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Crispy and crunchy. Who wouldn't like wafers, especially with coffee or afternoon tea. Before you can put your favourite wafers on your table, they go through a several-step production process. Two stages of the production process - baking and cooling are at constant risk of fire.
Preventive protection such as a detection system should be installed properly to secure these zones in the production line. The FIREPRO system provides a comprehensive solution to the problem.
This case study will present you unique fire protection solution for the food and baking industry.
The beginning of the wafer production process is simple; the dough is dosed into molds, so-called "baking tongs." Wafer dough passes through the oven. Baked products have ignition temperatures very close to the average oven operation temperature. Temperatures in the oven can reach up to 300 °C. Higher temperature in combination with crumbs, dust, or stopped production line can result in a fire that can spread further in the production line.
When the wafers (or any product) are baked, the cooling phase of the production process begins. Fresh from the oven, the wafer plates are unloaded on a conveyor. By-products (fragments, crumbs) fall below the furnace, onto the conveyor, and are transferred to a container outside the furnace.
The analysis of the risks from laboratory tests showed that the ignition temperature of the wafers was between 290 °C - 320 °C. This temperature corresponds with the oven temperature. The combination of high temperature and low humidity can lead to ignition. During baking, so-called air cushions are formed on the wafers in the molds, which facilitate the ignition.
Due to the close arrangement of the wafer plates in the cooling tower, the flame can transfer to the other pieces very quickly (as shown in the video). Within a few moments, the entire aftercooling tower may be on fire. Not only wafer sheets but also their fragments pose a fire hazard. The ignition of the wafers in the cooling tower is shown in the video.
The presence of combustible substances, gases, or vapors is generally dangerous in all industrial plants. Damage caused by a subsequent fire or explosion can be irreversible. Although you do not usually eliminate the risk of fire, tragic consequences can be prevented with suitable fire protection.
The FIREPRO system monitors working areas and protected zones. If detectors identify an emerging fire, the system can activate extinguishing in milliseconds and, if necessary, shut down the operation. FIREPRO prevents the occurrence of a fire in its infancy, minimizes damage to property and technology, production delays, and prevents injuries or death of employees.
FIREPRO system offers an efficient detection system with LumEx 2 IR/UV detectors. These sensitive optical detectors constantly monitor all critical points in the production line. When a flame is detected, the detector sends a signal to the control unit. Control unit evaluates it and activates the optical-acoustic signaling. Every operation takes place in units of milliseconds. The control unit is also connected to the control system of the wafer production line and immediately shuts it down. Only this type of protection will minimize costs and downtime caused by fire.
IR/UV optical detector indicates the flame and sparks in the monitored technological section. LumEx 2 is equipped with a purge air adapter to ensure IR and UV spectrum sensing accuracy. Internal memory ensures independent data archiving. A pollution detection feature is included, and the LumEx 2 is also designed to eliminate false alarms.
The control unit is installed near the protected equipment within reach of the operator. The CONEX control unit can also connect optical or acoustic signaling, signals to/from the control system, and other interlocks and connections. Control unit evaluates and archives information from detectors. It serves as a user interface for the operating personnel.
The main focus on designing the fire protection is, in this case, set on fire detection. At RSBP we divided the hazardous area into three separated detection zones. LumEx 2 optical detectors were installed in especially chosen places to secure the whole baking and cooling process.
One of the optical detectors monitors area UNDER the wafer conveyor between the oven and cooling tower.
The second monitored zone is ABOVE the conveyor between the oven and cooling tower.
Third detection zone is the cooling tower and its nearby area.
LumEx 2 optical detectors are suitable for production processes with increased hygienic demands. Thus they are the optimal solution for the food industry.
The detection system recognizes and correctly evaluates the origin and occurrence of the flame in the monitored technological section. The detection system is controlled through CONEX control unit. CONEX control unit is connected to the superior system of the production line. If the fire is detected, the CONEX control unit transmits a signal to the superior system, which reacts according to operating procedures, for example, by shutting down the production line.
