Custard filling machine

Types of Custard Filling Machines

A custard filling machine comes in different types, each specially designed to make and fill custard into pastries, buns, and other products. Here are some of them:

• Manually Operated Custard Filling Machines

  These are filling machines that an operator manually controls. The machine has a hand lever used to control the amount of custard dispensed into pastries or other products. Manual custard filling machines are often used for small bakeries or those that make custard-filled products in small quantities. Because operators control them, they allow for some customization of how much custard is filled into each pastry.

• Semi-Automatic Custard Filling Machines

  These machines use a manually controlled hopper to hold custard. The hopper is at the top of the machine, and the custard is gravity-fed down through the nozzle to fill pastries. Nozzles of different sizes are used in semi-automatic machines to fill various products. Like manual models, semi-automatic custard filling machines offer some customization but are faster than manual models because the operator moves the lever rather than manually placing each pastry.

• Automatic Custard Filling Machines

  Fully automated custard filling machines have programmable settings that allow operators to fill custard into various products at high speed. They use a conveyor system and a large hopper to hold the custard and feed it into the nozzles that are set up over a conveyor belt. The custard is dispensed through the nozzle to fill products as they go by. Nozzles on automatic machines usually come in sets that can be interchanged to accommodate products of different shapes and sizes. Some models also have multiple hoppers to fill products with more than one kind of custard or fill with custard and a different kind of topping simultaneously.

• Depositor-style Custard Filling Machines

  These custard filling machines have an electronic control panel and a custard hopper. The amount of custard is preset on the control panel, and the custard is deposited into products as they move past the nozzle overset at the desired intervals. Like the automatic models, depositor-style machines can often be set up with different nozzles and hoppers to accommodate various custards and products.

Specifications and maintenance of custard filling machines

Specifications

• Machine weight:

  The weight of the custard filling machine depends on its design and the materials used. The average weight of a small machine is about 150 kg. Large industrial custard filling machines weigh several hundred kilos due to their larger size and more powerful motors.

• Capacity and flow rate:

  A small machine has a capacity of about 5 litres to 20 litres per hour. Mid-sized machines can fill between 20 and 50 litres per hour, while larger ones can fill 200 litres or more in an hour. Large industrial machines usually have a tank of 50 to 200 litres with a flow rate of 500 to 2000 cups per hour. The filling speed may vary according to the viscosity of the custard, the cadences of the production line, and the adjustment of the machine.

• Power and voltage:

  The power of a custard filling machine can vary according to its type and capacity. Generally, the power of small machines is between 0.5 and 2 HP. Mid-sized machines have motors with powers of 2 to 5 HP, and bigger ones have 5 HP or more. The voltage can be single-phase 220V or three-phase 380V.

• Pneumatic pressure:

  The pressure of the pneumatics can be 3 to 10 bar for custard cartridges and between 7 and 12 bars for custard pumps.

• Material and structure:

  The dispenser is usually made of AISI304 stainless steel, a material that is easy to clean, hygienic, and resistant to the corrosion of some chemical agents. Parts in contact with food are made of food-grade plastic. The baseplate is made of hot-dip galvanized steel for corrosion resistance.

Maintenance

• Daily cleaning:

  After each use, disassemble the parts in contact with custard, including tanks, pipes, nozzles, and dispenser plates. Rinse them under running water to remove any remaining custard. Clean the parts with mild detergent and soft brushes or sponges to avoid damaging them, and ensure that all detergent residues are removed. After cleaning, make sure all the parts of the filling machine are properly dried.

• Periodic disinfection:

  Weekly, perform a deep cleaning of the filling machine by cleaning and disinfecting the food pipeline. Clean the main part of the filling machine on a sterile work surface and carefully clean and disinfect all parts in contact with food. Run a diluted solution of disinfectant through the food pipeline, ensuring all parts come into contact with it. Follow the disinfectant manufacturer's instructions precisely, and run clean water through the system afterward to remove any residue of the disinfectant.

Applications of custard filling machines

Modern custard filling machines have numerous applications in the bakery, dairy, and confectionery industries. Here are some ways these machines are used:

• Bakery production lines: A custard filling machine is used to fill pastries, custard-filled donuts, eclairs, cream puffs, custard tarts, and cupcakes efficiently. The automated filling process ensures consistent portion control, reduces product waste, and streamlines production lines.
• Multinational custard-packaging companies: Those companies looking to package large volumes of vanilla custard in sealed containers should consider using a custard filler machine. When combined with other packaging machinery, these machines can fill and seal thousands of custard containers in a single hour.
• Dairy product innovation: Dairy companies do not only use custard filling machines to produce custard; they also use them to create other dairy products such as flavored puddings, yogurts, and gelatins. With the versatility of custard filling machines, these products can be filled in cups, bottles, or jars quickly and precisely. What this means is that food-processing companies can now experiment with different variations of dairy products, thus creating more opportunities for chefs and other end users to explore different tastes and flavors.
• Customization and decoration: Apart from the mass production of custard-filled products, custard filling machines can also be used for customization and decoration purposes. Some bakeries use these machines to fill cupcakes, donuts, and other pastries with flavored custards. While doing this, they look for specific flavor profiles that are unique to their bakery. This act helps them to stand out from their competitors. Scheduling custard filling machines for customization and decoration is ideal for artisan bakeries and specialty patisseries.

How to choose a custard filling machine

While selecting the right custard filling machine for a particular application, there are some key parameters and features that it is important to consider:

• Production capacity:

  Consider the required production capacity, which depends on the volume and frequency of custard production. The ideal choice will be a machine whose capacity matches production requirements. Whether it is a small-scale, tabletop, or larger, industrial-scale machine, the chosen one should be able to handle the required volume efficiently to avoid any unnecessary delays.

• Filling accuracy and control:

  It is important to prioritize a custard filling machine with precise filling control and a programmable control system. These features will enable with adjustable filling speed, volume, and accuracy. Such a machine can help to ensure consistent and accurate custard portion sizes, minimize wastage, and improve overall product quality.

• Flexibility and product compatibility:

  When selecting a custard filling machine, one must consider its flexibility and compatibility with different custard types and flavors. It should be capable of handling various consistencies and formulations of custard, aligning with the specific production needs. Moreover, custard filling machines come with different types of containers, from jars and cups to pouches and bottles. Hence, it is essential that the chosen machine can accommodate the required custard containers to avoid any unpredictable costs and delays later on.

• Sanitation and ease of cleaning:

  Opt for a custard filling machine that is designed for easy sanitation and cleaning. Stainless steel construction, removable parts, and automated cleaning programs can simplify the cleaning process. Such a machine will help to maintain product safety and prevent cross-contamination.

• Operational requirements:

  Consider the operational requirements of the custard filling machine. Evaluate the level of automation desired, such as automatic or semi-automatic filling. Additionally, consider the essential skills and training requirements of the staff operating the machine. Choosing a custard-filling machine that suits the available workforce can help streamline production and minimize operational challenges.

• Budget constraints and ROI:

  Finally, while it is important to consider the budget constraints, also think about the long-term return on investment (ROI). Analyze the machine's performance, efficiency, and maintenance costs to assess its overall value. Investing in a reliable, robust custard filling machine with good performance can reduce future expenses and enhance productivity.

FAQ

Q1:What can a custard filling machine be used to fill?

A1:Custard filling machines are not limited to custard filling. They can be used to fill various products such as pies, donuts, cupcakes, eclairs, pastries, and other baked goods with different types of fillings.

Q2: Can a custard filling machine handle multiple flavors of filling simultaneously?

A2: Some custard filling machines come with the option to handle multiple flavors simultaneously by usingSeparate product containers. This feature allows for batch production of various items at once,Reducing filling time and increasing production efficiency.

Q3: Can a custard filling machine handle different types of dough products?

A3: Yes, custard filling machines areDesigned to fill various products, includingDifferent types of dough. However, followingThe manufacturer's instructions and recommendations is essentialWhen using the filling machine for distinctDOUGH products to ensure proper filling andAvoid damaging the machine.

Q4: What are the safety features of a custard filling machine?

A4:Safety features may vary depending on the model and manufacturer, but typical custard filling machinesafety features include emergency stop buttons, safety guards, and protection againstOverheating or overloading.

Q5: Can a custard filling machine be integrated with other baking equipment forAutomated production?

A5:Yes, many modern custard filling machinesCan be integrated with other baking equipmentAutomated production lines. Automation canEnhance efficiency, streamline processes, and supportHigh-volume production.