Baker Perkins TruWeight weight system

Baker Perkins has designed a cookie weight control technology for wirecut machines that make cookies, filled cookies, bars and filled bars. The TruWeight assisted control weight system for wirecuts is designed to reduce variations in cookie piece weights by individually adjusting the output from each die cup.

The patent-pending system can provide savings in dough and waste by enabling operators to detect and compensate for process variations. Process variations can affect piece weights over time and across the width of the line. The system gathers and processes weight data, instructing operators on the adjustments necessary to each lane. During production, prompts guide the operators through a systematic weight check procedure, with the data fed to the PLC via Ethernet or IP.

In tests, standard deviation on sugar dough improved by 52%, from 1.26 to 0.60 g (on 49.2 g pieces); while chocolate chip dough deviations improved by 33%, from 1.57 to 1.05 g (on 42.7 g piece). The tests indicate that the offset between the average and target weight of dough piece can be reduced, decreasing giveaway without producing underweight product.

The technology calculates average weights, compares them with the target stored in the recipe and provides machine operators with recommendations of which lanes to adjust, and by how much. Manual and stepper-motor actuators are available, with the latter enabling changes to be made without stopping the wirecut machine.

The product range can be extended with an encapsulation module, to include cookies and fillings completely enclosed by dough. This allows products to be produced on a standard wirecut at high production rates.