How Continuous Mixing is Revolutionizing Dough Production - Part 1

In the world of baking, continuous mixing systems have emerged as a game-changer, revolutionizing the production of dough. This innovative technology offers numerous benefits, including improved dough quality, enhanced process control, and increased efficiency. One company that has embraced this advancement is Ditsch GmbH, a renowned pretzel bakery that has invested in a state-of-the-art continuous mixing system.

Ditsch GmbH, in collaboration with Zeppelin Systems GmbH, has implemented a cutting-edge continuous mixing system at its Oranienbaum site. This system combines the DymoMix pre-mixer with the CODOS final mixer, allowing for seamless and continuous production of high-quality wheat doughs. The installation of this system marks a significant milestone in the evolution of dough production.

One of the primary advantages of the continuous mixing system is the significant improvement in dough quality. According to Matthias Grollmisch, Engineering Manager at Ditsch GmbH, the DymoMix system makes dough for bread rolls and sticks more uniform and easier to process by machine. Moreover, the system saves approximately 40% of the mixing and kneading time, allowing for faster dough development. This increased efficiency translates into higher production capacity and reduces operational costs.

The integration of the continuous mixing system at Ditsch GmbH has also led to enhanced process control. The system is equipped with advanced digital controls that allow for precise monitoring and adjustment of various parameters, such as rotation speeds, temperatures, and pressures. This real-time monitoring ensures consistent dough quality and allows for immediate corrective actions if deviations occur. The ability to maintain optimal dough temperature throughout the mixing process is particularly crucial for achieving uniform production and high yields.

The Ditsch GmbH continuous mixing system operates in a carefully orchestrated sequence. The DymoMix, positioned directly above the CODOS mixer, continuously feeds the raw materials into the mixing compartment underneath. The dough is then fully kneaded in the CODOS mixer to achieve the desired consistency. Throughout the entire process, the temperature of the raw materials and dough is meticulously monitored. The dough temperature is controlled by adjusting the temperature of the added water and utilizing the cooling jacket installed on the mixer.

To ensure the highest standards of hygiene, the system is designed for easy cleaning. The DymoMix can be disconnected from the CODOS mixer, swiveled out, and the protective tube removed. The cleaning process involves washing the protective tube and manually cleaning the DymoMix tools. Additionally, the inlet pipe is removed from the CODOS mixer and cleaned by a system of directed-jet cleaners, which effectively removes any residue.

Continuous mixing systems have opened a world of possibilities for the baking industry. With advancements in technology and the increasing demand for diverse and high-quality baked goods, bakers are now exploring new methods and techniques to optimize their production processes. The continuous mixing system allows for greater flexibility, enabling bakers to tailor the mixing process to suit different products and achieve the desired outcomes. As the baking industry continues to evolve, the adoption of continuous mixing systems is expected to grow. Younger generations of bakers, who are more open to embracing new ideas and technologies, are driving this shift. With the ability to monitor and control various parameters in real-time, continuous mixing systems offer unparalleled precision and efficiency. The future of dough production is undoubtedly continuous mixing.

The implementation of the continuous mixing system at Ditsch GmbH pretzel bakery has proven to be a game-changer in the industry. This innovative technology has significantly improved dough quality, enhanced process control, and increased efficiency. With its small footprint, the DymoMix system allows for continuous dough production in a limited space, making it ideal for bakeries of all sizes. As the baking industry continues to evolve, continuous mixing systems will undoubtedly play a pivotal role in shaping the future of dough production.