Blog | Bakery Concepts International


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Which Would You Choose: 1.5 or 15kwh per ton?

Most of the time, more power is a good thing. But when you’re running a full-time food operation and looking to save money, you want to use as little electrical power as possible to get the job done. If you are looking to cut energy costs without cutting quality, consider the Rapidojet technology.

Rapidojet can create a 70% hydrated Biga with instantly developed gluten. This would usually take 15 kwh per ton to make. However, Rapidojet only uses 1.5 kwh per ton, while significantly cutting final mixing time in the existing mixer by up to 65%.

Too good to be true?

Not with this mixer. The design is simple: free-falling dry ingredients are shot with a high pressure stream of water. Check out this video to see just how it works:



Usually the biga and final ingredients would mix in the mixing bowl for 12 minutes. With this method of spraying the flour first with all the water, the mixing time is reduced to five to seven minutes. This means that every five to seven minutes, there is 1,000b of dough coming out of the mixer. Compare that to only 1,000b every 12 minutes with traditional mixing methods.

Because the dough is ready in only five to seven minutes, not enough friction is created to heat up the dough. Therefore, the need for ice or jacketed mixers is substantially reduced or eliminated.

In addition, since the temperature is not too high, less yeast and dough conditioners are needed. Higher dough temperature over activates yeast, so more yeast must be used. Also higher temperatures cause more stress in the dough and this makes the dough more difficult to process. That’s why standard mixing requires so much dough conditioners to be added in. 

Perhaps the most exciting thing is that this patented design for mixing helps increase your product’s hydration, thus total yield. Because the water is more homogeneously bound to the flour, 5% – 8% more water must be used in order to achieve the same level of machineability and “dough feel.”

Getting your money’s worth

Bran is instantly hydrated at up to 300% and VWG is instantly hydrated at 400%. Eliminate the time, equipment, labor and space required for your normal soaking of grains. Hydrocolloids such as starches, gums and pectin are instantly hydrated at levels as high as 2% – 8% solution.

Rapidojet should be viewed as the new ‘two-step’ form of mixing that every baker needs to check out. Not only is the product improved, but the cost is worth it.  The ROI on this equipment can be as quick as a few months due to the above said increase in output and reduction in ice, yeast and dough conditioners. That’s a whole lot of benefit out of 1.5kwh per ton!

Come talk to us about Rapidojet at BakingTECH 2017, Table #710, Feb. 26-28!


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Push Your Frozen Limits: Gums and Starches

Going in and out of the freezer can be tough on bakery products, especially ones consumers do not expect to be frozen. Thankfully, gums and starches not only help baked goods make the frozen journey, but they improve overall texture, taste and stability. The key to this is moisture retention. But what if I told you that you could get even more moisture retention with gums and starches – just by adjusting the way you mix?

The Rapidojet technology uses a high-pressure stream of liquid to fully hydrate dry ingredients, almost instantly. With our specialized modifications, such as a hydrocolloid mixing chamber, you’ll see the power of Rapidojet transform your use of starches and gums. As these ingredients are optimized and gel binding increases, your products will see improved moisture retention. This in turn will help with viscosity, thickness, freezing and re-thawing, as well as product stabilization and softness.

Starches

Let’s start with starches. We ran a series of tests with a pre-gel corn starch at different concentrations, and the results were astounding. With a 5% solution, there was a pronounced swelling effect over 30 minutes.

A pre-gelatinized starch was optimized with the Rapidojet mixing chamber. The idea with the mixing chamber is to reduce splash and only use the power needed to re-hydrate. During this pre-gel test, the mixing chamber on Rapidojet produced the regular 9% viscosity with just 8%.

When viscosity tests were performed, Rapidojet-hydrated starch solutions were proven to be thicker compared to controlled samples produced by conventional mixing. In other words, if you are mixing with Rapidojet, less starch will be needed to reach your required levels of viscosity.

How about hydrocolloids?

If you work with hydrocolloids, you probably know how difficult they are to hydrate. In most cases, plant personnel use high shear mixing equipment along with super-heated water to activate this lumpy mess. Not only does this take time, but the hydrocolloids are not fully optimized.

With Rapidojet, a blend of xanthan and locust bean gum at a 3% solution was tested. What resulted was an instantaneous, homogenous, lump-free gel using room temperature water. Viscosity tests revealed that this was too thick of a gel for our customer. Therefore, we reduced to a level of <3% to obtain the desired viscosity. This resulted in a machine return on investment (ROI) for the customer of less than one year.

Make ingredients live up to their full potential

As these tests show, the ingredients we use go a long way in improving final products. However, when they are mixed in a way that allows them to be fully optimized, the same ingredients can go much further. For many food producers, the Rapidojet technology allows them to push the limits.

Discover how you can push yours!


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Pizza-dough

Keep the Dough Rolling!

Everyone loves pizza. At least that’s what commercial baking trends have shown in 2016 as pizza sales reached the highest peak in the last four years. In fact, the average American eats an average of 23 pounds a year! Pizza dough suppliers are building bigger lines, with ability for more variety, according to reports. More artisan-type crusts are also seeing a jump in popularity.

Producing quality pizza dough depends on quick, efficient lines that can handle large quantities of dough. However, this is true for any product line. The equipment and process you use really does make a difference in the final product.

Equipment’s Role in Perfection

Sure, quality ingredients and recipes go a long way for dough and ultimately the final product that consumers will be happy with. However, you are really selling yourself short if you don’t prepare it in the right way. As was discussed last month, the way water interacts with dry ingredients impacts factors such as product hydration, dough extensibility and shelf life. Dough mixed with Rapidojet technology sees an increase in water absorption levels from 57% to 62%, while mixing time is cut in half!

After the dough is mixed, it’s still important to keep it moving effectively through your production line, without damaging it. One of our goals with Rapidojet technology is to empower food producers to better provide the quality products their customers want. That’s why we’ve been developing our “Dough Sheet Former.” A transfer pump (either supplied from a plant or one from Rapidojet) feeds dough to the sheet former, which delivers a continuous dough sheet to your make-up line—whether that’s pizza dough, flat bread, pita or corn chips. In most lines, dough comes out of a pressurized mechanism, which causes the dough to “snap back” or shrink under the stress. With Rapidojet technology, this “snap back” is reduced because gluten is fully hydrated, develops faster, becomes more extensible at a lower temperature.

The patented dough sheet former.

The patented Rapidojet dough sheet former.

But we don’t want to stop there. Processes can always be improved and innovation never stops. Dough hydrated and mixed with the help of Rapidojet is delivered through our sanitary and CIP-able transfer pump to the patented Rapidojet “Dough Sheet Former”. This continuous dough sheet with variable thickness is delivered directly onto the existing make-up line for processing.

Pizza and Beyond

The idea is to take full advantage of the benefits and simplicity of Rapidojet technology, giving you as much production space as possible. And with our tried and tested systems, that’s saying a lot. It would cut back the energy and labor used, while improving product consistency, shelf life and initial investment. Meanwhile, total yields would increase by around 5%. That’s a lot of pizza you could be selling to a hungry public!

Send an email to me at ken@bakeryconcepts.net and ask how Rapidojet can help improve your production process or read more about our improvement to dough.


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Water splash isolated on white background.

The Water Question

 

It’s the big question with whatever ingredients you’re mixing: how will water interact with what’s in the bowl? If this isn’t one of your big questions, it should be!

Your process for mixing usually starts with the main dry ingredient, such as flour. Getting the perfect texture, consistency and shelf life—from crumbly dry masses to liquid batters and everything in between—depends greatly on the amount of added water. It also depends on how much of that water is bound and retained.

However, when it comes to how water interacts with your dry ingredients, the options are limited. This is where the problem arises. More often than not, substances have a hard time being properly hydrated. When ingredient particles are hydrophobic, water is repelled and runs off. On the other hand, hydrophilic ingredients bind water immediately, making that water unavailable for other ingredients, therefore, “stealing” the water away. Traditional mixers must run for a long time to ensure that proper hydration occurs, which provides enough water to the hydrophilic ingredients. Long mixing times overheats and stresses the dough. This is the downside to a traditional mixer.

So how do you hydrate your mix?

The key to effectively hydrating dry ingredients comes down to these factors:

  1. Long holding or fermentation times in the sponge stage.
  2. Highly accessible surface area at the time water makes contact
  3. High speeds for the difference substances at the time of meeting.

While it is not feasible for all bakeries to have a sponge process, I believe that the latter two points are valid for the technology I am about to discuss. This technology is called Rapidojet. With the high-pressure mixing of Rapidojet, liquid is shot through a high pressure nozzle at a speed of 250 to 500 km/h and then broken down into a fine spray that meets free-falling dry ingredients. The high speed and large surface area of interaction allows the water to penetrate much deeper than other mixers. It also takes away the factor of the high stress from a traditional mixer and there is no increase in product temperature.

This is where it gets really interesting.

Rapidojet causes dry ingredients to have a much higher capacity for binding water. Wheat dough mixed with Rapidojet will have an increased hydration of 5-10%. Wheat gluten is activated in a matter of seconds, using only 10% of the normal keading energy. In fact, I was sold on Rapidojet technology after what it did to vital wheat gluten in my video.

Pre-hydration of flour results in a fully developed dough with a short time.

Pre-hydration of flour results in a fully developed dough with a short time.

It works wonders on other dry ingredients as well. Rapidojet can produce liquid pre-fermentation and solid pre-fermentation—such as sponge or biga. This is truly revolutionary because the introduction of water and oxygen to the pre-ferments increases fermentation activity, resulting in faster fermentation rates and dough maturity. Rapidojet dough has shown more fermented flavors than non-Rapidojet dough. Alternatively, straight dough produced using the Rapidojet method has also shown an increase in fermented notes within the bread.

So maybe the big question should be: how is hydration holding back your mixed products? And how can you properly hydrate to your advantage?

Learn more how the Rapidojet can help your products, whatever they are, here!


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Ken Schwenger and Dr. Knoll discuss the benefits of Rapidojet.

IBIE 2016 Was a Success!

IBIE 2016 was a phenomenal show! Thanks to everyone who stopped by to learn more about the exciting possibilities of the Rapidojet technology. As one person said, it was “the most exciting equipment at the show!”

Ken Schwenger and Dr. Knoll discuss the benefits of Rapidojet.

Some of the BCI team discusses the benefits of Rapidojet to a crowd at IBIE.

Over the four days, we ran a series of demos giving a full range of bakers, millers and food processors the opportunity to see our patented technology in action. For example, we demonstrated how Rapidojet is changing the way bakers use bran. Bran is rising in popularity as a healthy option. Yet with traditional mixing methods, bran products often turn out dry with no volume or shelf life. Not so with Rapidojet. We proved that the patented high pressure of Rapidojet instantly hydrates bran at 300% and it was impossible to squeeze any water out of it. It’s been shown that this pre-hydration of bran increases yield, shelf life and loaf volume while reducing mixing time in the bakery’s existing mixer by about 10%.

Rapidojet_bran

In no time at all, Rapidojet spits out hydrated bran.

Bran

What’s the secret?

The secret to this is instant and full hydration. Any dry ingredient is shot with a high-pressure stream of liquid that fully satisfies it for water. As a result, total yield, product quality and shelf life go up while mix times are reduced by as much as 65% when pre-hydrating Ingredient Flour to the existing mixer. This is because we instantly develop gluten.

Bran is just one example of what Rapidojet can process. From bran to any flour, potato flakes, hydrocolloids, sprouted grain and much more, we can handle it. With all the interest generated at IBIE, it raises the big question: When is Rapidojet going to take over the food industry?

Ken Schwenger and Dr. Knoll discuss the benefits of Rapidojet

Can you believe this fully-hydrated bran?