Diosna: Everything from a single source

Everything from a single source

Linear transport system + It is almost impossible to find two dough fermentation processes that are exactly alike. This was something that both the bakery product maker and DIOSNA as the equipment manufacturer and technology specialist experienced when it came to realizing a large-scale system for the preparation of Biga predoughs. The long resting periods for the predough in particular were a real challenge for the planning engineers, as were the large production volumes with up to three tons of dough per hour.

In a production line for predough fermentation starters, not only the individual pieces of equipment need to work perfectly, but the way they interact and work together has to be perfectly optimized as well. DIOSNA delivered an overall concept for developing this type of process – bringing everything together. One advantage here is that the dough experts at DIOSNA are able to offer the key processes in dough production from a single source. From measuring out the raw ingredients to preparation of the fermentation starter, along with internal logistics, final quality control and cleaning concepts – everything is covered.

Step by step, DIOSNA worked with silo and automation specialist Shick Esteve, its sister company from the Linxis Group, to develop a plant concept that set new standards both in terms of complexity and automation.

Intelligent space concept

The system places incredibly tough demands on the space concept in terms of the range of different transfer stations, the mixing process, and the cleaning units. These include a dough resting

DIOSNA Dierks & Söhne GmbH

Am Tie 23 49086 Osnabrück, Germany Phone: +49 541 33104 0 E-mail: technology@diosna.com Website: www.diosna.com

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.

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.

At this part of the installation the predough, namely the Biga, is prepared, the heart of the final dough, expecting long and gentle ripening.

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.

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. 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.

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.

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. +++

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