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ANKO successfully designed a compact and highly efficient Roti Production Machine for a client in the Netherlands

An ANKO Client has been producing a variety of high-quality Roti (Indian style flatbread) and has established a distribution system in wholesale, retail, and supermarkets. During the COVID-19 pandemic, the local food market in the Netherlands experienced a dramatic increase in demand for frozen Roti, as more people were cooking at home. While the company’s production capacity was not able to meet the new demand, they reached out to ANKO and requested assistance to help them transition into automated production. Due to the pandemic and travel restrictions, this client mailed their ingredients to Taiwan and ANKO started production trials and communicated with this client remotely. ANKO’s engineers customized a production solution utilizing ANKO’s SD-97W Automatic Encrusting and Forming machine and APB Pressing and Heating machine for automated Roti production. This production line is compact and highly efficient which exceeded the client’s expectations.

Case-ID: NL-004

Roti (Indian Flatbread)

ANKO Team Research Problem Solving or Solution Delivery

Solution 1. Critical production adjustments: Sustaining the exact flatbread texture and filling ratio as clients requested.

This client had sent the dough and filling ingredients to ANKO’s headquarters in Taiwan for analysis. After physical assessments, ANKO’s engineer confirmed that the recipe they were using was suitable for handmade Roti but too dry and tended to break during automated production. Automated food production requires standardization to ensure uniformity and quality control. When using a recipe for handmade products, it usually involves recipe and ingredient adjustments and the need to determine how to reach the desired product flavor, texture, and consistency. In this case, the client wanted the exact same flatbread and filling ratio that is, firm and hearty. ANKO’s engineers formulated a recipe for the automated production and produced Roti that met the client’s expectations and requirements.

This client uses Chana Dal (Bengal Gram)

After critical adjustments, Roti formed and cooked perfectly

The product texture met the client’s requirements

Solution 2. Customized Automated Roti Producing Equipment to meet our client’s specific requirements

When our client contacted ANKO, they were producing Roti with a 23cm diameter, and they made a forecast to produce Roti with a diameter of 30cm, which required a customization process on their equipment…(Please contact ANKO for more information)

The new product weighs almost 140g

After heat pressing, the flatbread has a diameter of 30cm

The texture and consistency of a piece of cooked Roti

Food Equipment Introduction

• Place pre-mixed dough and filling ingredients into ANKO SD-97W’s hoppers separately
• Products are shaped with forming molds
• Place each filled dough pieces onto ANKO’s APB Pressing and Heating Machine’s conveyor
• The filled dough is then heat pressed into Roti flatbreads

Compact and Highly Efficient. Different Automated Roti Production Line Designs

ANKO has two automated flatbread and wrapper-making machines that are built for different production scales. One is designed for large production plants that start their production by pressing with the dough, then onto baking, cooling, stacking, and counting the products automatically with a capacity of 3,600pc/hr. The other is built for clients with limited space. ANKO combines the SD-97 Series Automatic Encrusting and Forming Machine and the APB Pressing and Heating Machine. This creates a highly efficient product line that has the capacity of producing 1,000 to 2,000 pieces of products per hour. If clients want to expand their production, they can also include additional food preparation equipment from ANKO. ANKO’s SD-97 series and APB machine can produce Roti, and many other flatbreads, such as Chapati, Paratha, and desserts, such as Gulab Jamun and Rasgulla. This Machine is highly versatile and popular.

Roti dough formed with SD-97W

Rounding by hand

Place dough onto APB for heat pressing and forming

Solution Proposal

A total Roti Production Solution to meet all your production requirements

ANKO did

Are you contemplating transitioning into an automated food production operation but have questions regarding machine configuration and procurement? ANKO is the leading company in the automated food machine manufacturing business. We have over 46 years of experience in international business and professional consultancy in factory space configuration, production flow arrangements, equipment planning, recipe optimization and adjustment, and more.

ANKO can help you more

As an example, ANKO provided this client with automated Roti forming, pressing, and heating equipment, as well as packaging and quality inspection machines. This saved our clients valuable time so that they could focus on their food production.

For information, please click Learn More or fill out the form below, and we will get back to you as soon as possible. 

 

Machines

SD-97W

ANKO’s SD-97W Automatic Encrusting and Forming Machine is one of our best-selling products. It has a capacity of 1,000 - 4,000 pcs/hr. The filling system can process a wide range of ingredients, such as vegetables with larger pieces, different types of meat, viscous cheese, jams, and anything more fluid such as a chocolate filling. This machine is compact (1.2 x 0.8m) and can produce plain or filled roti; it is suitable for food factories, central kitchens, and restaurants.

More importantly, it includes a built-in Internet of Things (IoT) system to ensure that the production can be overseen by managers in real time on a mobile device, and the data can be collected and processed through Big Data Analytics to support decision making. We have also installed a maintenance reminder program to ensure consistent productivity. This client has also acknowledged the future possibilities of developing new products using SD-97W, and they endorse the productivity and value of our machine and technology.

APB Series

ANKO’s APB Pressing and Heating Machines can produce perfect Flatbreads at the thickness of 1 to 3 mm with great consistency and formation. The heating temperature is controlled at 200C. This machine comes in two separate models suitable for different production requirements. APB-1 has the capacity of producing 800 to 1,000pcs/hr., and APB-2HS has the capability of producing 1,600 to 2,000pcs/hr. They can create various products such as Roti, Chapati, Tortilla, and Peking Duck Pancakes. A safety shield that complies with the European CE certification is also available for enhanced protection.

Video

SD-97W is the best Automated Machine for producing Stuffed Pastries ─ The future of food production involves automated food machines. ANKO’s SD-97W is fully automatic and can produce a wide range of ethnic food products with minimal manual labor and has a high capacity. It can increase a business’ production output and create new opportunities.

When manually producing Roti, it is difficult to maintain the same pressing pressure and time, resulting in product inconsistency. Using ANKO’s APB Automatic Pressing and Heating Machines, the pressing time and temperature can be programmed to always produce high quality products with great consistency.

Country

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  Netherlands

  Netherlands Ethnic Food Machine And Food Processing Equipment Solutions

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  Our food equipment solutions for clients from over 114 countries. You can click on the following categories to view cases. Each case shows how ANKO conducts food machine solutions - from the beginning of ingredient preparation, machine design and manufacture, troubleshooting and after service.

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Category

Frozen Food

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Food Factory

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Food Culture

Roti is one of the staple foods in Northern India; it is a simple and hearty unleavened flatbread, also known as Chapati. Roti can be made plain or filled with different ingredients and is commonly made at home, frequently consumed twice or three times a day. Traditionally, lentils or chickpeas are filled in the Roti to add extra flavor, protein, and nutrients to the flatbread. Many vegans and vegetarians use plant-based oils and vegetable fillings, while people who are allergic to gluten may use gluten-free flour to make their Roti.

The popularity of Roti followed in the footsteps of Indian immigrants who have traveled to Canada, The United Kingdom, Malaysia, Guyana, and Suriname in South America. Suriname was once occupied by the Dutch in the 1970s, and soon after the Surinamese people immigrated to the Netherlands, they brought Roti and various Indian bread with them. Roti is often served with chicken curry and lamb. Vegetarian curries made with potatoes, tofu, long beans, eggs, or pumpkins are also very popular. Roti can also be wrapped with different ingredients and made into a Roll, which is easy to eat and perfect for takeout food. Hence, Roti Rolls have become increasingly popular in restaurants and on food delivery menus. In the Netherlands, frozen Roti can be purchased at supermarket chains; they are usually sold as a packaged item at an affordable price. They are also easy to prepare and fit into the home cooking culture in the Netherlands and around the world.

Handmade Recipe

Food Ingredient

Atta/Clarified Butter or Ghee/Salt/Water

How to make

(1) Add salt to Atta then add Ghee and mix well (2) Add water to the mixture to form a smooth dough (3) Place the dough in a container and cover with a cloth to let it rest for 20 to 25minutes (4) Remove the dough and divide it into six equal pieces (5) Use a rolling pin to roll the dough into flat circles with an 8 to 9 inch diameter (6) Heat the pan and add a little cooking oil (7) Place the raw flatbread to cook until golden brown

Downloads

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  Catalog of SD-97W

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  Catalog of APB Series

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