Blog | Bakery Concepts International

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biga-bakery concepts- rapidojet

Watch your Biga Yield Grow!

You bake with preferments to improve bread’s texture, aroma and hydration all with less yeast. So why not improve your biga so it can in turn better enhance your products? By optimizing your biga to the max, you will see big advantages in terms of yield and product quality.

How do I optimize Biga?

The key to biga working wonders in your products is its hydration. This Italian-style stiff preferment has a 50-60% water absorption. It plays an important role in hydrating flour during the mixing process. But what if by just changing the way you mix, you could drastically improve that hydration, along with other things?

To truly optimize biga, try a Rapidojet mixer. It shoots free-falling dry ingredients with a high pressure stream of water, instantly hydrating them. With the Rapidojet technology, we can pre-hydrate 100% of the ingredient flour with 100% of the ingredient water to the existing mixer.

Then, the minors and micros such as salt, yeast and dough conditioner are added at the bowl and the mixing process is finished. A fully-hydrated mixed dough is a happy one, and is proven to increase yield.

Biga mixed with Rapidojet, sees  at least a 4% higher total yield when all the flour is pre-hydrated into the existing mixer. Other customers have realized a total increase in yield via more homogeneous hydration of 8% with the same degree of “dough feel” and machinability.

Get huge cost savings, QUICK!

For Biga, there is at least 50% less mixing time in the existing mixer when all flour is pre-hydrated via Rapidojet and minors and micros are added at the bowl. Most other customers are seeing a reduction of 65% in mix time. At only 1.5 kW hr. / ton of output vs. the normal 15 kW hr. / ton from a typical horzontal mixer, Rapidojet represents a HUGE amount of energy savings.

Impressed yet? Here are a few other benefits you can expect with the Rapidojet technology:

  1. Significant reduction in the amount of ice or glycol required to keep the dough cool.
  2. The need for dough conditioners is drastically lowered.
  3. Reduced need for yeast or accelerated proofing.
  4. Longer shelf life because of the more homogeneous bond between drys and liquids. This slows starch retrogradation, the primary cause of staling.
  5. Increased consistency of the final baked product.

You bake with biga to improve your products. So why not mix with Rapidojet to improve your biga yield?

Read more about how the Rapidojet technology is transforming mixing, or send me an email at

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Masa is efficiently and effectively mixed with Rapidojet.

Stop Being Corny with Batch Masa Mixing! Use Rapidojet

Tortillas. Chips. Tamales. Corn bread.

All of these delicious products rely on masa flour. And as food producers, you rely on masa performing to the best of its ability.  That’s why I’m so excited about the Rapidojet Technology and how it handles this corn flour. Rapidojet has no problem mixing masa, let alone improving your production efficiency.

Why Masa?

Healthy nutrients are locked away in the corn kernel—such as fiber, ferulic acid, xanthophyll and carotenoids—which make consumers happy. Another thing that’s making more and more customers happy: gluten-free products. This industry can expect to grow around 6% globally between 2015 and 2019, according to reports.

Why Rapidojet?

On this blog I talk a lot about the wheat flour side of things. Yet just as the food industry is a diverse one, ingredients are diverse as well. What’s really exciting about the Rapidojet technology is that it can handle diverse products and still offer the benefits and savings associated with continuous mixing.

Here are four reasons to use Rapidojet as a continuous mixer for masa:

  1. Decrease power usage. When mixing masa, there is more than an 80% reduction in the mixing energy used. Rapidojet consumes only about 1.5 kW hr. / ton of output, compared to approximately 15 kW hr. / ton of output from a traditional mixer.
  2. Cut labor costs. With continuous mix and the ability to eliminate mixing bowls, labor costs drop more than 80%.
  3. Improve sanitation and safety. There is a significant reduction in sanitation and safety exposure and costs due to the elimination of multiple, moving mixing bowls.
  4. Better product. The consistency of your product will go up with Rapidojet as a continuous mixer.

See for yourself! This video shows masa continuously mixed by Rapidojet and delivered directly into the Masa Hog:

There you have it! This patented technology will revolutionize masa flour in your products. Put it to work in your product line, and get those corn-goods rolling!

Discover what other special food product lines Rapidojet can improve for you! Learn more by contacting me at

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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.


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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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 and ask how Rapidojet can help improve your production process or read more about our improvement to dough.