -5 C -15 C 3h -25 C Store +2 C Calculated by the computer Pre- Recovery "TLR" TheKOMA Formula +8 C Cool Prooving +15 C Interaction of time, temperature, air motion and relative air humidity. Bracing +5 C Quality is in the making! 6h 6h until 10h SunRiser computer controls Ample evaporator surfaces for Recovery devices 5

6 Blast freezing IBF/KTT MAXIMUM POWER KTT - Blast freeze tunnel with stand evaporators Massive construction, maximum cooling capacity, innovative evaporator constructions and intelligent air flow these are the requirements towards a capable and powerful blast freezer. All these characteristics are combined in an impressive manner in the KOMA Industrial Blast Freezer IBF. Large hourly outputs of up to 600 kg/hour are no problem. The ceiling evaporators, custom made for KOMA, with the tilted fan motors are spacesaving and allow for trouble-free integration to existing production systems. Optional also with the KOMA RackCommander, the automatic rack transport system. You need more power, foods of oven temperature need to be blast frozen? The KOMA Blizzard KTT provides even more instant cooling capacity due to his enormous stand evaporators. And of course, on demand, the KTT is also available along with the automatic rack transport system. IBF (Industrial Blast Freezer) Blast freeze tunnel with licensed custom ceiling evaporators 6

7 Rack Transport System The KOMA RackCommander provides optimisation and automation. The computer control allows for automation of the complete process of production. Production cycles that include fermentation, chilling and blast freezing can be automated, ideally controlled and efficiently timed via the rack transport system. Ground-clear assembly (hygiene!), rack transport via jackscrew-tensionsystem, state-of-the-art sensor technology and computer controls guarantee a trouble-free production process, so there is no need for moving the racks by hand anymore. The integration of automatic sliding doors is also trouble-free and even the backhaul of the racks can be included to the automatic cycle. Automatic rack transport system Rack Commander, two rows with automatic sliding doors KOMA RACK COMMANDER Production cycle consists of: Fermentation Bracing Blast freezing Packing with integrated rack transport system KOMA post curing room with connection to the automatic rack transport system RackCommander 7

8 Combined cold room Modern and competitive production facilities make high demands on refrigeration technique. The planning of the refrigeration must be adapted to the production process. KOMA combined cold rooms, that provide several rooms with different temperature ranges all in one unit make put demands on service technicians, project managers and our assembly teams and require precision in planning and implementation. Our experts are glad to support you with the planning on site and assist you in analysing the existing production processes and provide you with a custom refrigeration solution that is optimised for your facilities requirements. Glycol-frost heave protection heaters driven energy neutral via the waste heat of the refrigeration units as well as electric heaters, heat exchangers at the refrigeration units, centralisation of the refrigeration units, installation of the condensers on the roof and sound pressure level are just a few of the aspects that have to be considered when planning a modern and efficient type of refrigeration. OPTIMAL PLANNING STATE-OF- 8 Glycol floor heater (without cover)

9 Combined cold room THE-ART COMBINED COLD ROOMS Evaporator with large surface and speedcontrolled (by RPM) fan motors Installation of separate condensers on top of the flat roof Blast freezing, Storing, Recovery, Retarder proving, refrigeration all combined in one unit NRE noise reduction housing for refrigeration units Blast freezing tunnel IBF (-18 C / -38 C) Deep freezing rooms (-18 C / -28 C) Retarder prover (-20 C / +40 C) Recovery / SlowRecovery (-20 C / +20 C) Cold storage rooms (+2 C / +8 C) 9

10 Controls Today, modern computer controls are standard on all KOMA devices. The following controls are in use with KOMA products: -1 Touch Screen input directly via the screen Automatic cycle arbitrarily divisible in phases Additional phases may be added or deleted Every period allows for free programming of parameters as to Fan speed Fan impulses Relative humidity Temperature Duration Gradient or slope of the curve Self-explanatory, logical programming -4 The new multifunctional controls by KOMA SunRiser AT Units: SunRiser, Recovery, Provers TOUCH-screen input panel All programme sequences are freely programmable Air speeds and humidity are adjustable in 1%-steps Each day can be programmed freely as part of a week-programme TeleGuard remote monitoring MonoCell AT Units: Deep freezing room, cold storage rooms Blast freezing time and duration are freely programmable Automatic programme selection of fan impulses for blast freezing and storage periods Free choice of time and the featured adjustment of defrosting programmes as part of a weekprogramme TeleGuard remote monitoring Units: Blast freezers KTT and IBF Guaranteed quality monitoring and logical programming Quick cooling time and duration are freely programmable Air amounts and speeds may be adjusted in 1%-steps and thus an ideal adaptation to your quality demands is ensured Direct intervention at failures Permanent monitoring of all entered data Automatic backup of all programme data due to supplementary battery supply in case of failures, power breakdowns etc. TeleGuard remote monitoring 10

11 TeleGuard / KRASS TeleGuard Security online for your KOMA units. All of the KOMA units can be remotely monitored via the TeleGuard system. All of the controls in use with KOMA units are compatible with TeleGuard so that we can guarantee you maximum security. Failures are immediately reported to our monitoring department at our service headquarters. The staff is able to establish a direct connection to your refrigeration unit in order to take a real time look at all relevant data or even for editing purposes. Thus, temperatures and pressures (high pressure, low pressure, oil pressure) may be checked, icing up of the evaporator can be detected and, even an open door is recognized and KOMA immediately informs the customer. Further, our staff is always glad to assist you in adjusting your unit s programming. KRASS - Software Our software provides various possibilities for the recording and evaluation of the temperature curves. Whether it chart or table illustration, temperature recording that meets the legal requirements (HACCP obligation of documentation and storage). It also allows for control of the system via a central PC, which may be located at your Home Office or any other location. The software is easy to install on any standard PC, but we will definitely assist you with that also. Just contact us. MonoCell AT Units: Blast freezers, KTT, IBF Guaranteed quality monitoring and logical programming. Quick cooling time and duration are freely programmable. Air amounts and speeds may be adjusted in 1%-steps and thus an ideal adaptation to your quality demands is ensured. Direct intervention at failures. Permanent monitoring of all entered data. Automatic backup of all programme data due to supplementary battery supply in case of failures, power breakdowns etc. TeleGuard remote monitoring Note: Subject to technical modifications and alterations. Illustrations and charts serve for visualization/illustration purposes and may change in practice. Status 7/

12 Satisfied customers report TeleGuard perfect service KOMA my partner from the beginning RECOVERY excellent quality Well done! We know the differences Expansion thanks to cooling know-how by KOMA SunRiser No Compromises! RECOVERY the right decision Positive energy balance! You didn t promise too much Together with steady progress Recovery, IBF, SunRiser,... the complete solution KOMA Koeltechnische Industrie B.V. Energieweg 2 NL-6045 JE Roermond Tel.: +31 (0) Fax: +31 (0) nl-info@koma.com KOMA subsidiaries in: Belgium, Germany, France, Great Britain, Italy, Spain, U.A.E. (Dubai) and Japan