INDUSTRIAL MIXING PROCESS – CLEAN LABEL PRODUCTS BAKERY SEMINAR - MAY 14th 2019 José CHEIO DE OLIVEIRA -R&D MANAGER
PLANNING WHO WE ARE WHO WE ARE UNDERSTANDING MIXING PROCESS UNDERSTANDING MIXING PROCESS PARAMETERS TO BETTER CONTROL PARAMETERS TO BETTER CONTROL CLEAN LABEL PRODUCTS CLEAN LABEL PRODUCTS 2 2019-05-14 -VMI - MIXING FOR CLEAN LABEL
WHO WE ARE – VMI THE LARGEST PORTFOLIO OF MIXING SOLUTIONS 3
WHO WE ARE – VMI 250 continuous mixer 390 Automatic sytems 110 Horizontal mixers (vaccum) 250 (Planetary mixers) 4
Introduction to Bakery/pastry applications Short dough: Hard dough: Batters: Cakes, sweet biscuits, semi sweet, Dough: Bread, madelines, shortbread, biscuits, rich brioche, muffins, ginger nuts, tea, marie, baguette waffles digestive crackers 5 2019-05-14 -VMI - MIXING FOR CLEAN LABEL
MIXING PROCESS FOR BATTER/DOUGH Hydration and dissolution of ingredients Uniform distribution of all components Air bubbles incorporation & distribution Development of protein network Tweedy, APV •On stage mixing •Ingredients blending •Ingredients blending •Gluten development •Ingredients dispersion •Low energy •Ingredients hydration •High energy •Air incorporation •2 stage mixing •Kneading •On stage mixing •Temperature •Time to be controlled •2 stage mixing •Temperature •Rework high •Minor rework •Temperature to be controlled •Rework high •Batter smooth viscous or liquid •Crumbly, short, dry, bity, cool •High rework •Dough smooth elastic oily •Smooth, extensible, fine aerated uniform warm Short Bread Hard Batter dough dough dough 6 2019-05-14 -VMI - MIXING FOR CLEAN LABEL
IMPACT OF CLEAN LABEL ON MIXING SOLUTIONS CL means no artificial ingredients, enhancers, preservatives… SO the quality of the dough/batter is not the same 7 18/04/2019
MIXING COULD BE A PART OF THE SOLUTION MECHANICAL EFFECT DOUGH HOMOGENEITY AIR BUBBLES INCORPORTATION DOUGH CONSISTENCY INGREDIENTS DISPERSION DOUGH AERATION PRESSURE/VACCUM APPLICATION HOW/WHY MIXING COULD HEMP TO DOUGH/BATTER QUALITY 8
MIXING PARAMETERS: DOUGH CONSISTENCY WHAT IS KNEADING ?? End of homogenization MIXING Homogenization Hydratation 0 min 1 min 2 min 3 min STRUCTURATION Energy transferred Network formation 4 min 6 min 7 min 5 min AERATION Mixing optimum Air entrapment 9 min 11 min 8 min 10 min OVERMIXING Network break Dough rheology 14 min 12 min 13 min 15 min 9 2019-05-14 -VMI - MIXING FOR CLEAN LABEL
GLUTEN NETWORK STRUCTURATION (Mechanical effect /depend on mixer) COMPRESSION EXTENSION AERATION, Air incoporation Dough aeration ENERGY INPUT Inclusion distribution Mixing intensity 10 2019-05-14 -VMI - MIXING FOR CLEAN LABEL
KNEADSTER –COMPLIANT MIXER 11 2019-04-18 -VMI - MIXING FOR FROZEN
KNEADSTER – A COMPLIANT MIXER 12
KNEADSTER - MERGING FORK & SPIRAL MIXER Combining fork mixer (dough handling) & spiral mixer (mixing time) 14 12 Temps de pétrissage (mn) 10 Echauffement global (°C) 8 6 4 2 0 SINGLE SPIRAL SINGLE SPIRAL FORK MIXER Axe Oblique Simple Spirale Double Spirale KNEASTER Kneadster MIXER MIXER 13
BATTER AERATION CONTROL ON PLANETARY MIXER 1200,00 Densité versus Uch 1000,00 800,00 Density (g/l) 600,00 - Optimum density reached for2 <Uch < 6 Uch= F ( center distance, tool, Ratio, V satellite ) 400,00 Densité patmo Hl15 200,00 0,00 0 5 10 15 20 Uch PARTENERSHIP: INRA (national agronomic research institute) 14
Sponge cake microscope AERATION CONTROL views –With pressure - Same results for different operating conditions (pressure) 1000,00 800,00 600,00 400,00 Sponge cake microscope Densité 0,1 bar Hl15 views –Without pressure Densité 0,5 bar HL15 Densité 1bar HL15 Densité patmo HL15 200,00 Densité patmo HL30 Densité 0,5 bar HL 30 Densité 0,5 bar HL30-12 mn 0,00 0 2 4 6 8 10 12 14 16 18 15
BATTER AERATION CONTROL ON PLANETARY MIXER Air incorporation and density change PRODUCT'S DENSITY MAPING 2 AIR INORPORTAION POSSIBILITY SPONGES TWINKIES POUND CAKE CREAM CHOCOLATE CHEESE MOUSSE MUFFINS 1 MERINGUE EGG WHITE CREPES BUTTER CREAM CHANTILLY LAVA CAKE 0 0 0,2 0,4 0,6 0,8 1 1,2 DENSITY (KG/L) 16 2019-04-17 -VMI - MIXING FOR LONG SHELF LIFE
ULTIMIX – MIXING TOOLS Tools for a wide range of recipes Adaptability with its quickly interchangeable tools 2 or even 3 tools HDPE Scraper in addition to the 2 to Capability to record up to 99 recipes of 30 phases + DENSITY EVOLUTION - 17 17/04/2019 17
MIXING PARAMETERS: AIR BUBBLES INCORPORATION Pressure/ vacuum applications control STRUCTURE STEACKINESS RHEOLOGY P P1=P(+) MIXING KNEADING P ATM P2=P(-) TIME 18 2019-05-14 -VMI - MIXING FOR CLEAN LABEL
MIXING PARAMETERS: AIR BUBBLES INCORPORATION Mixing prepare the final texture of the dough and consequently the after baking Cells Number Cells sizes Wall between Cells 19 2019-05-14 -VMI - MIXING FOR CLEAN LABEL
IMPACT OF PRESSURE and SALT on DOUGH EXTENSIBILITY PRESSURE DURING MIXING = EXTENSIBILITY of DOUGH RESISTANCE TO EXTENSION (g force) PRESSURE (mb) 20 SALT
CONTINUUM – product structure and vacuum mixing INTEREST OF VACUUM MIXING • Dough quality (stickiness & plasticity) • Reduction of size of gas nuclei • Faster start of expansion during baking • More homogenous gas cell distribution • Better frozen/thaw quality NON VACUUM VACUUM 21 18/04/2019 21
TO CONCLUDE… MIXING UNDERSTANDING A REAL TOOL TO BETTER CONTROL CLEAN LABEL PRODUCTS 22
THANKS! You are welcome at VMI & in our lab!
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