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Sponsored Innovation Feature - summer 2020

DIOSNA

Spiral or Wendel Mixer, be spoilt for choice ...

"Humans make around 20,000 decisions every day," says Munich brain researcher Ernst Pöppel, "most of them lightning-fast." Fortunately, we take longer to make important decisions in our professional lives, we collect information, weigh things up and examine exactly what the purpose of our new acquisition is.

Exactly one of these decision-making processes forms the focus of this article which addresses one of the best-known manufacturers of mixing and pre-dough machines: DIOSNA Dierks & Söhne GmbH & Co. KG from Osnabrück.

Every choice is a good choice

Whenever a bakery has to decide between a Spiral or a Wendel Mixer, there are basically two important categories to think about. The materials and raw materials respectively, recipes to be processed and the technical requirements. Both considerations must be clearly defined in order to understand the customers' expectations before obtaining the best advice. DIOSNA customers appreciate that the company has a large equipment portfolio for a wide range of applications. The most important features, however, are the handmade tools. They are hand-forged to the tubs in order to keep the distance between the tub wall and bottom as small as possible. Because it is well known that the smaller the space between the two, the better the mixing result.

DIOSNA customers appreciate that the company has a large equipment portfolio for a wide range of applications

Working with a checklist

All sales representatives have a checklist in their head that they discuss with their customers to find out which mixer fits perfectly into their concept and their scopes of application. Here is a brief overview with typical questions that may be posed:-

  • Which types of dough should be processed and what end products should be produced?
  • How much is produced,?
  • Large quantities of a product or many different products with the same system?
  • What technology is the customer currently working with and which parameters are relevant?
  • What information is available about the mixing times, the pouring temperature and is ice currently being used for cooling the dough?
  • What roles do hourly output and mixing efficiency play? What quality standards does the customer wish to fulfill?
  • What is the required texture of the dough when it is kneaded, for example, rather dry or damp, short or elastic respectively plastic?
  • Is there more information about filling quantities, automated processes and other requirements? E.g. the particularly high hygiene standards required in the production of an industrial bakery.
  • and what does the buyer wants to improve compared to his current system and what is important to them regarding the DIOSNA Mixing Machine?

All depends on the Dough

In order to specify the most appropriate solution, it is important to know which types of dough are used due to their disparate characteristics. For instance, a mixing time that is too short can have negative effects on the dough quality and, therefore, on the final outcome.

Dough rest

A challenge with modern production plant systems is that the required rest period for dough can't always be maintained in day-to-day business which in turn affects the dough's rising result. If the combination of water and flour is incorrect, the freshness of the end products is reduced, and the resulting volume is unsatisfactory. Of course, DIOSNA has gained a lot of experience over the years and they are happy to pass it on to their customers. Effects such as autolysis, fermentation and the entire influence of DIOSNA pre-dough technology also play an enormous role in controlling the best possible dough production and outstanding product quality. Explaining this in particular goes beyond today's scope but can be discussed in more detail in another article or face to face.

Mixing time

With an optimal mixing time, you achieve optimal stretching of the gluten, which makes the dough smooth and elastic and a baked product which has the desired size and a typical porosity. Baguettes require different methods than those say for the production of ciabatta; A bun has a different texture than that of a mixed wheat bread product and so on. A mixing time that is too short will render a lower coefficient of elasticity and smoothness resulting in less volume and a more compact crumb in the final baked product.

Dough rest and mixing time

After mixing

Put simply, the final dough after mixing, forms the basis of the end product. Finely coordinated recipes are designed for the production of appetizing baked goods for increasingly demanding consumers. In order to do justice to this it is also essential to face what happens after the dough is made. There are many different methods that are taken into account for which we offer advice, e.g. does the bakery work with or without a dough resting period, if so, how long? Do the baking professionals only work with a break in the fermentation process or is the dough also frozen? Only if all factors, from the first vision of which baking creation is to be created, through the selection of ingredients and the effective, harmonize with each other, the result be a perfect pastry that meets the highest standards.
In order to ensure the production of, for example, of perfect pastry that meets the highest standards of manufacture, all stages of the process must harmonize together, from initial visualization and design, ingredient selection, right through to an efficient manufacturing process.

Difference in the mixing of your product between the Spiral and Wendel Systems

One of the most important questions asked during the decision process is, will there be an obvious difference in the mixing of your product between the Spiral and Wendel Systems. DIOSNA has carried out a controlled series of tests on different dough types with both types of mixer, the results of which, are shared with customers upon request. To establish the most suitable products and processes, customers can use the on-site testing facilities in the bakery in addition to a visit to the Technology Centers in Osnabrück, Isemhagen in Germany and Kansas City in the USA.

There, a team of technical experts, technologists with worldwide experience and PhD food specialists, take intensive care to achieve the best results with the customer's original ingredients. DIOSNA benefits from many years of expertise, a very well-equipped analysis laboratory and a large machine portfolio. Put together these components allow DIOSNA to match customers' expertise and to make the right recommendations for all their different requirements.

DISONA Wendel MixerDIOSNA Wendel Mixer

What most customers appreciate about the Wendel Mixer is the shorter mixing time, so the dough does not heat up as much which has a positive effect on the consistency. Sometimes customers think about setting up several smaller Spiral Mixers rather than a single Wendel Mixer with several tubs. DIOSNA's recommendation is to use the Wendel Mixer wherever large amounts of dough are required in a short space of time.
Specific qualified advice can only be given if the DIOSNA experts know how the finished dough is processed. E.g. it is significant whether the end product is baked directly in production or whether the fermented and frozen dough is delivered to the retail outlets and stores.
Where smaller production quantities are required, it is often more practical to use the smaller Wendel Mixer, however, it is important to note that the filling quantity of the smallest model – the WV 120 requires at least 50kg to 60kg of dough to be produced. Thanks to its special design with the two tools rotating counter-directionally, the Wendel Mixer is very well suited for all conventional doughs.
Using a Wendel Mixer, it is advisable to knead the wheat dough a little longer, because with this machine the adhesive tightens more. For most doughs, a higher water absorption of 3-5% will be achieved when using a Wendel particularly when using European flours.

Good results can also be achieved with solid doughs, e.g. lye with a dough yield of 148, and with leaf and cold-kneaded Danish pastry. All systems work so precisely and reliably that they are successfully operating in other industries as well such as in the production of protein, nutrition and chocolate bars where it is also extremely advantageous to produce a homogeneous consistency in a short space of time through intensive mixing.

DIOSNA Spiral MixerDIOSNA Spiral Mixer

The Spiral Mixer is often used as a universal mixer, its flexibility means it and can be used in any bakery for all conventional types of dough. The range includes full filling quantities to very small doughs, as required. So, it is ideal for bakeries with a lot of space or a wide range and less production volume.
A Wendel Mixer should have about 40-50 percent of the maximum fill quantity to achieve a good mixing result. In contrast, the Spiral Mixer achieves a good mixing result already by 10 percent of filling quantity.
The product range of the DIOSNA Spiral Mixers is very diverse, there are many different sizes and variants. The model range of 12kg-160 kg of dough is available as a mobile version with the bowl permanently installed. Alternatively, there are machines with a removable bowl for dough production of 120kg-240 kg. Another special feature is a modification to the mass mixer. Bisque, vanilla creams, various mixes and sand masses or different fillings can be produced easily in parallel. If both versions contain a spiral tool or an interchangeable tool, they will both have the same tub size. Tubs can be exchanged with one another.

Bisque, vanilla creams, various mixes and sand masses or different fillings

Conclusion:

Efficiency plays a major role for all bakeries. It is, therefore, of immense importance for DIOSNA to carry out a cost-benefit analysis with the customer. Is a Spiral Mixer the better solution for the customer? Or are the additional costs of a Wendel Mixer justifiable? Are the advantages of better mixing in a shorter time, the higher water absorption and the lower dough temperature so important that long-term production can be more efficient and economical? DIOSNA's technology has developed steadily in recent years and work processes have also been partially automated. The best example is their transponder technology using RFID bowl tracking at the mixers, which offers great support in avoiding sources of error in the process chain. It is very important to consider the craftsmanship and philosophy of the bakery when making recommendations.
Buying a mixer or mixing system is a long-term investment. The average durability of the DIOSNA Mixers is approx. 30 years! Diosna Dierks und Söhne GmbH has more than 135 years of experience in the production of high-quality mixers and rely on the ambitious MADE IN GERMANY standard. Working closely with the customers constantly brings a high level of expertise for the baking trade, advisory skills and in the development of machines and dough technology. These are precisely the reasons why DIOSNA Machines are still and becoming increasingly popular.

Bisque, vanilla creams, various mixes and sand masses or different fillings

DIOSNA, quality made in Germany since 1885