The Complete Guide to Hydraulic Dough Dividers for Commercial Bakeries

Introduction to Hydraulic Dough Dividers

For commercial bakers looking to streamline their production, a hydraulic dough divider is an essential piece of equipment. Hydraulic dough dividers allow bakers to quickly and efficiently divide dough into evenly sized pieces for consistent baking results. In this comprehensive guide, we'll explore how hydraulic dough dividers work, their key features and benefits, and what to consider when choosing one for your bakery.

What is a Hydraulic Dough Divider?

A hydraulic dough divider is a specially designed machine that uses hydraulics to quickly and evenly divide dough into individual pieces of a specific weight. The divider contains pockets that open to receive a chunk of dough. The pockets then close and the dough is sealed off. A hydraulic piston pushes the dough through a forming die to achieve the desired shape and weight.

This automated system allows dough to be divided into hundreds of pieces per minute, far faster than can be achieved by hand. Hydraulic pressure ensures each piece reaches the correct desired weight, removing human error and minimizing waste. This speed and consistency is essential for high volume commercial bakeries.

Types of Hydraulic Dough Dividers

There are two main types of hydraulic dough dividers:

• Single Pocket Dividers: These basic dividers contain a single pocket that moves under the hopper to receive dough, seal, and eject a piece. They produce pan breads, rolls, and buns.
• Multi-Pocket Dividers: These advanced dividers have multiple pockets moving under the hopper. This allows very high output up to 1,800 pieces per hour. Best for high volume bakeries.

Key Features of Hydraulic Dough Dividers

Hydraulic dough dividers have several key features that enable their fast and consistent dough dividing abilities:

• Hopper: The stainless steel hopper stores dough and feeds it into the pockets. Hoppers are sized to hold enough dough for continuous production.
• Pockets: Made of food grade plastic for non-stick performance. The pockets receive dough from the hopper, seal, and eject pieces.
• Hydraulic System: Hydraulic pistons apply consistent pressure to push dough through the forming die for precise sizing.
• Control Panel: Allows the operator to adjust divider settings like dough weight, pocket size, speed, and more.
• Forming Die: Interchangeable dies in various shapes are used to form dough pieces for different products.

Benefits of Using a Hydraulic Dough Divider

Investing in a hydraulic dough divider offers commercial bakeries many benefits including:

• Speed: Divide up to 1800 pieces per hour, far faster than human hands.
• Consistency: Precise sizing and weighing of each dough piece.
• Efficiency: Minimal dough waste thanks to optimized division.
• Labor Savings: Require less people to divide dough.
• Flexibility: Quick changeover between different dough textures and formulations.
• Easy Operation: Many accessories and options for fast setup and cleaning.
• Cost Effective: Improve productivity and profitability.

Choosing the Best Hydraulic Dough Divider for Your Bakery

With many different models on the market, selecting the right hydraulic dough divider for your needs is an important decision. Here are the key factors to consider when choosing a dough divider for your bakery:

Output Requirements

First, determine your bakery's output requirements. What quantity of dough pieces do you need to produce per hour? Single pocket dividers output 300-1400 pieces per hour. Multi-pocket dividers output up to 1800 pieces per hour for high volume bakeries.

Dough Types and Formulas

Consider the types of dough you work with. Hydraulic dividers can handle slight to moderate viscosity doughs including wheat, rye, ciabatta, and whole grain. Make sure the divider can quickly adapt to different formulas and dough textures.

Weight Range

Hydraulic dividers should accommodate the weight range of your dough pieces. Most can divide 10g up to 6000g pieces. Scaling buckets can extend the minimum weights down to 5g.

Dimension Range

The divider must produce dough pieces in the sizes you need. Look for a model that can accept different forming dies and pistons to create a wide range of dimensions.

Easy Changeover

Check that the divider allows quick changeover between different dough formulations and products. Toolless removal/insertion of parts enables fast changeovers in 5 minutes or less.

Durability and Reliability

As a major capital investment, a hydraulic dough divider should deliver years of trouble-free service. Look for robust stainless steel construction and food grade plastics that can withstand busy bakery environments.

Aftermarket Service and Support

Consider the manufacturer's service network and technical support. Local availability of parts and service will minimize downtime if repairs are needed.

Budget

Hydraulic dough dividers range from around $10,000 up to $30,000 for more sophisticated models. Determine your budget and look for the divider that meets your requirements within that price range.

Operator Friendly Design

An ergonomic divider with easy to clean parts will be appreciated by your staff. Look for lots of accessories and options to optimize the divider for your specific bakery and products.

Operating a Hydraulic Dough Divider

While hydraulic dough dividers greatly simplify the dividing process, the operator does need to follow proper operating procedures to maintain accuracy and efficiency:

Prepare the Dough

The dough must be properly mixed, rested, sheeted, and rounded before loading into the hopper. This ensures the dough has consistent texture for even flow into the pockets.

Adjust Settings

Based on the dough formulation, adjust the divider settings for desired piece weight, pocket size, speed, and other parameters.

Load the Hopper

Fill the hopper with enough dough for continuous production. Loading height should remain fairly constant.

Control the Flow

Control the dough flow into pockets so they are properly filled without overfilling. Adjust flow rate as needed.

Monitor Production

Visually inspect dough pieces to ensure proper weighing and forming. Check scale periodically to confirm weights.

Change Settings and Dies

When switching products, change the divider settings, swap forming dies, and adjust other parts quickly. Minimal downtime between changeovers is key.

Perform Preventative Maintenance

Follow the manufacturer's schedule for cleaning, lubricating, and replacing wear items. This prevents issues before they can disrupt production.

Maintaining a Hydraulic Dough Divider

To keep your hydraulic dough divider running smoothly:

Daily Cleaning

Thoroughly clean all dough contact parts daily. Disassemble for cleaning access. Avoid water spraying electrical components.

Check Hydraulic Oil

Regularly confirm hydraulic oil is at proper level and replace hydraulic filters as needed.

Inspect Wear Items

Check forming dies, gaskets, seals, and other wear parts. Replace immediately if excessive wear present.

Lubricate Moving Parts

Apply food grade lubricant to hinges, slides, bearings, and chains. This prevents binding and jams.

Calibrate Scales

Confirm weighing accuracy monthly by calibrating with test weights. Adjust as required.

Address Leaks

Repair any hydraulic leaks immediately to prevent unsafe conditions and damage.

Train Staff

Ensure staff are trained on proper cleaning, operation, adjustment, and safety procedures.

Conclusion

With its speed, consistency, and efficiency, a hydraulic dough divider is a smart investment for high volume bakeries. Choosing a divider that meets your production needs and offers durability, reliability, and easy operation will provide many years of service. Proper maintenance and staff training keeps the divider in optimal condition. By automating the dividing process, hydraulic dough dividers give bakers more time for new product development and creativity.

FAQs

What sizes of dough pieces can a hydraulic divider produce?

Hydraulic dividers can produce dough pieces weighing as little as 5 grams up to 6000 grams. Different pocket sizes, pistons, and dies allow a wide range of dough piece dimensions.

How fast can a hydraulic divider operate?

Single pocket dividers can operate at speeds of 300-1400 pieces per hour. High output multi-pocket dividers can produce up to 1800 pieces per hour.

What types of dough can hydraulic dividers handle?

Hydraulic dividers work well with slight to moderately viscous doughs including wheat, whole grain, ciabatta, and rye. Sticky doughs can be challenging.

Does a hydraulic divider require special skills to operate?

Hydraulic dividers are designed for easy operation. However, training staff on proper cleaning, safety, adjustment, and maintenance procedures is important.

How much does a hydraulic dough divider cost?

Costs range from about $10,000 for basic models up to $30,000 for very sophisticated high capacity dividers.