ADVANCED DOUGH HANDLING SYSTEMS
adjust movements dynamically, improving precision while maintaining gentle handling to protect dough structure. These advances align with the industry’s growing focus on flexibility, consistency, and reduced waste. Finally, enhanced temperature and
process control systems ensure that dough remains within its ideal processing window, even in high-capacity environments. The integration of data collection, data analysis, and mechanical expertise, offers bakeries full visibility and control over every stage of dough processing.
Terry: The AMF Dough Guardian Plus, which is a dough monitoring and control system, can help optimise mixing. It is able to track energy consumption and provide historic curves and data for real-time monitoring. A camera mounted on the mixer
canopy also allows operators to see the consistency and behaviour of the dough while in the mixer, in real time. Combined with instant feedback when errors occur during ingredient loading, this solution enables operators to correct issues quickly, helping to ensure consistent dough quality and reducing product waste.
Michael: We believe that bakeries need a high degree of transparency to allow them to increase production efficiency. Our Smart Production Insights (SPI) tool gives production and shift managers real- time insights into the most important
LABOUR COSTS OR ACCESS TO LABOUR IS ONE OF THE BIGGEST CHALLENGE FACING BAKERIES. THIS HAS LED MORE BUSINESSES TO LOOK FOR WAYS TO AUTOMATE THEIR SYSTEMS
performance data of the line via a clear dashboard. Even downtimes caused by minor malfunctions are clearly recorded. By continuously
collecting
data and
visualising key performance indicators in real time, significant improvements in overall line efficiency can be achieved. Our Watchdog tool monitors all of the drives on the line – measuring and continuously analysing the motor current and temperature of each drive. As soon as the value calculated by algorithms reaches a specified deviation from the defined target value, a warning is sent to a defined group of operators, who can react accordingly before the drive unit becomes damaged or even destroyed.
Sam: Traditional dough mixing systems usually take a large batch of dough and break it down into smaller pieces for transportation to the hopper of the forming machine. The dough typically starts out on the wetter side and gradually dries to an optimal performance before it then becomes too dry. We can offer a solution called Continuous Mixing which instead provides a stream of optimally moist dough to the forming machines when required. Unlike batch systems, if the line stops it is not necessary to discard any dough. Continuous mixing can also simplify the dough feed system to the forming equipment. Batch systems typically require large troughs, trough dumpers and laytime conveyors to hold batches from the mixer. Conversely, continuous mixing provides a continuous stream of dough which eliminates the need for this equipment. Furthermore, it can provide dough in chunks, kibbled and streams to feed directly into the hopper and there are lower labour requirements for the line, which can help overcome labour shortages.
Fabrice: To meet the challenge of producing premium crusty breads without compromising
production efficiency,
Mecatherm has developed new dividing and moulding technologies designed for highly hydrated doughs. The M-NS II divider, for example, preserves dough
30 • KENNEDY’S BAKERY PRODUCTION • OCTOBER/NOVEMBER 2025
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