ABOUT THE COMPANY 
Bakeries, pastries and confectionery
- LINES FOR PRODUCING FREE SET TYPES OF BREAD - typical Czech…
- LINES FOR THE PRODUCTION OF COMMON BREAD AND PASTRIES - rolls, buns, pressed shapes of Viennese type pastries
- LINES FOR THE PRODUCTION OF TOAST BREAD A complete line for typical continental or English style toast, equipped with a specially modified tunnel baking band oven.
- “MULTI-LINE” TYPE LINES In recent times it has become one of the fastest growing segments. The advantage of these lines is that they enable you to bake various types of products, baked either in individual forms, or in its sets, or on trays (plates) of same of varying dimensions all in one production line.
- LINES FOR THE PRODUCTION OF DURABLE PRE-BAKED PASTRIES These lines are used in the production of various types of bread or pastries, where the given type of product is produced using standard methods up until the baking process, then it is in the oven for the shortest possible time necessary and then frozen immediately. Products frozen in this manner are maintained in low temperatures for the entire duration of their storage and transport, until they are finally completely baked in finishing ovens directly in the store, petrol stations or at home in an everyday oven.
- LINES FOR THE PRODUCTION OF “NATIONAL SPECIALITIES”
- LINE FOR THE PRODUCTION OF SOLET STYLE STICKS
(BREADSTICKS, GRISSINI, PRETZELS)
Complete continual line for the production of various types of salted sticks, operates with an output from 100 kg/hour in a wide assortment of sticks produced from dough lightened with baking powder, respectively ammonia. The technology of forming is solved by a roller press, which presses out a strip of dough with the help of calibrated nozzles. - LINES FOR THE PRODUCTION OF COOKIES AND EASTER RAMS (RUSSIA) Completely new technological solution, which eliminates manual work and old-fashioned non-economic procedures.
- LINE FOR THE PRODUCTION OF GINGERBREAD Complete group of machines and gingerbread production equipment from skilled levels of work to fully automated continual production lines. The scope of the delivery is determined by the demand on production assortment and production unit performance. The continual line can also be used for the production of cookies and cakes. Recyclable waste processing forms another part of the production’s assortment of accessories. Lines are completed with fully automated or, semi-automated gingerbread dough makers, extruders and rotary moulders with graved rollers (according to the shape of the product and type of gingerbread dough), facing and glazing machines for glazing with chocolate or sugar, devices for filling the gingerbread with marmalade, jam etc., a product dryer, a cooling tunnel, cooling conveyor bands and packaging.
- LINES FOR THE PRODUCTION OF SHORT PASTRY
- PRODUCTION LINES FOR DURABLE PASTRIES (cookies, cakes etc.)
- LINES FOR THE PRODUCTION OF SPONGE CAKE BISCUITS Automatic continual lines designed according to the required type of sponge cake biscuit production, sponge cake layers etc. The basic characteristics of the continual line are determined by the tunnel baking band oven in a specific solution based on the required assortment and production volume.
- LINES DESIGNED FOR THE PRODUCTION OF ARAB BREAD These lines are created from a flour silo, a mixing centre with a water and flour doser, a divider, a pre-proofer, a forming line, a main proofer, then a high-temperature oven, cooling conveyor bands and finally packaging.
- LINES FOR THE PRODUCTION OF DOG BISCUITS
Our company J4 s.r.o. not only deals with the production of band baking tunnel ovens, but also with the supply of complete, custom made production technological units not just for, bakeries, pastries or confectionary businesses, but also for businesses focussed on the production of dog biscuits and other animals and also for all such businesses where tunnel baking band ovens are suitable equipment for baking, drying or other similar product processing. These complete supplies are realised in cooperation with both Czech and foreign producers and suppliers of bakery, pastry and confectionery equipment.
Such complete production lines or, parts of them are suitable for semi and fully automated industrial large capacity production factories and mid-sized ones. You have the option to control the entire production process via a computer, which can manage up to 48 various recipes together with special software. Such configured lines are also regarded as unmanned lines, simply operated under supervision, which significantly minimises the demand on the number of employees needed to be present during the process of production of such an equipped line. The level of advanced technology enables the equipment to be connected for automatic settings and adjustment of both individual production processes, and their mutual interoperation as a single, complete production unit. Our production lines can also be equipped with a monitoring device with output on a computer, which monitors adherence to the technological parameters of baking products and its possible record for further control or evaluation.
As the latest novelty, we also offer these lines in PRO.FUTURO variant, which not only enables the use of the latest technological novelties in combination with the highest quality components, but it also includes a four-year warranty on the entire facility.
Production lines can be delivered complete – from flour silos, through dough preparation, dividers, forming, proofing, baking, or even cooling or slicing through to packaging and stacking on pallets, or also as individual completely functioning technological components in cases of investments into the replacement of older production technology for new technology, while saving some of the original equipment which will continue to operate satisfactorily in combination with the installation of new technological modules. Furthermore, it is also possible to supply these individual technological modules in the event of spreading out investments over a longer-term horizon where the existing, unsatisfactory production technology will be gradually automated and replaced by new technology in various phases of time. In case of considering either complete or time distributed investment, we will be glad to help you with selecting the optimum tailor-made solution for the respective type of business and production.
- mixed kinds shaped in trugs or without, round, oval and other shapes
- rye bread, rye-wheat, wheat-rye or wheat bread
The preparation of dough for these lines is solved according to the type of bread and then mainly according to the dough ingredients. Concerning these lines and primarily in the case of baking dark dough, from pure rye, to rye-wheat dark dough, it is most suitable to use our high temperature pre-bake oven, primarily with granite plate, or another type of conveyor band. These high temperature pre-bake ovens enable high finishing temperatures to be reached, which are especially needed for dough containing rye. Once the bread has passed through the pre-bake oven, it is then transferred to the traditional oven with the help of a bridge conveyor. As opposed to others, this oven no longer needs to be equipped with a steam zone nor does the structure have to be adapted to baking with higher temperatures.
For all types of bread and dough the preparation of dough must be solved using a typical bowl system (the dough is mixed using the traditional bowl method, then it can go through the maturing conveyors and from them into the hopper of the divider and then continue to the forming line). Depending on the type of dough (primarily without yeast culture), it is possible to consider the effect of using these continual production lines for production volumes of over 300 kg/hr.
Regarding dark rye dough, either mixed with wheat or purely rye, where the dough preparation calls for yeast culture, so-called three or more degree yeast culture conduction can be applied to dough production, which can concern either continual dough preparation without the use of a bowl or, technology with a bowl mixing centre, maturing conveyors and a classic divider – this technology is universal and can also be used in the production of other types of dough. Such lines are effective in instances of production volumes exceeding 1000 kg/hr with a minimum daily use of 8÷10 hours.
We are capable of delivering all of these production lines as key-turn projects, so that in case of need we can just supply their individual functioning technological units. Completeness is deemed delivery beginning from the flour silo with a flour and other ingredients dosing systems, to either a typical mixer with a bowl or, to a line for continual dough preparation. This also includes a divider, forming device of individual dough pieces and their ensuing setting in trugs in the proofer, from where they are turned out of the trugs onto the conveyor band of the tunnel oven once they have passed through the proofer. Furthermore, line delivery includes the aforementioned tunnel oven, and/or complete with a pre-bake oven and then the line can be further equipped with moistening (water spraying) equipment of the raw bread at the oven infeed, and moistening the baked bread at the oven outfeed point. After baking, the bread can be placed into the trolleys by hand, in which they are then transported to the dispatch hall, or this can be solved by automated conveyors of various lengths, connected to the oven outfeed, behind which a semi or fully automated bread slicer with ensuing packaging can be positioned on the line in case of need.
- short pastry from proofed and puff pastry
- batons (Russia)
We supply these lines as semi-automated (with various degrees of automation according to the client’s needs) and also as fully automated which operates solely under supervision from the preparation of the dough all the way through to packaging the baked goods.
For this type of production, the oven is generally equipped with lower air circulation in the baking chamber - duothermem, which aids in increasing the heat transfer using convection, creating a unified colouring of the product on all sides and in creating the lower crust of the bread. The conveyor can be constructed based on a link plate band, which is primarily distinguished for its higher bearing capacity, operational life and air circulation improved by duotherm in the oven baking tunnel.
This allows a wide assortment of products to be realised on one production line, such as:
- toast
- bread prepared according to special recipes, baked in forms or in various unit sizes of forms or on trays
- hamburger buns, hotdogs etc.
- ciabatta, pan rusico etc.
- baguettes
- pizza bottoms
and many more… All in various sizes and weights…
One of the main advantages of producing these pre-processed products is their long shelf life in the event of extremely long transportation distances.
Each country has its specific bread.
The following are produced using J4 baking ovens:
- Arab bread
- Asian and Caucasian bread (lavash, barbari, sangak)
- ciabatta
- Scandinavian bread (from rye flour)
- Russian form bread (special type with cooked dough)
- cakes from corn or potato dough etc.
The lines are equipped with a silo for flour and other raw materials, and a packaging automat forms the end of the line. The technological modules are solved in accordance with the specific requirements of each locality and type of baked product.
In cooperation with Czech and foreign producers, we supply complete production lines with forming devices for the production of gingerbread of various shapes and sizes, from very soft dough to extremely firm dough. In case of interest, it is possible to test the production technology in testing laboratories either, here at our site or, at our partner’s.
These lines can be semi or fully automated in consideration to needs and the type of the respective production and can equally serve for a variety of skilled production of smaller series of a wide range of products while maintaining effective production volume.
- stuffed cakes
- fancy bread, cross buns etc.
Automatic continual lines designed according to the required type of production of cookies, cakes etc. The basic character of the continual line is determined by the tunnel baking band oven in a specific solution based on the required assortment and production volume.
- cookies of all types (set, pressed, cut)
- filled and glazed (coated) cookies
- hard cookies
- biscuits, rusks…
In cooperation with Czech and foreign producers we supply complete production lines with forming devices for the production of durable pastries of various shapes and sizes, glazed, filled or unfilled, from very soft dough to hard dough. In case of interest, it is possible to test the production technology in testing laboratories either, here at our site or, at our partner’s.
The high-temperature tunnel baking band oven works in spheres of high baking temperatures of up to 550°C with all types of gas and liquid fuels and a very short baking period (from 30s). The ovens can be equipped with either, gas emitters in the space below and above the band, or with typical burners with an intensive convection component for transferring heat in the upper and lower part of the oven baking chamber
Lines for the production of biscuits for dogs and other animals
For lines of this type, ovens with a mesh band are generally used, without a steam zone, with turbulence zones - duotherm, or hot-air curtain or STIR technology in various baking and drying lengths. These lines can be composed from standard baking production technology (dough preparation – mixing – dividing – forming – baking – packaging) just as for common baking production, and from special technologies for the preparation of dough intended for animal consumption. The ovens can be built combined from direct heating and indirect heating cyclotherm or convection parts.
According to baking needs and the character of the baked product, the ovens in these lines can certainly also be equipped with other types of conveyor bands.
