AL.MA. Srl · Italy

AL.MA. DN540 multi-station dumpling line with continuous dough mixer

The dough is made without stopping, a shuttle distributes it across the stations and the trimmings go back into the mix

• 2250 kg/hin the five-station configuration
• 3–5stations to choose from
• 2000 kg/hcontinuous mixer
• 540 mmsheet width

Request a quotation Data sheet: AL.MA. DN540 multi-station dumpling line with continuous dough mixer (PDF) Watch video

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

The equipment in brief

The multi-station AL.MA. DN540 is a factory-scale solution for single-sheet dough products. A continuous dough mixer prepares the dough without stopping and discharges it into the shuttle hopper, which distributes the dough across the stations. Each station works in parallel and independently of the rest, while twin-deck conveyors carry the finished products out and return the sheet trimmings to the mixer at the same time.

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 dumpling and vareniki plants
• operations of a tonne an hour and above
• export-oriented plants
• plants with a staged expansion plan
• factories with their own brand

How it works

1. Continuous mixingThe GR.IM.2000 makes dough as a flow, without stopping for batches.
2. Shuttle distributionThe shuttle hopper travels above the line and hands dough to the stations.
3. Station workEach station sheets the dough, doses the filling and forms the product.
4. Product outfeedThe upper belt of the twin-deck conveyor carries the goods to the line outfeed.
5. Trimming returnShredders cut up the unused sheet and the lower belt takes it back 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.

Two-tier conveyors run along the line. Formed products with filling drop onto the upper belt and travel towards the line outlet. 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. 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 5-station configuration

All parts in contact with dough and filling are made of stainless steel and other non-toxic materials suitable for the food industry. The equipment complies with current CE standards.

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 removable supports, access ladder, side guards, chequered anti-slip decking
• Group of mixing bowls in polished stainless steel, PTFE shaft seals with quick removal
• AISI 304 stainless steel mixing shafts with independent geared motors
• Volumetric doser — continuous screw flour doser with variable speed under inverter control, maximum and minimum level sensors
• Peristaltic pump for liquids with variable speed under inverter control
• TURBOMIX — rapid pre-mixing system, the bladed shaft is removable for sanitary cleaning
• Electropneumatic discharge, stainless steel electrical cabinet to CE standards

Shuttle dough distribution system for 5 stations

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

• Stainless steel construction, frame and guides made of round tube
• Stainless steel trolley with a pneumatic system feeding dough to the sheeters
• Encoder-controlled drive ensuring an accurate discharge position
• Automatic pneumatic gate opening
• Safety devices

CA540FA sheeter

An automatic machine producing a 540 mm dough sheet. One sheeter is installed at each station.

DN540 forming machine

An industrial machine forming single-sheet dough products with an interchangeable die — one shape per die.

PLA100 lobe pump and scrap cutter

The pump feeds filling continuously and handles meat, cheese and vegetable fillings, including delicate ones containing pieces. Tilting cover with a safety grid, screw removable without tools.

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

Two-tier conveyors and scrap return system

Two two-tier conveyors run along the line. The upper tier carries finished products to the line outlet, the lower one carries cut-up scrap in the opposite direction, to the return system. The belts are made of material certified for food products.

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

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.

The total power is calculated for the main equipment: the dough mixer, five sheeters, five forming machines and five pumps. The power of the shuttle, conveyors and scrap cutters is confirmed at order.

Product range and dies

DN series lines with interchangeable dies produce single-sheet dough products: dumplings, ravioli, cappelletti, tortelloni, pinzati and other 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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