AL.MA. Srl · Italy

AL.MA. RSA540 multi-station ravioli and varenyky line with continuous dough mixer

Four stations of 700 kg/h each, a shared mix and a shared scrap return

• 2800 kg/hin the four-station configuration
• 3–5stations to choose from
• 2 × 540 mmdough sheets
• 2500 mmstation pitch

Request a quotation Data sheet: AL.MA. RSA540 multi-station ravioli and varenyky line (PDF) Watch video

Supply · installation and commissioning · staff training · service across Ukraine

The equipment in brief

The multi-station AL.MA. RSA540 is a factory-scale solution for two-sheet dough products. A GR.IM.2000 continuous mixer prepares the dough without stopping and discharges it into the NAV-4 shuttle hopper, which distributes the dough across the stations. Each station is a sheeter, a forming machine, a lobe filling pump and a scrap shredder; the stations work in parallel and independently of each other, while a twin-deck conveyor carries the products to the shock freezing tunnel and at the same time returns the shredded trimmings to the mixer.

Manufacturer photos

Photos from the manufacturer’s materials.

Key advantages

Who this equipment is for

A multi-station line is installed at factory scale:

• frozen semi-finished product factories
• large vareniki and ravioli plants
• operations of a tonne an hour and above
• export-oriented plants
• factories with a staged expansion plan
• producers with their own brand

How it works

1. Continuous mixingThe GR.IM.2000 makes dough as a flow at up to 2000 kg/h.
2. Shuttle distributionThe NAV-4 travels above the line and hands dough to the stations.
3. Station workEach station sheets two webs, doses the filling and forms the product.
4. Outfeed to freezingThe upper belt takes the products to the shock freezing tunnel.
5. Trimming returnShredders cut up the sheet and the lower belt returns it to the mixer.

Operating principle

The continuous dough mixer prepares dough without interruption and discharges it into the shuttle hopper. The shuttle travels above the line and distributes dough between the stations. Each station consists of a sheeter, a forming machine, a lobe pump for filling supply and a scrap cutter; the stations work in parallel and independently of one another.

A two-tier conveyor runs along the line. Formed products with filling drop onto the upper belt and travel towards the blast freezing tunnel. Trimmings of unused dough sheet, cut up by the scrap cutters, drop onto the lower belt and travel in the opposite direction — to the conveyor returning scrap to the dough mixer. The dough sheet goes back into production, so the line runs with virtually no raw material loss.

Scaling and maintenance

• The line can have from 3 to 5 stations; output grows in proportion to their number
• The system can be ordered for the full number of stations while being equipped with machines only in part — for example, four stations with two equipment sets. Unused stations are switched off from the control panel
• When output needs to grow, machines are purchased and installed on the free stations — the line does not need rebuilding
• Any station can be stopped for scheduled maintenance without stopping the line: the remaining stations keep running

Line composition in the 4-station configuration

The equipment is made of AISI 304 stainless steel and other non-toxic materials suitable for the food industry and complies with current CE standards. The blast freezing tunnel that receives the finished product is supplied at the customer's request — see the Blast freezing section.

GR.IM.2000 continuous dough mixer

A continuous dough preparation unit made entirely of AISI 304 stainless steel. It serves all stations of the line.

• Tubular base frame on four removable supports, access ladder, side guards, chequered anti-slip decking
• Group of mixing bowls in polished stainless steel, PTFE shaft seals with quick removal, drain hole with a plug for washing water
• AISI 304 stainless steel mixing shafts with independent geared motors; through-type stirrers with a conical seat and adjustable position
• Volumetric doser — continuous screw semolina doser with variable speed under inverter control, transparent feed spout, maximum and minimum level sensors
• Peristaltic pump for liquids with variable speed under inverter control
• TURBOMIX — rapid pre-mixing system under inverter control, the bladed shaft is removable for sanitary cleaning
• Electropneumatic discharge, safety top cover, stainless steel electrical cabinet to CE standards

NAV-4 shuttle dough distribution system

A system for automatic dough distribution between four sheeters. The trolley travels on a rail track above the line and discharges dough at the required station.

• Stainless steel construction, tubular base frame and guides, removable supports
• Hoppers for connection to the machines of the line
• Distribution trolley with a stainless steel product container; containers on quick clamps for washing
• Motorised trolley drive with a motovariator under inverter control
• Electropneumatic product discharge
• Operation is programmed and performed automatically; stainless steel electrical cabinet to CE standards

Station equipment

Each of the four stations has the same equipment: a sheeter, a forming machine, a filling pump and a scrap cutter.

CA540FDA double-sheet sheeter

The scrap cutter cuts up unused dough sheet: cutting group with stainless steel rollers, drive speed proportional to the laminator speed, belt transferring scrap to the lower conveyor tier.

Two-tier conveyor and scrap return system

The tiers run towards each other: the finished product goes to the blast freezing tunnel, the scrap to the return system. The scrap return system is a belt elevator conveyor loading the continuous dough mixer: construction entirely of stainless steel, food-grade belt, independent variator drive.

General specifications

The total installed power of the main equipment in the 4-station configuration is approximately 106 kW (dough mixer, four sheeters, four forming machines and four pumps). The power of the shuttle, conveyors and scrap cutters is confirmed at order.

Calculating the output. The forming machine is limited by the number of cycles per minute. The output is calculated as: cycles per minute × products per cycle × weight of one product × 60. On average the forming machine runs at about 90 cycles per minute (up to 110). The number of products per cycle is set by the die, so the actual output depends on the chosen shape and product weight. The figures given are indicative.

Product range and dies

The forming machines with interchangeable dies produce double-sheet dough products: square and rectangular ravioli, round ones (including classic dumplings), half-moons (varenyky) and figured shapes. One die is included with each forming machine and the shape is chosen by the customer; additional dies, including custom shapes, are made to order. The full AL.MA. shape catalogue is included in the PDF datasheet.

Why customers buy from us

AL.MA. Srl builds the machine. We are responsible for making it work on your product in your workshop — and for keeping it working. That is eight steps, and all of them are ours:

1. Selection for your product
2. Delivery
3. Installation
4. Commissioning
5. Staff training
6. Warranty
7. Service
8. Spare parts

Supplier in Ukraine: EURO CLASS TECHNOLOGY LLC, 27 Vadyma Hetmana St., Kyiv 03056 · tel. +38 044 225 93 72, +38 067 566 0 566 · kyuri@ec-cibo.kiev.ua

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