GEA Bakery Solutions  ·  1

GEA Bakery Solutions

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GEA becomes a major

force in the bakery sector

Together, more than 100 years of experience

in the bakery sector.
GEA is one of the most important organizations worldwide
specializing in the production of high performance, complete
solutions for the bakery industry, tailor made for every customer.
The experience comes from the acquisition of the two Italian
companies Comas and Imaforni: trusted suppliers to the world’s
most advanced bakery factories.
The cooperation with leading companies in this sector is a
feature that makes GEA stand out, guiding the customer towards
better technical and technological choices to help meet desired
production requirements.
GEA is as a partner of excellence, committed to the needs of its
customers.
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Our experience at your service Why Turnkey Solutions?

A single business partner:

1 having GEA as the only business partner
means placing a single order for the
complete plant and clearly defining the
responsibility for the achievement of the
end result.

2 Project coordination:
our engineers coordinate and supervise
Cakes Cookies / Biscuits Pies / Tarts Crackers Layer cakes Snacks the design engineering and the
manufacturing of all the machines on
the plant.

Just turn the key.

Delivery within expected times:
2 Oven Loader 3 Tunnel Oven
We take care of everything else.
3 GEA guarantees the customer that
all the parts of the plant arrive right
Specifically designed for High-efficiency ovens with independent heat GEA puts itself forward as the main contractor for manufacturing in time for installation and running.
different kinds of baking trays. distribution across each zone to bake every
type of cake perfectly. complete production plants, from the dough mix to packaging.
1 Toppings Applicator
To dispense chocolate We select the best suppliers and provide a perfect interface between
chips, almonds, hazelnuts
etc. and give an elegant machines. This creates excellent, highly automated, versatile plants
4
touch to your products. 3
Vibration or volumetric for our customers and gives them the security of GEA’s experience Integration:
type available. we will take care of the
2 and quality. mechanical and electrical
interfacing of all machines.
Our food technologists are available to help customers develop new
1 products and improve existing recipes – then just ‘turn the key’.
Start-up:
14 5 Our staff use their experience to
coordinate the project enabling
13
12 the earliest possible start-up time.
14 Volumetric Piston
Depositor
4 Spiral Cooler
Precise depositing of all 11 Open air or equipped with
kinds of cake batters, with
insulation and forced cooling
or without solid inclusions.
system.
It can be equipped with an 12 Oil Sprayer
automatic cleaning in place To grease the
system (CIP). baking trays. 10
4
5 Volumetric Piston Injector 6 Packaging Line
11 Tray washer
It inject with high accuracy liquid, Sourced from partner
Washing and drying of the 9
13 Automatic Denester viscous and aerated fillings. Can companies with proven
baking trays in an optimal
For all kinds of paper cups be equipped with automatic experience on the specific
way to ensure the continuous
and aluminium foils. cleaning in place system CIP. field.
and efficient operation of the
plant. Sourced from partner 8
companies with proven 7
experience in the specific field.

5 6
10 Depanner 9 Volumetric Piston Injector
It picks the baked products from the It injects with high accuracy
trays and places them precisely on the liquid, viscous and aerated
cooling conveyor. Needle or vacuum fillings. Can be equipped with
heads are available. an automatic cleaning in place
system (CIP). 8 Buffer 7 Oven Unloader
It absorbs the excess Specifically designed for
product during technical different kinds of baking
stops and eases line trays.
operation.
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Cake lines

The depositing, injecting and decorating of cakes

and cup cakes has always been our great passion.
The product range from GEA includes the compact piston It is possible to produce different types of cakes on the same line
depositor and multi-piston depositors, used on industrial tunnel owing to simple change-overs and the automatic washing of the
ovens and running at very high capacity production. In addition depositors through an optional CIP system.
to volumetric depositors and injection machines, GEA offers a Our extensive experience, combined with the use of the most
series of complementary machines to automate the complete advanced technologies and with a wide range of accessories (e.g.
production process, such as cup denesters, greasers for baking servo-motors, co-injection, independent deposit, etc.) makes GEA
trays and decorating units before or after the oven. a leader in the market.
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Pie lines

Technical perfection for a perfect pie

This concept is the basis for the whole range of GEA pie maintaining the consistent depositing and blocking accuracy
machines. Our solutions can be tailored to the needs of both that always identifies GEA products. The production of empty
high capacity plants and smaller-scale production lines. All the pie shells can take place inside trays or foils and is enriched with
lines are designed to achieve maximum production flexibility several kinds of fillings. A range of accessories is also available
due to the easiness and quickness of product change-over, by for the molding of personalized lattice tops or lids.
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Soft biscuit and cookie lines

We know how
The world of softdough biscuits includes a family of products a fully customized, complete production line for a huge variety
whose manufacturing is based on the rotary molding process. of rotary biscuits, wire-cut cookies, smooth biscuits, two-color
The high-capacity rotary molder can be integrated with a co- filled cookies and fig-bars. The GEA biscuit and cookie lines offer
extruder with individual lobe pumps and a range of downstream the highest performance and excellent accuracy in every single
units, including decorating rollers, glazing machines and biscuit, guaranteed by the experience that GEA has acquired over
depositors for creams, jelly or granular products. The result is the years and by the constant effort to satisfy customers.
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Hard biscuit and cracker line

Beyond standard performance

Hard biscuits and crackers are manufactured on a GEA forming The line is completed with a dough sheet relaxing web, a rotary
line consisting of a sheeter, a lamination unit and a set of gauge cutter, a scrap pick-up machine, a scrap return conveyor and an
rolls. Our experience shows that more regular products are oven panner. Devices such as a sugar/salt/flavor sprinkler and a
obtained by gently processing the dough sheet. The dough mass glazing unit can be installed on the line to increase the variety
formulation, and the way it is handled throughout the gauging of products. GEA supplies production lines up to 2,000 mm in
process, are the key factors to avoid stressing the dough sheet. width, far beyond the current industry standard.
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Layer cake lines

The right degree of automation for every customer

GEA layer cake lines meet the needs of those companies that sanitation, which is fundamental for these applications. All the
produce several types of fresh and frozen cakes daily. In fact, parts can be easily removed and washed with a water jet.
each line is designed to offer the maximum flexibility and to GEA plants worldwide all have different degrees of automation
maintain the highest degree of automation. In these machines, and run at up to 5,000 cakes/hr.
GEA design engineers have given particular attention to effective
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Pizza lines

Pizza lines ‘made in Italy’

Italy is the land of pizza and so GEA has developed great sauce; finger depositors for cheese, IQF vegetables and oregano;
experience in this field by engineering and manufacturing lines and water sprayers to prepare the pizzas for freezing.
for laminated or blocked pizzas. Topping is performed by either GEA designers have paid special attention to the sanitary
targeting the deposit (target system) or by covering the surface standards of the machines which are made of stainless steel
completely (waterfall system) with ingredient recovery units. and certified food-grade materials. Easy change-overs allow the
The range of machines, used before and after the oven, consists production of different types of pizza: from the thick American
of waterfall and spraying depositors for homogeneous tomato pizzas to the traditional Italian.
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Snack lines

Top quality lines for better snacks

Baked snack products is a growing market sector. The modular of processes capable of making innovative baked snacks (not
design of snack forming units allows the creation of different fried), such as potato and corn chips, for the health-conscious
configurations to better meet bakeries’ needs and fit into the consumer. Additional devices, such as sprinklers to top the
space available. Snack lines are composed of a sheeter followed product with salt, sesame and flavors and the oil sprayer, can be
by one or more gauge rolls, a rotary cutter and a scraps pick-up added as necessary.
conveyor. Our purpose-built equipment allows the development
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Special lines for bread processing

Adding value to your bread

GEA machines have a range of special features designed to minimizes waste and reduces the downtime when cleaning.
increase the commercial value of bread products for customers. Production capacities can vary from 5,000 to 25,000 pcs/hr. GEA
Working closely with the bread industry, GEA has developed also offers automatic production lines for gluten-free bread and a
a system that can cut and then fill baked baguette or ciabatta volumetric depositor-extruder machine for depositing rye bread
loaves with a range of different sauces. The system can be doughs and sticky dough mixes that are hard to handle.
integrated into an existing baguette processing line, and offers
options including ‘no product’ and ‘no fill’. A recirculation system
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Tunnel ovens

... and now let’s bake it!

The baking process turns the dough into a tasty product. Cakes, has always been fundamental to GEA. Through constant
biscuits, pizza and crackers have different baking needs in innovation we have been able to reduce the environmental
terms of heating methods and temperature profiles. GEA can impact of our plants by providing consistently significant fuel
supply a wide range of tunnel ovens with the following heating savings and the lowest possible emissions to the atmosphere.
systems: direct gas fired, radiating (cyclotherm), convection and
electric, which can be combined into hybrid configurations. Such
configurations, unlike traditional single heat transfer systems,
enable more flexibility in the baking process: different products
processed in the same oven; improved texture; and a more
uniform color of the baked product. The care of the environment
4 ways to improve
energy efficiency.
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Automation

Process automation
A series of special machines complete the GEA range to increase conveyors, automatic cup denesters, tray greasers and special
the level of automation within the plants: robotized systems depositors for granular, powdered and wet products.
for the handling of molds and products, tunnel oven loading/ This technology helps to provide our customers with the highest
unloading systems, automatic cooling systems, tray feeding level of automation and versatility available.
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Customer satisfaction GEA Service –

is GEA main objective For your continued success
Improve the life cycle costs of your bakery plant
and equipment with GEA Service.

We work alongside our customers in close partnership, supporting • Beginning of Life Services – Getting you started
them throughout the entire life cycle of their equipment and with seamless support for instant productivity
solutions ensuring lasting business success. However, to keep and performance.
your plant operating at optimum performance, and to ensure • Lifetime Services – Keeping it running
your continued success, it needs to be maintained. That’s where with the cost-efficient way of ensuring peak
GEA Service comes in. safety and reliability.
• Extended Life Services – Constantly improving
Thanks to integrating the latest automation and control by sharing our knowledge to safeguard your investment.
solutions, like remote assistance, the status of your bakery • Consulting & Enhanced Operations – Together with you
Bakery Experience Centre machines can be monitored by our automation engineers in by enduring commitment to you and your business.
real-time by ensuring precise and efficient support.
Experienced food technologists
at your service. Working with GEA Service means partnering with a dedicated
The GEA Bakery Experience Center (BEC) The GEA Bakery Experience Center labs team of service experts. From project engineering, installation,
consists of technological and testing labs are available both in GEA Comas and GEA and commissioning to maintaining and improving the
where various production tests are carried Imaforni facilities with selected equipment performance of your bakery plant and equipment.
out. GEA skilled personnel assist and guide and technologies that simulate complete
customers to choose the technology and production processes. Our expert food
production processes that prove to be the technologists are available to support
most suitable for each particular product, customers in finding the best production
using data gathered from specific machines. processes, develop new recipes and improve
The BEC provides research and development existing ones, with special attention to
trials on new products for customers and enhancing shelf life and product quality.
Made to the minute. Every hour,
pre-tests lines prior to shipment.
every day, with GEA Service.
 GEA Iamforni. All rights reserved. Subject to modifications. Printed in Italy.
We live our values.
Excellence • Passion • Integrity • Responsibility • GEA-versity

GEA is a global technology company with multi-billion euro sales operations in more than 50 countries.
Founded in 1881 the company is one of the largest providers of innovative equipment and process
technology. GEA is listed in the STOXX ® Europe 600 Index. In addition, the company is listed in selected
MSCI Global Sustainability Indexes.

GEA Comas. All rights reserved. Subject to modifications. Printed in Italy.

GEA Comas
Viale dell’industria 12 Tel +39 0445 660 222 [Link]/contact
36015 Torrebelvicino, Italy Fax +39 0445 661 534 [Link]

GEA Imaforni
Via Strà, 158
37030 Colognola ai Colli Tel +39 045 6174 711 [Link]/contact
Verona, Italy Fax +39 045 6150 065 [Link]