With new-generation technology, bakeries can work smarter, not harder, on sheeting and laminating dough bands for any number of products.
Variations in a dough band are not a rare occurrence from batch to batch. They can be caused, to various degrees, by any number of changes – from the dough temperature and resting times to differences in the recipe, or the uncontrolled return of rework dough. When fluctuations exceed a certain level, they lead to variations in the dough flow on the sheeting line. Differences can occur in the thickness or width of the dough band, and changed parameters can also lead to blistering, shrinkage, curling of the edges, uneven dough density, stickiness, or even surface tearing.
RONDO has developed several control systems with algorithms that automatically adjust the sheeting line settings to maintain a constant flow of the dough, regardless of changes in the dough characteristics. This is done without the need for any manual intervention from the operator.
Above all, no stressed dough
To achieve this, the first step is to thoroughly assess the type of product and its corresponding dough characteristics, as well as the optimum process needs and the expectations regarding the quality of the final result. Based on this information, RONDO can evaluate the adequate dough band former for the specific application.
Taking the MIDOS system as an example, “It is perfect for yeast-raised doughs, with or without resting time before the dough band forming process starts, RONDO specialists explain. The MIDOS does not require oil while shaping the dough, which is a plus for the quality of the product, as well as for process safety and the overall hygiene in the facility.
The delicate structure of the dough is protected throughout the process. The gluten network is particularly sensitive to stress, especially during the transformation from a dough bulk to a dough band. This is why RONDO sees applying the lowest possible forces as a must. “Damage done at the beginning of the process cannot be recovered,” they underline, as the integrity of the gluten network can only be evaluated after baking. Various rheological measurements can offer an indication of its status, but it is only 100% confirmed by baking the product – too late for any corrective actions.
Inconsistencies over time can occur, and they can mostly be seen from one batch to another. New flour batches can lead to inconsistencies, as well as changes in the facility’s temperature. Also, “Shifting from a slightly older dough from the previous batch to freshly mixed dough from the next batch brings a big difference,” RONDO notes. Its systems will automatically adjust to such changes it detects, to maintain the flow of the dough constant throughout processing. Even under changing conditions that influence the dough, this reduces variations in the sheeted dough’s characteristics to an absolute minimum.
+100 dough layers can be laminated for yeast-free pastries
Product flavors start from the dough
Pressing the dough to shape it from block to band should not risk hurting the gluten structure at any time; then, the outside variables can be managed for consistent results. ‘Inside’ variables, intrinsic to the dough, are also accounted for – and they can vary widely. The preparation of the dough is often influenced by current trends or seasonal and regional preferences: “Several inclusions could already be mixed into the dough, such as olives, dried tomatoes, or various spices. Inclusions have no influence on the sheeting of the dough band,” RONDO specialists explain.
The systems are designed to support recipe diversity in every aspect. For example, “Adding toppings such as spraying oil or sprinkling herbs can be implemented in the line configuration. By-pass functions are also available, when a certain feature is not needed for the product on the line,” illustrates RONDO.
The Swiss company’s sheeting systems can support any production volumes, for sheeting and laminating. Thanks to the continuous, constant flow throughout the process, the equipment workload is relatively low, so high operating speeds can be achieved, as needed. When high-volume operations are the priority, the line’s capacity can be increased two- or three-fold, by increasing sits width. Line widths of up to 1,500 mm are standard for RONDO. Flexibility in production volumes is ensured: “With the RONDO Process Control, capacity changes from +/- 30% can be easily done; the line will readjust itself.”
For improvements in sheeting, RONDO is targeting reduced product changeover times, operation-friendly design, improved waste management and lowering the amount of scraps, as well as the hygienic design of the systems, for longer production runs.
Laminating in progress
RONDO designed laminating as a continuous process, for any number of dough layers. Determining the optimum count is a matter of what’s expected from the product. For yeast-raised laminated products for anything from croissants, pains au chocolat and other similar pastries, a number of layers ranging from 12 to 24 is generally considered sufficient. This value rises sharply when looking at laminated products without yeast; in this category, a layer count of 64 to over 100 is considered normal. Why? “The volume increase during baking comes from the physical changes that occur: when water evaporates, it separates and lifts each layer. This is why, the more layers, the better the results, for non-yeast laminated products,” RONDO points out.
The good thing is that, although the number of layers has an influence on the layout of the line, it does not affect its capacity. The choice in the laminating ingredient – margarine or butter – will determine the system’s design and the necessary components, and the matching process. Margarine is more tolerant of higher room and dough temperatures, for example, which means that it’s possible to laminate the dough without resting or cooling times. But resting times and intermediate cooling will increase the product quality, which should be taken into consideration. Alternatively, resting and intermediate cooling are a must when using butter.
“The MIDOS is perfect for yeast-raised doughs, with or without resting time before the dough band forming process starts.”
RONDO specialists
The key, in any case, is in consistently forming each layer. “Layer creation and control are defined by defined speed differences and the correlation between several speeds. Different speed correlations result in different layerings. With our know-how and the understanding of machine settings and dough flow, the layering process can be set to obtain consistent results reliably,” RONDO highlights.
The company has been working on further improvements to the process and the corresponding technology. Notably, the process control feature can help achieve high-quality end products, thanks to its ability to independently adjust the process to the dough properties, whenever necessary.
The good news is that it applies to any type of dough, recipe, line setup, environment conditions, shift, or season. The results will always be great.