Cheese Making Moulding/PrePress and final pressing

 

PrePressVat

The Curd and Whey are discharged to the Pre-Press Vat by a Curd pump.

The Curd and Whey are spread through 2 spreading distributors.

Inside the Vat and on top of the bottom a moveable reinforced polypropylene belt is placed for good and fast drainage. The Stainless steel bottom is constructed from rows of whey troughs for correct and controlled whey drainage.

The front end of the Vat is equipped with a sliding door which also acts as a guillotine when cutting the Cheese. Behind the guillotine, a row of adjustable knives is fitted on a bar across the width of the Vat.

On the top of the Vat, a pressing plate is placed which automatically can be moved down for pressing and for C.I.P.

The whole unit is supplied with the electrical drive for belt and pressing plate and pneumatically pressure on the Cheese.

After filling the Pre-Press Vat, the pressing plate is automatically moved downwards to the cheese and the pressing is effected over the entire surface. The pressure on the Cheese mat is adjustable between 0 and 35 g/cm2.

After the pre-set time the pressing plate is moved automatically up to its parking position and the bottom belt starts to move the Cheese mat through the knives. When the belt has moved over a distance and the pre-set length of the curd block has moved through the knives, the guillotine cuts the mass crosswise. The Cheese blocks, up to 400 mm high are now lying ready for further transport or for manual placing in moulds.

After crosswise cutting and lifting the guillotine the belt will move to the next row of cheese through the knives. The belt is moved forward and backwards by electrical driven motors placed at the front and rear end of the vat completely covered by a stainless steel shroud.

 

Pre-PressMachine

NDT Pre-Press & Mould Filling Machine is a result of the experience we have gained during our projects for production of semi-hard and hard types of Cheeses, Dutch type of Cheeses. It pre-presses and moulds all types of Cheese with or without whey. The last version is a fully automatic solution with level control so one person is only needed for the start and the end of each batch. The Machine is flexible for different dimensions of Cheeses and can easily be changed to other formats.

For moulding and pre-pressing of circular and rectangular Cheeses with and without Whey. Capacity: Filling of max.1-3 multi moulds per min. The machine works in totally automatic cycles and is adapted and synchronised with the rest of the production line through a recipe system.
It guarantees an accurate dosing achieving constant dimension and weights with a total exploitation of the curd, increasing the efficiency and the production capacity within the maximum hygienic conditions.

OPERATION PRINCIPLES

The unit has 5 sections

a) Draining section for pressing without whey.

b) Distribution chamber for columns with entrance of whey and curd when pressing with whey

c) Pressing Column with different pattern of the draining holes and dimensions for each of the horizontal sections

d) Cutting, portioning and additional pressing at the outlet of the columns

e) Discharging of cheese into the moulds

Step 1. Entering of Curd grains and whey

With Whey

The Whey and Curd are lead into the distributing chamber horizontal and at the periphery of the distribution chamber in a way to obtain as good circulation and spreading of the curd grains as possible.

Without whey

The curd grains with whey enters the unit over a distribution tray in order to spread the curd grains over the overall width of the specially designed filter plate to drain off the whey without destroying the curd grains.

The Whey is lead to a separate outlet. Then through a fine filter in a balance tank where the whey by level control is pumped to the CFC – Cheese fines Collector. The CFC is for removing smaller fines in order to make the whey ready for separation. (Separate supply).

The Curd grains are slowly falling down on the filter plate to the distribution chamber into the columns.

Step 2. Distributing of Curd into the columns

With Whey

The level of whey will be fixed at a high point at all times during the pre-pressing in the Distribution Chamber.

The agitator gently agitates and makes a distribution of the curd grains in order to fill the columns equally.

In some cases where the level needs to be increased, the system will return whey from the balance tank to the distribution chamber.

Without Whey

The curd grains arriving from the filter plate is gently distributed with the agitator equally into the columns.

Step 3. Pressing in the columns

With Whey

The columns and the chamber for the columns are filled with whey during the entire pressing operation till the last cheese leaves the column. The columns are divided horizontally into 3 sections with independently draining of whey. The volume of whey drained from each section is made in Steps and in a way that the flow inside the columns is downwards and forcing the curd grains to move downwards inside the columns till it reaches the compact layer of curd grains. Before emptying the PPFM of cheese into the moulds, the columns must be filled up with curd grains.

The height of curd grains and level of whey above the curd grains represents the pressure put on the cheese mass formed in more and more compact state downwards in the columns.

Circulation and draining of whey from each horizontal section give an accurate control of the pressing pressure and the capacity of the PPMF.

An advanced software makes sure that this control is done automatically according to the set points.

Without Whey

The curd grains falls down from the distribution chamber to the bottom of the columns and build up to the top before any discharging of cheeses are done. Each horizontal section is draining whey directly to the balance tank for whey outlet.

The capacity of filling the columns decides the pressure of the cheese before discharging.

Step 4. Cutting, portioning and additional pressing

The section is equipped with a 2 stage knife system for cutting the cheese incorrect height and weight and matrices to fit the actual dimension of each cheese coming out of the columns.

The bottom of the matrices is movable from bottom to the knife.

When starting the portioning bottom of the matrices moves to the knife (which is the bottom of the columns).

The knife goes backwards to open for the cheese out of the columns. The bottom of the matrices moves downwards by a servo motor system in an accurate position to give the required height of the cheeses. The knife moves for cutting the cheese block from the column.

There is the possibility to add additional pressure for a few seconds at high pressure to improve the shape of the cheese block. This adjustable pressure is controlled in details by a load cell.

When pressure is off, the matrices bottom moves to the lowest position in the matrices. And the matrices are moved horizontally to the discharge position.

Step 5. Filling of the Moulds

A multi mould is ready in position for filling. When the matrices enter the discharge station the total weight of the cheeses in the matrices are registered. The multi mould is moved upwards to make the fall length as short as possible for the cheeses. A guillotine that forms the bottom of the matrices in this section moves quickly away and the cheeses fall into the moulds. The multi mould is lowered and leaves the PPMF. The matrices are moved back into cutting position.

 

MoultiMouldsSystem

NDT Multi Moulds are manufactured from a food quality plastic material, grooved and perforated for well proven draining qualities, meeting all technical requirements for cheese production. Complete welded with sharp corners.

The moulds have a special spring system for ensuring the equal pressure on the total surface of the cheeses.

NDT Automatic Multi Mould Storage System
Vertical, multi mould accumulation, model MULTIPLE COLUMNS, automatic with one channel for multi moulds placed in parallel with the Pressing Tunnels.
• Moulds are moved in and out with an indexing conveyor.
• Pneumatic lifting system
• Filling and emptying of moulds simultaneously
Manufactured in stainless steel AISI 304, supported and equipped with adjustable ball feet and support plates.

NDT Mould/Lid Washer
Functions description:
In the four zones, spray nozzles are strategically placed in accordance with the mould and lid construction, which secure an efficient internally and externally cleaning of the mould and lids.
In the first chamber, the moulded cartridge is spread internally and externally with circulated rinse water, which has been used in the fourth chamber.
In the second and third chamber, the moulded cartridge is spread internally and externally with a detergent solution of up to 85°C temperature. The solution is collected into the corresponding tank and re-circulates through a pump.
The detergent solution is heated by steam in a coil in the bottom of the chamber. The detergent concentration is automatic controlled. Detergent is adding via a dosing pump.
Into the fourth chamber, clean water rinses the mould from detergent residues.
After that, the water is preceded through a pump into the water tank in order to be reused in the pre-rinsing zone. After the pre-rinsing zone, the water is drained.
Each vat has a filter in order to protect the pumps from dirt.
All pumps are stainless steel constructed equipped with stainless steel cover.
Mould cartridges and lids are transported through the washing machine with a stainless steel chain conveyor.
The washing machine is complete including sensors, transmitters, conveyor including two driving stations with motors and shroud for each conveyor.
The Mould/Lid Washer can be CIP cleaned by the CIP Station.
Construction:
The machine is a two-line washing machine, one line for moulds and one for lids. The two lines share circulation pumps, water tank and detergent tank.
The washing machine is linear, insulated and constructed from stainless steel AISI 304.
The washing chamber is divided into four zones. The machine is equipped with a cover, which includes a vapour abduction system and openings in order to make exit inspection easy.
The washing machine is manufactured with:
• Water vat.
• Hot detergent solution vat.
• Connections with both steam piping network and well water piping network.

Mould Handling System
Consist of:
NDT lid applicator
NDT mould index conveyor
NDT mould discharge conveyor
NDT mould turning unit
NDT mould and lid conveyors

NDT lid applicator
Function description:
From a position just before the lid applicator, a Multi mould with curd blocks is transported to a fixed position in the lid applicator. From a waiting position just before the lid applicator, a lid is transported to a fixed position in the lid applicator. The lid is gripped with a gripping device and is in a vertical and horizontal and vertical movement placed on top of the mould.
Construction:
The lid applicator is manufactured of stainless steel AISI 304, with adjustable ball feet and support plates
The lid applicator is cleaned manually.
The conveyor is including sensors, transmitters, three air cylinders lid stops and driving stations with one motor and shroud.

NDT mould index conveyor
Technical data:
Length approx.5,5 meter
Function description:
The conveyor is designed to place the Multi moulds in a correct position in front of the final press tube
Construction:
The indexing conveyor is manufactured of stainless steel AISI 304, with adjustable ball feet and support plates
The indexing conveyor consists of a flex belt manufactured of acetal plastic. The belts are running on a slide rail.
The indexing conveyor is including sensors, transmitters, mould stops and one driving stations with motors and shroud.
On the conveyor is a mould waiting position in front of each pressing tubes.

NDT mould discharge conveyor
Technical data:
Length approx. 5,5 meter
Function description:
The conveyor is designed to transport Multi moulds away from the final press tubes.
The conveyor is designed with sensors in front of each final press tubes, to ensure that the place in front of pressing tunnel ready for emptying is free for moulds
The discharge conveyor stops when one final press tube is indexing.
Construction:
The indexing conveyor is manufactured of stainless steel AISI 304, with adjustable ball feet and support plates.
The indexing conveyor consists of a flexible belt manufactured of food approved plastic. The belts are running on a slide rail.
The indexing conveyor is including sensors, transmitters, mould stops and one driving stations with motors and shroud.

NDT mould turning unit
Function description:
From a waiting position just before the turning unit, washed Multi moulds from the mould washing machine is transported to a fixed position in the turning unit. The moulds are turned 180° around a fixed point in the length direction, ready for further transport to the filling station.
Construction:
The unit is manufactured of stainless steel AISI 304, with adjustable ball feet and support plates.
The turning unit is cleaned manually.
The unit is including sensors, transmitters, air cylinders mould stop and turning wheel forced by one motor with the shroud.

NDT mould and lid conveyors
• From washing machine to mould turning unit
• From mould turning unit to filling place
• From washing machine to Lid applicator
• From Lid "take-off" to washing machine
• From discharge unit to washing machine
• From discharge unit to Brine/storage
Construction:
The conveyors are manufactured of stainless steel AISI 304, with adjustable ball feet and support plates
The conveyor chain consists of two flex chains manufactured of food approved plastic. The chains are running on a slide rail.
The conveyors are cleaned manually.
The conveyors are including sensors, transmitters, mould stops and one driving stations with motors and shroud for each conveyor.
Collecting trays with outlet under all conveyors

FinalTubePress

Technical data: 
Enclosed un-insulated final press system consisting of:
• 1 – Single Tube including air pressure cylinders with separate compressed air supply and pressure control.
• Each Tube consists of 28 pressing positions each with 1 air cylinders.
• Each Tube is approx. 17,5 meter long and approx. 950 mm wide.
• Pressure: max 400 g/cm2
Construction:
The final tube press in manufactured in stainless steel AISI 304, and is supported by equipped with adjustable ball feet and support plates
The Tubes is placed parallel to each other at a distance of 100 mm, and the front and the rear opening of the Tubes are rested on the index conveyor and discharge conveyor.
Each press Tube is equipped with one compressed air supply. Pressure and pressure time can be a pre-selected individual in tree steps.
The press is equipped with whey collection separate for each tunnel, with one whey and CIP return pump shared for the whole press.
The moulds are transported in and out of the press Tubes in the same movement after the principle of first in first out, by means of one index conveyor pulled by one air cylinder.
The press Tubes are designed fully CIP cleanable and are cleaned in independent sections.

2 Final Presses are linked together in one batch following one Cheese Vat in filling, pressing, emptying and cleaning.

The press system is including valves, internal pipe system, sensors, transmitters and pumps for automatic collection of whey and CIP liquids.

Measures may change prior to supply.

FinishingVat