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bakery equipment engineering

The Future of Bakery Engineering

If there’s one thing we all want to see, it’s the baking and food industry grow. I’m not just talking about expanding our product lines and sales, but laying the groundwork for expanding ideas and inspiring young leaders; making room for innovation and a fresh way of approaching problems.

That’s why I’m a supporter of the  American Society of Baking and their commitment to community, integrity, education and leadership. This group of commercial baking professionals, food technologists, engineering, equipment, ingredient and service experts know that by creating a space to share and spark ideas, baking technology can make great leaps forward. ASB offers educational material, webinars, and the BakingTech conference, among other things.

The Future of Baking Engineers

One challenge facing the baking industry right now is a gap between a retiring skilled workforce and younger, qualified replacements. In the July issue of the ASB Magazine, Executive Director of ASB Kent Van Amburg says, “Industry wide, companies are facing a shortage of skilled employees…We want to help promising individuals find the educational training to build careers in this field.”

A recent study by ASB and ABA, The Workforce Gap in U.S. Commercial Baking: Trends, Challenges and Solutions, revealed that the baking industry desperately needs engineers, machinists and maintenance personnel. So ASB started the Engineering/Maintenance Scholarship Program, which awards five $4,000 scholarships to help aspiring engineering students get the education they need to make a difference in the baking industry.

“We focused our funding on those areas and immediately found incredible individuals who are passionate about making a name for themselves in this industry,” Van Amburg said in the ASB Magazine article.

Innovation for Hydration

Helping support engineers in the baking industry really does make a difference by opening the door for innovation. BCI’s patented Rapidojet Technology owes its start to Food Engineer and Inventor Dr. Bernhard Noll. He came up with an idea to revolutionize the way we approach hydration and mixing.

future engineering Rapidojet

Dr. Noll doing a Rapidojet demonstration.

Now, bakeries are seeing up to a 65% reduction in mixing time and 8% higher yields with biga, and huge cuts in labor, power and equipment costs. All because someone took a chance to think outside the box. The soaking time for bran and other grains has been eliminated while instant hydration of 300% has been achieved.

If we want to take our businesses and products beyond the safety of “it’s always been done this way,” then it’s time to start looking to the future and how we can get there, together.

To find out how you can be a part of the future of hydration and mixing, email me about Rapidojet at ken@bakeryconcepts.net.

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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 ken@bakeryconcepts.net

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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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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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It’s been quite a while since sliced bread was the best thing…

Now, come see Rapidojet at IBIE

Rapidojet pre-hydrating flour baking equipment

It’s almost here—the “biggest, most comprehensive event in the U.S. for the grain-based food industry,” otherwise known as the International Baking Industry Exposition (IBIE). It’s also a perfect opportunity for you to see the Rapidojet technology at work. Bakery Concepts will be joining over 20,000 baking professionals from all over the world in Las Vegas this October. We’re excited to network with our peers and see what all of you bakery innovators have been working on. But we’re also excited to show off what WE’VE been doing with the Rapidojet.

Rapidojet loaf volume difference

Difference in loaf volume when using hydrated bran from Rapidojet (left) vs. dry bran added to the mixer.

Rapidojet is not just any bakery equipment, it represents the newest innovation in the industry. During the convention, our team will be putting on two demonstrations, twice a day, every day:

1)      Instantly hydrating bran at 200%. No more soaking time!

2)      Fully mixing Masa for tortilla and pumping it through our Axiflow transfer pump.

IBIE logo

Find us in the exhibit hall at booth #1821 so that we can answer any questions about the full range of what the Rapidojet technology can do. Here are a few highlights:

  • Increase in total yield of up to 8% for bread/bun doughs – Via our high pressure liquid injection, the bond between drys and liquids is more complete and homogenous. Thus, to achieve the same level of machinability and “dough feel”, we must add more water.
  • Reduction in mix time in conventional mixers of up to 65% – When pre-hydrating ingredient flour to the existing, conventional mixer, the high pressure of Rapidojet instantly develops gluten. Then, just add your Minors and Micros and incorporate. These first 2 factors alone will give you better shelf life and an ROI of less than 1 year for large operations.
  • Significant Reduction in Power Consumption – Rapidojet is much more efficient than conventional mixing.  Approximately 1.5 kWh hr./ton of output is used compared to 15 kWh hr./ton for the average mixer.
  •  Precise Temperature Control – Ice and glycol can be substantially reduced or eliminated. There is no more than a 2oF increase in temperature via Rapidojet. Final product temperature is controlled by incoming liquid and dry ingredient temperature. There is also minimal friction imparted upon the product during mixing.
  •  Extreme Versatility in Product Output – Adjustments to hydration and recipe via plc can be accomplished while the mixer is running.  It has the ability to run from 10% hydration to 1500% depending upon what is being hydrated or mixed.  With Rapidojet it is possible to hydrate any free flowing powder or grain. We can produce a stiff Biga, a flowable liquid sponge or hydrate minor ingredients with the same machine (i.e. Pre-Gel Starch hydrated at a 4% solution instantly. 700 – 7,500 kg./hr. of total output from one machine)
  •  Significant Reduction in Ingredient Costs – Due to higher hydration and lack of heat/friction there is in increase in yield along with a decrease in usage levels of ice/glycol, yeast, vital wheat gluten and dough conditioner.
  •  Virtually zero gluten washout – when pumping fermented sponge through a heat exchanger. This will also reduce downtime that is normally required for this sanitation process.
  • Increased Product Safety and Consistency – The machine is designed and built with the Z50.2 Standard in mind.It’s NEMA 4x, IP 65, 12 gauge, 304 SS. Sanitary design along with automated ingredient feeding (by others) reduces scaling errors and contamination. The Mixing Chamber, the alternative to the standard Mixing Bowl, can be cleaned in the dishwasher!
  •  100% Gelatinization– This is possible using superheated water (mix and heat at the same time).  This has resulted in substantial natural shelf life extension via a huge reduction in normal starch retrogradation.

Look for us at booth #1821 at the Las Vegas Convention Center Oct. 8-11! Register now for IBIE.

IBIE Best in Baking award in Baking Equipment

Rapidojet has been given the honor of being part of the IBIE 2016 B.E.S.T. in Baking Program. We are working hard to create a more sustainable and environmentally friendly bakery industry.