Innovative PLEASURE equipment to support the technology

Demonstration: Innovative PLEASURE equipment to
support the technology (20 minutes)
Alain LE-BAILa,
Mathieu SADOTa, Nikhil NAIR a, Sylvie CHEVALLIERa, Guenaelle LERAYa,
José CHEIOb & Mark DEBOEVEREc
aOniris,
UMR 6144 GEPEA CNRS, Nantes, F - 44307, France
aCNRS, Nantes, F - 44307, France
bVMI, Rue Joseph Gaillard, 85600 Montaigu, France
cPromatec Food Ventures BV Rootven 24a, NL-5531 MB Bladel
* corresponding author: [email protected]
[email protected]
PLEASURE PROJECT: INNOVATIVE PROCESSES
ATMOSPHERIC MIXER
VACUUM MIXER
DOUGH SHEETER
CONCLUSION
ATMOSPHERIC MIXER
- BRUSHLESS MOTOR; ACCURATE ONLINE MEASURE OF POWER
- TOUCHLESS INFRA RED TEMPERATURE SENSOR
- SPECIFIC TOOL + NO PIVOT ROD IN THE MIXER
Temperature
sensor
Rotating mixer bowl
SPEC:
3 kg DOUGH CAPACITY
PROGRAMMABLE BOWL SPEED
PROGRAMMABLE TOOL SPEED
Spiral tool
Temperature
sensor
ATMOSPHERIC MIXER
IMPACT OF TOOL SPEED
Rotating mixer bowl
TTP: TIME TO PEAK
Spiral tool
Kneading
•  Increase of tool rotation speed effect:
Ø  ì tool power
Ø  î kneading time
Ø  ì dough temperature
•  Impact of salt reduction:
Ø  î kneading time
T (°C)
•  Impact of fat in the formulation
Ø  î kneading time
Ø  î tool power
PLEASURE PROJECT: INNOVATIVE PROCESSES
ATMOSPHERIC MIXER
VACUUM MIXER
DOUGH SHEETER
CONCLUSION
PLEASURE PROJECT and DOUGH PROCESSING
Low pressure Kneading
Spiral tool
VMI SPIRAL MIXER
Pressure modulation
Range - 0.9 to + 0.5 Atm
PLEASURE PROJECT and DOUGH PROCESSING
Low pressure Kneading
LID – MOBILE
PART
CONTROL PANE
TOUCH SCREEN
MOTOR and
GEARING
ELECTRICAL
CABINET
VACUUM,TEMPERATURE
CONTROL SYSTEM
WATER JACKET
and BOWL
PLEASURE PROJECT and DOUGH PROCESSING
Low pressure Kneading
WATER JACKET SYSTEM around MIXER BOWL
T SENSOR (DE)
PLATE HEAT
EXCHANGER
EXTERNAL COOLING BATH
PUMP
HEATER
MIXER BOWL
WATER JACKET
-  Control of dough temperature; water jacket around the mixer’s bowl
-  Important to control dough rheology
-  New opportunities in dough mixing … !
PLEASURE PROJECT and DOUGH PROCESSING
Low pressure Kneading
Infra red temperature sensor
Touchless;fast and accurate
Water jacket – temperature control
Sensor installation:
Temperature, NIR, others….
USER – INTERFACE
VMI VACUUM MIXER
USER – INTERFACE
VMI VACUUM MIXER
Plots during expoeriments: power,
cumulative energy, pressure, temperature..
PLEASURE PROJECT and DOUGH PROCESSING
Low pressure Kneading
Spiral tool
VMI PROTOTYPE SPIRAL MIXER
Pressure modulation
Range - 0.9 to + 0.5 Atm
VACUUM (PRESSURE)
MIXING:
î GLUTEN OXYDATION
ì DOUGH RHEOLOGY
CONTROL OF DOUGH
AERATION
PIZZA DOUGH
ì  DOUGH RHEOLOGY
î DOUGH STICKINESS
PAN BREAD
ì DOUGH & BREAD POROSITY
PLeASURe PROJECT
SALT & LIPIDS REDUCTION STRATEGY; CEREAL DOUGH
• 
Laminated dough (pizza & puff pastry)
• 
Target = - 25% Salt or less + Reduction of saturated
fat
PROCESS STRATEGY :
a)  LOW SALT MIXING ( - 50 % to - 75%) (ì STICKINESS)
b)  ENCAPSULATED SALT EMBEDDED IN DOUGH DURING SHEETING
c)  LIPID MIX REDUCED IN SAT. LIPIDS (ì STICKINESS)
Sel enrobé B
ENCAPSULATED
SALT (1.25 / 2 mm)
FLOUR
MIXING
î SAT.
LIPIDS
SHEETING
DOUGH with
ENCAPSULATED SALT
î SALT (-25% to – 50%)
SALTINESS PRESERVED
2010- Noort et al - Journal of Cereal Science. Vol 52. p 378-386.
MIXING & ENERGY APPROACH
POWER (W)
« OPTIMAL » MIXING
BAKER’S POINT OF VIEW
tPEAK
POWER (W)
MIXING
Proteins and starch hydration
Oxydation of thiols groups
Prot-Prot. disulfure bonds
SE (J)
SPECIFICENERGY
SLOW =
MIXING
FAST =
KNEADING
TIME
TIME TO PEAK of MAX. POWER = t
tPEAK
PEAK
: END OF MIXING
Kilborn, R.H. et Tipples, K.H., 1972. Factors affecting mechanical dough
development. Effect of mixing intensity and work input. Cereal Chem. 49: 34-47.
résultats
SALT REDUCTION & MIXING
Mixing in Spiral mixer
(« SPI11 » - VMI-France)
Power (W)
¡ 
î SALT : ì TORQUE & î MIXING TIME
Salt Dissolution :
water needed
NO SALT
SALT
- NaCl delays dough mixing
-  Gluten netw ork is more
cohesive
-  î dough stickiness
NaCl
Helps to create
the gluten network
2012- Beck et al – Impact of sodium chloride on wheat flour dough for yeast-leavened products. I.
Rheological attributes. Journal of the Science of Food and Agriculture. Vol 92 (3), p 585-592.
TIME
PIZZA DOUGH RECIPES
PIZZA DOUGH PROPERTIES
Extensibility
Stickiness
SALT, LIPIDS and MIXING
DOUGH POROSITY
IMPACT OF PRESSURE and LIPIDS ON DOUGH POROSITY (NOMINAL – FULL SALT )
î PRESSURE = î DOUGH POROSITY
30
POROSITY
Porosity (%) (%)
25
20
15
10
5
0
0
-100
-200
-300
148
-400
74
-500
Pressure (mbar)(mb)
PRESSURE
-600
0
111
37
FAT
Fat (g)(g)
185
222
SALT, LIPIDS and MIXING
DOUGH STICKINESS
STICKINESS
(g force)
Stickiness (g force)
IMPACT OF PRESSURE and SALT on DOUGH STICKINESS (HALF FAT RECIPE)
î PRESSURE DURING MIXING = î DOUGH STICKINESS (same trend for all fat
10
9
8
7
6
5
0
-100
31.5
-200
-300
18.9
-400
12.6
-500
Pressure (mbar)
-600
6.3
0
(g)
T
L
Salt
SA(g)
25.2
SALT, LIPIDS and MIXING
DOUGH EXTENSIBILITY
RESISTANCE TO EXTENSION (g force)
IMPACT OF PRESSURE and SALT on DOUGH EXTENSIBILITY (FULL FAT RECIPE)
î PRESSURE DURING MIXING = ì EXTENSIBILITY of DOUGH
OTHER FAT: SAME TREND @ FULL SALT è OXYGEN INTERACTS WITH GLUTEN/LIPIDS NETWOR
PRES
SURE
(mb)
)
SALT (g
INTEREST OF PRESSURE - VACUUM MIXING
PAN BREAD
-  Reduction of size of gas nuclei in the dough
-  Faster start of expansion during fermentation
-  More homogenous gas cell distribution
-  ì dough rheology ?
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P
P1=P(+)
PATM
MIXING
KNEADING
P2=P(-)
TIME
Va (L air/L degazed dough)
VAIR (L AIR/LDEGAZED DOUGH)
RESULTS
IMPACT OF TOOL RPM ON DOUGH
POROSITY
0.43
TOOL-BOWL (RPM)
0.41
0.39
180-15 RPM
0.37
0.35
120-10 RPM
0.33
0.31
96-8 RPM
0.29
0.27
0.25
0.23
0
200
400
600
800
1000
NUMBER OF TOOL REV. TO t PEAK
TOOL REV. COUNT vs DOUGH POROSITY :
•  NO IMPACT OF TOOL RPM ON DOUGH POROSITY
•  DOUGH POROSITY IF PROPORTIONNAL TO COUNT OF
TOOL REVOLUTIONS.
60s
P1 = 0 mbar
4.25
45s
4.15
30s
4.05
3.95
3.85
4.25
4.05
P1 = 500 mbar
45s
30s
3.85
3.75
3.65
3.65
3.55
3.45
-500
60s
BREAD SPECIFIC VOLUME
(mL/g)
BREAD SPECIFIC VOLUME (mL/
g)
RESULTS
IMPACT OF LOW PRESSURE LEVEL & DURATION
ON BREAD VOLUME
-400
-300
-200
P2 (mbar)
-100
0
P1 = 0 mbar (MIXING @ Atm. PRESSURE):
TREND TO ì SPEC. VOL. WITH î P2
3.45
-600
-400
-200
P2 (mbar)
0
P1 = +0.5 Atm (500mbar) :
ì SPEC. VOL. OF BREAD
BEST VOLUME :
30 s @ P2=-0.2 Atm
45 s @ P2=0 Atm(atm Pressure)
CONTINUUM :
NEW CONTINUOUS DOUGH MIXER DEVELOPPED BY VMI
AWARDED AT EUROPAIN 2014
« INNOVATION TROPHEE »
CONTINUUM :
CONTINOUS VACUUM MIXER
A RUPTURE TECHNOLOGY FOR THE BAKING INDUSTRY
CONTINUUM :
IN LINE PROCESS CONTROL OF MIXING
!  Mixing
!  Dough
control = Final product control
aeration, dough rheology, …
CONTINUUM :
IN LINE PROCESS CONTROL OF MIXING
Tweedy (625)
!  Mixing control = Final product
!  Example sliced bread.
VMI Optimum (630)
control
PLEASURE PROJECT: INNOVATIVE PROCESSES
ATMOSPHERIC MIXER
VACUUM MIXER
DOUGH SHEETER
CONCLUSION
DOUGH SHEETER
PROTOTYPE SHEETER BASED ON
RONDOSTAR ECO SFE 6607H sheeter
Table width:
Table length:
Rolls length:
Rolls gap:
Rolls diameter:
Conveyor belt width:
Conveyor belt speed:
Engine power:
Supply voltage:
Interface:
650mm
3490mm
660mm
0.2-45mm
84mm
640mm
85cm/s
2.0kVA/1.2kW
3 x 200-480 V, 50/60 Hz
100 automatics programs
DOUGH SHEETER
Salt duster
Roller
s
Protection
grid
Touch screen
interface
Conveyor
belt
DOUGH SHEETER
Temperature and laser sensors
Salt Duster
Torque sensor
Laser sensors
Temperature sensors
Torque Sensor: 5 N.m max range
Temperature sesor: Infra red
Laser sensors: dough thickness (10 µm)
DOUGH SHEETER; SALT DISTRIBUTOR
Salt reservoir
Distributor – variable spee
dough
Upper &
Lower roll
Conveyor belt
DOUGH SHEETER; SALT DISTRIBUTOR
Dusting speed
grains/(m.s)
Conveyor belt speed
m/s
Dimmers
permits to
control the
added salt
DOUGH SHEETER; SALT DISTRIBUTOR
Images Analysis
Image acquisition of dough after black salt dusting
COLOR to RGB + THRESHOLDING + BINARISATION
DOUGH SHEETER; SALT DISTRIBUTOR
Calculation of average distance between salt grains :
Evaluation of average amount of salt per cm²
Prototype dough sheeter
(Rondostar ECO)
h0
Upper
roller
hIN
DOUGH
STICKINESS
DOUGH
ELASTICITY
hOUT
Lower
roller
STICKINESS + SPRINGNESS
CONTRIBUTIONS
Final
thickness
hOUT
STICKINESS CONTRIBUTION
Salt & fat effect on dough plasticity
OBSERVED STRAIN (hIN-hOUT)/ hIN
hout=0
1
§ NO SALT EFFECT ON DOUGH PLASTICITY
§ THRESHOLD FOR DOUGH ELASTICITY (SMALL DEFORMATON)
§ DOUGH BECOMES PLASTIC FOR LARGE DEFORMATION
0.9
0.8
P ATM MIXING
0.7
0.6
NO FAT
0.5
0.4
0.3
0.2
0.1
hIOUT= hIN
100% elastic (hOUT=hIN)
0
0
0.1
0.2
0.3
0.4
y = 1.17x - 0.2609
R² = 0.99185
0.6
0.7
0.8
0.9
IMPOSED STRAIN (hIN-h0)/hIN
h0=hIN
no fat nominal salt
0.5
no fat -25% salt
y = 1.2006x - 0.2663
R² = 0.99713
no fat -50% salt
y = 1.1379x - 0.2404
R² = 0.9964
1
h0=0
no fat 0% salt
y = 1.1023x - 0.222
R² = 0.9931
Salt & fat effect on dough plasticity
hout=0
P
ATM
MIXING
FULL FAT
hIOUT= hIN
100% elastic (hOUT=hIN)
Salt & fat effect on dough plasticity
ELASTIC
PLASTIC
IMPACT OF SALT REDUCTION ON DOUGH DURING SHEETING
î  SALT : GLOBAL î DOUGH RE-EXPANSION AFTER SHEETING (MORE PLASTIC)
î SALT ì STICKINESS IS LESS IMPACTING THAN î DOUGH PLASTICITY
IMPOSED STRAIN : 67%
DOUGH STABILITY AFTER SHEETING & BAKING
DOUGH DISK : 10 cm diameter
BAKING: Impact of sheeting on gluten network structuration
è SCHRINKAGE and DEFORMATION OF THE DISK OF DOUGH
è  Equivalent diameter + LENGTH / WIDTH RATIO
è L/W RATIO
STABILITY RATIO AFTER BAKING
SHEETING DIRECTION
MIXING PRESSURE & SHAPE STABI
6
% increase in length/width ratio
L/W % CHANGE
IMPACT OF PRESSURE ON L/W AFTER BAKING
è  LOW PRESSURE = MORE STABLE DOUGH
è  ì SALT ; LESS STABLE, ì ELASTICITY (AFTER BAKING)
NO FAT
5
4
3
2
1
0
-1
0
0
-100
31.5
-200
25.2
-300
18.9
-400
-500
Pressure (mbar)
PRESSURE
(mbar)-60
-600
6.3
0
12.6
Salt (g)
SALT
(g)
MIXING PRESSURE & SHAPE STABILITY
FULL
FAT
8
% increase in length/width ratio
L/W % CHANGE
IMPACT OF PRESSURE ON L/W AFTER BAKING
è  LOW PRESSURE = SMALL DECREASE OF STABILITY (OPPOSITE to NO FAT)
è  ì SALT: MORE STABLE, î ELASTICITY (OPPOSITE to NO FAT)
è OVERALL: TREND TO SMALL î STABILITY WITH ì FAT ; GLUTEN-LIPID INTERACTIONS ….
7
6
5
4
3
0
0
-100
31.5
-200
25.2
-300
18.9
-400
12.6
-500
PRESSURE
Pressure(mbar)
(mbar)
-600
-600
6.3
0
Salt (g) (g)
SALT
Conclusion
Ø  PRESSURE DURING MIXING
ü  î PRESSURE = î Dough stickiness and porosity
ü  î PRESSURE = ì Dough extensibility
Ø  BAKING STABILITY
ü  No fat: ì Salt ì deformation during baking
ü  Full fat: ì Salt î deformation during baking
ü  Pressure has small effect
ü  è Fat is more impacting than salt on shape stability
EVIDENCE OF LIPID-GLUTEN INTERACTION, …
LIPID FORMULATION è ROLE IN BAKING STABILITY?
CONCLUSION
- INNOVATIVE LOW PRESSURE MIXER DEVELOPPED
è NEW FRONTIERS FOR SALT REDUCTION IN CEREAL DOUGH
- INNOVATIVE PROTOTYPE DOUGH SHEETER
è BETTER CONTROL OF DOUGH SHEETING
SPECIFIC APPLICATIONS FOR SALT DISTRIBUTION
ACKNOWLEDGMENTS
• Jacques LAURENCEAU, Valentin CLAUDIN, Luc GUIHARD, Christophe
COUEDEL – ONIRIS
• Sylvie CHEVALLIER – IMAGE ANALYSIS & Micro CT – ONIRIS
• TORQUE SENSOR : Institute of Fluid Mechanics (Technical Faculty
Friedrich-Alexander University Erlangen-Nuremberg - GERMANY).
• KYENCE NL and KYENCE France
QUESTIONS?

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