DOUGH HANDLING


three cost factors comprise a system. Those are metering,


mixing, and post-mixing


dough handling. For batch mixing, three costs also comprise a system – metering, mixing and dough handling.


The key concept to understand is that


when the throughput of a continuous mixing system increases, the cost of the system changes at a much lower ratio because the ingredient metering portion of the cost is nearly constant no matter what the new throughput is.


When considering batch mixing, the cost of the model is quite different. Basically, doubling the throughput of a batch mixing system increases the cost by 80% to 100%. Both the mixer and the downstream metering system must double in capacity.


Continuous mixing is fully automated, requiring less labour than batch mixers: Does higher dough output require more personnel in the mixing area? The intuitive answer is yes. Mixers are larger. More mixers are required. Ingredients are added in larger


quantities. Larger dough quantities are discharged and must be delivered to the downstream equipment. Failing to deliver dough on time results in a larger reduction in production.


With a batch mixing system, all these factors require more employees. This is not the case with continuous mixing, as the system is fully automated. First, the ingredient addition and mixing are controlled by the recipe control system. Second, the dough is automatically cut into smaller chunks by the mixer or allowed to flow as a rope. This means no additional dough sizing and handling is required. As a result, no more employees are required at higher capacities. With any size continuous mixer,


the


operator has two primary responsibilities. The first is to occasionally inspect the dough quality as a final verification of the quality prior to forming. The second responsibility is to address any system alarms. As batch sizes increase other concerns


arise. Most crucial among these is training. Batch processes tend to be manual in nature, requiring operator intervention. This is even more so as the dough volume increases. This requires a great deal of training to ensure the mixing steps are completed correctly. As the dough requirement increases with a batch system, the demands on the staff are multiplied. In the case of continuous mixing, no matter what the rate, only one operator is required and for only a small portion of the day.


New roll production line for Plentz


The Plentz bakery and patisserie was founded


by Carl Plenz in Schwante in Brandenburg, 1877, in Germany.


Today, the artisan bakery business is still family owned, with recipes having been passed down through the generations. When the old bread roll production line became unable to keep up with demand, Plentz Bakery knew it was time to find a replacement. “When we started looking into a replacement production line, we soon realised there was a lot to consider. It’s not just about a machine, but about a process that includes new refrigeration technology and new processes,” Karl-Dietmar Plentz. During a visit to


said


the Südback trade fair in Stuttgart, Karl- Dietmar took a look at the latest version of the Koenig Eco Twin, which was featured on the booth. Following the first meeting at the show, the Plentz Bakery team were invited to view an Eco Twin line in live operation, which led to it being specified to replace the ageing production line The Eco Twin is well suited for the production of small baked goods and is said to be an efficient roll line for artisanal bakeries, offering product variety thanks to quickly changeable stamping tools, cutting station and optionally available rounding unit. The compact line can produce almost all common types of buns – for example


32 Kennedy’s Bakery Production October/November 2024


Kaiser rolls, cut rolls and Housky rolls. For easy cleaning and maintenance, the line is designed to ensure easy accessibility to all the modules.


Following installation of the Eco Twin production line bread roll production at the bakery now runs more efficiently. The depositing of the dough pieces is program-controlled and runs in five rows.


After processing, the dough pieces are deposited in planks, gently guided over a cooling curve before being delivered to stores by refrigerated transport. Using the Eco Twin line, the bakery is able to produce all round or long rolled baked goods.


bakeryproduction.co.uk


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