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?