Layer cakes offer the ultimate in indulgence for birthdays and special occasions, or just to enjoy as a special treat. From Black Forest gateaux to cream-filled carrot cake, all layer cakes are made by alternating sponge cake with syrup and creamy fillings, jams or icings, and topping each creation with decorations including whipped cream stars, chocolate coating or sprinkled nuts, chocolates or coconut.
Producing perfectly tiered layers relies on the most accurate depositors and gentle sponge handling, combined with optimized automation to speed throughput, and minimize waste. GEA can configure highly automated and flexible layer cake lines that allow our customers to process different types of fresh and frozen cakes every day. Our technologies ensure evenly textured sponge, precisely dosed fillings and just the right amount of toppings.
Sheet layer cakes
Sponge layers are baked in large rectangular tray and sandwiched together with one or more imaginative fillings, and finished with toppings and decorations. Easy to cut into individually sized portions, sheet layer cakes are ideal for packaging into slices that can be enjoyed as a treat anywhere during the day or evening.
Round layer cakes
Whether large or small, multi-layered or with just two layers, round layer cakes come in every color, texture and taste, from birthday cakes and wedding cakes, to simple sponges for a weekend treat. Accurate depositing of batters, fillings and toppings, and gentle handling ensures perfectly layered products and minimal waste.
GEA layer cake lines, depositing and filling equipment guarantee to process any type of batter and mix, and to handle and deposit the widest range of fillings, toppings, coatings and decorations, including cream rosettes. GEA equipment has been developed to offer optimum flexibility to make product switchover fast and with minimum down time. State-of-the-art automation ensures the highest quality, even at the most demanding throughput, and hygienic design allows efficient, effective cleaning, with reduced water usage.
Our dedicated layer cake system offers guaranteed versatility to produce fresh, frozen or baked layer cakes, with minimal stoppage time when changing between products with different recipes and of different shapes and sizes. Highly flexible and capable of automatically handling and layering sponge and accurately depositing filling, the system can continue for any number of required layers, and handle liquid or thicker fillings, as well as particulates, and toppings including icing with chocolate. Optional sponge loading systems increase automation even further.
GEA offers a complete range of depositors for handling a wide range of sponge batters and mixes, fillings and toppings Whether for fluid or viscous fillings, smooth whipped creams or fillings with particulates, our systems can handle any type of filling. Options include heated hoppers and stirrers for fillings at controlled temperatures. Highly accurate independent volumetric cylinders ensure accurate dosing to minimize waste, and servo-motor-driven heads increase precision and speed.
To increase upstream automation GEA offers a range of denester models that can pick and place any size or type of paper containers and plastic blisters with lids for the most delicate of layer cakes. GEA ovens have been developed to ensure that every sponge baked will be perfectly raised, colored and textured, thanks to independently controlled heat distribution across each oven zone.
And for frozen cakes, highly energy efficient freezing spirals from can be integrated seamlessly into a process line, and will guarantee to retain optimum product quality.
GEA doesn’t just provide equipment and processing lines. Customers can rely on the expertise and knowhow of our food technologists and processing experts to help optimize existing recipes, develop exciting new recipes, and test out processes on GEA equipment.