Biotechnology for better fresh baked goods
Fermentation reveals who is able to handle liquids. As the market leader, we have profound knowledge of the properties of viscous and compressible media. In pre-dough and sourdough production our customers can be sure that they will always obtain perfectly hygienic products of a consistently high quality thanks to our plant engineering.
Our complete portfolio for the user-friendly production of liquid sponge and sourdoughs:
- System control
- Storage containers for the precise dosing of raw materials according to the recipe
- Water mixing unit for mains water and hot water
- Agitator vessels for dissolved or liquid yeast
- Shear flow mixer ShearDos and DymoMix with short mixing times for lump-free dough production
- Fermenters / fermentation pipework
- Heat exchangers for cooling
- Storage tanks
- Automated cleaning of pipes and tanks
Liquid sponge production
The quality of wheat dough baked goods is determined by the raw materials and to a certain extent by the application of liquid sponge. The use of liquid sponge is essential in order to meet the increasing high quality standards of the consumer. By the use of liquid sponge a natural baking additive is developed that ensures that the baked goods have a crispy crust, taste more flavourful, remain fresh longer and have an extended shelf-life.
For the continuous production of liquid sponge water, wheat flour and yeast suspension are metered gravimetrically and volumetrically into the continuous mixer and immediately mixed together. A homogenous dough is produced already after a short time which is then pumped from the mixer to the fermentation tank. The “first-in, first-out” principle ensures a constantly high quality and freshness of the dough. When the fresh liquid sponge is pumped into the storage tank, the dough is cooled by travelling through a heat exchanger in order to halt the fermentation process. The liquid sponge is then ready to be taken for the production lines.
Decisive reasons for the use of liquid sponge:
- Presoaking of the flour constituents
- Kneadable dough
- Better processing qualities
- Natural fermentation
- Remains fresh longer
- Milder, well-balanced taste
- Soft, elastic crumb
- Higher dough-yield volume
- Reduction in the dough resting period
Today, sourdough is not only used for rye flour. It is also produced with other types of grain, such as e.g. wheat and spelt in order to use the positive influence of sourdough on the baked goods. In the past and today, sourdough is prepared by a single- or multi-stage process in dough bowls and metered manually, which is a time-consuming and personnel-intensive process. This and the increased quality requirements led to the development of the automatic batch-wise and the continuous production of sourdough – these two processes provide numerous advantages. Which process is the right one for you depends on your requirements.
Continuous rye sourdough production
This process basically works like the previously described continuous liquid sponge production. For the continuous production of sour dough, starter, water and flour are metered into the shear flow mixer ShearDos instead of metering yeast suspension. The starter is produced in a specially provided fermenter. If necessary, the sourdough is cooled down in a plate cooler to 5°C-15°C and prepared for the production in a storage tank. The fermentation time is 10 – 12 hours. The specific feature of this process is the fact that the equipment (ShearDos, fermentation tanks and storage tank) can be fitted with a WIP-functioning (washing in place), which meets the strict hygienic requirements of the food industry.
The sourdough production comprises the use of a flour mixture and the sourdough production in a single- or multi-stage preparation. The development of these two kinds of preparation is based on the consideration of a targeted increase of yeast or the generation of a specific acid with aroma. Flour is pneumatically conveyed into a holding hopper and is then metered by an adjustable conveying screw into the fermenter. Parallel to metering of flour, the mixing water is added. A constant comparison of the quantities metered ensures that the desired mixing ratio is observed. As a third raw material the starter is added. Afterwards, homogenous mixing of the raw materials in the fermenter and the hydration of the flour is carried out. The system allows to adjust several preparation stages with variable dough yield and temperature.
After a fermentation time of approx. 12 to 18 hours the finished sourdough can be cooled down in the double-walled fermenter to the desired storage temperature of approx. 15°C. Thus, the sourdough is available for a period of several hours at a constant quality. The double-walled and insulated stainless steel tanks fulfill the task of a fermenter and that of a storage tank. An intelligent electrical control system provides operator prompting and regulates the chronological and the technological fermentation process.
Decisive reasons for the use of sourdough:
- Baking of rye sourdough is possible
- Fluffiness and acidification of the dough
- Elastic crumb
- Better to slice
- Better aroma
- Well-balanced taste
- Bread remains fresh longer
- Extended shelf-life
- Saving of acidification agent and yeast