Automated continuous mixing delivers real-time process assessment and consistency round the clock.
© VMI
In the mix: VERYMIX
VMI’s VERYMIX continuous mixer also monitors and controls several parameters, including the energy throughout the process. “From premixing to the end of the mixing process, the viscosity and the formation of the gluten network are monitored thanks to the energy tracking,“ explains Mélanie Gay, Marketing & Digital Development at VMI. Everything can be managed from the HMI, from recipe formulation, dosing, programming, to monitoring and traceability. “Whether it is the ingredients consumed or the amount of dough produced, you can check on the curves to view the flow control of the dosing devices. In this way, you can check that the flows and the calibration of the powder dosing scales are maintained,” she illustrates. Recipe data, consumption balance, alerts and any other requested parameters can be exported to Excel files or made available to the Manufacturing Execution System, for a better understanding and optimization of production cycles. The information can be accessed in real-time and past performance data is also available. It can be visualized by duration or by team/shift.
Given the breadth of data, numerous adjustments can be made, including the preventive adjustment of the process, for example, according to the use and data VMI collects and analyzes on request. The VERYMIX flow rate can adjust itself automatically, based on experience feedback from previous cycles. Parameters can also be measured and adjusted manually, including mixing time and intensity, dough temperature before, during, and after mixing, energy transmitted to the dough, and the opening of the glycol valves, VMI’s specialist explains. “The ability to optimize the use of VERYMIX is a point that is of great interest to our customers, whether it is the process itself, the costs associated with its use (e.g., energy consumption), or maintenance.”
Pre-hydration can also be controlled; VMI’s horizontal pre-mixer (HPM) integrates ingredients in the bowl in two zones, one for powders and one for liquids in the form of spray droplets, and a third zone specific to mixing. “Flour, sugar and other baking ingredients are combined with water and immediately form a homogeneous dough and the beginning of a gluten network,” VMI’s specialist explains. These steps are designed to make the mixture more homogeneous and the process more effective, allowing for a wider range of hydration, from 40% to 110%. The HPM works directly above the VERYMIX, and continuously transfers hydrated raw materials into the mixer underneath, where the dough is mixed to the required consistency. “Its horizontal design, in addition to taking up less space and providing a better seal, eliminates the risk of clogging,” adds Gay.
”From premixing to the end of the mixing process, the viscosity and the formation of the gluten network are monitored thanks to the energy tracking.“
Mélanie Gay, Marketing & Digital Development, VMI
To maximize efficiency, the VERYMIX offers a wide range of mixing parameters that can be used according to the production criteria, and quality required: the mixing rotor is adapted to the dough, the bowl shape is optimized for continuous operations and times and mixing intensities are adjustable. This level of process control allows for flexibility: “Classical sponge and soft doughs, as well as firm doughs, with or without fermentation times and frozen doughs can now be prepared efficiently.”
Very accurate dosing
The VERYMIX continuous mixer automates powder and liquid ingredient dosing as well as scrap dough management. Flour, salt, sugar, powdered milk, gluten, improvers and other raw materials are weighed by three stainless steel load cells. These load cells can be fed automatically by intermediate hoppers, or by manual loading hoppers (big-bags). Water, egg, milk, liquid yeast, flavorings, liquid sugar and brine are also precisely dosed. The system features dosing pumps and electromagnetic or mass flow meters to weigh liquids.
The quantity of scrap to integrate can also be dosed: “Scrap dough should not be neglected: for bread, it can amount up to 25% of the weight of the flour and for some puff pastry, it can even surpass 50%,” Gay highlights. The VERYMIX continuous mixers make it possible to automate the flow management towards resting phases or for a transfer to the line, while also reintegrating the dough scraps. For its latest improvements to the system, ”According to the mixing phase, VMI has worked particularly on the shape of its tools and tanks, specific to premixing, kneading or fermentation steps.” The latest addition to the VERYMIX is a mobile cleaning in place (CIP) station which can be connected to the liquid dosing stations: “Since they are so flexible, CIP systems make it easier to manage standard cleaning protocols, and limit production downtimes when changing product,” she highlights.
The article is part of an extended feature, which was originally published in [BBI 2 – 2022]. Read the full article in the magazine:
