An ISO 9001:2000 Company

R&D Engineers
Profitable Ideas for Cone & Wafers

ZA Series
Cone Baking Machine

RS-Series
Cup/Cone Making Machine

ZWA Series
Wafer Baking Plants

WA Series
Wafer Baking Plants

Contents
1.0 Ice Cream Cone Baking Machine (Moulded) 1.1 1.2 1.3 1.4 Cone Selection Guide Ice Cream Cone Baking Machine - ZAW / ZA Series ZE Series Ice Cream Cone Machine ZA-1 Lab Model for Ice Cream Cone 2.0 Ice Cream Cone Baking Machine (Rolled) 2.1 Rolled Sugar Cone Machine 3.0 Wafer Biscuit Plants 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 Wafer Biscuit Introduction & Process Chart Wafer Design Selection Guide Wafer Plant Sample Lay Outs Wafer Biscuit Plant - WA Series Wafer Biscuit Plant - ZWA Series Wafer Biscuit Plant - ZWT Series Wafer Biscuit Plant - ZW Series Wafer Biscuit Machine - WT Series Wafer Sheet Coolers - SC Series Creaming Machine Series - CR Series Wafer Cutting Machine - WC Series Wafer Book Cooler - BC Series 4.0 Supporting Equipment 4.1 4.2 4.3 Batter Mixers / Mix Plant RS Tube Rolling Station Replacement Moulds & Dies offered for all plants 5.0 Others 5.1 5.2 Waffle Cone Maker Belgian Waffle Maker 37 38 34 35 36 05 06 07 10 11 12 13 15 17 18 19 20 22 24 25 26 27 29 31 33

02

About us
Established in 1991, R&D Engineers is India's foremost manufacturer of baking machines for Wafer Biscuits, Ice Cream Cones and Rolled Sugar Cones. We are located in Hyderabad India. Our clientele are market leaders from food, bakery, chocolates, and confectionery to hotel and restaurant industry. R&D Engineers team of engineers guarantee a high quality of production. The professional team works with the aim of customer satisfaction by implementing new technical developments, giving optimum solutions, which increase the competitiveness of professional manufacturers and allow them to make attractive and quality products at a reasonable price.
03

Facilities

High Quality precision machining is possible on our CNC Machine. We use the latest application of CAD / CAM Solution for meeting customer demands

Dedicated Staff to answer all your queries

04

Ice Cream Cone Baking Machine

ZA W Series Automatic

ZA Series Automatic

ZE Series Semi- Automatic

05

ICE CREAM CONE Design Selection Guide:

These designs are intended to illustrate the various die possibilities. This is a short representation of the vast selection possible. I. MOULDED CONES - Standard Cone Designs

Z-5225a

Za-36b00a

Za-7230a

Z-5200e

Ze-29G73

Za-4515

Za-56d20

Z-49S10_v3

II. Premium Cone Designs

Za-6073

Z-3303 **

Z-30a70 *

Z-93d32 *

III. Special Cone Designs

Z-25R10 **

Z-5227*

Z-5212 *

Z-8200 *

* Only possible with ZA series plant ** Only possible with ZE series plant

06

Automated Ice Cream Cone Baking Machine

Adva nt ag es !
European Blower European Gas Train Advanced Control Panel Modular & Ground Tracks Advance Door insulation

ZA-W Series

ZA Series
07

ZA-W / ZA Series Automatic Ice Cream Cone Baking Machine

The ZA Series are efficient ovens for the large scale production of all kinds of ice cream cones, moulded sugar cones, cups and hollow wafers. According to the output required these machines are supplied with 12,18,24 30, 36 baking moulds or higher. These ovens can be heated by Liquid Petroleum Gas(LP Gas) or Electricity. An automatic stacking device can be supplied as an extra. The machine is driven by motor with a variable speed attachment. The baking moulds are mounted on carriages fitted on to an endless chain. These moulds pass under an automatic batter depositor at a selected speed between 90sec. to 3 minutes. The batter pump is synchronized with the movement of the moulds to ensure accurate injection of the batter into the center of the mould. On emerging from the oven an automatic stripping device removes the waste batter. These moulds automatically open and the baked cones are ejected onto the stacking conveyor and are subsequently packed. The baking moulds are manufactured from special quality cast alloy to ensure dimensional stability, homogenous and dense surface, to enable thermal stability and heat accumulation and excellent thermal conductivity. The diameter of cones decides the number of cavities in the moulds. The mould carriages is so designed to give a quick changeover from one set of moulds to another for the production of a different size of cone. The efficient insulation of the baking chamber gives a minimum loss of heat and efficient utilization of energy.

Workers required
One skilled and two unskilled workers are required to complete all operations.

Operational Area required

The total operational area required is about 1000 to 15000 Sq.ft.(100-150 sq.meter)

Batter Depositor
The depositing head of the Batter depositor moves at the same speed as the baking moulds and so deposits the liquid batter centrally in the mould engravings.

Gas Burners
Our efficiently designed burners ensure uniform heat for even baking characteristics. It also ensures an optimal gas consumption.

08

Stripping Device
The cam-operated stripping knife, removes the small lumps of the batter that form on the outside of the moulds at the steam slots during the process.

Cone Ejector
The ejector mandrel, synchronized with the speed of the passing moulds, move into loosen the cones from the open baking mould. The cones then drop into the chutesfeeding onto the conveyor of the stacking device.

Technical Data
This data given underneath describes for baking machines on LP Gas heating (Baking cycle 1.5 minutes) ZAW 12 / ZA 12**
Cones 3900 3600 3240 2880 2520 2160 1800

Type
Max.Hourly output at cone diameter of Up to 29mm (11 cones/mould) Up to 32mm (10 cones/mould) Up to 36mm (9 cones/mould) Up to 41mm (8 cones/mould) Up to 47mm (7 cones/mould) Up to 56mm (6 cones/mould) Up to 68mm (5 cones/mould)

ZAW 18 / ZA 18
Cones 7900 7200 6500 5800 5000 4300 3600

ZAW 24 / ZA24
Cones 10500 9600 8600 7700 6700 5700 4800

ZAW 30 / ZAW 36 / Za30 ZA 36

Cones 13200 12000 10800 9600 8400 7200 6000 Cones 16000 14400 12900 11500 10100 8600 7200

IF GAS HEATING*
LP Gas consumption Kg. Per hour approx Electrical load in KW* (for LP Gas heated plant)
4-8 3.2 8-12 3.2 12-15 3.2 15-18 4.0 18-21 4.0

IF ELECTRIC HEATING*
Electrical load in KW* Consumption in KW (Approx.)
45 35 Length Width Height 3580 1100 1700 65 46 87 62 108 77 130 92

DIMENSIONS IN MM
(without automatic staking device)

4800 1100 1700

6015 1100 1700

7205 1100 1700

8415 1100 1700

WEIGHT & SHIPPING DETALS

Net Weight Kg Weight includung seaworthy packing Shipping space approx. In Cubic feet/m
3

3000 4250 11

4000 5250 18

5000 6500 25

6000 7500 36

7000 8500 47

* The capacities indicated above are maximum values. The exact capacity depends on baking time, recipe and cone size ** Small plant may have longer baking cycle Modifications reserved *** If Sugar is used in the batter recipe, the production capacity would reduce.

09

ZE Series Semi-Automatic Ice Cream Cone Baking Machine

The ZE series of semi-automatic machines are used for baking ice cream cones, sugar cone and cups. These machines are easy to use and robust. The heating is by electrical heaters designed to optimize energy use and thermal distribution; still flexible for high production on nonstop basis for 24 hours. The upper section of the machine holds the male portion of the moulds. The lower section holds the female portion of the moulds. The two side pillars are used as guides for vertical opening and closing of the baking moulds. Depending on the diameter of the product, the moulds sections consists of four to six rows of dies.

Procedure & Machine Operation

Batter preparation: A mixture of wheat flour, maize starch, vegetable fat, preservative colors etc., is churned into a paste in a suitable batter mixer. The batter is infused by means of a very exact, adjustable batter depositing device on the preheated moulds. The mould is opened and closed by levers. The moulds are provided with a special closing device. Heating is by electricity. Cones are automatically ejected into a container at the end of the baking cycle when the lower mould is opened. These baking machines can be operated by an unskilled worker performing a few simple actions.

Technical Data
Diameter Output of cone (mm) per hour 20 24 27 31 32 33 38 42 46 56 60 4,300 3,800 3,400 3,000 2,900 2,900 2,500 1,900 1,400 1,200 800 Length Width Height Width (approx. In Kg.) Net Weight Packed for shipping Electrical Connected Load (approx. In KW) Hourly Power 7-10 450 530 9-12 Dimensions in mm 1,200 1,300 1,700

Consumption with electric heating (approx. In KW)

* The capacities indicated above are maximum values. The exact capacity depends on baking time, recipe and cone size etc., ** If Sugar is used in the batter recipe, the production capacity would reduce.

10

Machine for Ice Cream Cone (ZA-1) Lab Model

ZA1 LAB Model Cone Baking Machine
The ZA1 Series is an efficient test baking tong for laboratory scale production of all kinds of ice cream cones, cups and hollow wafers. They are characterized by the highest standards in precision, operating ease and utmost durability. They are easy to use and robust.

Heating System
These Machines are supplied only with electrical heating. They are mainly used as a laboratory equipment, for the purpose of product development. The temperatures for the upper and lower plates can be adjusted by means of a thermostat.

Baking Moulds
The baking moulds are manufactured from a very special quality cast alloy to ensure dimensional stability and a homogeneous and dense surface to enable excellent thermal stability and conductivity.

Special Products

Technical Data
Dimensions in MM Length Width Height Electrical Load Kw Weight in Kgs Net Gross Shipping Volume m3 150 250 1.0 175 275 1.0 ZA-1 1030 800 1200 4.0* ZAK-1 1250 800 1200 4.0*

ZA-1 Std. Edition

ZA-K-1 Special Edition

* May Vary with Cone Design

11

Automated Rolled Sugar Cone Machine

RS-Series With Rolled Cone attachment

RS-Series With Cup making attachment

Rolled Sugar Cone Design Selection Guide

Natural

Flat Top

Heart

Tulip Cup

Roll

This is a sort representation of the Vast Selection Posssible

12

Rolled Sugar Cone Machine (RS - series)

The RS-Series of machines are designed with latest technical standards for economical results. These machines are clearly laid out and easily accessible. The bearings and lubricants used are of long life and the links between the baking plate are also maintenance free.

Procedure
The prepared batter mix is put into a holding tank. A measured volume of batter mix is pumped through dosing pipes, which deposit it onto each of the baking plates, these plates move continuously through the oven. The lower baking plates have a grid-patterned surface that imprints its pattern on the outside of the cones. The hinged top baking plates have a limiting ring for giving a thick ring on the top of the cone. As the top plates close down onto the bottom ones, the limiting ring enters the groove to form a barrier as the batter mix spreads over the plate - this boundary forms the top rim of the cones. The lower plates are heated from underneath by a gas burner. As the baking plates return on the underside, a lower gas strip burner heats the other baking plate. As the baking approaches the take-off point, the top plates are lifted up. A knife edge lifts the baked wafer sheets off the bottom plates, then they are swept around the transfer table by spring-loaded remover heads to the cone-rolling unit.

Batter dosing
Wafer thickness is determined by the distance between the closed baking plates, and is fixed during machine manufacturing. Batter dosing determines the final wafer size and shape. The deposit is normally directed into the center of the baking plate, but then has to be adjusted for the wafer length.

13

Rolling device
The wafer is taken off the lower plate and handed over to the horizontally formatted rolling device. The rolling which results from this principle is the requirement for a wafer with a distinct squared pattern and an even thickness of the wafer which allows a slow and careful turning of the rolling core.

Cup making device

R&D engineers developed new cup presses. Mechanically guided pressing tools lead to precise product results. The tools can also be changed very easily which shortens the changeover time noticeably. Different products can be produced on one single cup press. The wafer is taken off the lower plate & moves over to cup punching station, that results in the cup formation. These are used to produce cups of different sizes.

Conveyor
Baked cup and cone are gently dropped to a transfer conveyor.

Control panel
Control panel contains all units for the Automatic Baking Machine and incorporate the following functions : Safety switches with over load and over voltage relays, fault current circuit breaker and automatic burner. Optional temperature measurement by sensor can be provided.

Technical data
Types Size of Plate Type of Heating of rolling [all types of gas, (approx.) possibilities <Mmmm> propane, butane, natural gas] Number of Electrical Production L.P.Gas tongs/multiple Consumption load in capacity usage KW <pcs/h> per hour Possible products

120 s cycle time *

RS 24 RS 36 RS 48 RS 60 250 * 250 250 * 250 250 * 250 250 * 250 all types of gas all types of gas all types of gas all types of gas 24 36 48 60 5-7 7-10 10-14 15-18 5 5 5 5 rolled sugar cones, waffle 1080-1100 cones, waffle bowls, waffle 1440-1500 sheets 1800-1900 700-750

* The capacities indicated above are suggested values. The exact capacity depends on baking time, recipe and cone size

14

Wafer Products

15

Wafer Biscuit Production Oven

R&D

WA Series
Plate size 350 X 470

ZWA Series
Plate size 290 X 460

ZW Series
Plate Size 230 X 290

ZWT Series
Plate Size 270 X 370

16

Wafer Biscuit : An Introduction

Wafer is a specialized type of biscuit in that they are formed from a batter which is baked between pairs of heated metal wafer tongs. The sheets so formed are typically thin but may bear intricate surface patterns with deep relief. Wafers which are sold in biscuit markets are usually formed as large flat sheets, which are subsequently cream sandwiched before cutting and may be chocolate enrobed. The majority of wafer biscuits are based on the large flat sheets, and the techniques and technology involved in the production of these will be the basis of account given here. The wafer sheet itself is generally baked from a simple batter containing little or no sugar. It is a tasteless product which has a smooth surface(though patterned by virtue of the engraving on the plates between which it was baked) and a very open cellular structure within. Sandwiched wafers are rich in cream filling (approx to 70% by weight). When filled wafers are chocolate enrobed or form part of a chocolate moulded bar, the wafer components becomes the crisp & crunchy center for the product.

Process Chart
1

3
2

5
4

1. Wafer Oven 2. Batter Mixer 3. Wafer Sheet Cooler

* Out of Our Scope of Offer

4. Planetary Cream Mixer* 5. Cream Spreading Machine 6. Book Cooler

7. Wafer Cutting Process 8. Wafer Fanning Device* 9. Packing Process*

Hollow Wafer Designs/Sample Die Photographs

17

Wafer Design Selection Guide

2.5 X 0.4 (900 )

2.5 X 0.4 (450 )

4.0 X 0.6 (900 )

6.0 X 1.0 (450 )

8.0 X 2.0 (900 )

8.0 X 2.0 (600 )

Regular Designs

10 X 2.5 (600 )

10 X 2.0 (450 & 00 )

12 X 3.0 (900 )

12 X 3.0 (600 )

12 X 3.0 (450 )

12 X 3.0 (450 & 00 )

Special Designs

A P

Round shell Design

Canape Design
T

D B C

A - Angle of Reeding B - Body C - Depth of Engraving D - Depth of Engraving P - Pitch of reeding T - Total Thickness

Heart Design

Tray Design 18

Design Requirements

Wafer Plant Layouts - Suggestions

WA - 72 Lay out

LEGEND 1. WA 72- OVEN 2. MIX PLANT 3. SHEET COOLER 4. CREAMING MACHINE 5. BOOK COOLER 6. WAFER CUTTING M/C 7. WAFER DISTRIBUTION DEVICE

ZWA Plant Lay out

LEGEND 1.ZWA24-SERIES 2.MIX TUB 3.SHEET COOLER 4.CREAMING M/c 5.BOOK COOLER 6.WAFER CUTTING

19

WA Series Wafer Biscuit Plants

Plate Size 350 x 470 mm

WA series baking plant

The WA Series of Wafer Biscuit Baking Machine are designed for fully automatic production of wafer sheets with fine medium or deep-reeding, as well as wafer sheets with hollow forms for all types of shapes. According to the out put required it may be equipped with 48, 60 and 72 baking plates. The standard plate size is 470 x 350. These baking machines can be heated by L.P.G. (Or if preferred by Electricity). Universal triangular burners are used for baking effect in gas plant by using twin row method. This brochure details gas heated plants.

Heating
High Efficiency triangular burners can be adjusted for an extremely even application of heat over the entire surface of the baking plates.

Features
The machine features a sturdy and torsion resistant steel frame work. The tong chain is extremely strong and almost maintenance free.

Operation
When the batter gets deposited, the upper and lower baking plates are pressed together and locked. The high closing pressure is absorbed by large size closing rollers located above and below the tongs. Locking is effected by means of hook, and bearing clearance which has no effect on the closing mechanism or on the thickness of the wafer sheet. Batter depositing system ensures uniform sheet weights and waste free and optimum batter usage.

20

Insulation
Fully opened hinged doors run along the entire length on both the sides of the baking machine & permit total access to the interior for ease of cleaning and maintenance. Heat loss is made minimum by a special protection and insulation.

Control panel
Control panel contains all units for the Automatic Baking Machine and incorporate the following functions : Safety switches with over load and over voltage relays, fault current circuit breaker and automatic burner. Optional temperature measurement by sensor can be provided.

Technical data Type

Output of wafer sheets/hour Cream filler Wafers/hour (Kgs)

Plate Size : 350 mm x 470 mm

WA48
1440 200-225 30-35 9Kw

WA60
1800 250-275 38-42 9Kw

WA72
2160 300-325 44-48 9Kw 14000 1350 2450 13500 46

Gas Heating: L.P.Gas consumption Kgs/hr (approx) Electric load in Kw. Dimensions in mm. Length Width Height Weight in Kg.(approx.) Shipping space in cubic meters(approx.)

10000 1350 2450 9000 32

12000 1350 2450 11250 40

BASED ON 120 Sec. Baking cycle * The capacities indicated above are suggested values. The exact capacity depends on baking time, recipe and cone size

21

ZWA Series Wafer Biscuit Plants

Plate Size 290 X 460mm ZWA Series Semi Automatic Wafer Baking Machines
The semi automatic wafer baking machines of the ZWA series are suitable for the production of first class quality flat wafers. These machines can be Equipped with 12, 18, 24 30 & 36 baking plates (tongs)according to the required output. The machine is built with a steel frame of rigid construction. An endless chain conveys the baking plates on their carriers through the baking chamber, driven by a chain drive infinitely variable in speed through its range. The standard size of the baking plates is 290mm x 460mm (about 11 x 18). Also special size of baking plates can be supplied on request. These baking plates can easily be exchanged to produce wafers of different designs. The oven can be heated by L.P.Gas or if preferred by Electricity.

Batter
Wheat flour, Maize starch, Vegetable fat, preservatives etc are mixed with water to form the wafer batter. The batter is discharged onto the baking plates by a cam operated pump. The pump can be very accurately set to give an efficient distribution of batter with maximum economy and minimum wastage. Adjustment, clearing and maintenance of the pump is simple and quick.

Baking plates
The plates are made of special alloy. The selection of alloy and casting procedure ensures dimensional stability, a homogenous and dense surface, thermal stability, good heat accumulation characteristics and excellent thermal conductivity. Special finishing is done to ensure trouble free release of wafer sheets. The wafer thickness is quickly and easily adjusted by applying spacing shims.

Heating (either by liquified petroleum gas or electricity)

By Gas : The gas heating system has automatic ignition with safety devices. In case of gas, air or power failure, a automatic cutout device on the heating system will operate. The oven is equipped with special burners. Precise controls for the mixture of gas and air gives high efficiency combustion. On gas heated machines, the exterior of baking plates have pyramidal shapes cast-on, to give increased surface area and thus better heat exchange. By Electricity : On electrically heated baking plates, the current is conveyed via copper conductors and by spring loaded contacts to the individual baking plates. The heating elements are fixed into the baking plates and insulated.

22

Drive and controls

The control panel can be mounted at the discharge end of the oven or at a distance of up to one meter for ease of operation. This provides control for the drive, batter pump, blowers and ignition. The drive is by an electric motor through a gear box and chain drive protected by an overload safety clutch. Baking time is adjustable between 1.5 and 3 minutes by means of potentiometer on the control panel, provided suitable batter is used.

Sheet take-off
The batter is discharged onto the baking plates by a cam operated pumps. The precision-built pump gives an efficient distribution of batter. Air blowing facility for simple removal of the wafer sheet from the baking plates.

Heating
High Efficiency triangular burners can be adjusted for an extremely even application of heat over the entire surface of the baking plates.

Technical data

Plate Size : 290 mm x 460 mm ZWA12

12 360 40-42

TYPE
No.of Baking Plates (tongs) Output of Wafer Sheets/Hr* Cream filled Wafer Biscuits in Kg/Hr* (Approx)

ZWA18
18 640 72-75

ZWA24
24 860 96-100

ZWA30
30 1080 120-125

ZWA36
36 1300 145-150

IF GAS HEATING*
L.P.Gas consumption Kgs/hr Electrical load in KW 8 3.5 10-12 3.5 14-16 3.5 18-20 3.5 20-23 3.5

IF ELECTRIC HEATING*
Load in KW Consumption in Kw (approx) 47 37 4,250 1500 2000 70 56 5,750 1500 2000 94 75 7,250 1500 2000 118 94 8,750 1500 2000 141 100 10,250 1500 2000

DIMENSIONS IN MM
Length Width Height

WEIGHT & SHIPPING DETALS

Net Weight in kg.(approx.) Including export packing kg. (Approx.) Shipping space in Cubic Meters approx. 3,500 4,500 20 5,500 6,750 25 7,000 8,500 30 8,500 10,000 36 10,000 12,500 42

* Based on 100 Sec baking cycle. * The capacities indicated above are suggested values. The exact capacity depends on baking time, recipe and cone size ** Shorter oven required longer baking cycles.

23

ZWT Series Wafer Biscuit Plants

Plate Size 270 X 370 mm ZWT Wafer Baking Machine
The Automatic wafer Baking Machine ZWT Series is designed for fully automatic production of wafer sheets with fine, medium or deep reeding as well as hollow wafer sheets. It may be equipped with 12, 18, 24,30,36,42 baking tongs.

Heating system
The automatic baking machine is equipped with high efficiency burners that can be adjusted for an extremely even application of heat over the entire surface of the baking plates.

Special Design

Heating (By Liquified Gas(LPG) / Natural Gas)

By Gas : The heating system has automatic ignition. In case of gas, or power failure, an automatic cutout device on the heating system will operate.

Baking plates

Regular Design

The plates are made of special alloy. The selection of alloy and the casting procedure ensures dimensional stability, a homogenous and dense surface, thermal stability, good heat accumulation characteristics and excellent thermal conductivity. Special finishing is done to ensure trouble free release of wafer sheets. The wafer thickness is quickly and easily adjusted by applying spacing shims.

Technical Data

Plate Size : 270 mm x 370 mm ZWT12 360 18-20 4-5 3.5 3400 1100 2000 1300 1800 4.5 ZWT18 640 36-40 6-8 3.5 4600 1100 2000 1900 2500 5.5 ZWT24 860 48-50 8-10 3.5 5800 1100 2000 2500 3250 7.0 ZWT30 ZWT36 1080 65-70 12-14 3.5 7000 1500 2000 3100 3900 15.0 1300 80-85 16-18 3.5 8200 1500 2000 3700 4600 18.0 ZWT42 1500 90-95 18-20 3.5 9400 1500 2000 4300 5000 20.0

ZWT AUTOMATIC WAFER BAKING MACHINE

Output of wafer sheets/Hr

Cream filled wafers/Hour (Kgs.approx.)* GAS HEATING: LP Gas Consumption/Hr ELECTRIC LOAD (Kw) DIMENSIONS (approx in mm.) Length Width Height Net Weight in Kgs Weight incl. Seaworthy packing Shipping space in m
3

* The capacities indicated above are suggested values. The exact capacity depends on baking time, recipe and cone size

24

ZW Series Wafer Biscuit Plants

Plate Size 230 x 290 mm ZW Semi Automatic Wafer Baking Machine
The Automatic Wafer Baking Machine ZW Series is constructed for the production of first class quality flat wafers. According to the output required, it may be equipped with 12, 18, or 24 baking tongs. The Machine consists of a solid steel frame of angle works and has adjustable legs. An endless link chain carries the baking plant, mounted on the baking tongs. The batter is discharged onto the baking plates by a cam operated pump. This pump can be very accurately set to give an efficient distribution of batter with maximum economy and minimum wastage. Adjustment, clearing and maintenance of the pump is simple and quick. The baking machines can be heated by L.P.Gas or if preferred by Electricity. The baking chamber is effectivly insulated, ensuring efficient use of energy.

Baking plates
The plates are made of special alloy. The selection of alloy and the casting procedure ensures dimensional stability, a homogenous and dense surface, thermal stability, good heat accumulation characteristics and excellent thermal conductivity. Special finishing is done to ensure trouble free release of wafer sheets. The wafer thickness is quickly and easily adjusted by applying spacing shims.

Heating (Either by liquified Gas or electricity)

By Gas : The heating system has automatic ignition. In case of gas, air or power failure, an automatic cutout device on the heating system will operate. By Electric : On electrically heated baking plates the current is conveyed via copper conductors and by spring contacts to the individual baking plates. The heating elements are fixed into the baking plates and insulated from external environment.

Technical Data
ZW AUTOMATIC WAFER BAKING MACHINE

Plate Size : 230 mm X 290 mm

ZW12** 360

ZW18 640

ZW24 860

ZW30 1070

ZW36 1280

Output of wafer sheets/Hr*

IF GAS HEATING: LP Gas Consumption/Hr ELECTRIC LOAD (Kw) for LPG Heated Plants IF ELECTRIC HEATING
Connected load in KW

4 3.5

6 3.5

8 3.5

10 3.5

12 3.5

27 20 2500 1100 1500 1300 1800 4.5 18-20

40 32 3300 1100 1500 1900 2500 5.5 36-40

51 40 4100 1100 1500 2500 3250 7.0 48-50

63 50 5200 1100 1500 3250 4100 9.0 60

75 60 6300 1100 1500 4050 5000 11.0 75

Current Consumption in KW/Hr (Electrical) DIMENSIONS (approx in mm.) Length Width Height

Net Weight in Kgs Weight incl. Seaworthy packing Shipping space in m

3

Cream filled wafers/Hour (Kgs.approx.)

* The capacities indicated above are suggested values. The exact capacity depends on baking time, recipe and cone size

25

Wafer Biscuit Tongs - WT Series

Plate Size 270 x 370 mm WT Manual Cream Wafer Plants
WT Series Cream wafer plants are used for the manually operated production of cream wafer biscuits. The machine is characterized by a simple mechanism that is sturdy and flexible. These machines are low cost and economical in operation, depending on the output required; WT-6 Mounted they can be supplied with 6, 9 or 12 Wafer on Special Stand baking tongs. This Brochure details a set of six Wafer tongs (6WT) production and Capacities. Cream spreading table, cutting machine, batter mixer, cream mixer & packing machines ensure that production is continuous.

Baking Plates
The plates are made of special alloy. The selection of alloy and casting procedure ensures dimensional stability, a homogenous and dense surface, thermal stability, good heat accumulation characteristics and excellent thermal conductivity. Special finishing is done to ensure trouble free release of wafer sheets. The wafer thickness is quickly and easily adjusted by applying spacing shims.

Machine Operation
The batter is fed to pre-heated wafer tongs by a special dosing device. Baking takes 1.5-3* minutes. The baked sheets are cooled. Subsequent operations are creaming, sandwiching &cutting. The wafers are then packed.
Workers required : Six unskilled workers are required to complete the production. Operational area required : The total operational area required is about 750 Sq. Ft. Capacity & output details : Production from 100 to 125 kgs* can be made in 8 hrs.(using 6WT)

Technical Data
Plate Size 270 mm X 370 mm approx. No. of Wafer Tongs WT =6 Nos.
Technical Specifications Output of wafer sheets/Hr ELECTRIC HEATING: Connected load in KW Current consumption in KW/Hr DIMENSIONS (in mm) Six Tongs are packed as 3 Stations x 2 Cases Length Width Height Net Weight in Kgs Weight incl. Seaworthy packing Shipping space in m 3

WT6 240 15 12

1420x2 440x2 750x2 640 900 2.0

WT - 1 Mounted on a Stand WT - 1 - Spl for Special Product

Cream filled wafers/hour* (Kgs. Approx.) 20-25

* The capacities indicated above are suggested values. The exact capacity depends on baking time, recipe and cone size

26

WAFER SHEET COOLER - SC Series

Model SC-6

Sheet Coolers are used to cool the baked wafer sheets in ambient air. The baked wafer sheets enter the Arch Sheet Cooler. Where uniform cooling & stress relieving takes place. They are then fed to the creaming machine for further process. Wafer Sheets up to a size of 470 X 290 mm can be handled by these type of arch coolers and can be custom designed as per clients requirement. The wafer sheet cooler is designed in the form of an arch so that operator can supervise several machines and move from one to other with out hindrance. The wafer sheets are fed into pairs of metallic wire brackets which are positioned to each other. The wire brackets are fastened to a pair of endless roller chains forming an endless chain of holders. Sensing device notes when a sheet has been placed in a bracket and signals the motor to advance the chain one step so that an empty bracket awaits the next wafer sheet. The carrier brackets, guide plates, and all other components of the unit coming into contact with the product are fabricated from stainless steel. Wear-resistant plastic rails are used to guide the carrier chain. The cooler is fabricated from modular components thus allowing the length, width and carrying capacity to be varied easily and as required.

Technical Details

Different Sizes of wafer sheet in mm Dimensions Length Width Height Passage Height Connected Load (Kw) Frame Constructed Net Weight Gross Weight Shipping Volume

SC6- 470X350 4000 mm 1100 mm 2800 mm 1700 mm 0.37 OUT 0.12 IN

Stainless steel / All over

700 Kgs 900 Kgs 12 CBM

27

SC5 Sheet Cooler

SC4 Series Sheet Cooler

SC Series Sheet Cooler

Technical Details
Different Sizes of wafer sheet in mm Over all Length Width Height Passage Height Connected Load Frame Constructed Net Weight Gross Weight Shipping Volume SC5- 470X350 SC4- 350X470
SC0-230X290 SC1-270X370 SC2-290X460 SC3-350X470

4150 mm 1000 mm 2650 mm 1700 mm 0.6 Kw

Stainless steel / MS Frame work / Cladding

2400 mm 1020 mm 2250 mm 0.5 Kw

SS

2700mm 820-1020mm 1900mm 0.5 Kw

SS

510 Kgs 710 Kgs 8 CBM

300 Kg

210 Kg

5.5 CBM

5.5 CBM

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WAFER CREAMING MACHINE

Cream spreading machines can apply a wide range of creams to all kinds of wafer sheets. Normally these machines operate either on contact system or film system.

CR6 Machine - With Spiral book maker

Spreading machines spread an exact amount of fat cream onto the wafer sheets and automatically stack the requested number of spread sheets together with the un creamed top sheet into a wafer block. A thermostat allows to heat the cream spreading roller as well as the counter-roller up to an exact temperature. The speed of the two rollers and of the spreading belt can be variably adjusted, independently of each other.

The desired thickness of the individual cream layers is obtained by regulating the speed and the distance between the rollers. It prevents the cream from being spread in front of the wafer(cream wedge), which allows efficient spreading of cream. A paddle in the cream hopper provides for uniform distribution of the cream on the spreading roller. Flexible sealing lips in the cream hopper prevent leakage of liquid creams when the machines is out operation. The uncreamed top sheet passes the spreading roller without contact due to camcontrolled lowering of the spreading table. After spreading, wafer blocks are formed out of two to seven wafer sheets with the spiral stacker. There the wafer sheets get maximum support and are stacked. Even delicate wafer sheets with heavy creams can be processed. Exact block formation guarantees a minimum of cutting residue in the following cutting process. The requested number of cream layers is set by a selector switch and electronically controlled by light barriers.

CR5 Machine - With Linear book maker

CR5 is a high efficient machine. Contact system allows the application of very thin layers of cream and the processing of liquid cream. The spreader head is lowered so far by means of a hand wheel, so that the fluted spreading roller touches the wafer sheet to be spread. The swinging pressure roller located below the conveyor belt is adjusted in such a way that the conveyor belt presses the wafer sheet against the spreading roller. Pressure must be equal from both sides. The CR5 is a high-efficiency machine. 300 books can be spread and put together to make wafer blocks, of up to five sheets; in one hour. The desired quantity of the cream layers can be adjusted by means of a counting device. A stacking device puts the spread sheets together to make a wafer block.The machine has a spreading unit which operates using a contact system (3). The spreading rollers are heated by electricity and the heating is accurately adjustable. The number of revolutions made by the spreading rollers as well as the speed of conveyor belt are infinitely variable independent of each other.

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CR4 Machine - Semi Automatic

Cream Spreading Machines type CR4 can apply a wide range of creams to all kinds of wafer sheets up to a width of 480 mm. Normally these machines operate on the contact system but can also be supplied with an additional device for creaming by the film system. The spreading head contains a grooved spreading roller and a counter roller. Spreading roller are heated and thermostatically controlled. These two rollers are driven by an infinitely variable speed motor in opposite directions to obtain the desired quantity of cream, Spreading

ACR - Semi Automatic

This machine is used for the automatic spreading of wafer sheets with fat cream by the contact system, for the manual wafer block formation & for the automatic wafer sheets with the sizes 230mm X 240mm.

1. Film Method 3. Contact Method

2. Reverse Film Method 4. Film Method for Hollow Wafers

Technical Data ACR

Size of the Wafer Sheet Width of spreading roller Wafer Sheets per minute( max) Electrical Load (Kw) Size of the machine (approx) Length X Width X Height Net weight (appr.kg) Net export packing (kg) Shipping space (appr.m3) 273x373 330mm 15 1.5 2135x 615x1370 600 800 1.8

CR4
270x370 290x460 360mm 455mm 15 1.5 2135X 615X1370 450 550 4.25

CR5*
290x460 285mm 18 (Max) 2.5 2900x 650x1400 650 900 3.0

CR6-1*
290x460 462mm 36-40 (Max) 3.5 1950x 1250x1550 700 900 4.0

CR6-2*
350x500 462mm 36-40 (Max) 5 2700x 1250x1550 700 1200 4.0

*Pneumatic connection required

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WAFER CUTTING MACHINE

We manufacture a series of cutting machines, WC machine can handle different sizes of wafer sheets (230 mm x 290 mm, or larger). These are fully automatic machines for cutting flat and Hollow wafers filled with cream. These machine take over the cooleddown wafer blocks coming from the cooling device or creaming machine and cut them into required number of blocks. In the cutting operation the wafer book are first pushed through one set of cutters and then at a right angle (perpendicular) through a second set of cutters. Fixed and tensioned cutting wires in removable frames are used. Changeover to other cutting sizes is facilitated by quickly and easily changing the cutting frames and pushers. These machines are designed for high-capacity plants. They occupy less space.

Operation
A number of wafer blocks having together a height of about 70 mm are put between pressing piece and cutting frame of the first table and lightly pressed to the pressing piece as well as to the striking point. It is necessary that the block lie at the striking point if both sides of the block are to be cut evenly. If after the first cut, it shows that the two waste strips are not equally wide; this can be corrected by adjusting the striking point. During practical operations it has shown that the width of the waste strip should be about 5mm, which is absolutely necessary if the entire block is to be cut cleanly.

Wafer Distributor
For chocolate enrobed products we could also offer as an option of Wafer Distributor for our wafer cutting machines

WC3 Machine

WC4 Machine

WC5 Machine 31

WCM Machine

Possible Cutting Layouts

Wafer cutting Machines without feeding device Wafer cutting Machines with feeding device

A-1

A-2

B-1

B-2

A-3

A-4

B-3

B-4

Technical Data Machine Variables

Size of the Wafer (Possible) Stack Height (mm) Minimum Cutting Width (mm) Cutting Wire (spring steel in mm) Connected load (Kw) Dimensions (mm) Length Width Height Net weight (appx. Kgs) Shipping volume (CBM)
*Pneumatic connection required

WCM
270x370

WC1
230x290

WC2
270x370

WC3
290x460 350x470

WC4*
290x460 350x470

WC5*
470x350

10 to 70 16 0.5

10 to 70 10 to 70 70 16 0.5 1.5 16 0.5 1.5 16 0.5 1.5

70 16 0.5 1.5

70 18 0.5 1.5

1450 1130 675 110 1

1700 940 1150 650 2

1700 940 1150 650 2

1700 1600 1200 310 4

1700 1600 1200 310 4.5

2400 1700 1200 480 4.5

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WAFER BOOK COOLER

Cooling Process
Book Cooler is a machine used for cooling the cream between the wafer books before they enter the cutting machine. The cooling capacity can be changed according to the product requirement & capacity required. The wafer book cooler BC-Series machine is a compact design, fabricated from modular sections. This unit is developed by a combination of a number of modules & will provide required cooling time and also fit in the space available. The bracket, guide plates, and all other parts coming into contact with the product are fabricated from stainless steel. After spreading the cream on the wafers and completing the preparation of wafer book, it must be cooled in order to harden and set the cream prior to cutting. Partially setting the cream is required for clean cutting & in turn clean cutting is required for clean packing. The movement of wafer books can be watched through the windows provided on the inlet and outlet of the tunnel. The wafers are passed for following process either to a cutting device or to an intermediate container.

Cooling Unit
The cooling unit is a refrigerated system, designed for continuous duty cycle working. The system consists of air-cooled single stage Hermitically sealed compressor based cooling unit. Refrigeration gas is ozone friendly (min ODP); HCFC R-22 and with forced air circulation. The compressor is mounted on vibration isolators.

Technical Details Machine Variables

Wafer Book Sizes (mm) Electrical Load (Kw) Refregiration (kcal/hr) Dimensions (mm) Length Height Width

BC1
230X290 270X370 10Kw 5000 3700 780 2050 7

BC2
290x460 10Kw 5000 4850 780 2050 8

BC5
290X460 470X350 18.5Kw 10000 6000 780 2050 10

Shipping Space in CBM

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SUPPORTING EQUIPMENT BATTER MIXER

TM0 (standard)

TM2 (standard)

TM3 (standard)

BM- 3 RS

Batter Mixing

TM3 Sp (with control panel)

R&D Engineers has a series of mixing plant depending on the capacity of batter required to be made. Primary requirement for the production of quality batter is that all ingredients must be fully mixed together so that the batter will be homogeneous. The particularly carefully mixing procedure is achieved by the strong vertical currents induced in the batter. In the mixer center, the batter is induced to flow in the downward direction; on the periphery, the batter then flows in the upward direction. The batter mixer is used for the fully automatic production of batter for feeding one or more Baking Plants either manual/automatic. Consistent batter is required for quality products (cones/wafers). The age of the batter, or the time between mixing and use, has also a marked and effect on the sheet quality. Thus, to insure that the Automatic Wafer Baking Machines are being supplied with batter that is always fresh, it is important to prepare smaller batches at a time.

Features of MP100
MP100 is a sophisticated mixing plant in which an extra intermediate holding tank is provided along with the mixer. The selector Switch is provided for a variable mixing time. When mixing is complete the mixer shuts it self off automatically and the batter is pumped into an intermediated holding tank. A stirring device is supplied in the holding tank also. From this holding tank the batter can be continuously pumped to the batter depositing station. Batter Pump is easily accessible, easy to clean, made of Stainless Steel.

Technical Details Batter mixer

Tank Capacity Connected load in Kw (3 phase) Length (mm) Width (mm) Height (mm) Net Weight (apprx)

Mix Plant - MP 100

TM0
25 lts 0.75 450 450 1000 50Kgs

TM2
65 lts 1.2 780 780 1600 70 Kgs

TM3
95 lts 2.2 900 600 1400 90 Kgs

MP100
100 lts 4.5 1625 740 1690 200 Kgs

BM-3 RS
100 lts 3.2 1170 660 1270 115 Kgs

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RS - TUBE ROLLING STATION

Used along with RS / RSCM Series Machines

We supplies automatic Tube Rolling Station for best quality and precise rolled sugar wafer tubes. The Rolling machines are designed with latest technical standards for an economical results.

Technical Data:
Sheet Diameter Tube Diameter Rolling Time No. Of Stations Size of Cuts Connected Load in KW Speed Dimensions(MM) Length Width Height Weight (Net) Shipping Weight (Gross) 1100.0 600.0 1020.0 90.0 Kg 138.0 Kg
**Variable Cutting Length

Max 175 MM Min 16 MM 8 - 10 Seconds 1 16 X 35 MM 0.37 138 RPM

Automatic Ejection

Cutting Device

35

Replacement Moulds & Dies offered for all plants

Exchange baking plate for Wafer Plants

Exchange baking moulds for Cone Plants

* Submit actual plant specimen or detailed drawing. ** A huge library of international designs in our database. 36

WAFFLE CONE MAKER (RSCM)

Waffle Cone probably the hottest item in the ice cream business today. Whether its Vanilla or Chocolate with Ice Cream, Yogurt or soft server; waffle cone increases frozen desserts sales 25% to 50%. To maximize sales of Ice Cream / Sundaes you need both a great taste in cone itself, plus good aroma to attract people to buy this freshly baked Ice Cream Cone. Youll probably sell twice as many certainly more, when you have the ACTION and AROMA. The aroma of freshly baked waffle attract the customers attention immediately. Thats the key.

How to Make ?
RSCM: Model 100 Single Plate 220v, 1.5kw Capacity: 50 cones* per hour Batter Preparation Wheat Flour,Sugar, Emusified Oil and Water make the batter in a couple of minutes. Pouring the Batter Pour the batter on the heated plate and shut it.The baking takes about 45-120* seconds.

Remove with the knife Remove the hot waffle sheet and roll it on the Wooden roller or Nylon roller

Manual Rolling Wooden roller for manual rolling. Ideal to try new sizes

Manual Cup Punching Machine

Exciting Possibilities . . .

37

BELGIAN WAFFLE BAKER (RSCM)

Belgian Waffle probably the hottest item in the ice cream business today. Whether its Vanilla or Chocolate with Ice Cream, Yogurt or soft server; waffle cone increases frozen desserts sales 25% to 50%. To maximize sales of Ice Cream / Sundaes you need both a great taste in cone itself, plus good aroma to attract people to buy this freshly baked Ice Cream Cone. Youll probably sell twice as many certainly more, when you have the ACTION and AROMA. The aroma of freshly baked waffle attract the customers attention immediately.
Design 01 (Round)

Design 02 (Heart)

How to Make ?

Batter Preparation Wheat Flour, Sugar, Emulsified Oil and Water make the batter in a couple of minutes.

Heating The initial heating of the plates takes about 15-20 minutes. Lightly Brush with Fat.

Exciting Possibilities . . .

Pouring the Batter Pour the batter on the heated plate and shut it. The baking takes about 60-120* seconds.

Remove with the knife Remove the hot waffle sheet.

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ISO 9000:2001 Certified

CE Certified

Export Excellence Performance Award

39

R&D Family World Wide

We are here

Quality Policy
The company is committed to achieve customer satisfaction & market leadership by Timely delivery and quality product. Reliable and cost effective product. Ultimate quality service and competitive prices. Spontaneous changes as per customer feedback. Team work and continual improvement. Effective utilization of resources.
All rights reserved. No part of this brochure may be reproduced or transmitted in any form or by any means, electrical or mechanical including photocopying, recording or by any other form of information storage or retrieval system without permission in writing from the publisher. R&D Engineers adopts a policy of continues improvement and whilst every effort has been made to provide accurate and up to date information, the information contained in this brochure should be used for guidance purpose only and does not form part of any contract. The technical data and illustrations are subject to change without notice

R & D Engineers
English - V_5.0 - 2009

An ISO 9001:2000 Company

A-41, IDA Kukatpally, Phase II, Road No.4, Via I.E.Gandhi Nagar, Hyderabad - 500037. INDIA. Phone : +91-40-23079121 / 7985 Fax : +91-40-23078668 E-Mail : i n f o @ r n d w a f e r s . c o m