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    Batch vs. Continuous

    What is Batch mixing // what is Continuous mixing?

    BATCH –  batch mixing means all ingredients are (manually) loaded into a mixer for duration until they are homogeneously distributed or mixed. After that, they are discharged and a new batch is being produced. Batch processing has been the chosen technology of the bakery industry for many years.  Even though a batch system is still the most widely used system, it might not be the best choice for your particular application.

    CONTINUOUS – a continuous mixing process works based on the first in first out principle, whereby the composition and the mechanical behavior of the dough is constant at all times. Besides that, the process is characterized by a short residence time with low energy consumption.

    Batch mixing vs. continuous mixing
    Batch mixing vs. continuous mixing
    Batch mixing vs. continuous mixing
    Batch mixing vs. continuous mixing

    The rise of continuous..

    Continuous mixing / kneading and other automated Industrial dough mixing processes are gaining more and more favor. A growing number of bakery operators are considering a continuous mixing / kneading approach to their Production process. When the first Industrial bakeries came into being, batch mixers could satisfy the bakers needs and wants. However, as food demand grew so did the size of the food Production factories and conclusively Production output. Batch mixers became larger and ovens longer. Typically, the larger the batch of dough, the longer it takes to process the mass. The moment this line is stopped (for some reason) the dough produced by a certain batch will easily be lost.

    As a result, newer technologies can produce larger quantities of dough (up to 12.000 kg/hr) in one and the same system. These continuous dough solutions are fully automated and require almost no manpower, accurate recipe control and a constant consistent product Quality. You must be thinking..why didn’t we hear of this technology sooner?

    The answer is that until around 20 years ago, the bulk handling and metering technologies were not advanced enough to feed the mixer at rates high enough to meet the demand of the continuous mixing process. The past two decades, this technology (for bulk handling and metering) have advanced immensely enabling an extremely accurate dosing of seperate ingredients into the Industrial dough mixing system. Consequently, more and more bakeries question whether to choose batch or continuous dough mixing. On the one side, the long tradition of batch mixers and on the other side technology improvements and increased Quality demands of todays consumers.

    Careful comparison

    continuous mixing
    continuous mixing
    continuous mixing
    continuous mixing
    TRADITIONAL MIXING

    Batch mixing is seen as the most established and traditional way of blending raw materials – simply because these mixers were available when continuous did not exist yet. The development of improved mixing, controlling and metering resulted in continuous mixing systems that are reliable, easy-to-use and able to provide a consistent product Quality. Nevertheless, Sobatech understands that organizing your production process in a new innovative way can be exciting. Therefore, Sobatech has its own pilot plant allowing you to overcome possible perceived risks of changing to a new innovative type of mixing.

    PRICING

    A large misconception in the process of evaluating both processes is that continuous mixing is perceived to be more expensive than batch mixing. The rootcause of this misunderstanding lies in the fact that the cost of a continuous mixing system is compared to the cost of a batch mixer. A continuous mixing system obviously includes much more than solely the continuous mixer. If you compare solely on a mixer-to-mixer basis, you will find similar capital investments.

    BULK DELIVERY OF RAW MATERIALS

    Generally, the same delivery systems can be used for both batch as well as continuous food processing (possibly pneumatic transfer from silo to receiver).

    DOSING INGREDIENTS

    The pricing difference between a batch or continuous system depends on whether you feed your batch mixer manually or automated. In case of a continuous mixing system, the dosing of raw materials is always done automatically at the mixer and requires greater automation and accuracy (the Quality is independent of the skills of the workers). Even though, the initial investment of the automated dosing systems might be higher on a continuous mixing system – on the long term the improved metering technology will represent significant cost savings. Think of less waste due to more accurate weighing during packaging (as a result of a more consistent product quality) and minimzed labor costs (due to the high automated grade of a continuous production environment).

    DOUGH DISCHARGE

    Batches of dough typically come in a not-usable form, meaning that additional equipment is required to resize the batches. This additional proces step creates unnecessary shear and exposure of the dough. The continuous mixing proces creates continuous streams of dough that can be cut in-line if desired – there is no need for additional equipment that resizes the batches.

    Naturally, the amount of savings related to a continuous system typically increase as production rate increases. 

    PRODUCT QUALITY

    Apart from the operational cost savings, many Industrial food producers prefer a continuous proces as it increases product Quality consistency and control. Typically a continuous Production line creates a dough that has minimized variations in development, homogeneity and temperature. Every piece of dough has to go through the continuous mixers in order to be discharged – meaning every piece of dough has had the same mechanical treatment. Besides that, the mixing chamber and mixing tools have a relatively large contact surface. This results in a constant (and controlled) development of the dough. Consistent doughs are easier to extrude and weight, while inconsistent doughs (due to amongst others the head and tail of a batch process) create variations in flow and varying piece weights with it (creating inconsistencies during packaging).

    Product temperature calculator

    Curious about the optimum temperature for your production line? Make free use of our thermal calculator. Enter your details below and you can get started within 1 minute.

    Product temperature calculator
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    Product temperature calculator

    Your calculation

    Dough capacity
    Gross dough capacity (kg / hr)
    Net dough capacity (kg / hr)
    Your ingredients
    Ingredient % kg / hr Input temperature (ºC)
    Flour % kg / hr Input temperature (ºC)
    Water % kg / hr Input temperature (ºC)
    Pre dough (based on 100% water & 100% flour) % kg / hr Input temperature (ºC)
    Liquid yeast (based on 100% fresh yeast & 150% water) % kg / hr Input temperature (ºC)
    Butter or different kinds of oil, like palm or sunflower oil % kg / hr Input temperature (ºC)
    Starch or gluten % kg / hr Input temperature (ºC)
    Rework like scrap dough % kg / hr Input temperature (ºC)
    Salt as a solid % kg / hr Input temperature (ºC)
    Sugar as a solid % kg / hr Input temperature (ºC)
    Melting ice % kg / hr Input temperature (ºC)
    Dry Additive I % kg / hr Input temperature (ºC)
    Dry Additive II % kg / hr Input temperature (ºC)

    Total % kg / hr Input temperature (ºC)
    Calculated Calorific value of raw materials prior to processing
    Moisture percentage in the flower
    Calculated reaction heat depending on the recipe and the moisture of the flour, moisture is
    Cooling capacity of the double jacket in the Mixer and the Kneader
    Estimated dough temperature rise due to kneading energy
    Calculated dough temperature including reaction heat and kneading energy

    Your results

    Estimated dough development (Wh/kg)
    Estimated net power for the kneader (kW)