Blog | Bakery Concepts International


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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?


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ibie logo

B.E.S.T. in Baking 2016|Rapidojet Bakery Equipment

Why were we selected for Best in Baking? Learn the answers from Dr. Noll himself. Come hear him speak on High Pressure Hydration/Mixing on Saturday, Oct 8th at 12:40pm on stage at the Innovation Spotlight Theater located in the “Idea Lab”.

Best in Baking award

Want to see the Rapidojet in action? Here is our Demo Schedule, and what we intend to do:

  1. Bran demo at 320% hydration Sat, Sun, Mon at 12pm, 2pm & 4pm with pumping through the Axiflow product transfer pump into a bucket.
  2. Masa Flour demo Sat, Sun, Mon 4.45pm  No Masa Flour demo on Tuesday. We intend to do full mixing with Rapidojet and pump the dough through the Axiflow product transfer pump into a bucket.
  3. Bran Demo Tuesday 12pm and 2pm.

See you at our IBIE booth at #1821!

October 8-11, 2016

 

If you still have questions, please contact me here.


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How about some ROI numbers?

Return on Investment for Rapidojet

Rapidojet Baking Equipment ROI on bread products

We’ve said it before: Rapidojet saves you money. With bread products, you can easily get money going back into your business in a short time. Depending on the size of the machine, the number of shifts run and how much hydration is used, a bakery can have a return on investment (ROI) of up to $1,100,656 a year! Even a small machine with just one shift can have a $62,807 ROI annually.

There are five main areas where Rapidojet technology cuts costs for your business:

1) Dry ingredients

Rapidojet technology shoots dry ingredients—such as flour, bran, vital wheat gluten, starch, potato flakes, whole grain, etc, with a high pressure stream of water creating instant hydration. The level of hydration also increases, with water intake rising by up to 10%. This causes a minimum of 2.5% of flour reduction per year, meaning $13,900 to $396,000 in savings per year.

2) Baking improver

Baking improvers, such as dough conditioners, are added to dough mixes to help increase hydration and improve the functionality of gluten. However, with instant and full hydration, the need for conditioners is significantly reduced—by 30%. This means your operations can cut between $18,200 and $324,000 a year, depending on the size of your operation.

3) Cooling

This is another area where you can expect big savings with Rapidojet. Mixing times with these machines are much, much shorter than traditional methods because the gluten is instantly developed.  Rather than forcing two ingredients together, causing heat and friction, they are instantly mixed, generating less heat. So your dough will no longer need as much ice or coolant. You can once again expect between $17,900 to $323,000 in savings annually.

4) Energy

Rapidojet can be used as a no-time dough process. With hydration and gluten development happening almost instantly, the energy savings are impressive. Depending on the size of operation, 21,840 to 393,120 kWh are saved per year.  This could be anywhere from $2,621 to $47,174 saved.

5) Labor

Rapidojet mixing is convenient and time saving. It can be run continuous or batch, delivering dough directly to the divider on a roll or bread line. This eliminates batches, bowls and a large decrease in labor cost. We estimate this means over $100,000 per year in labor savings for your bakery.

All of these ROI’s are for bread product lines. However, we are continuing to explore the use of Rapidojet technology, from sprouting grain to mashed potato flakes. Who knows how many more ways it will cut costs for your operations?
Find out how much you could be saving with Rapidojet! Download the Rapidojet Flour Saving ROI Calculator (MS-Excel) or contact me for more information.