using doughlab to mimic commercial high energy dough ... · using doughlab to mimic commercial high...
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Using doughLAB to mimic commercial
high energy dough development and
predict flour blend performance.
Bronwyn Elliott and Mark L. Bason
Perten Instruments of Australia
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Introduction
• doughLAB
• 300g/50g (lab/factory scale)
z- arm mixing to determine
flour processing quality.
• Same results as Farinograph
for conventional test (63
rpm, 30°C).
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doughLAB
• High energy / accelerated mixing: develop samples that are difficult to
develop, incorporate ingredients such as fat, reduce test time, give a
better indication of dough stability.
• Programmable temperature to cook starch / stress dough.
• Mimic commercial processes: rapid dough, high energy mixing.
• DLW software: instrument control, data acquisition, data analysis,
curve analysis, flour blending.
• Model flour blends to predict their performance without having to run
extra tests. Blending different flour varieties and mill streams enables
the miller to reduce costs and maximize profits while blending to
specification for specific customers and specific uses.
• Relevant and timely information about products and processes: water
absorption, mixing energy, stability.
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DLW Software Data Analysis
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Goals
• Assess the quality of commercial flour mill streams and their
blends by low and high energy mixing.
• Assess ability of virtual mixing to predict actual blend quality.
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Methodology
• Samples
• Prime hard wheat from Qld 2009 harvest
• Commercial pilot scale mill (155 Kg flour recovered)
• 13 mill streams
• 4 break
• 5 reduction
• Size, break middlings, bran & fines
• Blends
• Straight (all fractions at yield ratios)
• High/Low WA (1st & 4th break)
• High/Low mix stability (1st break & 4th reduction)
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Mill Schematic
1Bk
2Bk
3Bk
4Bk
A
B
C
D
E
BM
B2
SIZ
BF&F
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Blends (%)
Stream Straight WA HiLo Stab HiLo
1Bk 8.2 50.0 50.0
2Bk 7.1
3Bk 5.2
4Bk 2.6 50.0
A 17.7
B 4.1
C 13.2
D 11.4 50.0
E 7.4
BF&F 4.7
SIZ 3.6
B2 9.5
BM 5.2
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Testing & Analysis
• doughLAB with 300g sigma-arm mixing bowl
• AACC 54-21 (63 rpm slow blade, 30 oC, 20 min, 500+/-20 FU)
• Same WA for 120 & 180 rpm tests
• Measuring
• WA (%)
• DDT (min)
• Stability (min)
• Softening (FU, 5 min)
• Peak Energy (Wh/Kg)
• Virtual Blending
• Weighted averages
0
100
200
300
400
500
600
0 5 10 15 20 25 30
time (min)
torq
ue (
FU
)
arrival time
softening time
MTI time
development time
peak
resi
stance
stability
departure time
MT
I
soft
enin
g
bandwidth
(at peak)
specified time
torq
ue
resistance
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Results & Discussion:
Mixing Characteristics of Mill Streams
• There was a wide range in the mixing properties of the different mill
streams as measured by the doughLAB.
• Break streams
• Within the group: WA , Stability , other
• Reduction streams
• Most parameter higher than for break stream flours
• Within the group: DDT , Energy , Stability
• Other streams
• Very high WA in BF&F
• Large difference in mixing parameters
• Results reflect generally higher proportion of damaged starch, bran
(esp. pentosans) and protein through the milling steps.
• Large ranges in the results show potential to blend to specification.
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Mixing Curves (63 rpm)
Break streams
Reduction streams
Other streams
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WA (63 rpm)
0
10
20
30
40
50
60
70
80
90
WA (%)
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DDT, Stability, Peak Energy (63 rpm)
0
5
10
15
20
25
30
35
1B
k
2B
k
3B
k
4B
k A B C D E
BF&
F
SIZ
B2
BM
DDT (min)
Stability (min)
Peak Energy (Wh/Kg)
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Effect of High Speed Mixing
• Faster tests (<10 min)
• Removal of spurious ‘hydration’ peak
• Process relevant
180 rpm
120 rpm
63 rpm
180 rpm
120 rpm
63 rpm
Break Reduction
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DDT, Stability, Peak Energy
0
5
10
15
20
25
30
35
1B
k
2B
k
3B
k
4B
k A B C D E
BF&
F
SIZ
B2
BM
DDT (min)
Stability (min)
Peak Energy (Wh/Kg)
0
2
4
6
8
10
12
14
16
18
20
1B
k
2B
k
3B
k
4B
k A B C D E
BF&
F
SIZ
B2
BM
DDT (min)
Stability (min)
Peak Energy (Wh/Kg)
0
2
4
6
8
10
12
14
16
1B
k
2B
k
3B
k
4B
k A B C D E
BF&
F
SIZ
B2
BM
DDT (min)
Stability (min)
Peak Energy (Wh/Kg)
63 rpm 120 rpm
180 rpm
• Clearer trending in stability data
at higher speeds within the
reduction group (A-E)
• Dough development energy
requirements decreased slightly
with faster mixing
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Mill Streams for Blends (63 rpm)
Straight HiLo WA
HiLo Stability
All fractions at yield ratios
High/Low mix stability (1st break & 4th reduction)
High/Low WA (1st & 4th break)
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Straight Flour Blend
63 rpm
120 rpm
180 rpm
• All mill streams
• Blue = Actual
Red = Virtual
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WA Blend at 120 rpm
Blue = Actual
Red = Virtual
WA Hi/Lo
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Stability Blend at 120 rpm
Blue = Actual
Red = Virtual
Stability Hi/Lo
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Actual vs Virtual Mixing Results
Flour blend Speed WA DDT Stab Soft(5) Pk E
Straight 63 64.8 (65.0) 17.2 (18.5) 18.2 (20.7) 13 (6) 16.9
120 5.5 (6.2) 5.4 (6.2) 54 (44) 12.4
180 3.3 (3.6) 2.3 (2.6) 115 (121) 12.0
HiLo WA 63 62.5 (61.8) 10.8 (13.2) 5.9 (10.0) 41 (17) 9.0
120 - 5.0 (5.7) 2.7 (4.8) 94 (47) 9.1
180 - 3.1 (3.5) 1.5 (2.0) 162 (121) 9.8
HiLo
Stability 63 63.7 (63.3) 17.2 (16.2) 22.5 (16.4) 5 (13) 17.0
120 - 6.3 (5.8) 6.5 (5.6) 40 (49) 14.2
180 - 3.5 (3.2) 2.8 (2.4) 82 (113) 12.8
Average
Error - 0.4 0.8 2.0 20.3 -
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Conclusions
• Mill fractions exhibited a wide range of dough mixing
properties as measured by the doughLAB.
• High speed testing provided more relevant and timely
information about dough processing quality, including
water and mixing energy requirements, for different
products and processes.
• The doughLAB software’s virtual mixing function
provided reasonable prediction of actual mixed flour
performance. It can be used to assist the miller in blending
operations. It is possible to reduce costs and maximize
profits while blending to specification for specific
customers and specific uses.
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Acknowledgments
• Matthew Rees, BRI
• Sam Bason
• Jennifer Dang