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Sponsored Innovation Feature - SPRING 2021

DIOSNA

Hygienic Design Technology. All the benefits your bakery needs.

Have you thought about the possibility of having a dough mixed in the shortest possible time, with the ideal gluten structure development, a higher water absorption and the lowest possible temperature? It sounds impossible, right? Well not for us!

At DIOSNA, we have created the perfect balance between efficiency, great product quality, safety and reliability. We understood, many years ago, that once the dough was optimally mixed, that the bread would turn out perfectly. Since then, we have dedicated ourselves to achieving perfection for all of our mixing systems.

Colder doughs, lower mixing times, higher dough yields, higher water absorptions, safety guidelines, etc. This has been our mission and main purpose; we would be more than delighted if you could benefit from it all!

DIOSNA Wendel MixerOur DIOSNA Hygienic Design Wendel Mixer (WH 240EWH 600E) with an Under Bowl Discharge system gives you all these benefits and much more.

The Wendel Mixer of the Hygienic Design Line (WH series) is the latest development of the Hygienic Design series. It comes in 3 different sizes: up to 240 kg, up to 400 kg and up to 600 kg of dough.

The design of the mixer is based on the guidelines of the European Hygienic Engineering & Design Group (EHEDG).

The two counter-rotating DIOSNA Wendel Tools allow the most efficient mixing and energy balance.

By means of folding – and not just stretching the dough – the perfect development is obtained in the shortest possible time. In fact, this system results in up to 50% less mixing time versus other mixing technologies and increases the dough production and high mixing capacities per hour (up to 3,000kg/hour per mixer).

With a Wendel Mixer, total mixing times may vary from 6-8 minutes (depending on the type of dough), whereas with other mixing systems, mixing times may vary between 12-20 minutes.

"90% of the energy input is used for developing the dough, with just 10% being lost as temperature increases"

The very efficient way in which energy is introduced into the system and the way in which it is used, translates into cooler doughs. As a reference we could make some simple comparisons:

  • With our Wendel Mixers, 90% of the energy input is used for developing the dough with just 10% being lost as temperature increases, which means 0.5-1.5°C increase in temperature for each minute at high speed.
  • With a traditional spiral mixer (without a centre bar), 65% of the energy input is used for dough build-up and 35% is lost as temperature increases, which means a 2.5°C increase in temperature for each minute at high speed.
  • With a traditional spiral mixer (with a centre bar), 75% of the energy input is used for dough build-up with 25% being lost as temperature increases, which means a 2°C increase in temperature for each minute at high speed.
  • With a horizontal mixing system, 50% of energy input is used for developing the dough whilst the other 50% is lost as temperature increases, resulting in a 5°C increase in temperature for each minute at high speed. With this set-up, therefore, it is crucial to include a cooling system in the mixer. Such cooling systems are completely unnecessary for both our Wendel Mixer range and continuous horizontal mixer (DIOSNA ContinoMIXX) with special tools, simplifying the entire operation and reducing the factory’s total energy consumption.
  • The gentler mixing system in our Wendel Mixers allows the proteins in the dough to bind with more water resulting higher dough absorption (up to 3% more, compared to spiral) in comparison with other mixing technologies.

"The Wendel Tools system uses a much gentler mixing action than the norm, allowing, in some cases, the reduction in the usage of dough improvers"

Obtaining an ideal dough absorption is critical for ensuring proper yeast and enzymatic activity, to ensure the correct pan flow in sandwich breads and all types of buns and for creating the correct rheology needed to obtain the perfect volume. The final result of all this leads to brighter, smoother and drier doughs enabling you the baker to reduce the amount of dusting flour or oil used in the makeup stages (dividing and rounding) and benefit from further quality gains.

Where a mixing system does not ensure the correct binding of water, other quality issues may arise, such as sticky doughs, poor machinability, unsuitable proofing times, asymmetric loaves and poor volume.

The Wendel Tools system uses a much gentler mixing action than the norm, allowing, in some cases, the reduction in the usage of dough improvers or the addition of vital wheat gluten lacking in poorer quality flours. This less vigorous yet high performance system, processes doughs containing fruit, nuts, chocolate pieces etc., without them being crushed.

The Hygienic Design feature of the Wendel Tools (Line WH series)The Hygienic Design feature of the Wendel Tools (Line WH series) is vital for quality assurance due to their open design and frame construction, a feature which dramatically reduces the available areas for excess dough to become trapped. By the end of the mixing cycle when the dough has been removed from the system, the bowl and the tools remain completely clean, which is extremely important for faster equipment transitions during recipe changes. Moreover, their stainless steel profiles make them completely washable and resistant to corrosion and rust over time owing to their, hygienically optimised surfaces designed to deter microbial and particulate contamination of the end product. Finally, rounded profiles and electronic drives allow for a much more thorough washdown after use (IP 66).

Wendel Mixer (WH 240E - WH 600E) Under Bowl Discharge systemOur Wendel Mixer (WH 240E - WH 600E) Under Bowl Discharge system allows an automatic discharge of the dough immediately after mixing. The automatic opening on the bottom of our bowls allows optimal dough emptying and includes the addition of a special scraper made of metal detectable polyethylene (PE) making it easier to clean. Importantly, the scraper is equipped with a temperature sensor, which allows the operator to decide if mixing should be governed by mixing time or dough temperature. Mixing could also be controlled by energy input (kW / J).

Centre emptying enables the dough to be conveyed quickly and directly into stainless steel trolleys or on conveyor belts without lifting or tipping. The height of the complete mixing and discharge system is at all times adjusted to the specific needs of the rest of the line.

DIOSNA Dierks & Söhne GmbH is a worldwide known German manufacturer that specialises on Dough Mixing, Pre-Dough Equipment and Dough Technology.

We are a Company of the Linxis Group and are deeply appreciated by clients for our expertise. We have been a reference in premium quality for more than 135 years and all of our machines and automated systems are manufactured in Germany and supplied all over the world.

Along with our DIOSNA Bakery & Food Service, we support our customers with flour analysis (moisture content, aW, protein-gluten content, damaged starch, Farinogram, etc.) providing them with valuable information to help them adjust their formulas and processes. We also offer the holding of bespoke seminars and training sessions on specific subjects such as kneading, innovation, product development. DIOSNA sets great store on customer satisfaction and offers them the possibility to thoroughly test their products in the Technology Centres in Osnabrück, Isernhagen, Germany (see below) and Kansas City, MO, USA.

DIOSNA Isernhagen Sales Workshop in Germany

In conclusion

DIOSNA can help you to design and produce doughs that are mixed in the shortest possible time, contain an ideal gluten structure, higher water absorption at the lowest possible temperature.

Working with DIOSNA, you can have confidence in having the support of a reliable and competent partner who will develop for you the best kneading and mixing technologies specifically adapted to your unique manufacturing process.

Learn more about our Hygienic Design Technology

DIOSNA, quality made in Germany since 1885