Objective
The requirement was to produce a giant crumpet in the same time scale as standard crumpets while keeping the high standards we all have come to know and love.
The system should produce Giant crumpets and have the flexibility to produce standard crumpets relatively easily.
Challenge
- Limited available space within the factory.
- Giant crumpet had never been produced previously.
- Time scales to get the plant working in time for the advertising campaign.
Solution
PVSL used all our experience to design a twin line crumpet plant to fit inside the limited space available, we had to change the configuration of the process to enable the equipment to fit but still operate and produce crumpets to the required high standard.
We developed our “cross flow manifold” which enables the batter mix to be pumped around the top of the hot plate depositor at a constant rate and pressure. Each crumpet benefits from being the exact same size and weight within the specification of the client requirements.
We found the giant crumpets reacted in a different way when being dispensed on the hot plate, we relocated the pumps for the cross flow manifold , this gave a consistent weight to each nozzle on the depositor, a few tweaks with the mixing / pump speeds and fermenting times and the system was producing the giant crumpets just in time for the advertising campaign.
