Modernization of the Bread Production Line at PAC Hořovice

PAC Hořovice successfully transitioned to automated mono-line bread production with a continuous proofer while maintaining semi-automatic production of specialty breads.

PROJECT OVERVIEW 

• Customer: PAC Hořovice

  Supplied technology:

  • Cyclothermic deck oven line with a continuous proofer
  • Cyclothermic deck oven line for semi-automatic production of specialty breads with manual unloading

  Production capacity:

  • 1,050 loaves/hour
  • 780 loaves/hour

  Control system: MultiControl

  Project objective:
  Modernize the bread production process by separating production into:

  • a fully automated mono-line with a continuous proofer for high-volume bread production,
  • and a semi-automatic line dedicated to specialty breads.

Key Project Challenges 

• Transitioning from tunnel oven baking to deck oven technology
• Dividing production into an automated mono-line and a semi-automatic specialty bread line
• Improving bread quality while increasing production flexibility 

Implemented Solution

The modernization project was designed as two independent production lines. 

The primary objectives were:

• improving bread quality, particularly the characteristics of the bottom crust
• increasing production efficiency
• expanding the specialty bread portfolio

Automated Mono-Line with Continuous Proofer

• Cyclothermic deck oven bread line
  • 3 × Variant 35/8 cyclothermic deck with total baking area 105 m²
  • Single-circuit design 
  • Continuous proofing synchronized with the baking process thanks to the sufficient number of oven decks

• Continuous Proofer
  
  • A fully automatic continuous proofer designed for gentle dough handling.

    Main benefits:

    • Suitable for standard dough weights between 1,000–1,200 g
    • Minimal manual labour
    • High production efficiency

• Automation & MultiControl

  • The complete production process is controlled by the MultiControl automation system.

    Operators simply select the required product recipe, while all process parameters are managed automatically, reducing operator error and ensuring consistently high product quality.

    The line also includes:

    • loading equipment,
    • product handling systems,
    • product finishing equipment,
    • automatic transport of baked products to cooling and dispatch.

Semi-Automatic Specialty Bread Production  

• Cyclothermic deck oven bread line
  
  • 3 × Variant 26/7 cyclothermic deck ovens with total baking area 78 m²
  • Single-circuit design
  • Ceramic baking plates providing excellent crust characteristics and artisan product quality

• Automation and MultiControl

  • Although designed for semi-automatic production, the entire process is also integrated into the MultiControl platform.

    As with the automated line, all peripheral equipment is fully connected and centrally managed.

RESULT

Production Capacity

• 1,050 loaves/hour
• 780 loaves/hour

Flexibility

Two dedicated production lines enable efficient high-volume bread production while maintaining the flexibility required for specialty bread manufacturing.

Operational Reliability

The dual-line concept also provides valuable production redundancy, ensuring business continuity in the event of maintenance or unexpected downtime.