DIOSNA
At this part of the installation the predough, namely the Biga, is prepared, the heart of the final dough, expecting long and gentle ripening.
Biga Dough
Temperature control was one of the most important aspects in the development of the overall process. The Wendel Mixers from DIOSNA have always stood out with low heat transfer into the process. Higher degree of automation for reliable production It is thanks in part to a very sophisticated automation concept that the line runs like clockwork. To do this, Shick Esteve, a sister company of DIOSNA, developed a bespoke software solution especially for this plant. Cleaning is supported by the hygienic design of the machines.
Over two storeys, more than 100 containers rest in a huge dough resting room, each holding over 120 kg of dough. However, smaller batch sizes also need to be integrated on a regular basis. After the resting time, the containers are automatically moved out from the resting room and are then transported following the FIFO principle to a transfer station. Here the containers are transported upwards and emptied into the stainless steel vats of a kneading system. The empty containers then move automatically to a cleaning station.
Effective cleaning concept In terms of cleaning, the CIP (Clean in Place) and WIP (Wash in Place) systems offer resourcesaving, simple, and efficient cleaning for all line components. For example, the containers of the predough resting system are automatically cleaned at 50°C by spray nozzles, with no need for chemicals. The stainless steel vats are scraped out during the emptying process into the hopper (wall scraper). Scrap dough can accrue in the process steps for dough preparation.
The transferred predough is initially processed by two further batch mixers using a separate silo connection, during which further ingredients are added by dosing devices. Thus, the final dough is prepared. Dough Mixing is followed by a second resting period, which is controlled via a fully automated linear transport system. Only after this second, significantly shorter maturing period, the dough is transferred to the make-up line.
Conclusions and outlook This article looks at just a few of the aspects that are particularly important in automated dough production processes. The key issue is the transfer points. This is the only way to ensure that three tons of dough per hour can be continuously processed without any problems – and with full compliance with all quality and hygiene requirements. +++
C O M PA N Y R E P O R T S
At the heart of the process is the automated mixing concept. All steps are monitored and documented here so that subsequent approvals are made easier. Two Wendel Mixers from the ‘Hygienic Design’ line (WH series; WHA240) ensure gentle dough development with minimal rise in temperature. As well as the dosing device, the Wendel Mixers feature rounded stainless steel profiles to enable faster and more thorough low-pressure cleaning later on.
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system, ‘Hygienic Design’ Wendel Mixers, which work in tandem to deposit dough in the resting container via the under bowl discharge principle, a linear transport system with tilting lifter, highperformance Wendel Mixers, and hoppers with dough portioning devices. Because space was limited in the plant – particularly in terms of the large amounts of dough that were to be produced – a two-level storage concept with automated logistics was developed.
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