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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: alain.lebail@oniris-nantes.fr alain.lebail@oniris-nantes.fr
PLEASURE PROJECT: INNOVATIVE PROCESSES
VACUUM MIXER
CONCLUSION
DOUGH SHEETER
ATMOSPHERIC MIXER
ATMOSPHERIC MIXER
Temperaturesensor
Rotatingmixer bowl Spiral tool
- BRUSHLESS MOTOR; ACCURATE ONLINE MEASURE OF POWER - TOUCHLESS INFRA RED TEMPERATURE SENSOR - SPECIFIC TOOL + NO PIVOT ROD IN THE MIXER
SPEC: 3 kg DOUGH CAPACITY PROGRAMMABLE BOWL SPEED PROGRAMMABLE TOOL SPEED
ATMOSPHERIC MIXER IMPACT OF TOOL SPEED
Temperaturesensor
Rotatingmixer bowl Spiral tool
TTP: TIME TO PEAK
Kneading Ø ì tool power Ø î kneading time Ø ì dough temperature
Ø î kneading time Ø î kneading time Ø î tool power
• Increase of tool rotation speed effect:
• Impact of salt reduction: • Impact of fat in the formulation
T (°C)
PLEASURE PROJECT: INNOVATIVE PROCESSES
VACUUM MIXER
CONCLUSION
DOUGH SHEETER
ATMOSPHERIC MIXER
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
Figure 1: Cut view – general over view
MOTOR and GEARING
CONTROL PANEL TOUCH SCREEN
ELECTRICAL CABINET
VACUUM,TEMPERATURE CONTROL SYSTEM
LID – MOBILE PART
WATER JACKET and BOWL
PLEASURE PROJECT and DOUGH PROCESSING Low pressure Kneading
PLATE HEATEXCHANGER
WATER JACKET
MIXER BOWL
HEATER
PUMP
EXTERNAL COOLING BATH
T SENSOR (DE)
- Control of dough temperature; water jacket around the mixer’s bowl - Important to control dough rheology - New opportunities in dough mixing … !
WATER JACKET SYSTEM around MIXER BOWL
PLEASURE PROJECT and DOUGH PROCESSING Low pressure Kneading
Water jacket – temperature control
Infra red temperature sensor Touchless;fast and accurate
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
PAN BREAD ì DOUGH & BREAD POROSITY PIZZA DOUGH
ì DOUGH RHEOLOGY î DOUGH STICKINESS
PLeASURe PROJECT
SALT & LIPIDS REDUCTION STRATEGY; CEREAL DOUGH • Laminated dough (pizza & puff pastry) • Target = - 25% Salt or less + Reduction of saturated
fat
2010- Noort et al - Journal of Cereal Science. Vol 52. p 378-386.
FLOUR MIXING
ENCAPSULATED SALT (1.25 / 2 mm)
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)
î SAT. LIPIDS SHEETING
DOUGH with ENCAPSULATED SALT î SALT (-25% to – 50%) SALTINESS PRESERVED
Sel enrobé B
TIME
PO
WE
R (W
)
SLOW = MIXING
FAST = KNEADING
SE (J)
SPECIFICENERGY tPEAK
SE
(MJ/
kg d
ough
)
tPEAK
PO
WE
R (W
)
Proteins and starch hydration Oxydation of thiols groups Prot-Prot. disulfure bonds
MIXING & ENERGY APPROACH
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.
MIXING
TIME TO PEAK of MAX. POWER = t PEAK : END OF MIXING
« OPTIMAL » MIXING BAKER’S POINT OF VIEW tPEAK
Salt Dissolution : water needed
SALT REDUCTION & MIXING
î SALT : ì TORQUE & î MIXING TIME
NaCl
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.
Thèse: 1ers résultats
¡ Mixing in Spiral mixer (« SPI11 » - VMI-France)
- NaCl delays dough mixing - Gluten netw ork is more cohesive - î dough stickiness
Helps to create the gluten network
SALT NO SALT
Pow
er (W
)
TIME
Extensibility Stickiness
PIZZA DOUGH PROPERTIES
PIZZA DOUGH RECIPES
037
74111
148185
222
-600-500
-400-300
-200-100
00
5
10
15
20
25
30
Fat (g)Pressure (mbar)
Por
osity
(%)
IMPACT OF PRESSURE and LIPIDS ON DOUGH POROSITY (NOMINAL – FULL SALT ) î PRESSURE = î DOUGH POROSITY
PRESSURE (mb) FAT (g)
SALT, LIPIDS and MIXING DOUGH POROSITY
PORO
SITY
(%)
0
6.312.6
18.925.2
31.5
-600-500
-400-300
-200-100
05
6
7
8
9
10
Salt (g)Pressure (mbar)
Stic
kine
ss (g
forc
e)
SALT, LIPIDS and MIXING DOUGH STICKINESS
IMPACT OF PRESSURE and SALT on DOUGH STICKINESS (HALF FAT RECIPE) î PRESSURE DURING MIXING = î DOUGH STICKINESS (same trend for all fat levels)
SALT (g)
STIC
KINES
S (g
for
ce)
SALT, LIPIDS and MIXING DOUGH EXTENSIBILITY
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 NETWORK
PRESSURE (mb) SALT (g)
RESI
STANCE
TO E
XTE
NSI
ON (g
forc
e)
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 ?
PATM
P
TIME
P1=P(+)
P2=P(-)
MIXING KNEADING
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RESULTS
TOOL REV. COUNT vs DOUGH POROSITY : • NO IMPACT OF TOOL RPM ON DOUGH POROSITY • DOUGH POROSITY IF PROPORTIONNAL TO COUNT OF TOOL REVOLUTIONS.
0.23
0.25
0.27
0.29
0.31
0.33
0.35
0.37
0.39
0.41
0.43
0 200 400 600 800 1000
Va (L
air
/L d
egaz
ed d
ough
)
NUMBER OF TOOL REV. TO t PEAK
IMPACT OF TOOL RPM ON DOUGH POROSITY
180-15 RPM
120-10 RPM
96-8 RPM
TOOL-BOWL (RPM)
V AIR
(L A
IR/L
DEG
AZE
D D
OU
GH)
P1 = 0 mbar (MIXING @ Atm. PRESSURE): TREND TO ì SPEC. VOL. WITH î P2
RESULTS IMPACT OF LOW PRESSURE LEVEL & DURATION
ON BREAD VOLUME
3.45 3.55 3.65 3.75 3.85 3.95 4.05 4.15 4.25
-500 -400 -300 -200 -100 0
BR
EA
D S
PEC
IFIC
VO
LU
ME
(mL
/g)
P2 (mbar)
P1 = 0 mbar 60s
45s
30s
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)
3.45
3.65
3.85
4.05
4.25
-600 -400 -200 0
BR
EA
D S
PEC
IFIC
VO
LU
ME
(m
L/g
)
P2 (mbar)
P1 = 500 mbar 60s
45s
30s
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 control = Final product control ! Dough aeration, dough rheology, …
CONTINUUM : IN LINE PROCESS CONTROL OF MIXING
Tweedy (625) VMI Optimum (630)
! Mixing control = Final product control ! Example sliced bread.
PLEASURE PROJECT: INNOVATIVE PROCESSES
VACUUM MIXER
CONCLUSION
DOUGH SHEETER
ATMOSPHERIC MIXER
DOUGH SHEETER
PROTOTYPE SHEETER BASED ON RONDOSTAR ECO SFE 6607H sheeter
Table width: 650mm Table length: 3490mm Rolls length: 660mm Rolls gap: 0.2-45mm Rolls diameter: 84mm Conveyor belt width: 640mm Conveyor belt speed: 85cm/s Engine power: 2.0kVA/1.2kW Supply voltage: 3 x 200-480 V, 50/60 Hz Interface: 100 automatics programs
DOUGH SHEETER
Salt duster
Conveyor belt
Touch screen interface
Protection grid
Rollers
Temperatureand laser sensors
Torque sensor
Salt Duster
Laser sensors
Temperature sensors
Torque Sensor: 5 N.m max range Temperature sesor: Infra red Laser sensors: dough thickness (10 µm)
DOUGH SHEETER
DOUGH SHEETER; SALT DISTRIBUTOR
dough
Distributor – variable speed
Upper &Lower roll
Conveyor belt
Salt reservoir
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
DOUGH SHEETER; SALT DISTRIBUTOR
COLOR to RGB + THRESHOLDING + BINARISATION
Calculation of average distance between salt grains : Evaluation of average amount of salt per cm²
DOUGH SHEETER; SALT DISTRIBUTOR
Prototype dough sheeter (Rondostar ECO)
Final thickness hOUT
DOUGH ELASTICITY
Upper roller
Lower roller
DOUGH STICKINESS
hIN hOUT
h0
STICKINESS CONTRIBUTION
STICKINESS + SPRINGNESS CONTRIBUTIONS
y = 1.17x - 0.2609 R² = 0.99185
y = 1.2006x - 0.2663 R² = 0.99713
y = 1.1379x - 0.2404 R² = 0.9964
y = 1.1023x - 0.222 R² = 0.9931
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
OB
SER
VED
STR
AIN
(hIN
-hO
UT)
/ hIN
IMPOSED STRAIN (hIN-h0)/hIN
no fat nominal salt no fat -25% salt no fat -50% salt no fat 0% salt
100% elastic (hOUT=hIN)
§ NO SALT EFFECT ON DOUGH PLASTICITY § THRESHOLD FOR DOUGH ELASTICITY (SMALL DEFORMATON)
§ DOUGH BECOMES PLASTIC FOR LARGE DEFORMATION
Salt & fat effect on dough plasticity
h0=hIN h0=0
hIOUT= hIN
hout=0
NO FAT
P ATM MIXING
Salt & fat effect on dough plasticity
hout=0
FULL FAT
hIOUT= hIN 100% elastic (hOUT=hIN)
P ATM MIXING
Salt & fat effect on dough plasticity
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%
ELAST
IC
PLAST
IC
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
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
L/W
% C
HA
NGE
06.3
12.618.9
25.231.5
-600-500
-400-300
-200-100
0-1
0
1
2
3
4
5
6
Salt (g)Pressure (mbar)
% in
crea
se in
leng
th/w
idth
ratio
PRESSURE (mbar) SALT (g)
0
-600
MIXING PRESSURE & SHAPE STABILITY
06.3
12.618.9
25.231.5
-600-500
-400-300
-200-100
03
4
5
6
7
8
Salt (g)Pressure (mbar)
% in
crea
se in
leng
th/w
idth
ratio
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 ….
FULL FAT
L/W
% C
HA
NGE
PRESSURE (mbar) SALT (g) -600
MIXING PRESSURE & SHAPE STABILITY
0
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
Conclusion
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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