Bread Counter Stacker
The EXTRA FOUR Counter & Stacker was developed specifically around the handling characteristics and traditional packaging requirements of Lebanese and pita bread. By automating the final stages of counting, orientation and stack preparation, the machine helps bakeries reduce repetitive manual work while maintaining a controlled and continuous production flow.
Designed to integrate with EXTRA FOUR Lebanese bread production lines, including configurations producing up to 18,000 loaves per hour, the machine is engineered for continuous industrial operation. Its mechanical construction, automation system and selected industrial components work together to provide dependable performance throughout long production shifts. It can be manufactured as a single-lane machine, double, triple, or up to six-lanes.
The system is operated through an HMI touch screen, allowing bakery operators to manage stack quantities, loaf-flipping sequences, operation timings and product settings from one interface. Saved recipes can be recalled whenever the bakery changes bread dimensions, customer requirements or the number of loaves required in each package.
Fast and Hygiene Counting and Stacking
The machine receives finished bread after the cooling stage and automatically monitors the incoming loaves as they move through the system. Each loaf is detected and counted so that the machine can assemble stacks containing the exact quantity selected by the operator.
A programmable bread flipping system allows selected loaves to be turned upside down during the process. This makes it possible to preserve the traditional Lebanese bread packaging presentation, where the browned baked surface remains visible on both the upper and lower sides of the completed stack.
Once the selected loaf quantity has been reached, the machine completes the stack and prepares it for discharge toward the next packaging stage. Operating parameters including timings, stack quantity, sensor behavior and flipping configuration can be adjusted and stored through the HMI for faster and more repeatable production changeovers.
Role in the Production Process
After leaving the cooling conveyors, the loaves are transferred into the counter and stacker in a controlled sequence. The machine detects the incoming bread, coordinates its movement, performs the required flipping sequence and counts each loaf until the programmed stack quantity has been achieved.
Completed stacks are then transferred toward the downstream packaging equipment. When integrated with synchronization and automatic bagging systems, the machine creates a continuous transition from cooling → flipping → counting → stacking → synchronization → packaging, significantly reducing manual handling at the end of the production line.
Key Operational Features
Automatic Bread Counting
The machine automatically detects and counts each loaf, creating stacks according to the exact quantity programmed by the operator.
Programmable Bread Flipping
Selected loaves can be automatically flipped to maintain the traditional Lebanese bread presentation with the browned side facing outward on both sides of the stack.
HMI Touch Screen Control
An operator-friendly touch screen provides centralized control over stack quantity, machine timings, sensors, flipping parameters and production settings.
Unlimited Recipe Saving
Different machine configurations can be stored and recalled for various loaf sizes, customers and pack quantities, reducing setup time between production runs.
High-Speed Industrial Operation
Developed to work with EXTRA FOUR production lines reaching up to 18,000 loaves per hour, the system is designed for continuous high-output bakery production.
Premium Industrial Components
The machine incorporates NORD DRIVESYSTEMS motors, SICK sensors, FESTO pneumatic components and Ammeraal Beltech conveyor belts for dependable operation and long service life.
Suitable Bakery Applications
This machine is suited to bakery environments that require dependable performance and integration with industrial production workflows.
Lebanese Pita Bread White
Lebanese Pita Bread Whole Wheat
Flour Tortilla Bread
Pizza Base
Roti Bread
Chapati Bread
Pocket Pita Bread
Tannour Bread
Naan Bread
Lebanese Pita Bread White
Lebanese Pita Bread Whole Wheat
Flour Tortilla Bread
Pizza Base
Roti Bread
Chapati Bread
Pocket Pita Bread
Tannour Bread
Naan Bread
Published Machine Data
The EXTRA FOUR Lebanese Pita Bread Counter & Stacker can be configured from 1 lane up to 6 lanes, depending on the selected machine model, production capacity, bread size, and the specifications of the bread production line to which it will be connected. Electrical supply, voltage, frequency, control standards, and other country-specific technical requirements are defined individually according to each customer’s location, applicable standards, and project requirements.
Production Lines Using This Machine
This machine can be connected to bakery setups and bread lines where this production stage is required.
Lebanese & Pita Bread Production Line
Compact to high-capacity automated lines designed for Lebanese and Arabic pita bread production, delivering consistent baking quality and efficient dough processing.
Chapati, Flatbread & Wraps Production Line
Flatbread Production Lines combine precision dough processing with uniform baking; the lines deliver reliable, low- to high-capacity production while preserving the authentic texture and quality of every product.
Pocket Pita & Greek Bread Production Line
Pocket Pita Bread Production Line is engineered to produce authentic thick pocket pita bread with excellent pocket formation, uniform baking, and consistent quality. The line preserves the soft texture and traditional characteristics of authentic pocket pita bread.
Tortilla Bread Production Line
Consistently shaped and uniformly baked tortillas. In both flour and corn tortilla production, the integrated forming, baking, cooling, and handling systems ensure reliable quality, efficient operation, and reduced labor requirements.
Lebanese & Pita Bread Production Line
Compact to high-capacity automated lines designed for Lebanese and Arabic pita bread production, delivering consistent baking quality and efficient dough processing.
Chapati, Flatbread & Wraps Production Line
Flatbread Production Lines combine precision dough processing with uniform baking; the lines deliver reliable, low- to high-capacity production while preserving the authentic texture and quality of every product.
Pocket Pita & Greek Bread Production Line
Pocket Pita Bread Production Line is engineered to produce authentic thick pocket pita bread with excellent pocket formation, uniform baking, and consistent quality. The line preserves the soft texture and traditional characteristics of authentic pocket pita bread.
Tortilla Bread Production Line
Consistently shaped and uniformly baked tortillas. In both flour and corn tortilla production, the integrated forming, baking, cooling, and handling systems ensure reliable quality, efficient operation, and reduced labor requirements.
Request More Information About This Machine
Need a Counter & Stacker for Your Bread Line?Whether you are upgrading an existing bakery or planning a new production line, EXTRA FOUR can configure the right 1- to 6-lane counting and stacking solution for your bread size, capacity and packaging requirements. Contact our team with your production details and let us recommend the most suitable configuration for your project.
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