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Europe’s most advanced plant

19.03.2008 The Italian cereals producer Lameri S.p.a. has increased its capacities. Buhler built Europe’s most advanced multipurpose cereals plant for this customer in San Bassano. The family-owned business Lameri S.p.a. has been a producer of a wide variety of cereals since 1968. At its production sites in Cremona, San Bassano, and Cavezzo (Modena) the company makes semi-finished products for foods and feeds as well as ready-to-consume breakfast cereals for the entire European market. Lameria S.p.a. operates an affiliated company in Dijon in France which procures the grain required for cereals production.

Third Buhler plant
In 1992 and 2001, Buhler supplied extrusion systems to the company’s headquarters in Cremona, with which the Lameri family was highly satisfied. As a result, they awarded also the order for a third production line to Buhler. Not least among the reasons for this order was its special nature. In the company’s new factory in San Bassano, the most advanced multipurpose cereals plant of Europe was to be constructed. The assignment defined by Lameri S.p.a., a longtime Buhler customer, was to design, engineer, and build Europe’s most advanced multipurpose cereals line in the new factory in San Bassano. The special thing about this order was that the new line was to produce cornflakes by the traditional process using batch cookers as well as by extruder.

Installed in a new building
In the autumn of 2004, the Buhler specialists started planning the large-scale plant, which was to achieve a capacity of up to 1600 kilograms of cereals per hour. The plant went on stream in August 2006. The system was installed in a new building with a length of 200 meters, a width of 75 meters, and a height of 17 meters and located adjacent to the existing feed production plant of Lameri S.p.a. in San Bassano. For project manager Hansjörg Fritz, building this new facility was pure joy: “We were able to realize a highly functional and modern multipurpose installation under the very best of conditions.”

The term “multifunctional” refers to the special design of the plant, which allows indirect expansion of multigrain flakes and cornflakes as well as direct expansion of other breakfast cereals such as rice crisps, corn balls, and choco balls. The new cereals line of Lameri has been designed for round-the-clock operation. It can be run by two or three operators and one shift manager.

Room for a second line
The centralized plant is located in the large hall on three tiers. The frame is a 16 meter high steel structure of compact design. Mixing is done at the topmost level, preconditioning underneath it, and actual extrusion at the bottom level.

Ahead of the centralized unit are the raw materials receiving section and the various storage bins holding the raw materials. Following extrusion, the products are transferred to the final processing stages of spray-coating and packaging. The upstream and downstream stages have been designed with a second parallel line in mind, for which sufficient space is reserved next to the centralized unit. At Lameri S.p.a., everyone is entirely satisfyed with the new cereals line. The management at the headquarters in Cremona are already contemplating buying a second installation from Buhler.

Compact installation on three tiers: the heart of the new cereals plant of Lameri S.p.a. Compact installation on three tiers: the heart of the new cereals plant of Lameri S.p.a.