Baking & Snack - October 2017 - 85

Many mixers come
with data management
programs that remind
bakers when it's time to
lubricate a gearbox and
other preventive maintenance procedures.
AMF Bakery Systems

explained. "The logic of loading and unloading mixers
remains the same, always. On top of reducing downtime created by delays from operations, automated systems will constantly repeat the same tasks and processes
through the production schedule."
E.T. Oakes relies on PLCs and smart technology to
display total running hours and other vital information
on its screens that assist with predictive maintenance,
according to Bob Peck, vice-president of engineering.
"The touch screens show graphs that indicate how the
pump is wearing over time as well as other graphs that
indicate if flow meters and other devices are working
properly," he said.
Mr. Spaugy noted Shaffer's diagnostics screen assists
with troubleshooting by displaying mixer fault codes.
Meanwhile, VMI's teams can connect to a machine
remotely and assist its customers more efficiently. "Our
objective is to provide bakers with as many tools as possible to better understand and prevent any downtime
on our equipment," noted Terry Bartsch, president and
CEO, VMI America, LLC. "For example, the gear motors in our Verymix III vacuum kneaders are equipped
with sensors that track the number of hours these parts
are used. Before a problem can occur, the operator and
maintenance personnel are alerted when the parts have
reached a critical point so proper preventive maintenance can be performed."

Ramping up the amps
Getting the optimal performance from a mixer involves
a plethora of variables that make selecting one more

complicated than in the past. Today, one size doesn't fit
all. Rather, it's more about matching horsepower and
torque to provide proper development of the dough
without putting too much stress on the motors and gearboxes that could lead to an eventual breakdown.
During the purchasing process, bakers need to calculate the necessary amp load for maximum-sized batches
and various types of doughs for different styles of mixers.
It's not as easy as it seems, especially as a business grows.
When it comes to performance, size matters, but so
does the stiffness - or softness - of the dough. "We get
asked a lot about what's the best formula for determining the right-sized mixer because bakers tend to get it
wrong," Mr. Morabito observed. "Bakers think they have
a 1,000-lb mixer, but actually, it's an 800-lb mixer for
different doughs. It's a 1,000-lb one if you are doing soft
doughs, but if you are making bagels, you have to de-rate
it for the stiffness of the dough."
When mixing a different formula, he recommended
using an amp meter to determine the limits on the main
motor. "Mix as large of a dough as you want to mix, but
watch those amps. If your mixer motor is rated for 75
amps high, you shouldn't exceed that," Mr. Morabito said.
Don't forget dough temperature either. Many bakers
still use ice, which not only cools but also stiffens the
dough - and may even arrest its development, requiring longer mix times. That's a factor, especially with spiral mixers.
"If the doughs are mixed with a high amount of ice, or
the doughs are not as soft, use mixers with a gear wheel
instead of a friction wheel," suggested Richard Breeswine,

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