Servi-Doryl (Alpma) & Tecnal Soft Cheese Production Line – 13,500 Litres/Hour

Description

Manufactured by Servi-Doryl (Alpma) in 1998 and significantly upgraded by Tecnal in 2016, this automated processing line for the production of Soft Cheese incorporates robotic cutting and slicing, and offers an adjustable capacity of approximately 13,500 litres per hour, equivalent to one 150L basin every 36 seconds.

The installation is designed to handle mobile basins with a 150L overflow capacity, operating entirely automatically from filling to cleaning, based on pre-programmed recipes.

Please refer to the video below for a comprehensive overview of this specific plant and its production process from start to finish.

• Filling and Coagulation:
  Stanardised Milk is dispensed into the basins at a fixed station. The volume filled varies depending on product type and yield. Rennet is added at the same station via a pneumatic or small dosing pump.
  Basins travel on a slow-speed conveyor (e.g., 10.58 m/min) during filling and coagulation. The conveyor’s continuous movement, combined with adjustable slicing station placement, prevents curd lamination and allows for flexible coagulation times.

• Cutting and Syneresis:
  A Staubli robotic arm cuts the curd into uniform cubes, with a built-in delay to allow for draining after cutting.
  During syneresis, basins move forward in a stepwise manner. The timing to moulding is controlled via an adjustable transfer bridge. Whey is removed and mixed ahead of the moulding process, with both steps governed by the recipe settings.

• Moulding:
  Curd is poured into a distributor through a 90°C chute. The tilting angle and speed are adjustable, and the distributor’s speed is synchronized to ensure precise moulding over one or more trays. An operator oversees and optimizes tray filling. The distributor is moved manually between runs.

• Cleaning:
  After curd discharge, basins are automatically turned and cleaned in a tunnel washer, which operates in steps (pre-wash, wash, rinse).

• Pre-Draining and Handling:
  At the end of the moulding table, trays are automatically separated and stacked (up to 14 trays per stack). Pre-draining occurs on two mechanized tables (12.5 m and 8.5 m) over a 90-minute period, with a total capacity of 41 stacks. Timing adjustments are made based on stack height or table speed to maintain appropriate spacing.

• Unstacking and Final Handling:
  Trays are then unstacked, turned, and restacked, before being placed on a base stand. Tray extensions are moved manually.

Specification

• Manufacturer: Servi-Doryl (Alpma) & Tecnal
• Function: Soft Cheese Production Line 
  
• Capacity: 13,500 Litres/Hour
• Total number of Basins: Approx 140 pcs included with conveyoring
• Capacity of each Basin: Approx 130-150L
• Nominal rate: 1x 150L Basin every 36 seconds (or 100x Basins per hour)
• Suitable to produce Soft Cheese (e.g. Camembert, Brie) and also Feta or Mozzarella (with dry matter below 40%)
• Year of manufacture: 1998
• Upgraded in 2016 by Tecnal with Staubli automatic robotic arm for cutting/slicing, plus new automation, supervision, moulding system.
• The system is completely built in AISI 304 stainless steel and is totally arranged for the CIP automatic washing system.
• Spare parts available
• Documentation available
• Includes control panel (as photographed)

Country of Manufacture

France