PRODUCTION
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The best means to all ends Different types of products made with laminated dough have their own process requirements to achieve the desired characteristics. Flexible equipment is needed to support variations and to do so efficiently, especially in industrial baking facilities.
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Every type of dough and resulting product requires a specific laminating method. When laminating dough, fat layers can be shaped in different ways. Even distribution in the precise amount is key to perfecting this process, and therefore the best method for the product should be identified that best matches the product and its processing system. When making this choice, particular attention should be paid to evaluating the dough tensioning in the dough piece, especially on the sides of the slab. “We also look at the fat distribution in the base dough; the goal is that the fat layers are distributed as evenly as possible through the whole dough,” Rademaker’s specialists outline. Jan Willen Jansen, sales technologist, and Henri in ‘t Veld, head of product management explain how Rademaker lines can support the three laminating methods developed by the company: horizontal, overlapping or by cutting and stacking layers. Laminators are set up according to the production volumes, the type of fat used, the number of layers needed for the products, the desired thickness of the layers and the dough reduction method. Rademaker’s laminators can produce dough sheets up to 512 layers. “Because all these build-up layers need to be reduced to the required dough thickness, the reduction process needs to be done very
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gently. If not, there is a big risk of damaging the layering structure, which leads to a non-acceptable product,” they explain. Going over 512 layers will almost not be visible in the product and would bring no benefits. The number of layers can easily be adjusted from the control screen. The production will automatically change to an adequate production speed. In the case of large adjustments, the reduction steps must also be closely examined, Rademaker recommends. Once the optimum settings have been found, they can be saved in the system so that they are available again for the next production run. In addition, proofing systems are added where necessary, as well as a cooling and resting section – if the product requires this step: “To obtain the highest quality layers of dough, it may be necessary to cool and/or rest the dough sheets in a cooling and/or resting cabinet. Within the laminating process, the layers of dough and fat are essential for the baking structure of the final product,” they highlight. The type of fat (butter, margarine, shortening, low-trans or non-trans margarine) is determined by the type of product and the process which is
