Faster production, cost efficiency and quality consistency: these are the advantages that made the Chorleywood Bread Process such a success. With Royal Kaak’s MDD mixers, an entire range of products can enjoy the same production benefits, from buns to pizza, donuts and brioche.
In the past, breadmaking faced challenges with mixing consistency in the UK because the flour commonly used was quite weak and a lot could change with the environmental conditions in the bakery while the dough was resting in the bowl. Plus, moving the bowls around was a labor-intensive task.
The Chorleywood Bread Process (CBP) was developed at an eponymous research center in the ‘60s to meet these exact challenges. It was so efficient and quick at producing bread that it conquered the British bread industry – and for good reason. It was first adopted by artisan bakeries and then industrial operations followed. It went in a different direction than traditional dough production, which called for a slower pace and often included long fermentation times. Instead, the CBP uses high-speed mixing with intense mechanical activity. This works with weaker flour and, usually, additional yeast, so that the dough can withstand the shorter process and, by using vacuum – more water. Time is saved from the mixing speed and the significantly shorter fermentation times – with additives sometimes also added to compensate. The result after baking: bread with a light, airy texture.
Royal Kaak developed a range of dedicated mixers to principles of the CBP, aptly named Mechanical Dough Developers (MDD). The difference with this technology is that it improved the high-speed mixing process so that it can be used for a wide variety of products, aside from sandwich and toast bread – including many different specialties, such as breakfast products, soft buns, flatbread, breadcrumbs, rusks and even brioche and yeast-raised donuts, for example.
A complete process
The MDD is a complete high-speed mixing system, continuously updated to comply with all present-day standards. It is built in an enclosure for improved hygiene and lower noise levels. Ingredient handling and dosing are integrated, including a weighing capability.
we are mixing on energy. We do so because this method eliminates the risk of under-mixing or over-mixing.”
Ton van der Pas, Product Sales Manager, Royal Kaak
And, for the mixing process itself, vacuum is used to achieve products with a finer cell structure; alternatively, applying pressure results in a more open structure. Vacuum makes the air inside the dough expand with the change in air pressure. Mixing will then cause the air bubbles to divide into smaller ones. Repeating this sequence will result in having small air pockets evenly distributed throughout the dough. A different mechanism is triggered when using pressure: as the gluten network is formed while mixing, it holds on to the gas bubbles that are forming. By adding more oxygen into the enclosure, the gluten network strengthens and is able to retain the air bubbles, which, in turn, expand as the yeast is proofing, forming larger air pockets, respectively a more open product structure.
Why was this design choice made? Ton van der Pas, Product Sales Manager, Royal Kaak, explains: “It’s because we are not measuring mixing by time; we are mixing on energy. We do so because this method eliminates the risk of under-mixing or over-mixing, in case the exernal silos do not provide the mixer the exact amount of flour as expected.” The MDD measures the flour, water and other ingredients going into the recipe, with a method: first, the flour is brought in, and its weight and temperature are recorded. In parallel, water is pre-weighed and most of the needed amount is added, at the same time. According to final flour measurements, the remaining quantity of water, at the correct temperature, is added to the flour – for both weight compensation and temperature correction that are needed to achieve consistent results. The result will be a constant quantity and quality of dough over batches. In addition, the mixer itself is designed for efficient cooling during the mixing processes when needed, with a double-jacketed bowl as a standard feature.
The pressure and vacuum system allows for accurate control of the product texture and makes the mixer flexible for a wide range of products. “Adding pressure is an optional feature for our mixer. It comes with vacuum, as standard, and we can also apply pressure if required. In this case, the build of the mixer has to be adapted to the use of pressure,” the specialist explains.
The mixing process itself is adjusted according to the measurements and the dosing optimization, respectively: “A well developed dough requires a certain amount of energy (watt-hours per kg). Depending on the exact quantity of ingredients in the bowl, the mixing process will take more or less time to reach this result, on the premise that the same amount of energy is always applied to the dough,” he adds. In combination with the automated water temperature regulation, it gives the constant dough quality that the industrial bread production process requires.
Ingredient Handling & Dosing Syste, (IHDS)
When the mixing process finishes, the dough is ready to be discharged. The MDD also incorporates dough handling, which is done with a skip hoist – an inclined ramp that conveys the newly formed dough to downstream processes.
The MDD mixers can process batches of up to 462 kg of dough, making them a great option for high-volume production. Ideally, the batches should be as small as possible, the specialist notes: “The smaller the dough volume, the less of a head-tail effect you have. Since a lot of the dividers are volumetric, if density changes because of the yeast, product weights will also change.” Not only does this system mix fast, in about 3 minutes, but also in quick succession: while it is mixing a batch, the upcoming one can already start, by preparing the ingredients of the next selected recipe. The system can be completely automated, so no labor is required at any stage.
Bowl cooling
Fast mixing stays fast if the cleaning is also done quickly, and Kaak’s MDD has a unique feature allowing speed cleaning – but thorough, nonetheless. The cleaning tool is connected to the bowl and cleans it with high-pressure water. The bowl can be quickly filled, then drained, and it is ready to get back to work. There are several cleaning programs available, for various cleaning needs. Since it’s a closed system, dust, flour buildup, or any unwanted particles cannot access the mixer frame. The mixer itself is designed for high hygiene standards, to allow wet cleaning.
Patented CIP system
The MDD integrates complex features but remains easy to use correctly: its 3D PLC control allows the recipes to be controlled with complete accuracy and mixing parameters can be configured for the products, according to testing results. The quality will then remain constant.
