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Janssen F Series, Operating Instructions Manual

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The reproduction of any contents of these operating instructions, 
including in part, is only permitted with the written permission of 
Niederrheinische Formenfabrik 

Janssen

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Niederrheinische Formenfabrik 

Janssen

 GmbH, 2022

Summary of Contents for F Series

Page 1: ...Operating Instructions Janssen Cookie Former F250 UL F450 UL F600 UL Translation of original operating instructions 05_2020_US_CA...

Page 2: ...stions wishes and needs of our customers collected over many years thus creating a product to meet the requirements of the present and future as they become more demand ing in so many respects We are...

Page 3: ...1 Congratulations on your new Janssen cookie former We wish you great enjoyment pleasure with your new machine...

Page 4: ...2 Niederrheinische Formenfabrik Janssen GmbH Moerser Strasse 33 47798 Krefeld Phone 49 2151 24315 Fax 49 2151 29759 info nff janssen de www nff janssen de...

Page 5: ...3 Please read carefully before use Keep for future reference These operating instructions are part of the machine Your Janssen team...

Page 6: ...otes for the operator 2 1 Scope of delivery 12 2 2 Responsibilities 12 2 4 Instruction of the operating personnel 12 2 5 Liability 12 2 6 External interfaces 13 2 7 Marking of the machine 13 2 8 Spare...

Page 7: ...2 Settings 29 3 6 2 1 3 Language 30 3 6 2 1 4 Info 31 3 6 2 1 5 Select programme 32 3 6 2 2 Compact controller manually operated not programmable 33 3 7 Drive scheme 34 3 7 1 Drive scheme of the rolle...

Page 8: ...personnel 54 6 2 Requirements and safety 54 6 3 In house transport 54 6 4 Off site transport 54 6 4 1 Transportation restraint 54 6 4 2 Example of transport securing of an F250 on a pallet 55 6 4 3 Ex...

Page 9: ...9 11 Opening and closing the hopper 73 9 12 Installation and removal of the rollers 74 9 13 Knife setting for the cookie thickness 76 9 14 Installation and removal of the knife 77 9 15 Adjusting the s...

Page 10: ...after a longer standstill 117 11 Maintenance 11 1 Safety 118 11 1 2 Intervals maintenance schedule 118 11 1 3 Checking and testing the safety systems 119 11 1 4 Inspecting the machine 119 11 1 5 Requi...

Page 11: ...159 12 7 8 Cleaning the heater 160 12 7 9 Cleaning the housing 161 12 7 10 Cleaning the base frame 161 12 7 11 Cleaning the operating terminal 161 13 Repairs 13 1 Qualifications of personnel 162 13 2...

Page 12: ...ntling the machine 181 16 5 Disposal of the machine 181 17 Declaration of Conformity 182 18 Supplementary documents 18 1 Recipe book 183 18 2 Spare parts list 183 18 3 Electrical circuit diagrams 183...

Page 13: ...e reproduction of any contents of these operating instructions including in part is only permitted with the written permission of Niederrheinische Formenfabrik Janssen Copyright Niederrheinische Forme...

Page 14: ...ist personnel have appropriate technical training which enables them to correct faults and carry out maintenance Instructions for maintenance can be requested separately 1 3 Information for the operat...

Page 15: ...to the customer 1 6 Typographical conventions For easy and quick comprehension various types of information in this manual are supplemented by clear illustrations and symbols 1 6 1 Warnings This warn...

Page 16: ...ed to ensure that the operating instructions are delivered with the machine and made available to the customer 2 4 Instruction of the operating personnel The operator is obliged to ensure that instruc...

Page 17: ...ns and equipment of the machine can be identified You will find the number on the type plate and on the side panel of the gear unit side of the machine see following figures Masch Type F250 C UL 208Y...

Page 18: ...e or download it as a PDF Scan the following QR code with your smartphone or enter the following URL Link to the operating instructions www nff janssen de Info user_manual Link to recipes www nff jans...

Page 19: ...u in your production processes so that you can fully concentrate on the quality of your products 3 Hygiene is the third basic principle of our Janssen cookie formers All parts and components are extre...

Page 20: ...e sizes depend on the desired output quantity and the baking sheets used Baking surface 100 160 m2 hour Hopper volume 45 kg of dough Max sheet width 450 mm Depends on machine equipment Baking surface...

Page 21: ...er 4 and the pattern roller 3 A dough band forms around the outer surface of the kneading roller The pattern roller 3 which can be heated and replaced from the outside embosses raised shape geometries...

Page 22: ...ual cookies of different sizes and thicknesses with smooth or structured surfaces on flat baking sheets Changing the pattern rollers allows different products to be produced with the machine This figu...

Page 23: ...o form dough bands or lattice work of different dimensions and thicknesses with a smooth or structured surface into high cake trays Different dough bands can be formed using different dough band rolle...

Page 24: ...ished product The processability of the doughs depends mainly on the following 7 factors Selection of ingredients Preparation procedure Processing temperature Ambient atmosphere Kneading time Resting...

Page 25: ...ing kneading Ingredients 250 400 sheets h Dough feed Dough forming Sheet feed Packaging Baking process In the oven Sheet racks 120 650 kg h This figure shows the production process from the ingredient...

Page 26: ...on of the important components The subsequent sections provide information on the components with reference to Setup Operation Maintenance and Cleaning This figure shows the F450 cookie former diagona...

Page 27: ...h pattern roller holder optional second roller holder Roller lock Knife fine adjustment Roller heating Protective grid Dough hopper Type plate Fixed castors additional grounding point optional Folding...

Page 28: ...ide The swivelling dough hopper is located on the top of the machine body along with the swivelling protective grid 3 6 1 3 Dough hopper The dough hopper is closed by the hopper protective grid during...

Page 29: ...ts cuts There is a residual danger during the cleaning of the knife as in this case the knife guard must be raised to make the knife acces sible Section 9 13 Knife setting for the cookie thickness p 7...

Page 30: ...lified specialist section 11 7 1 Removal and installation of the heater p 144 3 6 1 10 Crumb tray The crumb tray is located directly below the pair of rollers and above the sheet transport in the mach...

Page 31: ...minal can be swivelled about its vertical axis and locked in place with a clamping sleeve The operating terminal can be equipped either with analogue buttons and potentiometers Compact or a touch disp...

Page 32: ...Section 10 5 Operation Performance controller with touch display programmable p 88 The following columns show the most important functions which are explained in more detail in section 10 5 The displ...

Page 33: ...Roller i MENU Settings BACK Permanent Semi Auto Automatik Select program Save program Mode Speed V1 maschine m min Program 03 4 0 i Speed V2 upper conveyor belt m min 4 0 i Speed V3 sheet transport m...

Page 34: ...ges can be selected here The entire user interface is displayed in the selected language Section 10 5 Operation Performance controller with touch display programmable p 88 This figure shows the Langua...

Page 35: ...ation is not stored in the memory of the controller located in the machine but on our website which is maintained and kept up to date on a continuous basis This figure shows the Info screen MENU BACK...

Page 36: ...ogrammes Section 10 5 Operation Performance controller with touch display programmable p 88 Select programme screen MENU Select program Program 01 Spekulatius BACK 01 Spekulatius 02 Kipferl 03 Kuchenb...

Page 37: ...heating and the sheet transport speed can be set manually The overall speed of the machine is constant at about 4 m min Section 10 5 Operation Performance controller with touch display programmable p...

Page 38: ...e a uniform drive scheme The pair of rollers is driven by a main drive motor via a gear transmission This illustration shows the pair of rollers with the drive gears Upper conveyor belt Kneading rolle...

Page 39: ...The upper conveyor belt is driven by a separate motor With the Performance controller this motor offers infini tely variable speed control With the Compact controller the speed is constant and cannot...

Page 40: ...belt is driven by a separate motor The speed of the sheet transport can be changed both with the Performance controller as well as with the Compact controller Drive for upper conveyor belt Drive for...

Page 41: ...bearing block with a slotted hole that is connected to the blade shaft and thus converts the rotational motion into a translatory motion The inclination or the distance of the knife to the kneading r...

Page 42: ...heet cakes dough lattice work for fruit cakes coconut biscuits pretzels Linzer biscuits vanilla crescents tartlets etc Special rollers can also be used to form white cakes brown cakes gingerbread and...

Page 43: ...components diameter greater than approx 0 5 mm in the dough e g nuts and whole almonds are predominantly unsuitable for processing as they can stick to the knife and prevent further continuous forming...

Page 44: ...specialist in house transport Training in transportation Experience in the transport of machines Installation Electrical installation Mechanical setup of the machine Electrically qualified person Fit...

Page 45: ...ks and prevent hazards that may be caused by electricity or mechanical systems Cleaning Cleaning under conside ration of the hygienic requirements in the food industry Cleaning specialist Operator Ins...

Page 46: ...rage conditions p 63 and 15 5 Removing from service and storage of the machine p 177 Installation conditions section 7 Installation conditions p 59 Assembly and installation initial start up section 7...

Page 47: ...are also required to observe the relevant accident prevention regulati ons safety regulations and occupatio nal health rules The operator is responsible for the intended use of the cookie moulding ma...

Page 48: ...ne must be disconnected from the power supply Control panel with EMERGENCY STOP button Stop button Enable button Start button Protective grid Hopper Pressing the EMERGENCY STOP button immediately brak...

Page 49: ...d and the drives are stopped Closing the protective grid and pressing the yellow Enable button deactivates the protective device and the machine can be started again 4 8 4 Circuit breaker for conveyor...

Page 50: ...u cannot injure yourself when the hopper is open The knife guard plate is lifted mecha nically by a Bowden cable in the gear unit housing when the hopper is closed and this exposes the blade so it is...

Page 51: ...es Compliance with this information is mandatory Make sure that these labels are not covered over and are always clearly legible Never manipulate the constructi ve safety measures 4 10 Further informa...

Page 52: ...lift the cover with one hand and with the other hand clean the now exposed knife with a damp cloth There is a risk of cuts when doing so Consequently we recommend using cut resistant gloves for clean...

Page 53: ...ding roller 3 which can fall to the floor and be damaged if handled carelessly 4 11 3 Closing range of the hopper The hopper must be opened and closed for roller changing and cleaning There is a possi...

Page 54: ...m minute Baking surface Compact controller or Performance controller Operating voltage 208Y 120 V 3 Ph PE 208Y 120 V 3 Ph PE 208Y 120 V 3 Ph PE Frequency 50 60 Hz 50 60 Hz 50 60 Hz Nominal power 1 5 k...

Page 55: ...to electrical circuit diagram www nff janssen de Info circuit_diagram 5 3 Declarations of conformity for materials used The materials used are suitable for the processing of foods section 3 3 Basic op...

Page 56: ...house transport a logistics specialist with training in transport or experience in the transport of machinery must be used 6 2 Requirements and safety Please make sure that the machine is in perfect a...

Page 57: ...so that the rollers are not unnecessarily loaded In the views you can see possible means of fixation using lashing straps In addition you can use stretch film for wrapping the machine to optimally sec...

Page 58: ...450 and F600 we recommend a EUR 2 euro pallet with the dimensions 100 cm x 120 cm or larger When transporting the pallet with a forklift truck make sure that the pallet is moved very carefully Ideally...

Page 59: ...ed and secured against falling over due to its high centre of gravity The possible lashing points for fixing the machine can be found in section 6 4 1 section 6 4 1 Transport restraint p 54 Before ini...

Page 60: ...Unpacking Note The following information is enclosed with the delivery note and is only listed here as a supplement as these operating instructions are generally only read after unpacking When the mac...

Page 61: ...7 1 Qualifications of personnel A qualified electrician is required for the electrical installation and for mechanical equipment a fitter with appropriate training and experience which enables them t...

Page 62: ...60 7 5 Dimensions and weights 7 5 1 Dimensions Weight F250 7 5 2 Dimensions Weight F450 1620 980 1600 808 238 kg 1620 1600 1620 808 1620 980 1008 2220 281 kg 1620 2220 1620 1008...

Page 63: ...61 7 5 3 Dimensions Weight F600 1620 980 2220 1158 311 kg 1620 2220 1620 1158...

Page 64: ...socket you can make a test run with the machine If the machine starts to run in reverse stop the machine immediately and unplug the power cord from the power socket The machine is connected clockwise...

Page 65: ...his purpose Section 12 Cleaning 7 9 Storage conditions 7 9 1 Storage of the machine The cookie moulding machine should be stored in a dry environment If necessary the machine should be covered with a...

Page 66: ...qualified electricians who with appropriate training education and experience are able to identify risks and prevent hazards that may be caused by electricity Qualified application programmers and sof...

Page 67: ...ntended use Always pull out the mains plug when carrying out maintenance and repair work on the machine Follow the five safety rules during initial start up or when carrying out maintenance work Gener...

Page 68: ...h internal pin Torx T40 for switch box door 6 Small electronics screwdriver for electrical terminals 7 Phillips screwdriver PZ 2 for electronic terminals on the main switch 8 Plastic hammer 9 Pin punc...

Page 69: ...doing so it is essential to observe the manufacturer s instructions area of use contact time temperature dry or wet cleaning etc For cleaning the machine we offer a special cleaning kit with a holder...

Page 70: ...training instruction and education 9 2 Requirements and safety Janssen cookie formers are ready for immediate use on initial start up They must be placed in the desired location and connected to the p...

Page 71: ...nt housing 9 4 2 Folding the sheet transport unit down For the unlocked joint the cover cap must be pushed out of the joint housing This allows the sheet transport to be folded down as well 1 1 1 2 2...

Page 72: ...l of the sheet guide p 132 9 7 Height adjustment of the sheet transport unit Depending on the height of the baking sheet the sheet transport unit can be adjusted so that it can be transported under th...

Page 73: ...llation For installation proceed in reverse order Note During installation you must press the handles in firmly to ensure that the gear wheels mesh correctly 9 8 Removal and installation of the convey...

Page 74: ...ned in the range of a quarter turn If the belt cannot be adjusted remove the belt and remove from the drive roller any dough residue that has settled on the drive shaft 3 and deflection axle 4 After c...

Page 75: ...orward very easily in order to fill the hopper with dough The hopper 2 can also be folded forwards for a roller change As soon as the hopper grid or the hopper is opened the machine stops Close The ho...

Page 76: ...the machine body Incorrect installation of the rollers is not possible due to their design The pattern and kneading rollers have guide grooves 2 on one side in which the driving pins 3 of the drives e...

Page 77: ...ow turn the roller lock with the quick release system 180 to the right position 2 To allow the driving pins to engage in the guide grooves of the roller turn the roller a bit while tensioning with the...

Page 78: ...ed on the roller according to your specifi cations However you can also form the cookies up to 3 mm thinner for a given engraving depth 2 Attention If the dough is too firm hard or cool there is a ris...

Page 79: ...eets The sensors can be easily adjusted in height manually using the fixing nuts If a sheet passes the sensor and it does not light up yellow either the distance to the sheet is too great the baking s...

Page 80: ...of cookies as viewed in the discharge direction with solid cookies Adjusting the distance from the dough sensor to the cookie The dough sensor should be positi oned about 2 mm above the cookie The se...

Page 81: ...g can be operated via the operating terminal with the Performance controller See section 10 5 3 7 Roller heating p 98 With the Compact controller the heating can be activa ted in two levels by means o...

Page 82: ...ugh box holder and then put back in place 9 20 Use of the roller holder The roller holder is the optimal way to store your rollers They are protected and always ready to hand Furthermore they can dry...

Page 83: ...e controller The operation of the cookie moulding machine and its controller is descri bed in the following section 10 MENU Main menu Back Programs Settings Info Language Admin emergency stop Arr t d...

Page 84: ...ty functions In general the machines stop imme diately if safety relevant devices are interrupted or disconnected such as the hopper grid the belt cartridge or the EMERGENCY STOP button Enable Release...

Page 85: ...r the control panel on the rear of the machine 3 The terminal can be conveniently swivelled about its vertical axis and locked in place with a rotating clamping sleeve The operating modes are set and...

Page 86: ...or production with dough 10 4 1 2 Automatic mode sensor operation If the operating mode switch is turned to Automatic and the machine is started using the start button the machine will only begin oper...

Page 87: ...When the first cookie has arrived at the dough sensor 4 both the conveyor belt and the sheet transport run and load the baking sheet until the sheet is completely covered with cookies and the machine...

Page 88: ...heat the surface of the pattern rollers with a roller heating feature This facilitates better release of the dough from the pattern roller except for honey or syrup dough For these doughs the roller...

Page 89: ...ing depending on the version 10 4 1 8 Restarting after a longer standstill After a longer standstill two cases must be considered Case one The production was interrupted for a longer time and there is...

Page 90: ...tion Operating hours display The most important functions are shown in the following columns The button bar on the right next to the display is identical to that of the Compact controller The display...

Page 91: ...nly one submenu per item 10 5 2 Main Menu The Menu button in the function bar takes you to the Main Menu There you can choose from the following areas which are explained separately on the following p...

Page 92: ...ngs can be made in this mode Speed V1 of the entire machine Speed V2 of the upper conveyor belt Speed V3 of the sheet transport Knife speed Roller heating MENU BACK Permanent Semi Auto Automatik Selec...

Page 93: ...n this mode Speed V1 of the entire machine Speed V2 of the upper conveyor belt Speed V3 of the sheet transport Knife speed Roller heating Cookie position relative to the front edge of the sheet MENU S...

Page 94: ...V3 of the sheet transport Knife speed Roller heating Cookie position relative to the front edge of the sheet Factor for row spacing Number of rows of cookies MENU Settings BACK Permanent Semi Auto Au...

Page 95: ...uit in mm close Notice Measure the length of the pastry in mm in running direction after forming L 10 5 3 2 Info pop up window When the buttons for further information are pressed explanatory notes wi...

Page 96: ...this case it should be noted that the cookies may no longer be optimally shaped This depends largely on the dough MENU Settings BACK Permanent Semi Auto Automatik Select program Save program Mode Spe...

Page 97: ...be stretched again by increasing the speed of the belt V2 slightly so that the pastry case is placed on the baking sheet with a geometrically round shape MENU Settings BACK Permanent Semi Auto Automat...

Page 98: ...et to run a little faster 2 so that the cookies do not fold over at the edge when transferred from the upper conveyor belt to the baking sheet 1 82 V3 V2 V3 V2 MENU Settings BACK Permanent Semi Auto A...

Page 99: ...2 the recipe must be changed or the dough temperature must be kept cooler Please note that at level 2 the mechanical loads are significantly higher and the mechanism wears out faster MENU Settings BAC...

Page 100: ...ess parame ters of the dough production must be changed MENU Settings BACK Permanent Semi Auto Automatik Select program Save program Mode Speed V1 maschine m min Program 03 4 0 i Speed V2 upper convey...

Page 101: ...he formed cookie Enter this value with an accuracy of about 1 mm MENU Settings BACK Permanent Semi Auto Automatik Select program Save program Mode Speed V1 maschine m min Program 03 4 0 i Speed V2 upp...

Page 102: ...te The higher the value the greater the spacing MENU Settings BACK Permanent Semi Auto Automatik Select program Save program Mode Speed V1 maschine m min Program 03 4 0 i Speed V2 upper conveyor belt...

Page 103: ...round 5 10 MENU Settings BACK Permanent Semi Auto Automatik Select program Save program Mode Speed V1 maschine m min Program 03 4 0 i Speed V2 upper conveyor belt m min 4 0 i Speed V3 sheet transport...

Page 104: ...Permanent Semi Auto Automatik Select program Save program Mode Speed V1 maschine m min Program 03 4 0 i Speed V2 upper conveyor belt m min 4 0 i Speed V3 sheet transport m min 4 1 i Knife Level 1 i Ro...

Page 105: ...ou can do this under Select programme or Save programme Section 10 5 8 Create new programme using Select programme and overwrite MENU Settings BACK Permanent Semi Auto Automatik Select program Save pr...

Page 106: ...ion 10 5 2 Main menu you can access the Language selection Different languages can be selected here The entire user interface is displayed in the selected language MENU Language BACK German English Es...

Page 107: ...can be accessed via an app on your smartphone by scanning the QR code or entering the URL provided The information is available for download in PDF format Note This information is not stored in the m...

Page 108: ...QR code and the URL link to our website MENU BACK Spare parts list Take a look at our website www nff janssen de Info spareparts MENU BACK Recipes Take a look at our website www nff janssen de Info r...

Page 109: ...de and the URL link to our website MEN ZUR CK Maintenance Take a look at our website www nff janssen de Info maintenance MENU BACK Instruction manual Take a look at our website www nff janssen de Info...

Page 110: ...and the URL link to our website MENU BACK Cleaning Take a look at our website www nff janssen de Info cleaning MENU BACK Electric circuit diagrams Take a look at our website www nff janssen de Info c...

Page 111: ...109 The QR code and the URL link to our website MENU BACK Questions Take a look at our website www nff janssen de...

Page 112: ...Kipferl Step 2 The selected button flashes and the programme must be confirmed with the Select programme button 2 at the bottom Step 3 You are then taken back to the Settings level 3 for the selected...

Page 113: ...ve programme takes you to an input window for the programme information step 3 see next page MENU Settings BACK Permanent Semi Auto Automatik Select program Save program Mode Speed V1 maschine m min P...

Page 114: ...entries Step 4 You can now Save the values or Quit the process MENU Save values under BACK Quit Save Program 1 Roller number 2 Roller number 3 Roller number 02 Kipferl 365 680306J 796 180625J 1 2 3 4...

Page 115: ...er your user ID and password and confirm them with OK You can obtain the user ID and the password from the write authorized person in your team or the write authorized person can enable your values by...

Page 116: ...factory All others are given consecutive numbers and can be configured and named individually Step 1 To create a New programme select a programme number that is still free e g No 08 as shown on the ri...

Page 117: ...lt The Permanent mode is suitable for this application Step 4 You can now save the values with Save programme MENU BACK Permanent Semi Auto Automatik Select program Save program Mode Speed V1 maschine...

Page 118: ...team or the write authorized person can enable your values by entering the access data With the enable your modifications are now updated in the programme Note You can overwrite and rename all progra...

Page 119: ...button must be pressed Only then is the machine once again ready for operation 10 5 10 Restarting after a longer standstill After a longer standstill two cases must be considered Case one The producti...

Page 120: ...Basic setting for the spacing of the knife to the kneading roller Lubrication of the gear unit Installation and removal of the heater Installation and removal of electrical parts or the controller 11...

Page 121: ...n immediate stop of all moving parts in the machine It must not be possible to switch these components on again until the blue acknowledgement button release reset has been pressed If this is not the...

Page 122: ...following situations The upper conveyor belt cartridge must be cleaned before each time the machine is taken out of or put into operation or after a working shift If the conveyor belt cannot be adjust...

Page 123: ...oved or installed in two steps for cleaning or replacement of the conveyor belt Removal Step 1 Swivel the dough sensor 1 upwards and the sheet transport 2 down wards 1 2 3 1 2 Step 2 Pull the conveyor...

Page 124: ...follows Removal Step 1 Turn the removed conveyor belt cartridge 180 with the handles facing down preferably on a table and position the cartridge with the gold coloured clamping levers facing your bo...

Page 125: ...body Doing so raises the frame for the conveyor belt guide 1 in the guide groove of the cartridge frame 2 This lever movement causes the belt to relax a little Cartridge frame with handle strip Clampi...

Page 126: ...3 Pull apart the frame for the conveyor belt guide and the cartridge frame With your left hand grasp and pull the belt drive shaft and with your right hand press the wiper on the cartridge frame cross...

Page 127: ...125 Step 4 Now you have disassembled the belt drive cartridge into its two compo nents Frame for conveyor belt guide Cartridge frame with handle strip 4...

Page 128: ...126 Step 5 You can now remove the conveyor belt to clean the cartridge or replace the belt Section 12 7 5 Cleaning Conveyor belt cartridge p 154 Deflection axle Belt drive shaft 5...

Page 129: ...everse order Step 1 Slide the frame for the conveyor belt guide into the belt as shown Centre the belt as shown below Note the direction arrow printed on the inside of the belt Step 2 Wrap the belt ar...

Page 130: ...uide frame into the guide groove of the cartridge frame as shown on the right Incorrect installation is virtually impossible due to the design of the guide system Frame for conveyor belt guide Cartrid...

Page 131: ...the belt guide frame with the belt into the car tridge frame press on the belt drive shaft until the belt guide frame engages and the clamping levers move up Push the clamping levers into the car trid...

Page 132: ...t transport drive belts The transport drive belts of the sheet transport system can be replaced easily as needed You can order the belts in the ideal length from us 11 3 1 Removal and installation of...

Page 133: ...n angle as shown Note Grease the head of the connector somewhat beforehand The pressing requires a bit of strength Step 2 Now twist the connector from the angled position into the hollow belt while pr...

Page 134: ...ep 1 The sheet guide must be inserted from the rear of the machine into the desired position and threaded diagonally to the thin cross member in front of the sheet transport drive shaft Step 2 Once th...

Page 135: ...133 1 3 2 Click Cross member Clamping screw Sheet transport drive shaft Baking sheet 1 2 3...

Page 136: ...moval and installation of the knife The figure on the next page shows the basic setup The knife blade is clamped in the knife bracket with two knife pins The knife blade tension is provided via the kn...

Page 137: ...clamping screw Knife clamping lever Knife pin Bearing position of the blade shaft Knife bracket Shaft offset Locking screw for bearing position Fine adjustment for bearing position Strip steel knife...

Page 138: ...the knife and undo the knife blade clamping screw 2 1 2 3 1 1 2 3 3 1 2 3 Step 3 Once the knife clamping lever is completely relaxed you can drive the two knife pins 3 out of the holes with a mandrel...

Page 139: ...e the knife blade clamping screw 2 to tension the knife blade The knife is optimally tensioned when the bracket is absolutely straight at the bottom Installation To install the new knife blade please...

Page 140: ...on fine adjustment is turned anti clockwise the cookies are cut off thicker on the right side R Turn it clockwise and they will be cut off thinner Ideally the cookies should be cut off to the left L a...

Page 141: ...optimum is for the knife to cut directly at the dough band of the kneading roller 1 This gives you the cookie thickness which has been engraved on the roller according to your specifications However y...

Page 142: ...istance of about 3 mm to the surface of the kneading roller and thus cut off the cookies with the maximum thickness which is also engraved in the pattern roller This means that the knife is located di...

Page 143: ...ife adjustment for cookie thickness Knife bracket 2 Blade shaft 5 Knife distance gauge Knife Cam disk 1 Axial bearing block 2 Blade shaft 3 Locking screws Blade shaft Knife position relative to kneadi...

Page 144: ...t are each driven by a separate motor The knife is driven by a motor via a conversion gear unit The hopper shaft is damped by a lever spring system The gear unit for the cookie thickness adjustment is...

Page 145: ...er 3 months in the case of daily use in 1 shift operation To do so lightly brush the tooth flanks of all gears with grease Note The gears run in during the first 500 hours of operation or after 3 mont...

Page 146: ...d by disonnecting the two connection cables on the heater housing and lossening the fastening screws The heating element can be removed by disconnecting the power plug on the heater housing and unscre...

Page 147: ...closed or clogged or the cross flow fan is blocked due to heavy contamination After the temperature switch off has been triggered the heating unit can be put back into operation manually To do this r...

Page 148: ...familiar with the necessary safety measures Before carrying out maintenance work in a de energized state observe the five basic safety rules 1 Disconnect 2 Secure against restarting 3 Verify absence...

Page 149: ...ut by technically trained specialist personnel Detailed information can be requested from the manufacturer All maintenance work must only be performed by qualified personnel who are familiar with the...

Page 150: ...onal injury Before restarting it is essential to restore the electrical equipment to its proper condition 11 8 2 Documenting maintenance Document the maintenance steps carried out on your Janssen cook...

Page 151: ...s Check that all cable glands are firmly seated and leak tight Check the cable routing and the bending radiuses If cable ducts are available make sure that the cables are routed through the cable duct...

Page 152: ...ting agents as much as possible Cleaning and disinfection are defined as follows according to DIN 10516 Cleaning Cleaning is the removal of unwanted substances e g food residues deposits from rooms sy...

Page 153: ...ing agents for cleaning the Janssen cookie formers and alkaline cleaning agents in the case of heavy soiling with fats and oils When doing so it is essential to observe the manufacturer s instruc tion...

Page 154: ...o grease or oil and remove deposits and residues Step 5 Clean all surfaces with clean water and a cloth This removes the dirt particles and detergent residues Step 6 Dry all damp surfaces with a dry c...

Page 155: ...opper grid and the hopper forward and clean the inside and outside of the hopper with a microfib re cloth and for coarser dirt with a medium hard plastic brush 12 7 2 Cleaning the rollers Remove the p...

Page 156: ...ed To clean the front and back of the knife lift the cover with one hand and with the other hand clean the now exposed knife with a damp cloth There is a risk of cuts when doing so Caution The blade i...

Page 157: ...racket and the blade shaft with a medium hard plastic brush or a cloth After the knife and knife bracket are clean clean the knife guard 2 1 12 7 4 Cleaning the crumb tray The crumb drawer 1 can be pu...

Page 158: ...er each shutdown Frame for conveyor belt guide You can clean the frame easily with rinse water and brushes Please also clean the belt drive roller thoroughly with a medium hard plastic brush as dough...

Page 159: ...d right away so that it does not shrink in circumference Important note The cotton band can become narro wer after washing and this is no reason for a complaint Cartridge frame with handle strip Defle...

Page 160: ...e trans port rollers with a damp cloth or a hard plastic brush Sheet sensors When you have opened the hopper and removed the crumb tray you can also clean the sheet sensors from above Sheet guide Remo...

Page 161: ...damp cloth and a medium hard plastic brush with the rollers conveyor belt cartridge and crumb tray removed All areas are easily accessible from above as well as from the back and front of the machine...

Page 162: ...d remove the heater once a month and clean the interior of the heater housing and the heater housing plate 2 regularly You can disconnect the heating element from the power supply by the plug and remo...

Page 163: ...can use a medium hard plastic brush 12 7 10 Cleaning the base frame Clean the base frame with a cloth and water For corners and edges you can use a medium hard plastic brush 12 7 11 Cleaning the oper...

Page 164: ...end using cut resistant gloves for cleaning and assembly when installing and removing the knife The figure shows cut protection gloves 13 4 Required tools Normal machine operation No special tools are...

Page 165: ...ents for proper forming of cookies In accordance with the intended use only food doughs may be formed in the Janssen F250 F450 and F600 series cookie moulding machines especially shortcrust doughs hon...

Page 166: ...epare the dough one day in advance so that the sugar can incorporate fully and the dough does not stick in the pattern roller especially with regard to the sugar content Store the dough overnight in a...

Page 167: ...tick Do a test with a handful of dough Press a piece of dough firmly into the roller and try to pull it out again If this works the nature of the dough suggests forming will be smooth and achievable w...

Page 168: ...rent or even require differences This means there are natural limits to the desire for the machine to adapt to the recipe With decades of experience in the development of cookie moulding machines our...

Page 169: ...ted recipes that you can process very well with our Janssen cookie formers Since doughs are generally made up of different natural ingredients the dough properties can have different effects depending...

Page 170: ...Thickness of the cookies 3 about 7 As JANSSEN has no influence on these dimensional deviations they are outside our area of responsibility and are therefore not a reason for comp laints The cookies a...

Page 171: ...1 The thinner warmer or softer the cookie the more the cookie is compressed and becomes slightly thicker and wider in the middle Rule 2 The thicker colder or harder the cookie the less the cookie is c...

Page 172: ...ttle binding because the recipe is not suitable for the machine 1 It may be necessary to knead the dough a little longer 2 Let the dough rest for about 5 8 hours cooled and covered with a linen cloth...

Page 173: ...adding fat or liquid 3 The dough stays on the kneading roller but accumulates on the knife 1 The dough is probably too soft and cannot slide over the cutting blade 2 The dough is probably too soft be...

Page 174: ...liquid or keeping it cooler Alternatively you can try setting the knife speed to level 2 The knife oscillates moves back and forth faster and may be able to cut the soft dough pieces better Caution L...

Page 175: ...The cookies have doughy edges or fringes around the edges The knife is too close to the kneading roller and is peeling the dough band off Adjust the knife setting a little thinner so that no dough is...

Page 176: ...eets are strongly deformed crooked 2 The sensor is defective You can check this by holding a metallic object against the sensor The sensor should light up yellow when it comes into contact with metal...

Page 177: ...er of the drive roller 1 Straight running can be adjusted with the small adjusting wheel for the belt adjustment If the wheel is turned to the left the belt also moves to the left If the wheel is turn...

Page 178: ...rectly 2 An EMERGENCY STOP button is activated 2 1 An EMERGENCY STOP button is defective 3 The conveyor belt cartridge is not inserted or not inserted correctly 1 Close the hopper grid and hopper and...

Page 179: ...177 If you cannot correct the fault your self contact your dealer or us...

Page 180: ...iod of stand still the machine should be taken out of service and stored correctly otherwise there is a risk of contamination for the subsequent production of cookies Never pull the mains plug while t...

Page 181: ...ng from service and storage of the machine Clean the machine carefully Section 12 Cleaning after shutdown Switch off the main switch on the front of the machine before discon necting the machine from...

Page 182: ...pany or by persons with training and experience in handling hazardous substances 16 Dismantling and disposal 16 2 Requirements and safety Environmental hazards may arise if not disposed of properly an...

Page 183: ...less steel for use in the food industry Anodized aluminium Bronze bearings Spring steel Electronic components and motors 16 5 Disposal of the machine After complete dismantling the machine s parts mus...

Page 184: ...slation applied listed below including any amendments thereto in force at the time of the declaration The manufacturer bears the sole responsibility for issuing this declaration of conformity 17 Decla...

Page 185: ...e recipe book from us 18 2 Spare parts list You can request the spare parts list from us 18 3 Electrical circuit diagrams The electrical circuit diagrams are attached to these operating instruc tions...

Page 186: ...184 Quick Start for Janssen Cookie Formers F250 UL F450 UL F600 UL supplementary to the original operating instructions 05_2020_US_CA...

Page 187: ...o that you have enough room to move around it Lock the steering castors of the machine 19 Quick start Step 2 Connect the machine to the power supply with the power cable and turn on the main switch Lo...

Page 188: ...yor belt cartridge If the sheets should get stuck you must set the height adjustment of the sheet trans port downwards slightly Note If some of the sheets differ extremely from the other sheets due to...

Page 189: ...ean and free of dough residue on both sides Note If the knife is not free of dough residues the cookies cannot be formed properly Step 7 Install the kneading roller and the pattern roller that is suit...

Page 190: ...3 Kuchenb den 04 Kipferl 05 Nussteig 06 Printen 07 Marzipan 08 09 10 11 Select program sheet transport convoyeur de plaques heating Chauffage de 0 1 permanent automatic Performance Compact MENU Main m...

Page 191: ...he desired cookie thickness Step 9 In the first step fill only a handful of dough into the hopper and switch the machine on in Permanent mode and make sure that the dough does not stick to the pattern...

Page 192: ...e lower edge of the dough sensor should be located about 2 mm above the formed cookie Very important If the cookie is 2 mm below the sensor the sensor lights up yellow 2 When you pull the cookie away...

Page 193: ...gs otherwise the desired number of cookie rows cannot be achieved MENU Settings BACK Permanent Semi Auto Automatik Select program Save program Mode Speed V1 maschine m min Program 01 Spekulatius 4 0 i...

Page 194: ...ost continuously and does not stop otherwise a row will be incorrectly formed due to the short standstill This cannot be prevented due to the process as the dough is elastic and a damaged area is left...

Page 195: ...tween the rows of cookies may become larger You can also see that for this Semi automatic mode the lower 1 setting options are not available This Semi automatic mode is more robust and process reliabl...

Page 196: ...the left or right turn the adjusting wheel very carefully in the direction in which the belt is to move The adjustment is very sensitive so turn the adjustment wheel only very slightly about 10 and w...

Page 197: ...195 We wish you much joy pleasure with your new machine...

Page 198: ...e reproduction of any contents of these operating instructions including in part is only permitted with the written permission of Niederrheinische Formenfabrik Janssen Copyright Niederrheinische Forme...

Page 199: ...Do you have any questions Contact us...

Page 200: ...n_cd_operating_instructions_F_Book_UL_200510 indd Niederrheinische Formenfabrik Janssen GmbH Moerser Strasse 33 47798 Krefeld Phone 49 2151 24315 Fax 49 2151 29759 info nff janssen de www nff janssen...

Page 201: ...n Cookie Formers F250 F450 F600 Supplement to original operating instructions 08_2022_EN jan_anl_F250_450_600_Forming_dough_texture_2022_EN indd jan_anl_F250_450_600_Forming_dough_texture_2022_EN indd...

Page 202: ...2 Niederrheinische Formenfabrik Janssen GmbH Moerser Stra e 33 47798 Krefeld Tel 49 0 2151 24315 Fax 49 0 2151 29759 info nff janssen de www nff janssen de...

Page 203: ...o different doughs 12 3 2 Tolerance range 12 3 3 Test roller 13 4 Faulty forming 4 1 Uneven forming due to soft doughs 14 4 2 Uneven forming due to sticky doughs 16 4 3 Uneven forming due to doughs th...

Page 204: ...Kneading time Resting time Processing parameters during forming For reference we would like to refer to our recipe book There you will find versatile recipes that can be processed with our Janssen Co...

Page 205: ...he kneading roller 4 and the pattern roller 3 A dough band forms around the outer surface of the kneading roller The pattern roller 3 which can be heated and replaced from the outside embosses raised...

Page 206: ...um biscuit thickness as engraved in the forming roller The knife cuts off at the base of the biscuits directly at the dough mantle of the kneading roller see view C view B and cross section view A A V...

Page 207: ...it thickness setting The ideal shaping thickness should be slightly below the maximum biscuit thickness setting see illustration on the right Note There is no exact value as it depends largely on the...

Page 208: ...ut at the base of the biscuits but at a greater distance from the dough mantle of the kneading roller see view C view B and section view A A Thicker imprints of the biscuits are visible on the dough m...

Page 209: ...9 Too thin biscuit thickness setting This biscuit thickness setting see illustration on the right is clearly too thin and can lead to faulty shaping results View B Cross section view A A too thin...

Page 210: ...he biscuits but also cuts off layers of the dough mantle of the kneading roller see view C view B and section view A A No imprints of the biscuits are visible on the dough mantle of the knea ding roll...

Page 211: ...o thick biscuit thickness setting This biscuit thickness setting see picture on the right is clearly too thick There is a fringed edge of dough around the biscuit View A A Cross section view A A too t...

Page 212: ...e outside our area of responsibility and are therefore not the subject of complaints subject of complaints 3 2 Tolerance range The biscuits are cut off after forming This cutting process causes the bi...

Page 213: ...r and wider in the middle Rule 2 The thicker colder or harder the biscuit the less the biscuits are compressed 3 3 Test roller If a high tolerance fit is required we strongly recommend that a test rol...

Page 214: ...nife Reason Too soft dough can have several causes 1 the dough is too warm 2 it has too much liquid or fat 3 the butter margarine is too soft or has unfavourable working properties 4 the dough has bee...

Page 215: ...th our machines Clarified butter vegetable fat or shortening can also be critical As a rule butter is less sticky than margarine Note on 4 The dough was kneaded too long Shortcrust dough consisting of...

Page 216: ...t sticks in the forming roller is missing in the biscuit Reason Sticking of the dough in the forming roller can have many causes 1 the dough has too little binding 2 the dough is too warm or too cold...

Page 217: ...oo soft see 4 1 1 1 2 and 1 2 4 shortcrust pastries usually have a little more binding than 1 2 3 shortcrust pastries Note on 2 The dough is too warm or cold Dough that is too warm or too cold tends t...

Page 218: ...ughs can have the following causes 1 The liquid or fat content is too low and thus too dry crumbly and without binding 2 The dough is too cold and therefore too firm 3 The dough has been kneaded too b...

Page 219: ...at room temperature 1 2 3 shortcrust pastry should be slightly cooler 13 17 C Generally the dough should feel grippy and smooth see Janssen Recipe book Note on 3 The dough is kneaded too short If the...

Page 220: ...also push together on the knife and cannot be formed Possible activities Change recipe or prepare new dough see Janssen Recipe book 4 5 Uneven forming due to too thick biscuits If the biscuits are too...

Page 221: ...small the problem arises that the smaller and lighter the biscuits the more difficult it is to form them evenly in a row The small biscuits adhere differently to the knife are deposited unevenly on th...

Page 222: ...ould be checked in any case with an additional test with the actual dough Depending on the characteristics of the dough this information can of course also be incorrect Marzipan or soft gingerbread fi...

Page 223: ...ft gingerbread dough that is very easy to form Exception 2 Kipferl made from 1 2 3 shortcrust pastry recipe from Janssen recipe book Exception 1 Fine leaf made from fondant dough All critical dimensio...

Page 224: ...thick biscuits there is a risk that the dough does not fill the deep mould and the biscuits are not fully formed see 2 This effect occurs especially with sharp edged biscuits A strong rounding of the...

Page 225: ...mportant If the outer dimensions are too small while the thickness remains the same see 3 there is a risk that the mould will no longer be filled optimally Small biscuits also have the problem that th...

Page 226: ...ss of the biscuits should generally be between 2 5 7 mm in special cases less or more depending on the dough and mould filling behaviour see 5 1 General information on pastry dimensions Most faulty fo...

Page 227: ...27 Do you have any questions Contact us...

Page 228: ...nl_F250_450_600_Forming_dough_texture_2022_EN indd jan_anl_F250_450_600_Forming_dough_texture_2022_EN indd 28 Niederrheinische Formenfabrik Janssen GmbH Moerser Stra e 33 47798 Krefeld Tel 49 0 2151 2...

Page 229: ...sen Cookie Formers F250 F450 F600 Supplement to original operating instructions R jan_anl_F250_450_600_Forming_knife_setting_2022_EN indd jan_anl_F250_450_600_Forming_knife_setting_2022_EN indd jan_an...

Page 230: ...2 Niederrheinische Formenfabrik Janssen GmbH Moerser Stra e 33 47798 Krefeld Tel 49 0 2151 24315 Fax 49 0 2151 29759 info nff janssen de www nff janssen de...

Page 231: ...haft 12 3 1 1 Adjust pastries thicker on the right side 14 3 1 2 Adjust pastries thinner on the right side 15 3 2 Forming too thin due to incorrectly adjusted knife shaft 16 3 2 1 Reduce distance betw...

Page 232: ...mperature Ambient atmosphere Kneading time Resting time Processing parameters during forming For reference we would like to refer to our recipe book There you will find a variety of recipes that can b...

Page 233: ...neading roller 4 and the pattern roller 3 A dough band forms around the outer surface of the kneading roller The pattern roller 3 which can be heated and replaced from the outside embosses raised shap...

Page 234: ...imum biscuit thickness engraved in the forming roller The knife cuts off at the base of the biscuits directly at the dough mantle of the kneading roller see view C view B and cross section view A A Wa...

Page 235: ...it thickness setting The ideal shaping thickness should be slightly below the maximum biscuit thickness setting see illustration on the right Note There is no exact value as it depends largely on the...

Page 236: ...ut at the base of the biscuits but at a greater distance from the dough mantle of the kneading roller see view C view B and section view A A Thicker imprints of the biscuits are visible on the dough m...

Page 237: ...9 Too thin biscuit thickness setting This biscuit thickness setting see illustration on the right is clearly too thin and can lead to faulty shaping results View B Cross section view A A too thin...

Page 238: ...he biscuits but also cuts off layers of the dough mantle of the kneading roller see view C view B and section view A A No imprints of the biscuits are visible on the dough mantle of the knea ding roll...

Page 239: ...o thick biscuit thickness setting This biscuit thickness setting see picture on the right is clearly too thick There is a fringed edge of dough around the biscuit View A A Cross section view A A too t...

Page 240: ...ped transversely to the shaping direction with different biscuit thicknesses The knife does not cut parallel to the base of the biscuits see view C and section view A A View C Cross section view A A D...

Page 241: ...eading roller The left bearing L of the knife shaft is fixed the right bearing R of the knife shaft can be shifted in position to a small extent so that the knife shaft can be aligned parallel to the...

Page 242: ...w turned a few angular degrees counterclockwise and fixed by means of the locking screw Goal The biscuits must be exactly the same thickness on the left L and on the right R in the direction of shapin...

Page 243: ...tion below clockwise by a few angular degrees and fix it by means of the locking screw Goal The biscuits must be exactly the same thickness on the left L and right R in the direction of shaping rotata...

Page 244: ...maximum biscuit thickness setting see illustration on the right Thick imprints 1mm see view C of the biscuits remain on the kneading roller mantle which means that the biscuits cannot be cut to the de...

Page 245: ...ce is 3 5 mm The blue knife distance gauge shows the number 3 5 3 2 1 Reduce distance between knife and kneading roller If the biscuits are generally shaped too thinly the distance between the knife a...

Page 246: ...kneading roller and tighten the locking screws on the axial bearing block Check that the distance gauge is relatively tightly clamped between the knife and the kneading roller on both sides to the le...

Page 247: ...he forming To do this set the biscuit thickness setting to the maximum value again At the maximum biscuit thickness setting a very thin band of dough 1mm should now be formed around the biscuits see i...

Page 248: ...ideal shaping thickness should be slightly below the maximum biscuit thickness setting see illustration on the right Note There is no exact value as this depends largely on the elasticity of the doug...

Page 249: ...dough mantle of the kneading roller see view C view B and sectional view A A Wafer thin imprints of the biscuits are visible on the dough mantle of the kneading roller A B A C Dough mantle on the knea...

Page 250: ...biscuits are formed too thick at maximum biscuit thickness setting that even a thick dough mantle 1 mm see view C of the kneading roller is cut off as well No imprints of the biscuits remain on the k...

Page 251: ...correct position in the axial bearing block Step 3 The biscuit thickness setting of the The knife must be set to the maximum thickness Step 4 It is absolutely necessary to adjust the knife shaft of t...

Page 252: ...the kneading roller and tighten the locking screws on the axial bearing block Check that the knife distance gauge is relatively tightly clamped between the knife and the kneading roller on both sides...

Page 253: ...the forming To do this set the biscuit thickness setting to the maximum value again Bei maximaler Geb ckdickeneinstellung sollte nun ein hauchd nnes Teigband 1mm um die Geb cke herum mit ausgeformt w...

Page 254: ...ideal forming thickness should be slightly below the maximum biscuit thickness setting see illustration on the right Note There is no exact value as this depends largely on the elasticity of the doug...

Page 255: ...e dough mantle of the kneading roller see view C view B and sectional view A A Wafer thin imprints of the biscuits are visible on the dough mantle of the kneading roller View View C With this setting...

Page 256: ...such as forming rollers forming roller adapters kneading rollers upper conveyor belts and knives 4 1 Uneven forming due to incorrect assembly of the forming roller adapters or non matching forming ro...

Page 257: ...rollers of the K series have adapters with bolts on both sides The bolts must not be removed under any circumstances and must have a tight fit in both the forming roller adapter and the forming roller...

Page 258: ...ng roller adapters If this is not the case a new F series forming roller should be created Caution Under no circumstances should you try to readjust the knife shaft in this case These extreme irregula...

Page 259: ...r flanges 4 2 Exceptions for the use of Forming roller adapters The F series forming roller adapters are suitable for K series forming rollers under the following require ments Forming roller adapter...

Page 260: ...ts for the intended Use 1 The forming roller adapters fit exactly in the inner ring 94 mm of the forming roller 2 The stabilising rod for K400 K450 K580 forming rollers 25 mm must fit exactly into the...

Page 261: ...ting of the machine for forming 1 The correct bearing of the forming rollers especially when using forming roller adapters for older Janssen forming rollers of the previous K series 2 Die korrekte Gru...

Page 262: ...nl_F250_450_600_Forming_knife_setting_2022_EN indd jan_anl_F250_450_600_Forming_knife_setting_2022_EN indd 34 Niederrheinische Formenfabrik Janssen GmbH Moerser Stra e 33 47798 Krefeld Tel 49 0 2151 2...

Page 263: ...s_controls_2022_EN indd jan_anl_F250_450_600_Settings_controls_2022_EN indd MENU Main menu Back Programs Settings Info Language Admin emergency stop Arr t d urgence stop machine machine d arr t start...

Page 264: ...2 Niederrheinische Formenfabrik Janssen GmbH Moerser Stra e 33 47798 Krefeld Tel 49 0 2151 24315 Fax 49 0 2151 29759 info nff janssen de www nff janssen de...

Page 265: ...mation about the drive scheme 1 1 Drive units 4 1 2 Forming process 4 1 3 Speed V1 V2 unnd V3 5 1 4 Sensors 6 1 5 Controls 6 2 General information about the controls 2 1 Control Compact with examples...

Page 266: ...ss Step 1 To shape pastries with Jansseen cookie formers the dough is placed in the hopper and pulled in and shaped by the pair of rollers Step 2 Immediately after forming the knife cuts the embossed...

Page 267: ...ng roller are approxi mately the same as the distances between the cookies of the formed cookies on the upper conveyor belt The speed V3 of the baking tray transport can be used to adjust a little the...

Page 268: ...sensor detects the incoming baking tray 1 5 Controls Janssen cookie formers can be operated with two basic controls Control Compact Control Performance The advantages and functions of the different co...

Page 269: ...the pair of rollers and the speed V2 of the upper conveyor belt run at a standard speed of 4 m min and cannot be varied The speed V3 of the baking tray transport can be set faster and slower for the r...

Page 270: ...so that the cookies do not bake together and if possible no row of cookies overlaps the edge of the tray at the end see illustration on the right Example 1 The speed V3 is usually about as fast as the...

Page 271: ...re clearly too large the speed V3 of the baking tray transport is too fast see Fig below Example 2 If the pastries push together on the baking tray or bend at the front edge the speed V3 of the baking...

Page 272: ...machine and the speed V2 of the upper conveyor belt should run at the same speed In special cases longer pastries very large figures or cake layers can be stretched by a slightly faster speed V2 of t...

Page 273: ...e can be operated in Permanent Semi Automatic and Automatic mode The Semi Automatic mode is comparable to the Automatic mode of the Compact control However in contrast to the Performance control the d...

Page 274: ...try row overlaps the sheet edge at the end see Fig below The speed V3 is usually about as fast as the speed V2 of the upper conveyor belt and the speed V1 of the machine The forming roller shown below...

Page 275: ...r Parame tereinstellung f r die optimale Backblechbelegung mittels der Reihenz hlung und dem Reihenabstand festlegen siehe Abb rechts Die untern abgebildete Formwalze konnte aufgrund der Geb ckgeometr...

Page 276: ...on the baking tray is very unfavorable Reducing the speed V3 of the lower baking tray transport would not be effective here since the pastries would be very strongly compressed MENU Settings BACK Per...

Page 277: ...rows of pastries In this case the placement of the baking tray is optimal MENU Settings BACK Permanent Semi Auto Automatik Select program Save program Mode Speed V1 maschine m min Program 03 4 0 i Sp...

Page 278: ...is inactive during the placement of the baking tray regard less of whether a cookie has been optimally or less optimally shaped under the sensor in between see figure below Example 4 Automatic mode I...

Page 279: ...ange of functions you want to use 3 1 Advantages of Compact control The Compact control stands for robust and simple operation It has only pushbuttons and rotary knobs and does not overload with exten...

Page 280: ...or different products It is particularly well suited if in addition to small pastries you also want to produce cake bases continuous dough bands for cake trays or longer pastries longer than approx 70...

Page 281: ...n Heating adjustable 3 levels adjustable 3 levels Operating modes Permanent Automatic large distances between rows of cookies cannot be reduced Permanent Semi Aut Automatic large distances between row...

Page 282: ..._anl_F250_450_600_Settings_controls_2022_EN indd jan_anl_F250_450_600_Settings_controls_2022_EN indd 20 Niederrheinische Formenfabrik Janssen GmbH Moerser Stra e 33 47798 Krefeld Tel 49 0 2151 24315 F...

Page 283: ...Recipe book for Janssen Cookie Former F Series and K Series Let yourself be inspired 06_2022_EN_USA...

Page 284: ...1 Niederrheinische Formenfabrik Janssen GmbH Moerser Strasse 33 47798 Krefeld Phone 49 2151 24315 Fax 49 2151 29759 info nff janssen de www nff janssen de Recipes for Janssen Cookie Former...

Page 285: ...2 3 160 220 C 12 ingredients mixing kneading 120 650 kg h 250 400 blades h shaping sheet feeding baking packing racks 2...

Page 286: ...endly alternative to the classic roll out processes Our recipe book shows you selected recipes which you can process very well with our Janssen pastry moulding machines Since doughs are generally com...

Page 287: ...tity used in relation to the other recipe components is important but also the type of fat The use of butter and or baking margarine with the fol lowing specifications is recommended for the productio...

Page 288: ...n the production of dough bands or cake bands on the other hand a slightly elastic dough can have advantages with regard to the forming result As a rule wheat flours with a grinding degree of between...

Page 289: ...es of the pastry can be significantly influenced As a rule fine grained sugars and icing sugar are used The latter is particularly recommended if the dough is to be processed directly without storage...

Page 290: ...t embedded flour components swollen flour components Ideal shortcrust pastry A shortcrust pastry that is easy to process is characterised by the fact that the flour components are em bedded in the fat...

Page 291: ...tries 14 Crunchy butter biscuit 16 Almond biscuit 18 Pretzels with nuts 22 Pretzels with chocolate 24 The baked goods listed below are characterised by a clear structure a firm crunchy break which is...

Page 292: ...Add egg yolk flavors and milk and mix for 2 min Step 3 Add flour and knead for 5 minutes Note Times may vary depending on the amount of dough volume of the kneading vessel 16 17 Ingredients granulated...

Page 293: ...nd egg yolk and mix for 2 min Step 3 Add flour and baking powder and knead it to a smooth dough Note Times may vary depending on the amount of dough volume of the kneading vessel 18 19 Ingredients gra...

Page 294: ...lt and butter for 3 min Step 2 Add egg and mix for 2 min Step 3 Add flour and knead it to a smooth dough Note Times may vary depending on the amount of dough volume of the kneading vessel 20 21 Ingred...

Page 295: ...rs and milk and mix for 2 min Step 3 Add flour and grated hazelnuts and knead for 3 5 minutes Note Times may vary depending on the amount of dough volume of the kneading vessel 22 23 Ingredients granu...

Page 296: ...flavors and milk and mix for 2 min Step 3 Add flour and knead for 5 minutes Note Times may vary depending on the amount of dough volume of the kneading vessel 24 25 Ingredients granulated sugar fine 1...

Page 297: ...Recipes for delicate shortcrust doughs 26 Short Bread 30 Vanilla Kipferl Linzer biscuits 32 34 The pastries listed in the following are characterised by a delicate crum bly consistency Tea Biscuits 2...

Page 298: ...ith centre bar Step 1 Mix sugar butter lecithin and salt for ca 1min at slow speed Step 2 Add egg yolk egg flavors and mix at slow speed for 0 5 min and at high speed for 0 5 min Step 3 Add starch and...

Page 299: ...r 1 min Step 2 Add flour and mix slowly for ca 2 min then fast for 1 min and slowly again for 0 5 min Step 3 Store dough in a cool place Step 4 Knead well before further processing Note Times may vary...

Page 300: ...semolina and mix for ca 1 min Step 4 Add flour and knead for ca 3 5 min Step 5 Store dough in a cool place Step 6 Knead well before further processing Note Times may vary depending on the amount of do...

Page 301: ...flour and mix for ca 1 min Step 4 Add flour and knead for ca 3 5 min Step 5 Store dough in a cool place Step 6 Knead well before further processing Note Times may vary depending on the amount of dough...

Page 302: ...37 Recipes for endless dough for molding of cake bases 36 Endless dogh endless lattice 36 Perfect for production in cake lines From cake base to lattice your cake production is supported optimally...

Page 303: ...ing powder and knead for ca 5 min Step 4 Store dough in a cool place overnight Step 5 Add remaining water and knead dough before starting production Note Times may vary depending on the amount of doug...

Page 304: ...41 Even special doughs run on Janssen machines whether hearty gluten free or vegetarian there is a wide va riety of biscuit mixes to choose from 40 Recipes for gluten free doughs...

Page 305: ...avors and milk and mix for 1 min Step 3 Add corn starch rice flour and tapioca starch and knead for 3 minutes Note Times may vary depending on the amount of dough volume of the kneading vessel 42 Ingr...

Page 306: ...45 Recipes for Printen dough and gingerbread dough 44 Gingerbread 44 Printen 46 Even the traditional sweet strong and durable doughs can be formed wonderfully in our machines...

Page 307: ...nead with the appropriate amount of egg yolk under the storage dough Step 3 Dissolve the remaining egg white in the potash and also knead in the egg yolk with the corresponding amount Step 4 Let the d...

Page 308: ...y Step 8 Knead well at slow speed Step 9 Cover the dough and let it rest at room temperature for at least one day Step 10 Briefly knead the dough before processing and then pour into the machine Work...

Page 309: ...51 Marzipan in any shape 50 With our machines it is also possible to form marzipan paste For example for the decoration of cakes...

Page 310: ...ant It is also possible to mix and shape shortcrust dough with marzipan 52 53 sugar sucrose Starch syrup and or invert sugar cream water FONDANT min 65 80 max 10 15 max 10 20 marzipan crude mass min 5...

Page 311: ...55 Recipes for savoury pastries 54 Savoury pastries and crackers are a tasty starter with a meal or a side dish with a glass of wine...

Page 312: ...nead for 1 min Step 3 Add water and knead for ca 9 minutes This basic recipe can be varied in many ways by adding hearty cheeses and spices such as chilli or thyme Note Times may vary depending on the...

Page 313: ...d water and and knead it to a smooth dough Step 4 Brush with egg yolk and garnish with spices Note Times may vary depending on the amount of dough volume of the kneading vessel 58 59 Ingredients firm...

Page 314: ...l rights reserved The reproduction of any contents of these operating instructions including in part is only permitted with the written permission of Niederrheinische Formenfabrik Janssen Copyright Ni...

Page 315: ...Niederrheinische Formenfabrik Janssen GmbH Moerser Stra e 33 47798 Krefeld Tel 49 0 2151 2431 Fax 49 0 2151 29759 info nff janssen de www nff janssen de jan_kat_rez_EN_USA_06_2022 indd...

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