Donuts, muffins, cupcakes: Flexibility for product diversity

All styles are in

Manufacturing donuts with less fat and sugar is a must. However, this is just the starting point as unusual shapes, new flavor experiences, creative textures and hybrid formulations are on the rise. What do they have in common with muffins and cupcakes? Aside from striving for unique creations, or rather because of it, there is a flexibility push on the equipment supporting their manufacturing.

+A multitude of options Depending on the size and desired capacity of the operation, there are several systems that best support the environment and production needs. FRITSCH, for instance, recommends the IMPRESSA donut for industrial production, and the MULTITWIST line for industrial as well as mid-sized bakeries. For bigger businesses in the mid-sized range, it can also provide a combination of its FRITSCH MULTILINE, which is used for the dough sheet production with the MULTICUT system for dough sheet processing. Mid-sized to small bakeries can also find their fit in lining up a sheeting line, the FRITSCH ROLLFIX with a transfer table and an Artisan Make Up Table (AMT) with a cutting roller for the processing of donuts.

A typical setup of a FRITSCH donut line starts with the sheeting section, followed by calibrating the dough sheet. The punching tool is next, shaping the donut and simultaneously collecting the scrap dough, which is subsequently returned via a scrap return system. The last production step on the line is loading the proofer.

The latest innovations prioritize gentle dough handling for sheeting and calibrating. For FRITSCH, this is provided by its soft dough technology. Such innovations can also be retrofitted: existing sheeting systems can be replaced by the gentle soft dough handling system. One of its new updates is the double guillotine that punches and removes the inner dough circle, and can also replace a previously installed cutting system. A FRITSCH line can be fully automated, requiring operators in mixing and packaging. All working parameters of each module are automatically monitored on an operator screen, including setpoints and live readings, for necessary changes. The only manual adjustment required is the tool swap when switching to a different product.

Among the production needs that influence the make-up of the FRITSCH donut equipment, the company notes: + Fast tool interchange when changing the product on the line, to minimize downtimes; + High flexibility regarding the dough characteristics, the donut shapes, the production capacity and product variation; + Easy to operate equipment.

© RONDO

Smart features particularly useful in donut manufacturing should include those providing flexibility and high performance, ensuring consistent product quality and a controlled process. FRITSCH also prioritizes process reliability in this respect, hygienic production and user-friendliness of the commands.

Concerns traditionally associated with donuts include fat absorption during frying, trans fats, and the sugar in the recipe and the glazing. The impact of hygienic considerations on the design of a FRITSCH line is high: “Due to the frying process that is at the core of donut manufacturing, the demand for cleanliness is high. Furthermore, avoiding fat mist all over the production area is mandatory,” the Uwe Benz, sales director Line Solutions, recommends. The management of the frying oil is also important, to avoid impact on taste, odor and acrylamide content.

For long-term improvements, FRITSCH sees a definite focus on preventive maintenance, integrated quality management, the traceability of line parameters and their impact on product quality, as well as smart, self-learning machinery.

All possible variations

FRITSCH equipment is designed for product variety: the gentle handling technology allows the handling of dough with inclusions such as dried fruits, whole grains, or chocolate. Softer doughs and doughs requiring long fermentation times are also suitable for processing, all products having the flexibility to vary in shapes, sizes and weights. To introduce new shapes into production on a FRITSCH line, new punching tools with different shapes are installed, to prepare anything from heart-shaped, hexagonal to rectangular donuts.

“Another great variety of shapes can be made with our MULTITWIST. It can easily produce twisted donuts in the shape of pretzels, rings, knots as well as plaited products,” Magdalena Bauer, Marketing team leader, notes. The tool exchange to switch in between these product shapes can be performed easily, without the need for any special equipment.

In addition, “Selling glazed donut holes with various flavors is also becoming a bigger business, we’ve learned,” Bauer highlights.

Smart donut lines

RONDO‘s fully automated donut lines allow output rates from 6,000 to 30,000 units per hour. They are equipped with IIoT solutions which allows them to be monitored remotely, parameters including line capacity, actual machine status and line settings. “Furthermore, the logged data can be used to optimize the production and the process reliability of the line,” the specialist points out. These donut lines are specialized to suit two manufacturing styles. + The direct dough band method uses a dough band former to form a thick and narrow dough band out of the bulk dough. This process helps to preserve the structure of the dough. Several forming units are used afterward (i.e., a satellite head, a cross roller and a calibrator) to bring the dough band to the desired thickness and to increase its width on the band. Gentle sheeting and forming is important in this step, stresses Alexander Weissbach, head of Technology and Product Management, and head of the

Dough-how Center at RONDO Burgdorf AG.

The dough band former used at the beginning of the process is the key to success, he explains, as it is within this first step that the final quality and weight accuracy are defined. The dough band former must be accurately balanced to process dough gently while forming a compact dough band. The dough band formers Smartfeeder and

MIDOS were designed for such delicate doughs. The satellite head, the first station where the rough band is thinned, also plays an important part in dough quality.

“Reducing the dough band thickness too aggressively will break the dough structure and the volume of the final product will be lowered. The satellite head of the Smartline can be adjusted in three ways to reduce the force during this step: the roller gap, the speed difference between the bottom roller and satellite head, and the tilt angle between the bottom roller and satellite head. The last feature is unique and patented. Changing the tilting angle will reduce the force during the reduction step. Therefore, the dough structure will not be destroyed. Furthermore, the weight accuracy can be improved,“ Weissbach tells us. + By comparison, a line using the laminating method is equipped with one or two laminating stations (the final section remains unchanged). The additional lamination sections will influence the structure of the dough by

creating additional cross-linkages in the gluten network. Therefore, the dough band gains more stability and the volume of the donut will be bigger.

Both methods will result in a consistent dough band for further processing – cutting the donuts into the desired shapes. “A very important side effect of the dough sheeting process is that the donuts absorb less fat during the frying process. This is due to the gentle sheeting process, which results in a dough band with a smooth surface and an intact gluten structure, ensuring that the surface of the dough band is not porous,” RONDO’s expert explains.

Answering requests

RONDO observes special donut shapes are increasingly in demand, and so is the flexibility to produce them all on one line, which also makes fast changeovers a necessity. Switching between different product shapes, sizes and weights can be done within minutes on RONDO lines, which are designed for tool-less changeovers. All line settings are stored in the PLC. Selecting a new recipe will automatically adjust the line according to the recipe details.

Manufacturers also tend to prefer working with softer doughs and pre-proofed dough for more flavorful products. The dough band method has several benefits concerning all these requests: softer and pre-proofed dough can be gently processed without sticking on the line and damaging its structure. RONDO’s guillotines can also be equipped with different stamping dies, to cut donuts into various shapes.

Another requirement is automation, as RONDO sees an increasing number of manufacturers increasing their capacity and automation level. This means synchronizing with suppliers of up- and downstream equipment, setting up common interfaces to optimize workflow. For example, RONDO’s make-up lines end with the panning of the donuts onto the proofer flights. In the absence of design guidelines for the proofers and the proofer flights, the company designs a modular panning machine that can be used to feed every proofer on the market.

In the long term, RONDO anticipates that IIoT systems that control and optimize line performance are the key figures. “Improving and optimizing changeovers and the production sequences will help maximize the efficiency of the line,” Weissbach anticipates.

Cupcakes and muffins, automated

Flexibility is the top priority when manufacturing cupcakes and muffins as well, as highlighted by the Unifiller Europe Flexline, one of the favorites among the Linxis Group specialist’s customers. This line can first be used for depositing muffin and cupcake batters, and (after baking) for the injection of fillings or cupcake decorations. Bakers and confectioners can also use this line to deposit batters for sponge/cakes, brownies and cheesecakes into various baking forms. After baking and slicing the cake layers, the Flexline can be used to apply the fillings (creams or jams with inclusions as big as whole strawberries) or for the automated applying of syrup onto the sponge layers.

Flexibility tops frequent requests Unifiller is receiving, shares Martin Hornsteiner, Senior Process Advisor at Unifiller Europe. Bakers can use this line not only for cupcakes and muffins but for many other products as well. “This is why we recommend our Flexline, with the Multi Station at its core. Thanks to the great flexibility of the Multi Station, customers can use this line for the production of a wide range of different products, including round and rectangular cakes, desserts, eclairs, macarons, or muffins,“ he details, adding that, “Our Multi Station is a working horse. It is 2.5 times faster than any gearwheel depositor and it can produce up to 16,000 muffins/h.”

Moreover, the Flexiline can easily be modified with additional components, for the exact customization needed. Along the conveyor, additional depositors like the iSpot can be included to apply decorations. Adding another Multi Station to the line (i.e., for injecting fillings into the cupcakes) will help increase production capacity.

The Unifiller accessories were developed for a wide range of products and applications. In general, spreader nozzles are used for cake production; injection nozzles are used for fillings; drip-free nozzles can be used for depositing any liquid products; the 360° twisting nozzles are used for twisted decorations on the cupcakes.

The standard Unifiller solution for cupcake and muffin production comprises a Multi Station and a Hopper Topper transfer pump. These machines are operated by one person who picks and places the trays from the racks to the Multi Station, and back to the racks. Capacities for such a solution are around 13,000 cupcakes per hour. Together with APEX Motion Controls, Unifiller now offers the Baker-Bot to take over picking and placing trays onto the Multi Station’s conveyor. “In this way, we have a fully automated ‘production island’ that can be used not only for the cupcakes and muffins but also for many other items produced on trays,” Hornsteiner tells us. The operator is only required for changing the fully loaded racks against the racks with empty trays to that autonomous production system. When the ‘production island’ is used, the line can be monitored

© Unfiller

via the Baker-Bot; with the standard Unifiller solution, monitoring works via statistics in the PLC. “Live adjustments are easy to do with our Operator Guidance via icons on the touchscreen of the PLC control,” the specialist from Unifiller adds.

For quick changeovers, Flexiline operators use a second set of machine parts that come into contact with the product. The clean parts are ready to be used on the cleaning and storage trolley, while the dirty parts go onto a second trolley for washing. By working like this the complete changeover takes less than 10 minutes, the specialist recommends.

The handling of the trays with the Baker-Bot from Apex Motion will be the next automation step. An additional cobot can be used to handle decoration tasks along the conveyor of the muffin and cupcake line. Automated product detection and depositing with a handheld nozzle using a cobot is just an example of how a cobot can help to automate production lines in a bakery. The result? Endless flexibility. +++

© Unfiller

ADVERTISEMENT

WHEN THE DOUGH QUALITY IS SIMPLY BRILLIANT.

CODOS NT: Pioneering through continuous method of operation.

In terms of quality, the CODOS NT mixing and kneading system from Zeppelin is practically unbeatable. Thanks to its innovative design, it always offers reproducible mixing results - and thus ensures consistent product quality every time. Around the clock, even with large mixing quantities.

When do you rely on Zeppelin quality?

WE KNOW HOW.