Mixers Innovation José Cheio De Oliveira
WHO WE ARE MARKET VISION LATEST DEVELOPPMENT THE CONTINUOUS MIXER
WHO WE ARE THE GROUP A Group supplier of equipments for the manufacturing of products in the food domain, the chemistry, pharmaceutical, cosmetic 8 COMPANIES Bakery Pastry Dairy Butter Cheese Cosmetics Pharmacy Chemicals $ 190 MILLION TURNOVER 60% EXPORT TURNOVER
WHO WE ARE VMI 2015 revenues of 55.0 million Headquartered in the West of France 210 employees Offering the broadest portfolio of mixing solutions worldwide Facilities More than 90 countries covered The industry s source for MIXING solutions
WHO WE ARE KNOW HOW OFFERING THE BETTER MIXING SOLUTION
THE LARGEST PORTFOLIO OF MIXING SOLUTIONS 250 continuous mixer 350 Automatic sytems 100 Horizontal mixers (vaccum) 200 (Planetary mixers)
MARKET VISION CONSUMERS EXPECTATION Market WORLWILDE CONSUMERS ARE CONNECTED CONSUMERS ARE BETTER INFORMED CONSUMERS ARE MORE DEMANDING CONSUMERS WANT QUALITY REGULARITY BETTER COST
MORE COMPLICATED MARKET SPECIFIC & DIVERSIFY PRODUCTS INDIVIDUAL PACKAGING GLUTEN FREE SHELF LIFE SOFTNESS COST FIBERS PLEASURE REPRODUCTIBILY
THE INDUSTRIAL CHALLENGE MASS PRODUCTION, DIVERSITY & REGULARITY FRESH DOUGH INDUSTRY FROZEN DOUGH INDUSTRY - Par-baked and frozen bread - Raw frozen bread: - Frozen pastry - Puff pastry COMMON PROCESS KYPOINTS : MASS PRODUCTION & DOUGH TEMPERATURE CONTROL
POUR FAIRE FACE AUX NOUVEAUX MASS PRODUCTION & DOUGH TEMPERATURE CONTROL DÉFIS THE CONTINUOUS MIXING STRENGHT!
PRINCIPLE: WHAT S A CONTINUOUS MIXER CONSISTENT & UNIFORM DOUGH STREAM TO THE PRODUCTION LINE CONTINUOUS INGREDIENTS METERING Each component, fluid or solid, is dosed with very high accuracy CONTINUOUS MIXING Continuous Mixing is the process of continuously metering ingredients directly into the mixing chamber and as a result, generating a continuous stream of mixed product at the exit of the mixer. DOUGH TEMPERATURE CONTROL The dough temperature is continuously measured and controlled via the process water temperature or via the cooling jackets of the mixer
CONTINUOUS MIXING: PROCESS BENEFITS ACCURATE RECIPE CONTROL High accuracy dosing of solid & liquid ingredients, including pre-dough & sponge MEASUREMENT & CONTROL KNEADING ENERGY & DOUGH TEMPERATURE. No head-tail effect: constant dough quality at every step in the process, no variations in dough on make-up line. HIGH EFFICIENCY IN KNEADING INTENSITY & DOUGH DEVELOPMENT. Lower energy consumption needed in dough making process. (40%less in continuous principle)
CONTINUOUS MIXING: PRODUCTION BENEFITS MORE TRACABILITY Constant monitoring & data logging of ingredient consumption & dough output. LESS FOOT PRINT A high capacity dough output in a smaller space LESS MANPOWER, Fully automated & recipe controlled dough production. Centralised process control. Dough production automatically adjusted to demand from make-up line. SIMPLY DOWNSTREAM DOUGH HANDLING EQUIPMENT No need for elevators, tilting bowls. At the same time there is less reject production, because as a result of the controlled forced conveying, there is less waste in the event of a line stop. DOUGH QUALITY INDEPENDENT FROM LINE OPERATORS.
CONTINUOUS MIXING: CONTINUOUS & FLEXIBLE?? FLEXIBILITY IN CAPACITY Reduce capacity with 30% of nominal capacity (keeping the same dough) Biggest capacity (8000 kg/h) FLEXIBILITY IN DOUGH DEVELOPMENT Changing kneading intensity (wh/kg) = dough development FLEXIBILITY IN MACHINE ADJUSTMENT Water added, dought development,temperature (adjustable during production )
CONTINUOUS MIXING: IMPORTANT DECISION FACTOR PRODUCTION RATE Continuous mixing is equally applicable at all rates.. A key difference is that for continuous mixers, as the production rates required increase, the costs do not increase at the same place. The result is larger systems cost much less per kg of dough produced. In addition, there is no increase in labor to produce at higher rates. NUMBER OF MAJOR CHANGEOVERS PER WEEK. More than two major recipe changes per day on average should be avoided. (color change,allergens,..)this is why many manufacturers target lines with the longest product runs for continuous mixing processes. For minor changes (minor recipe modification), most changes require only that the dough from the first process be pushed out of the mixer with the new recipe TECHNOLOGICAL PREFERENCE It s an automated system- If there is no PLC to controll processes in the plant, if the ingredient inventory is not computer controlled COULD BE A SOLUTION TO DO IT!
POUR FAIRE FACE CONTINUOUS AUX NOUVEAUX MIXING SOMETHING DÉFIS NEW???
POUR FAIRE FACE AUX NOUVEAUX CONTINUUM DÉFIS : CONTINUOUS MIXING UNDER VACCUM
CONTINUUM ANSWER TO SOFT BREAD PRODUCTION BATCH SYSTEM72.3 to 5.3 tons/hour MIWING TIME AROUND 4 min at very high speed Tweedy, APV Limited batch size (air inclusion distribution) PLEASURE : Scientific APPROACH VIII : horizontal vacuum mixer VERYMIX: Continuous mixer CONTINUUM - MERGING TECHNOLOGIES
CONTINUUM BORN WITH PLEASURE VACUUM (PRESSURE) MIXING PROTOTYPE: GLUTEN OXYDATION DOUGH RHEOLOGY CONTROL OF DOUGH AERATION PIZZA DOUGH DOUGH RHEOLOGY DOUGH STICKINESS TIN BREAD DOUGH & BREAD POROSITY
CONTINUUM PLEASURE RESULTS (TIN BREAD) TIN BREAD - Reduction of size of gas nuclei in the dough - Faster start of expansion during fermentation - More homogenous gas cell distribution - Change dough rheology P ATM P P1=P(+) MIXING KNEADING P2=P(-) TIME
CONTINUUM PLEASURE RESULTS (PIZZA DOUGH) IMPACT OF PRESSURE and LIPIDS ON DOUGH POROSITY (NOMINAL FULL SALT ) PRESSURE = DOUGH POROSITY 30 25 POROSITY (%) Porosity (%) 20 15 10 5 0 0-100 -200-300 -400 Pressure PRESSURE (mbar) (mb) 148 111-500 74 37-600 0 FAT Fat (g) (g) 185 222
CONTINUUM PLEASURE RESULTS (TIN Bread) Mixing prepare the final texture (after backing) Cells Number Cells sizes Wall between Cells
CONTINUUM - PRINCIPLE Traditional mixing sequences PRE MIXING (homogeneise) KNEADING (aeration & texturation) Continuous Vacuum Crumb structure mastering Reduced kneading chamber Better thermal efficiency (Rapport 2t/h 50 kg) Hight energy input level (30 Wh/kg CONTINUUM : Vaccum continuous mixer Cleaning in place (CIP)
CONTINUUM - DOUGH STRUCTURE & VACUUM MIXING MIXING CONTROL = CRUMB CONTROL INTEREST OF VACUUM MIXING Reduction of dough stickiness Increase of dough plasticity Reduction of size of gas nuclei in the dough Faster start of expansion during fermentation More homogenous gas cell distribution
CONTINUUM DIFFERENT APPLICATIONS
CONTINUUM FIRST INDUSTRIAL CONTINUUM UNDER CONSTRUCTION TIN BREAD APPLICATION INDUSTRIAL LINE : 7 T/hour
THANKS TO YOUR ATTENTION José CHEIO DE OLIVEIRA Tel : +33 (0)2 51 45 35 40 jcheio&vmi.fr Visit us at http://www.vmi.fr/ www.vmi-mixer.com Sales team comm-ind@vmi.fr Customer service service@vmi.fr Media center contact@vmi.fr