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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 homogenously 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.  The fact that batch mixing is the most widely used system does not mean it is the best choice for your particular application.

Batch mixer

 

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

Continuous mixing
Continuous mixing

 

The rise of continuous..

Continuous mixing and other automated dough mixing processes are gaining more and more favor, a growing number of bakery operators are considering a continuous approach to their Production process. When the first Industrial bakeries came into being, batch mixers could satisfy the bakers needs and wants. But 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.

Sprinkles - Sobatech continuous technology

Cakes - Sobatech continuous technologyCroissants - Sobatech continuous technology

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 (Sobatech’s dark-room principle), accurate recipe control and a constant consistent end 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, these technology (for bulk handling and metering) have advanced immensely enabling an extremely accurate dosing of seperate ingredients into the continuous mixing system.

Consequently, more and more bakeries question whether to choose batch or continuous 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.

We hope this website might help you in making the right decision. For a careful comparision of both processes, please see the following news item.

Sobatech continuous mixer
Sobatech continuous mixer

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)
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