GEA Pavan Installs Seventh Production Line For Polish Breakfast Cereal Producer

Monday, June 22nd, 2020

Earlier this year, GEA Pavan successfully handed over a seventh production line for manufacturing breakfast cereals to OBST. Both companies have been working in close partnership for 20 years.

In the 90s, Polish consumers started to replace traditional morning food like “Jajecznica”—a large meal composed of eggs and sausages—with breakfast cereal. During the years that followed, the shelves of supermarkets in Poland began filling with corn flakes and other breakfast cereals that were produced outside the country. Cereal producer, OBST, saw the opportunity to break into a growing market; the company partnered with GEA Pavan to provide a local source of breakfast cereals.

Earlier this year, GEA Pavan successfully handed over a seventh production line for manufacturing breakfast cereals to OBST. Both companies have been working in close partnership for 20 years. This long-lasting collaboration aims to turn marketable ideas into concrete and successful cereal products. The recent line addition allows the Polish company to go to market with innovative cereal products. In this case, it’s cereal shaped like pillows.

This new seventh line allows OBST to step into a new product area. Starting with one existing line used for cornflake production, GEA added machinery, transforming the line into one that produces cereal pillows. The die for two-layered whole meal cereals was applied directly to the extrusion head, allowing the production of coextruded pillows.

The filling system composed of a feeding system, a buffer and a dosing system, allowing for the filling of the pillow and perfect dosing calibration. The extruded product is initially processed by a two-layer forming unit which, by means of a roller, will give the product its typical pillow shape and at the end, separated through a rotating drum. Once separated, the pillows are dried in the oven and, once cooled on the belt, are ready to be packaged and distributed.

GEA Pavan Extrusion Technology Ensures High Efficiency & Product Quality

“GEA’s Pavan production lines assure high standards of quality and extreme flexibility. These are the most important factors in our success, as we now produce high quality breakfast cereals for 20 different product ranges. We are able to serve the most demanding consumers with specific lines: healthy products, sugar-free, with vitamins and wholegrains. We have also developed a “super oat”, specifically formulated to reduce cholesterol,” explains Boguslaw Obst, founder of OBST.

GEA’s Pavan extrusion machines, like the TT Twin-screw extruder series, make this happen. The technology ensures high efficiency and product quality, enabling the production of a wide range of final products, thanks to the perfect combination of time, temperature and mechanical input in the cooking phase.

The development of such a variety of products was also possible thanks to collaboration between the R&D departments of GEA Pavan and OBST. OBST’s R&D department is constantly working on introducing new innovative products by analysing the latest developments, technical solutions and innovations in the field of production technology. GEA Pavan’s research and development (R&D) activities are performed by a team of 30 people including process technicians, analysts and mechanics. Their research is conducted in a 2,000 sq m facility located in Italy. The facility is equipped with three pilot plants and four flexible production lines. A complete laboratory is equipped with instruments for chemical, chemical physical, rheological and nutritional / organoleptic analysis of food.

By testing new formulation at their Centre in Italy, the R&D team supported OBST in developing recipes for new products. “This, added to a very interesting balance between costs and quality offered, made us very loyal to GEA Pavan, resulting in us continuing to develop new products and increasing our production capacity,” remarks Obst.

“More than 20 years have passed since I decided to cooperate with GEA Pavan. I can confirm that this was the right decision,” Obst concludes.

 

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