Pneumatic turbine BTC series

Overview
A belt coater builds chocolate layers on free-flowing centers 5 mm and larger. It operates after center preparation and before polishing or packaging. Model selection is driven by required single-batch capacity.

Available models

• BTC1000 — Batch capacity: 300 L; Total power consumption: 4.1 kW; Base price (excl. VAT): 42.900,00 €
• BTC1500 — Batch capacity: 450 L; Total power consumption: 4.1 kW; Base price (excl. VAT): 50.000,00 €
• BTC2000 — Batch capacity: 600 L; Total power consumption: 4.8 kW; Base price (excl. VAT): 57.200,00 €

Process suitability

• Do not use if centers are smaller than 5 mm.
• Do not use if pieces cannot roll freely on the belt.
• Do not use if pieces fracture during repeated tumbling.
• Do not use for batches smaller than 50 L (below this the dripping or spraying stream falls between the centers and no shell builds).

Sealing
Sealing is generally required when the planned chocolate layer is thin for oil-bearing centers. A typical sealant is a gum arabic solution at 40–50% solids; sealing limits fat migration but does not prevent mechanical fracture.

Application method

• Low-density centers → Drip and spray: Puffed cereals, rice crisps and popcorn are sprayed; dripping causes clustering. The drip-and-spray build also works for dense centers.
• Dense centers only → Drip: Nuts, dried fruits, coffee beans. Spraying these slows the coating process. The drip build cannot spray; adding low-density centers later may cause clustering.

Belt Coater Selection (summary)
Required batch capacity | Select | Eliminate | Consequence
Up to 300 L | BTC1000 | BTC1500, BTC2000 | Both run partly filled: the setting air passes over a thin bed and cooling efficiency falls relative to the volume actually coated.
Above 300 L, up to 450 L | BTC1500 | BTC1000, BTC2000 | BTC1000 does not meet required single-batch volume; BTC2000 runs partly filled and cooling efficiency falls.
Above 450 L, up to 600 L | BTC2000 | BTC1000, BTC1500 | Neither smaller model meets the required single-batch volume.
Above 600 L | None | BTC1000, BTC1500, BTC2000 | No BTC model reaches the required batch capacity.

Configuration options (summary)

• Overpressure protection and PID-controlled dry heating on the dripping body: Available on all models. If omitted the upstream chocolate pump must tolerate pressure rises and the chocolate circuit remains unheated, risking chocolate setting during pauses.
• Spraying nozzles on the dripping body: Available on all models (requires the dripping body with overpressure protection and dry heating). If omitted the machine drips only and low-density centers will cluster.
• Top guard: Available on all models. If omitted product can overfall from the top opening during coating.
• Pneumatically activated back scrapers: Available on all models. If omitted chocolate residue must be removed manually during cleaning.
• Hot air blower for smoothing: Available on all models. If omitted surface tails on the product are not reduced during smoothing.
• Load cells for batch weight monitoring: Available on all models. If omitted batch weight is not monitored and charge quantity depends on the operator.

Belt coater vs coating pan
The belt coater executes stored recipes (fixed chocolate dose, belt speed and air durations) under PLC control and provides automatic reverse-belt discharge and repeatable cycles. A coating pan is operator-controlled and is operator-dependent for repeatability. Choose a belt coater when recipe repeatability and automatic discharge are required; choose a coating pan when manual process decisions must remain with an experienced operator.

Coating cycle steps

• Loading: Centers are loaded through the top opening onto the belt.
• Pre-coating / sealing (optional): A sealant layer may be applied to oil-bearing centers when the planned chocolate layer is thin.
• Chocolate application: Dripping, or dripping and spraying, according to the selected recipe step.
• Smoothing: Heated air from the optional hot air blower distributes the coating and reduces surface tails.
• Setting: Dehumidified cold air promotes controlled crystallization (process air at ~35–45% RH and 12–14°C supports stable setting for most chocolates).
• Discharge: After the final cycle the belt reverses and unloads coated centers automatically.

Warranty and lead time
AkayGAM belt coaters carry a 1-year warranty against manufacturing and construction defects. Lead time is typically 3–4 months from order because batch capacity, application method (drip or drip and spray) and selected optional devices are built into the machine at manufacture.

Inputs and required systems

• Prepared centers: Loaded into the coater; center preparation is outside this machine's scope.
• Chocolate feed system: Requires a pumped chocolate feed (a storage tank with pump holds chocolate at working temperature and delivers it to the dripping body or spray manifold).
• Conditioned air: Requires conditioned process air (temperature, humidity and flow) ducted into the chamber; the external air system must supply dehumidified cold air to support setting.

Technical characteristics / specifications

• AISI 304 stainless steel construction; aluminum dripping body; FDA-approved engineering plastics for side discs.
• Chocolate application configurable at order: drip, or drip and spray.
• PLC and HMI controlled process with named recipe storage and stored-recipe execution.
• Reversible main belt drive for automatic batch discharge; front lid with gas springs; pneumatically activated front guard.
• Electrical supply: 380 V, three-phase.
• Requires conditioned air at specified temperature, humidity and flow supplied from outside the machine.
• Requires a pumped chocolate feed (chocolate storage tank with pump).
• Model-specific data: BTC1000 — 300 L batch capacity, total power 4.1 kW; BTC1500 — 450 L batch capacity, total power 4.1 kW; BTC2000 — 600 L batch capacity, total power 4.8 kW.