DOUGH HANDLING


Batchversus mixing


continuous The debate


T


he mixing stage is a critical point of quality control in the production process for commercially baked foods. For many years bakeries have needed to evaluate and choice between two


different dough mixing solutions when automating the process – batch mixing or continuous mixing. Each has its advantages and disadvantages and determining the most optimal mixing solution for an application will depend on a variety of considerations. Batch mixing can offer versatility and flexibility, while its downsides are that it is a more labour-intensive process and there can be variations between different batches. Meanwhile continuous mixing, which involves a steady flow of ingredients into the mixer, creating a continuous stream of dough, is considered to work best in high-volume production. It has lower labour requirements and offers greater product consistency. However, it offers less flexibility for product variations and comes at a higher initial cost


For many years bakers have had to make a choice between batch and continuous dough mixing solutions. Has anything changed? Suzanne Callander reports.


continues


than batch mixing solutions. Throughput and initial


cost are often


the most significant considerations when choosing between a batch or continuous mixing solution. Bakers also need to consider their final baked product specifications, total costs, ease of operation, maintenance requirements, and the downstream processes. Batch mixing remains a mainstay of the bakery industry today because of its versatility and compatibility with other processes such as ingredient delivery and pre-hydration systems. Its initial cost also makes it a popular choice. Batch mixing


entails making large batches of dough, one set at a time, making it particularly suited to applications with recipe variations. At the end of the mixing process, the dough exits the machine, and the machine is ready for cleaning or for the next batch. During a continuous mixing cycle, ingredients constantly flow through controlled feeds into the mixer, being mixed for a predetermined amount of time and before being discharged. Continuous mixing offers high throughput and low energy use when compared to mixing dough in batches. When determining the type of dough mixer


for an application, AMF Bakery suggests bakeries consider the following:


Processing time: The time it takes for


the material to flow into the mixer through to the discharge outlet is known as the rate per moment (RPM). For longer RPMs, batch mixing is considered to be more appropriate because applications that rely on an even product blend need to be mixed quickly.


Productivity: Continuous mixing can offer 28 Kennedy’s Bakery Production October/November 2024 bakeryproduction.co.uk


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