Manufacturing donuts with less fat and sugar is a must. However, this is just the starting point as unusual shapes, new flavor experiences, creative textures and hybrid formulations are on the rise. What do they have in common with muffins and cupcakes? Aside from striving for unique creations, or rather because of it, there is a flexibility push on the equipment supporting their manufacturing.
A multitude of options
Depending on the size and desired capacity of the operation, there are several systems that best support the environment and production needs. FRITSCH, for instance, recommends the IMPRESSA donut for industrial production, and the MULTITWIST line for industrial as well as mid-sized bakeries. For bigger businesses in the mid-sized range, it can also provide a combination of its FRITSCH MULTILINE, which is used for the dough sheet production with the MULTICUT system for dough sheet processing. Mid-sized to small bakeries can also find their fit in lining up a sheeting line, the FRITSCH ROLLFIX with a transfer table and an Artisan Make Up Table (AMT) with a cutting roller for the processing of donuts.
A typical setup of a FRITSCH donut line starts with the sheeting section, followed by calibrating the dough sheet. The punching tool is next, shaping the donut and simultaneously collecting the scrap dough, which is subsequently returned via a scrap return system. The last production step on the line is loading the proofer.
The latest innovations prioritize gentle dough handling for sheeting and calibrating. For FRITSCH, this is provided by its soft dough technology. Such innovations can also be retrofitted: existing sheeting systems can be replaced by the gentle soft dough handling system. One of its new updates is the double guillotine that punches and removes the inner dough circle, and can also replace a previously installed cutting system. A FRITSCH line can be fully automated, requiring operators in mixing and packaging. All working parameters of each module are automatically monitored on an operator screen, including setpoints and live readings, for necessary changes. The only manual adjustment required is the tool swap when switching to a different product.
Among the production needs that influence the make-up of the FRITSCH donut equipment, the company notes:
+ Fast tool interchange when changing the product on the line, to minimize downtimes;
+ High flexibility regarding the dough characteristics, the donut shapes, the production capacity and product variation;
+ Easy to operate equipment.
Smart features particularly useful in donut manufacturing should include those providing flexibility and high performance, ensuring consistent product quality and a controlled process. FRITSCH also prioritizes process reliability in this respect, hygienic production and user-friendliness of the commands.
Concerns traditionally associated with donuts include fat absorption during frying, trans fats, and the sugar in the recipe and the glazing. The impact of hygienic considerations on the design of a FRITSCH line is high: “Due to the frying process that is at the core of donut manufacturing, the demand for cleanliness is high. Furthermore, avoiding fat mist all over the production area is mandatory,” the Uwe Benz, sales director Line Solutions, recommends. The management of the frying oil is also important, to avoid impact on taste, odor and acrylamide content.
For long-term improvements, FRITSCH sees a definite focus on preventive maintenance, integrated quality management, the traceability of line parameters and their impact on product quality, as well as smart, self-learning machinery.
All possible variations
FRITSCH equipment is designed for product variety: the gentle handling technology allows the handling of dough with inclusions such as dried fruits, whole grains, or chocolate. Softer doughs and doughs requiring long fermentation times are also suitable for processing, all products having the flexibility to vary in shapes, sizes and weights. To introduce new shapes into production on a FRITSCH line, new punching tools with different shapes are installed, to prepare anything from heart-shaped, hexagonal to rectangular donuts.
“Another great variety of shapes can be made with our MULTITWIST. It can easily produce twisted donuts in the shape of pretzels, rings, knots as well as plaited products,” Magdalena Bauer, Marketing team leader, notes. The tool exchange to switch in between these product shapes can be performed easily, without the need for any special equipment.
In addition, “Selling glazed donut holes with various flavors is also becoming a bigger business, we’ve learned,” Bauer highlights.
