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Encyclopizza®
is researched, written, and complied by John Correll.
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CONTENTS
Ingredient
Processing Methods
• Five Types of Mixers
Planetary
Mixers
• Sellers
• Sizes
• Dough
Capacity
• Types & Uses of Agitators
Types
& Uses of Food Processing Attachments
• Standard
and Optional Features
• Advantages & Drawbacks of Planetary Mixers
• Installation and Maintenance
• Operation
• Safety
Precautions
• Cleaning
Cutter-mixers
• Sellers
• Sizes
• Batch Size Capacity
• Mixing Speed
• Types & Uses of Cutting/kneading Shafts
• Standard and Optional Features
• Advantages & Drawbacks
of Cutter-mixers
• Installation and Maintenance
• Operation
• Safety Precautions
• Cleaning
• Cleaning Between
Sauce and Cheese
• Cleaning Between Sauce and Dough
• Full
Cleaning Procedure After Last Product
Spiral
Mixers
• Sellers
• Size & Batch Capacity
• Mixing Speed
• Features
• Advantages & Drawbacks
of Spiral Mixers
• Installation, Maintenance, and Operation
Reciprocating
Arm Mixers
Horizontal Mixers
Batch-type
Dividers & Rounders
• Installation, Maintenance,
and Operation
Continuous Dividers
and Rounders
• The Dividing Process
• The Rounding
Process
• Table Models
• Combination Divider-rounders
• Separate Dividers and Rounders
Slicers
• Sellers
• Types
• Features
• Optional Accessories
• Advantages & Drawbacks of Slicers
• Operation
• Safety Precautions
• Cleaning
• Between Products
• When Done Slicing
Disc-type
Cutters
• Manual Cutter
• Cutter Attachment
• Stand-alone Machines
Blade-type
Cutters
Grinders (Choppers)
Bowl
Chopper
Sauce Mixing Equipment
Cheese
Processing Equipment
• Manual Cheese Cutter or Slicer
• Large Volume Shredders
• Large Volume Dicer
•
Cutter-mixers
Measuring Equipment
• Thermometers
• Timers
• Scales
• Measuring Spoons & Cups
• Other Measuring Devices
•
Brix Refractometer
• Moisture Analyzer
• Risograph
Dough
Trays & Containers
Other Equipment
Purchasing Pointers
NOTE: Visit the Encyclopizza home page for the complete Table of Contents, including pizza dough/crust/sauce recipes.
MANY types of mixers and other machines can be used in preparing dough, sauce, cheese, and toppings. This chapter describes the main options, explains how the equipment works, and lists the advantages and drawbacks of each.
Lengths, weights, temperatures, and volume measurements are given in inches, pounds and ounces, degrees Fahrenheit, and quarts and cups (U.S. version). The following abbreviations are used: lb = pounds, oz = ounces, F = Fahrenheit, and qt = quarts. For conversion to other measurement systems, refer to the chapter on Measurements and Conversions.
Preparing pizza ingredients involves various methods. Defined here are the main
methods that might be used.
SCALING is the process of weighing out materials with a scale, as when ingredients are weighed out for making dough, or when a large piece of dough is divided into smaller units of a certain weight for making into finished baked goods (also called dividing).
MIXING is the process of combining ingredients together, as when flour, water, and other ingredients are combined together to form dough. It can be done manually (in small batches) or by machine. The machine used in mixing is called a mixer.
KNEADING is the process of folding, pressing, and stretching dough. The purpose is to develop the gluten contained in the dough. Kneading is accomplished during the latter stage of the mixing process after the ingredients have combined together.
DIVIDING, also called scaling, is the process of separating a large piece of dough into smaller units of a certain weight for making into balls (or some other shape). It can be done manually or by a machine called a divider.
ROUNDING is the process of shaping a piece of dough into a smooth, predetermined shape. In the case of pizza, dough is often rounded into balls. It can be done manually or by a machine called a rounder.
BLENDING, like mixing, is the process of combining ingredients together, as when making pizza sauce. While mixing is often applied to batters and doughs, blending is applied to other foods. It can be done manually or by a mixer.
CUTTING is the process of separating a piece of food into smaller pieces with a knife, either by hand or by machine.
SLICING is the process of cutting food into flat pieces of uniform thickness. The resulting pieces are often called slices, as in slices of bread and meat. Slicing can be done manually or by a machine called a slicer. Slicing vegetables also can be done with various types of vegetable cutters.
SHREDDING is the process of cutting or tearing food into small pieces, usually 1 to 2 inches long and 1/8-inch to 1/4-inch wide. It can be done manually or by a machine called a vegetable cutter (with a shredding disc). It also can be done with a vegetable cutting attachment on a mixer.
GRATING is the process of cutting or scraping hard food, such as Parmesan cheese or nuts, into small pieces about 1/8 to 1/4-inch long and 1/16-inch wide. It can be done manually or with a vegetable cutter (with a grating disc). It also can be done with a vegetable cutting attachment on a mixer.
GRINDING, also called mincing, is the process of crushing food into small particles. The machine used for grinding is called a grinder and also sometimes called a chopper. It also can be done with a grinding/chopping attachment on a mixer, or with a cutter-mixer (sometimes called a VCM).
CHOPPING is the process of cutting food into smaller pieces. It can be done manually or with a machine called a food cutter. It’s sometimes referred to as a “buffalo chopper” because the lid has a hump resembling a buffalo’s back. It also can be done with a cutter-mixer.
DICING is the process of cutting food into cubes, usually 1/8-inch to 1/2-inch in size. It can be done manually with a vegetable cutter (with dicing grids and disc) or with a special dicing machine.
There are many tools and machines for performing each of the above processes. The rest of this chapter describes them.
Except for the oven, the mixer is the most important piece of equipment in most pizzerias. There are five types:
• Planetary Mixers
• Cutter-mixers
• Spiral Mixers
• Reciprocating Arm Mixers
• Horizontal Mixers.
The types most commonly used in pizzerias are the planetary mixer and cutter-mixer. However, no type is best for all situations; each has advantages and drawbacks.
The
original mixer in pizzerias is the planetary type, so named because it contains
a set of planetary gears which cause the mixing shaft to revolve in circular motion
around the perimeter of the mixing bowl. Some folks also refer to this machine
as the “upright mixer.” It is versatile and wide-spread. For a photo, click
here.
Terminology Note
For years this machine has been called a vertical mixer. However, with the introduction of other vertical mixing machines, such as the cutter-mixer and spiral mixer (described in following sections), using the word “vertical” has caused confusion. In fact, it’s not uncommon for two persons to discuss the merits of “vertical mixers,” with neither of them referring to the same machine! So we now refer to this machine as a planetary mixer to avoid confusing it with the cutter-mixer and spiral mixer.
An early maker of planetary mixers was Hobart Corporation, and many of their older models are still in use today—testimony to the durability of the planetary-type mixer as well as to Hobart’s early stronghold on the mixer market. Today Hobart still sells many mixers. However, there are also many worthy competing models. Sellers of planetary mixers include (in alphabetical order):
• AMF Bakery Systems (340-qt. size) – (804) 355-7961
• Arimex – (201) 575-7500; 800-631-1132
• Berkel Inc. – (219) 326-7000
• Blakeslee – (708) 656-0660
• General Slicing – (615) 893-4820
• Hobart Corporation – (513) 332-3000; 332-3095
• Intedge Industries, Inc. – (803) 969-9601
• Middleby Marshall, Inc. – (708) 966-8300
• Polin USA, Inc. – (216) 425-4427
• Rondo, Inc. – (201) 488-0121
• Univex Corporation– (603) 893-6191
• Welbilt-Varimixer – (318) 865-1711; 800-222-1138
Planetary mixers are sized according to the volume of the mixing bowl. They range from 5 to 340 quarts, with the common increments being 12, 20, 30, 40, 60, 80, and 140 quarts. Models of 20-qt size or smaller sit on a table (although there is an optional 20-qt floor version). The most common size in pizzerias is the 60-qt model. However, a 30- or 40-qt machine might suffice for a smaller pizzeria; while a larger operation might opt for an 80-qt model. For a photo, click here.
Mixer companies provide capacity charts which state the maximum amount of pizza dough per batch that each model can be expected to produce. Oddly, even though motor sizes vary little from company to company, stated capacities vary considerably. When averaged out, the charts lead us to believe that a 30-qt mixer will produce 25 to 30 lbs of medium-stiff dough, a 60-qt will yield 60 to 70 lbs, and an 80-qt will mix 140 to 150 lbs. (A medium-stiff dough is a dough containing 50 percent water relative to flour weight.)
However, experience suggests that the optimum batch size is smaller than the maximum. With the maximum batch size the mixer works very hard, plus the dough rapidly climbs the dough hook. Optimum batch sizes for medium-stiff pizza dough are probably 30 to 40 percent less than the maximum, or approximately 20 lbs for a 30-quart mixer, 40 lbs for a 60-quart, and 100 lbs for an 80-quart.
Optimum Batch Size for Soft Dough
30-Qt Mixer —> 20 lbs
60-Qt Mixer —> 40 lbs
80-Qt Mixer —> 100 lbs
On a 60-qt. mixer, soft dough (containing 55 to 60 percent water based on flour weight) may be mixed on 2nd speed. Mix stiffer dough on 1st speed only.
In addition, the stiffness of the dough and speed of mixing affect the amount of dough a mixer can handle. Generally, the stiffer the dough and higher the speed, the smaller the batch size must be. At least three factors affect dough stiffness: flour protein content, dough temperature, and percent of water or oil in the dough. This translates into the following rules:
1. Generally speaking, the higher the protein content of the flour, the smaller the batch size must be.
2. The lower the water temperature, the smaller the batch size must be. For example, if using 50 degrees F water (instead of 70 degrees F), reduce the optimum batch size by at least 10 percent.
3. The less water contained in the dough, the smaller the batch size must be. For example, to mix a stiff dough with 40 percent water relative to flour weight, reduce the optimum batch size by 33 percent or more.
4. The higher the oil or shortening content, the softer the dough will be and, so, the more can be mixed per batch.
5. The higher the mixing speed, the smaller the batch size must be. For example, to mix a medium-soft dough at second speed (or over 100 rpm of the agitator), reduce the optimum batch size by 33 percent or more.
In conclusion, as regards mixer capacities, never exceed the manufacturer’s limits, reduce the batch size if using stiffer dough or higher mix speeds and, in general, consider mixing in smaller amounts than the maximum amounts given by the manufacturer. Also, older mixers might not accept the dough quantities listed above. When in doubt, call the manufacturer and ask for a batch size recommendation. Be sure to tell them the age of the machine and the size (horsepower) of the mixer’s motor, as older models sometimes have smaller motors than current mixers.
A key feature of the planetary mixer is its versatility, which comes from the various agitators and attachments that can be used with it. The agitators—that is, the implements which do the mixing—allow the machine to be used for all types of bakery applications. In addition, with attachments the mixer can be used for a number of food processing functions. First we examine the uses of agitators; then we look at attachments.
There are four main types of agitators—dough hook, whip, beater, and pastry knife.
DOUGH HOOK. Sometimes called the dough arm, the dough hook is the main agitator used in pizzerias. As the name implies, it’s used for making dough—namely, yeast dough. It performs two functions in mixing. First, it combines the ingredients together; second, it kneads the dough and, thereby, develops the gluten.
There are three variations of hooks: J-hook, spiral hook, and sweet dough hook. The original style, which is still used today, is the J-hook. It has a “J” or hook shape, which spawned the name dough hook. Oftentimes when people speak of the “dough hook” the J-hook is what they’re referring to. For a photo, click here.
The other two agitators are not hook-shaped at all, but the name has carried over. In many operations the spiral hook is replacing the J-hook. The spiral, so named because of its spiral shape, is used on the same products as is the J-hook, but some experts feel it does a better job of mixing and kneading dough, especially those mixed in one step (as most pizza doughs are). For a photo, click here.
The sweet dough hook is a cross between the dough hook and beater and is used for mixing softer, richer sweet dough, such as sweet rolls or Danish pastry. It performs both the kneading function of the spiral or J-hook as well as the creaming function of the beater, but not to the extent of either. Most pizzerias don’t need it. For a photo, click here.
BEATER. Also called the flat beater, batter beater, and sometimes “the paddle,” the beater is used for mixing cake batters and cookie doughs and also for creaming together sugar and shortening for frosting. In the pizzeria it might be used for mixing pizza sauce. It can also be used for mashing cooked vegetables and other soft foods. For a photo, click here.
WHIP. Sometimes called a wire whip, the whip is used mainly for incorporating air into a liquid, as when making foam-type products such as meringue, whipped cream, and light frostings. There are several variations. For whipping heavier foods, such as mayonnaise and mashed potatoes, there’s a reinforced whip and also a wing whip or wing beater, which is a cross between a whip and a beater. For a photo, click here.
PASTRY KNIFE. The pastry knife is used for cutting solid shortening into flour without kneading the dough or incorporating air into it, as when making pie dough. For a photo, click here.
Most mixers have an attachment drive hub located on the front or side of the motor
housing. The hub allows a person to operate a food processing attachment off
the mixer motor. A number of specialty attachments can be purchased but the two
main ones are the 9-inch vegetable cutter and the grinder.
9-INCH VEGETABLE CUTTER. This attachment, also called a vegetable slicer, accepts a variety of round discs (that happen to be 9 inches in diameter). They allow a person to slice, shred, or grate vegetables and other foods. A pizzeria can use the attachment for slicing vegetable toppings, such as onions and green peppers, and for shredding cheese. Some people also use it for slicing pepperoni and ham. However a conventional meat slicer does a better job. There’s a variety of discs to choose from, so a person can slice and shred foods to various thicknesses. For a photo, click here.
Many types of slicing and shredding plates can be used with the 9-inch vegetable cutter. For a photo, click here.
There’s also an optional speed drive adaptor that can be used with the vegetable cutter. It increases processing speed by more than three times.
To catch the food as it comes from a slicer or grinder, a tray support attachment can be purchased for holding a pan underneath. In place of this a large barrel or bin can be slid under the slicer and a pan placed on it.
In addition, Hobart sells a power dicer attachment which, when connected to the vegetable cutter, allows a person to create cubed and rectangular pieces of vegetable, cheese, and potatoes (for french fries). The cubes range from one-quarter to one inch in size. For a photo, click here.
GRINDER. Also called a chopper, and sometimes meat chopper or meat mincer, the grinder attachment is used for grinding (mincing, mashing) meat and other foods. It contains a large screw-shaped shaft which, when turned, chops the food into pieces and forces it through small holes in a metal disc. A pizzeria can use the tool for grinding meat into sausage and also for producing ground cheese. For a photo, click here.
OTHER ATTACHMENTS. Although seldom found in a pizzeria, other attachments that can be used with a planetary mixer include a colander (strainer) and roller attachment for puréeing foods, and an oil dropper attachment for making mayonnaise and salad dressings.
Planetary mixers come with a number of standard and optional features. The features vary from model to model. For specifics talk to a knowledgeable salesperson.
TYPE OF DRIVE. Some mixers are gear driven, others are belt driven. Each manufacturer claims advantages for its system, although there may be little or no difference from the operator’s standpoint.
HEAVY-DUTY MODELS. In addition to the size of the mixing bowl, the dough capacity of a mixer also depends on the size of the motor. The bigger the motor, the greater the torque; the greater the torque, the more dough a mixer can handle. At least one mixer company sells both regular and heavy-duty models. Heavy-duty models have larger motors and lower gear ratios than their regular-duty counterpart. When there’s a choice it’s best to buy the heavy-duty model, because making pizza dough is punishing work for a mixer and the heavy-duty version will likely last longer.
Be aware that some companys’ regular mixers are equivalent to other companys’ heavy-duty versions. So to accurately compare mixers you must evaluate specific components and features, such as motor size, gearing, etc. For pizza dough, a 60-quart mixer should have at least a two horsepower motor—preferably larger. (Minimum 8 amps at 208 to 220 volt, 60 cycle, 3 phase.)
Also, when buying an older used mixer, check the motor size. Older models often have smaller motors than similar-sized new models. Batch size should be matched to motor size, not mixing bowl capacity.
MIXING SPEED CONTROL. By “mixing speed” we mean revolutions per minute (rpm) of the agitator.
Mixers come with two types of speed controls: discrete and variable. Discrete speed controls—which are the most common—offer 3 or 4 set speeds, with 1st speed being the lowest/slowest and 3rd or 4th being the highest/fastest. Some heavy-duty models, which have lower gear ratios, come with only two speeds—1st and 2nd. Speeds vary with mixers, but typical speeds (agitator rpm) for a 60-qt mixer are as follows.
Approximate Mixing Speeds
Speed Agitator RPM
1st 70
2nd 125
3rd 200
4th 350
In discussing mixing speed it’s important to note the difference between agitator rpm and planetary rpm. For each revolution of the planetary, the agitator revolves at least twice. So, at first speed the planetary rpm of most mixers is about 30, while the agitator is 70. Here when we refer to speed we’re talking about rpm of the agitator.
It should be noted that heavy-duty mixers often have lower gear ratios to produce more torque, which results in lower agitator rpm’s and longer mix times.
Mixers with variable speed control allow the operator to set the speed at any point within a range. Typical ranges are 50 to 230 rpm and 70 to 320 rpm. A speed below 100 rpm is considered to be low or 1st speed.
Variable speed control offers more choice of mixing speed, but either system—discrete or variable—will work fine for making pizza dough.
TIMER. Mixers come with a timer. By setting the timer the mixer will shut off after a pre-determined mixing time. Some timers are mechanical, others are electronic. Electronic timers are more precise, but either one—mechanical or electronic—will work fine for mixing most pizza doughs.
ATTACHMENT DRIVE HUB. Most mixers come with an attachment hub, or power take-off, for operating food processing attachments. The most common hub (which will accept the widest number of attachments) is the standard #12 taper hub. Depending on the mixer, the hub is located on the front or side of the motor housing. Some mixer companies don’t allow using a food processing attachment while the machine is mixing; others do.
STAINLESS STEEL BOWL. Some mixers come with only a stainless steel bowl; others come with a choice of either stainless or tinned finish. Stainless steel is more expensive but holds up better to heavy use and acidic foods such as tomato sauce. After a number of years the finish on tin bowls wears off in spots and the bowl must be re-tinned. Also, after a few years tin bowls have a tendency to rust at the bottom if not completely dried after each washing. Although either bowl will work for a pizzeria, generally speaking a stainless steel bowl is preferred.
SMALLER BOWLS. For mixing small batches, optional smaller bowls with adaptors or collars can be purchased with most mixers. For example, 30- and 40-qt bowls can be used with a 60-qt mixer. Smaller bowls are used for mixing small batches of batters, meringues, and so forth that can’t be done in a large bowl. When the mixer is properly sized to the operation, most pizzerias have no need for a smaller bowl.
SPLASH COVER/BOWL EXTENSION. To eliminate splashing, which tends to occur at higher speeds and with maximum size loads, a cover or an extension which fits around the rim of the bowl can be purchased. It can greatly reduce splatter and wall washing in a pizzeria that blends sauce in the mixer.
AUTOMATIC BOWL SCRAPER. When mixing batters or liquids such as pizza sauce, the ingredients sometimes cling to the side of the bowl, resulting in incomplete mixing. To counteract that, the operator must shut off the mixer once or twice and scrape the sides of the bowl with a rubber scraper—a mild inconvenience. To avoid this, some mixer companies offer an optional bowl scraper that can be attached to the agitator. It automatically scrapes down the sides of the bowl during mixing. This can be handy for a pizzeria that blends sauce with its mixer.
WATER JACKET FOR MIXING BOWL. Although most pizzerias would have no use for it, a water jacket for the mixing bowl can be purchased. With it, hot or cold water can be circulated through the jacket, thereby keeping the mixing bowl contents warm or cool.
BOWL DOLLY. In some pizzerias it’s necessary to transport the loaded mixer bowl from the mixer to another spot. Large bowls loaded with over 50 lbs of ingredient can be difficult to handle. To assist in moving such loads, mixer companies offer optional bowl dollies or trucks. To avoid having to move a loaded mixing bowl (and using a dolly), position the mixer beside the dough prep table.
AUTOMATIC BOWL CLAMPING. Before mixing can start, the bowl must be attached to the mixer. Attaching and disconnecting a large (60-qt or larger) loaded bowl can be cumbersome. Therefore, at least one line of mixers comes with an automatic bowl clamping mechanism which eliminates having to juggle the bowl into position. Combined with a dolly, it virtually eliminates bowl handling. Whether this feature is significant depends on how much bowl moving you do. To minimize bowl movement, position the mixer beside the dough prep table.
POWER BOWL LIFTER. Mixers come with a mechanism for raising the bowl into place for mixing. On most mixers it’s manually operated. With loaded bowls (60-qt or larger) this takes time and effort. So for large mixers an optional power bowl lifter can be purchased. It can be handy for an operation that mixes dough all day, but for a typical pizzeria the option is more a luxury than a necessity.
EXTRA-TALL COLUMN. On large mixers, to remove the bowl the agitator or mixing attachment must be disconnected first. To avoid that inconvenience some mixer companies provide models with an extra-tall column on their 80- and 140-quart models. Since the largest mixer in most pizzerias is a 60-quart, this option sees little use.
PROGRAMMABLE CONTROL SYSTEM. At least one mixer company offers an optional computer control system which governs mixing time and speed. It allows the operator to pre-program 25 recipes with up to nine steps each. It is handy for making foods that require multiple mixing steps of varying times and speeds. However, since most pizza doughs are mixed in one step or, at most, two steps—such as one minute on 1st speed and eight to ten minutes on 2nd speed—this option has little use in most pizzerias.
OVERLOAD PROTECTION. If overloaded, such as with an overly large batch of very stiff dough, a mixer can break an agitator or internal component. So as a safety precaution, some mixers come with overload protection which automatically shuts the mixer off when it’s strained.
WARRANTY. Warranties on food service equipment are often lacking (i.e., limited to 60 days). However, at least one mixer company offers a two year warranty on parts and one year on labor, and another company offers one year on parts and labor.
The main advantage of the planetary mixer is its versatility. Equipped with a full line of agitators and attachments, no other mixer can perform as many functions (although one model of cutter-mixer which comes equipped with an attachment drive hub comes close). It can mix dough, blend sauce, shred or grind cheese, and cut vegetables and certain meat toppings.
A second advantage is the mixer’s durability. Properly used (i.e., not overloaded) and well-maintained, it is a very durable machine. Some models have lasted for decades—in large part because the machine runs s-l-o-w-l-y.
The main drawback of a planetary mixer is that it’s slow and labor intensive. At mixing dough it’s slower than the cutter-mixer and spiral mixer. In addition, the cutting/grinding attachments only process small quantities at a time and, therefore, are not the preferred tool for large quantity production. For example, to shred or grind mozzarella cheese, a 5 lb loaf must first be cut into many small rectangular blocks, and then hand-fed, one at a time, into the machine. Processing 40 pounds of mozzarella can be time-consuming. In short, for a small-volume pizzeria the planetary mixer’s slow speed and small batch size is not a big drawback; but for a larger volume operation, it can be.
Finally, even though the vegetable cutter attachment will slice a variety of meats and vegetables, the end product doesn’t always come out as uniform and neat-looking as when done with a conventional meat slicer.
For good operation and long life the machine must be properly installed and maintained. Always follow the manufacturer’s recommendations. Here’s a checklist of things that should be done.
• Position the mixer for easy cleaning. If possible, allow enough space (at least eight inches) between the machine and side walls or tables so it can be easily cleaned.
• Position the mixer for minimal dough moving and lifting. If possible, position the machine next to or across the aisle from the dough table (i.e., where dough will be processed into balls) so the dough can be lifted directly from the mixing bowl to the table.
• Hook it up properly, with correct voltage and amperage. Too little power will cause a machine to under-perform. Too much power could damage it. Get the electrical specifications from the manufacturer or from the spec plate on the back of the machine. Also, use proper wiring that meets code; never use an extension cord.
• Lubricate the mixer regularly and properly. Check the oil level at least every six months. Use the proper type of lubricant and also the proper amount—too much can be as damaging as too little. Failure to lubricate a machine properly can result in serious damage. Follow the maintenance guidelines in the operating manual.
• Clean the machine properly after each usage. Avoid abrasive materials such as steel wool and nylon pads. Use a detergent and soft cloth or brush. Don’t spray it unless the manufacturer says it’s okay. If the manufacturer provides instructions for how to dismantle and assemble the machine, follow them. Periodically oil the bowl yoke slide and attachment hub with a light coating of food grade mineral oil.
• Never overload the machine. It can break the dough arm and, possibly, an internal component. (See the Dough Capacity section for details on bowl capacities.) It also shortens the machine’s operating life.
• Obtain service when needed. Use only factory-trained service personnel. Do not attempt to repair internal components yourself.
For specific procedures on operating a planetary mixer, refer to the Sample Production Procedure in the Dough-making chapter. In addition, here’s a few more hints.
• Lock the bowl and dough hook securely in place. Before starting the mixer, be sure the mixing bowl is clamped securely in place on both sides and in the back and that the dough hook is locked over the shaft pin.
• Start on low speed. After adding a load of ingredients, start the mixer on low speed to avoid splashing.
• Stop to shift gears. Many models should be stopped before shifting to a different speed to avoid damaging the gears.
• Re-start with bowl lowered. When restarting a mixer with a load of stiffer dough (i.e., dough with 50 percent or less water based on flour weight), first lower the bowl, then turn on the mixer, and finally raise the bowl with the mixer arm turning. This reduces strain on the machine.
• Keep it clean and repaired. Clean the mixer after each usage (see following Cleaning section). Occasionally oil the bowl yoke slide and attachment hub with a light coating of food grade mineral oil.
Mixers and other food processing machines can cause serious injury when mishandled. Always exercise caution and follow the manufacturer’s instructions. For example:
• Never reach into the bowl when a mixer is operating. Turn it off first.
• Never spray the mixer with water to clean it.
Here’s a procedure for cleaning a planetary mixer. Do it as soon as possible after mixing, as dried dough pieces become harder to remove.
1. Gather supplies:
• Detergent
• Two pans or buckets (1 to 1-1/2 gallon size)
• Clean cloth
• Nylon pot brush (gong brush)
2. Set up two pans of washing water:
• Fill each pan with 3 to 4 quarts cool water.
• To one pan, add 1/4 pump (or 1/4 oz) detergent (the amount may vary with the brand).
• To the other pan, add nothing.
3. Set up the pot sink for washing and sanitizing.
4. As soon as possible after mixing, take the mixing bowl and dough hook to the pot sink. Clean them completely, including where the dough hook fits over the shaft. Let them air dry. (Turn the bowl upside down on a wire shelf or a table.)
5. With the pot brush and soapy water, scrub the mixer. Be sure to clean the mixing shaft, bowl saddle, and underside of the motor housing (over the bowl).
6. With the cloth and clear water, wipe the mixer clean.
NOTE: Occasionally apply a thin coating of food grade mineral oil to the bowl yoke slide and attachment hub.
7. Put away supplies:
• Hang up the cloth to dry.
• Rinse the pans and put away.
• Put away cleaning chemicals.
The
cutter-mixer originated in Germany where it was known as the schnellkutter, meaning
quick-cutter. After World War II it was introduced to the U.S. under the name
Vertical Cutter-Mixer. For brevity, people shortened it to VCM—a name that has
stuck to the present. However, to avoid confusing the machine with other types
of vertical mixers we have dropped the word “vertical” and simply call it cutter-mixer.
The cutter-mixer has been adapted to a wide variety of food and non-food applications. It can be used for mixing, kneading, chopping, blending, and emulsifying. Next to the planetary mixer it’s the most widely used mixer in pizzerias. For a photo, click here.
Essentially, the machine is a large bowl with a mixing spindle extending up from the bottom. A cutting/mixing shaft consisting of two blades fits onto the spindle. During mixing, the lid is closed over the top of the bowl. For emptying, the bowl is tilted forward until the contents fall or pour into a tray or bucket.
Unlike the planetary mixer, where the shaft revolves around the perimeter of the bowl, with the cutter-mixer it’s stationary. What’s more, the shaft turns about ten times faster than the planetary mixer shaft, reducing mixing time to one-tenth that of the planetary machine. Basically the cutter-mixer is an industrial-sized version of the food processor or blender that many people have in their homes.
Whereas dozens of companies sell a planetary mixer, only a few sell a cutter-mixer sized for pizzeria use. They are (in alphabetical order):
• Berkel Inc. – (219) 326-7000 (The Berkel cutter-mixer is made by Westglen; so, whatever we say about Westglen also applies to the Berkel machine.)
• Hobart Corporation – (513) 332-3000; 332-3095
• Robot Coupe USA, Inc. – (601) 956-1531; 800-824-1646
• Stephan Machinery – (847) 247-0182; 800-783-7426
• Westglen Corp. – (213) 564-3865 (Also sold under the Berkel and Butcher Boy labels.)
Cutter-mixers are sized according to mixing bowl volume. They range in size from 8 to 60 quarts. Stephan and Robot Coupe offer models in 15, 25, 40/45, and 60-quart sizes. Hobart offers 30- and 45-quart sizes. And Westglen (Berkel) offer strictly a 45-quart machine. Models of 15-quart and smaller sit on a table. For pizzerias, the 40/45-quart size is the most popular, but a smaller operation could make due with a 25/30-quart version.
In addition to the above, there are larger machines designed on the principle of the cutter-mixer—sometimes called high-speed and no-time mixers—made for high-volume bakery and commissary operations. Depending on their size they produce 2000 to 5000 lbs of dough per hour. Three companies that make them are Mono Bakery Equipment (800-233-0003), Rykaart (513-874-2950), and Stephan (614-771-0266).
The exact processing capacity of the cutter-mixer varies slightly from maker to maker. However, when averaged out we see that the 25/30- and 40/45-quart machines produce the following amounts.
Maximum Batch Size
25/30-Qt 40/45-Qt
Dough 25 lbs. 40 lbs.
Sauce 4 gal. 7 gal.
Cheese 15 lbs. 25 lbs.
As with all mixers, never exceed the recommended maximum batch size given by the manufacturer. Also, a very stiff dough may require a slightly smaller batch than the maximum listed above. In terms of tomato sauce, seven gallons is equal to about eight No. 10 cans of product. Finally, to mix small batches—that is, batches having less than half the maximum amount—a special mixing shaft is required for some models. Keep this in mind when deciding on the size of mixer.
The cutter-mixer is the fastest of the mixers. Some models come with one speed, others with two: low and high. For Stephan, Robot Coupe, and Westglen (Berkel), low speed is about 1750 rpm and high about 3500 rpm. The Hobart model has one speed: 1140 rpm, which means it’s processing times are about half as fast, or twice as long, as competing models. The cutter-mixer can also be operated in momentary on/off bursts—called jogging or pulsing—for mixing or cutting those foods which need only a few seconds of processing time.
Regardless of the model, every cutter-mixer is very fast. That means, for time-sensitive operations such as dough-mixing, cheese-chopping, and vegetable-cutting, you must adhere to the proper mixing time exactly. Unlike the planetary mixer, an extra 30 seconds of mixing or chopping can ruin the product.
Recommended processing times vary from company to company and also will vary depending on the exact nature of the product. In general, however, this is what you can expect.
Approximate Processing Times
R/S/W/B* Hobart
Mix Soft Dough 1.5 - 2 min. 2.5 - 3.5 min.
Blend Sauce 1 min. 2 min.
Chop Cheese 15 - 20 sec. 30 - 40 sec.
* Robot Coupe, Stephan, Westglen, Berkel
Dough
and cheese is processed on low speed; sauce on high speed.
For details on mixing times for various types of dough, see the chapter on Dough-making.
Most cutter-mixers come standard with two kinds of shafts: a cutting shaft and a kneading shaft. In a pizzeria the cutting shaft—also called knife shaft and cut/mix shaft—is used mostly for chopping cheese and blending sauce. It also can be used for grinding up Italian sausage and ground beef, cutting lettuce and vegetables, making potato salad, chopping cole slaw, and mixing sweet dough, cookie dough, and pie dough—among other things. With the Robot Coupe model the cutting shaft is also used for mixing pizza and bread dough. The blades on a Robot Coupe shaft can be adjusted to various heights for different foods and batch sizes.
A second shaft, the kneading shaft—also called knead/mix shaft—is used for making pizza and bread dough. Hobart, Stephan, and Westglen (Berkel) provide this implement.
Stephan and Robot Coupe also offer additional shafts for specialty operations. For example, Stephan offers a grating shaft for grating hard foods and mixing dry ingredients, a shaft with wide knives for cutting frozen foods, a shaft with wave cut knives for processing oily products, and one with low-angle knives for mixing small batches. Robot Coupe offers a special telescoping shaft for coarse chopping, such as when making Italian sausage. The blades on their regular shaft can be lowered for mixing small batches.
Caution!
The knife blades on the cutting shaft are very sharp and must be handled
carefully. For proper operation keep them sharp.
Here are some of the main features of cutter-mixers.
MOTOR SIZE. All cutter-mixers come with powerful motors that operate on 208 to 240 volt. For example, the 40/45-quart machines have the following:
• Hobart motor: 5 HP (low speed only)
• Robot Coupe motor: 32 amp; 10 HP low speed; 12 HP high speed.
• Stephan motor: 25 amp; 7-1/2 HP low speed; 10 HP high speed.
• Westglen/Berkel motor: 25 amp; 7-1/2 HP low speed; 9 HP high speed.
When compared to a 60-quart planetary mixer (which has a 2 to 2-1/2 HP motor) they’re mighty powerful.
STRAINER BASKET. Hobart and Stephan provide a strainer basket that fits into the mixing bowl and is used for separating chopped lettuce from the water. (Leafy greens are chopped in water.)
CASTERS. Robot Coupe mixers come with casters for easy moving. Other companies will supply two casters as an option (two casters allow the machine to be moved if necessary, but not easily).
TIMER. Some models come with shut-off timers. And some models come with a jogging, or pulsing, button for easy jogging (i.e., momentary on/off operation).
SPEED DIFFERENCE. Hobart machines run at a slower rpm (revolutions per minute). The company says it’s an advantage because there’s less chance of over-processing a batch of food. The competition says it’s a disadvantage because it results in longer processing times; plus if a timer is used there’s little or no chance of over-processing, anyhow.
REMOVABLE BOWL. On Robot Coupe models the mixing bowl is removable for easy washing. For easy cleaning of other models it helps to have a water hose mounted next to the machine and a floor drain in front of it—although they’re not essential.
ATTACHMENT DRIVE HUB. One of the Stephan models comes with a hub that accepts food processing attachments. This essentially allows it to do everything a planetary mixer does. However, unlike a planetary mixer, where the attachment is driven off the mixer motor, with this machine there’s a separate motor that drives the attachment. Conceivably, then, the mixer and an attachment could be operated simultaneously—space and labor allowing. Optional accessories include a vegetable cutter (i.e., slicer, dicer, shredder, grater), grinder, strip cutter, steaker (or cuber), and french fry cutter—among other things. They also offer a beating attachment which, in effect, is a 20-quart planetary mixer with dough hook, beater, and whip.
The company also offers a separate stand-alone drive motor that can be used for operating all those attachments. So, whether the cutter-mixer with a hub is a good choice depends on how its price compares to the price of buying a conventional cutter-mixer (without a hub) plus the stand-alone drive motor. The latter option has at least one advantage: The drive motor can be positioned anywhere in the kitchen, thereby making for more flexible operations and less congestion while operating the cutter-mixer.
In conclusion, there are distinct design differences from company to company. When shopping for a cutter-mixer, acquaint yourself with all the features and the price before selecting a brand. There’s much to understand about the machine so be sure to use a knowledgeable salesperson. Also, ask about the warranty. It varies from company to company.
DRAWBACKS. Compared to a planetary mixer (which is what it’s usually compared to), a cutter-mixer has the following drawbacks.
First of all it’s noisy. However, thanks to its speed the noise is short-lived.
Second, in some ways it’s a bit more difficult to operate, clean, and maintain than a planetary mixer. For example, there are more parts to dismantle and clean, blades must be sharpened periodically, and special methods must be used in processing certain foods. (Those factors differ from model to model.) However, none of these things are so difficult that the average worker can’t master them quickly.
Third, it won’t whip—that is, incorporate air into a liquid—as in making meringue or whipped cream. However, most pizzerias have no need for that anyhow.
Fourth, some people say it’s not as durable as a planetary mixer—that is, it won’t last as long without needing an overhaul or replacement parts. On the other hand, cutter-mixers almost never break a shaft or internal component due to product overload, as do planetary mixers. So, durability is a matter of definition.
SLOW VS. FAST MIXING. The main reason some pizzeria owners avoid the cutter-mixer is because they feel it doesn’t produce as good a dough as a planetary mixer. Their reasoning is: “Because of the cutter-mixer’s speed, the gluten in the dough isn’t given time to develop from the kneading process of the mixer.”
On the surface that argument would seem correct. However, baking experts point out that gluten development during mixing is not a function of time but, rather, is a function of the amount of kneading or agitation imparted to the dough. Further, they state that it doesn’t matter whether the optimum amount of kneading is performed in ten minutes or two minutes, the impact on gluten development is the same. In short, the proponents of cutter-mixers say that high speed mixing-kneading doesn’t necessarily result in lower dough quality.
In addition, some experts claim that high speed mixing actually produces a better product through (a) providing a more developed dough with better gas retention and (b) providing better hydration of the flour.
When the author compared dough from a cutter-mixer to that from a planetary mixer he noticed no difference in end product. However, to be fair we must point out that others say they’ve seen a difference between fast-mixed and slow-mixed dough. Of course the best way to resolve the argument is to test it for yourself—compare doughs and pizza crusts made from the same recipe, produced by both types of mixers. Be sure that proper methods, times, and temperatures are observed, otherwise test results will be misleading.
ADVANTAGES. The main advantage of the cutter-mixer is it’s FAST. As mentioned before, a 40/45-quart model can produce 40 lbs of dough in 2 minutes, chop 25 lbs of cheese in 20 seconds, and blend 7 gallons (eight No. 10 cans) of sauce in 1 minute—to name a few feats.
Due to its speed it can save considerable labor time, especially in a high volume operation. Basically, the higher the volume, the greater the savings.
Because it saves labor time, it can reduce labor costs, especially when there’s good production planning and scheduling by management.
Also, by reducing prep time it reduces confusion and activity in the kitchen.
Lastly, it’s highly versatile. It can make and process numerous foods. For many pizzerias it could be the only food prep machine that’s needed if toppings are purchased pre-sliced.
For good operation and long life the machine must be properly installed and maintained. Always follow the manufacturer’s recommendations. Here’s a checklist of things that should be done.
• Position the mixer for easy cleaning. If possible, allow enough space (at least eight inches) between the machine and side walls or tables so it can be easily cleaned.
• Position the mixer for minimal dough moving and lifting. If possible, position the machine next to or across the aisle from the dough table (i.e., where dough will be processed into balls) so the dough can be lifted directly from the mixing bowl to the table.
• Position a floor drain in front of the mixer, if possible. This is most easily done with new construction. It’s not required but it makes clean-up a bit easier.
• Position a spray hose near the mixer. If possible make it a reel-type hose. This works great when combined with a floor drain.
• Hook it up properly with correct voltage and amperage. Too little power will cause a machine to under-perform. Too much power could damage it. Get the electrical specifications from the manufacturer or from the spec plate on the back of the machine. Also, use proper wiring that meets code. Finally, near the machine install an easy-to-reach breaker box with on-off buttons (if suggested by the manufacturer).
• Lubricate the mixer as specified. Because cutter-mixers have no gears and fewer bearings than a planetary mixer, they require little or no lubrication. Regardless, check the maintenance manual and follow any lubrication guidelines.
• Clean the machine properly after each usage. Avoid abrasive materials such as steel wool and nylon pads. Use a detergent and brush. If the manufacturer provides instructions for how to dismantle and assemble the machine, follow them. (See Cleaning section for details.)
• Keep knife blades sharp. To produce good chopped product a cutter-mixer must have sharp blades. Follow the manufacturer’s instructions. The basic procedure is this. Once a week, draw a steel-working file 3 to 4 times across the top edge of each blade. Push the file into the blade rather than away from it. After filing the top, give the bottom edge one filing to complete sharpening. Occasionally the blades may need to be sent to a service dealer for re-grinding.
• Never overload the machine. It shortens the machine’s operating life and could cause damage. (See the Batch Size Capacity section for details on bowl capacities.)
• Obtain service when needed. Use only factory-trained service personnel. Do not attempt to repair internal components yourself.
Most cutter-mixer manufacturers provide operating guidelines. For specific procedures refer to the Sample Production Procedures sections in other chapters. In addition here’s a few more hints.
• Put a large clock with a second hand on the wall. Because of the cutter-mixer’s speed, length of mixing time is important. To help the operator gauge mixing times, hang a large clock with a second hand near the machine.
• Prepare products in a sequence that reduces cleaning. When preparing several ingredients in a row use a sequence that minimizes cleaning between products. Generally, the sequence should be one where a small amount of residue from a product will not harm the following product. For example, when preparing dough, sauce, and cheese, the most efficient sequence is to first chop the cheese (afterward wipe the cheese particles from the bowl with a clean cloth), then blend the sauce (afterward rinse the bowl clean with water), and finally mix the dough (afterward give the machine a full cleaning).
• When mixing dry and liquid ingredients, put liquids in the bowl first. For example, when mixing dough, first put in the water, then add the flour and dry ingredients. When mixing sauce, first put in the tomato product, then add the spices. This procedure insures thorough blending.
• When mixing pizza sauce, stir the spices into the tomato product. To avoid spices sticking to the bowl lid, add them on top of the tomato product and then stir them in with a rubber spatula before starting the machine. Or put half the tomato product into the bowl, then add the spices, and, finally, cover the spices with the remaining tomato product.
• Cut large pieces into smaller units. When chopping cheese or making sausage, cut large pieces into smaller units to insure uniform consistency and to allow the bowl to be filled to capacity. For example, 8-lb blocks of cheese should be cut in half. Meat should be cut into 1- to 2-lb pieces.
• Keep cheese cold. To minimize clumping or “balling,” chop cheese when it’s cold. The ideal temperature is 33 to 36 degrees F or, for high-moisture cheese, 28 to 30 degrees F.
• Chill meat to partially frozen condition. When making sausage or ground beef, use partially frozen meat (about 30 degrees F) to achieve best consistency. However, do not try to chop hard frozen meat (below 28 degrees) with the standard (narrow blade) cutting shaft as it could damage the blades.
• Use wide knife blades for cutting frozen foods. Cutter-mixers come standard with a kneading shaft and a cutting shaft consisting of narrow blades. For most pizzerias that’s enough. However, some models also offer additional blades, such as wide knife blades for processing frozen food. If you have those blades use them for frozen foods as it reduces the chance of breaking a blade.
• Remove bone and tendon before chopping meat. For the best product, carefully remove all bone and tendon (i.e., gristle) before processing.
• Make sure the bowl and mixing shaft are locked in place before starting the machine. Before turning on the mixer, check to make sure the bowl is locked securely in the upright position. Also, be sure to fasten the mixing shaft locking nut snugly.
• When you don’t know how long to process a food, cut the time short and do it in stages. When in doubt about how long to cut or mix something, process it for a short time, shut off the machine and examine the product. If more cutting or mixing is required, turn on the machine again for a short time. Repeat this procedure until desired consistency is achieved.
• When you don’t know what speed to use, run on low speed.
• When you don’t know what shaft to use, try the cutting shaft.
• Before mixing dough, remove the baffle (if the machine has one).
• Lower the blades for chopping smaller quantities. Some cutter-mixers have blades that can be adjusted to varying heights. If your cutter-mixer has such a feature, lower the blades when chopping small quantities to achieve uniform consistency.
• Follow manufacturer instructions for other foods. This material describes how to use a cutter-mixer for preparing dough, sauce, cheese, and sausage. However, it also can be used for preparing other foods such as cole slaw, tossed salad, potato salad, meat salads, salad dressings, whipped potatoes, meat loaf, croquettes, patés, purées, batters, frostings, and crushed ice. For specific directions on how to prepare these and other products, refer to the manufacturer’s guidelines.
Cutter-mixers and other food processing machines can cause serious injury when mishandled. Always exercise caution and follow the manufacturer’s instructions. For example:
• Do not put your hands near the blades. When emptying sauce, cheese, and sausage from the bowl, use a large rubber spatula. Do NOT scrape out the bowl bottom with your hands unless you first remove the cutting shaft. Dough can be pulled from the bowl in one piece without getting your hands near the blades.
• Do not open the lid until the machine has stopped mixing.
• Do not exceed recommended maximum bowl capacities.
When preparing several ingredients in a row, use a sequence that minimizes cleaning between products. For example, when preparing dough, sauce, and cheese the most efficient sequence is to first chop the cheese, then blend the sauce, and, finally, mix the dough.
After chopping cheese, to prepare the machine for blending sauce use this short cleaning procedure.
1. Remove the cutting shaft.
2. Tilt the bowl to pouring position.
3. With a CLEAN, DRY cloth, wipe the loose cheese from the bowl.
4. Upright the bowl, attach the cutting shaft, and use the machine.
After blending sauce, to prepare the machine for making dough use this short cleaning procedure.
1. Fill the bowl half full with warm (not hot) water.
2. Add 1 Tablespoon (1/2 pump) non-sudsing all-purpose cleaner (e.g., Soilax All-purpose Cleaner).
3. Close the lid and plastic inspection cover. Tighten the locking handle and insert the locking pin.
4. To turn on, flip the switch handle on-and-off with a single momentary snap. Before the blades stop moving, turn the switch to low speed for 5 seconds, then advance it to high speed for 30 seconds. While running at high speed, turn the mixing baffle counterclockwise. NOTE: Turning the cutter-mixer directly to high speed will cause soapy water to spray from the lid.
5. Turn off the cutter-mixer. Remove the locking pin and loosen the locking handle. Open the lid.
6. Pour the soapy water into a sauce dumping tub.
7. Repeat steps 1 to 6 using clear water.
8. Wipe clean the outside of the cutter-mixer with a clean cloth and clear water.
When done using the cutter-mixer it should be thoroughly cleaned and sanitized. The procedure varies with the model. For example, Robot Coupe has a removable bowl that can be washed in a pot sink. So the machine can be cleaned by the same procedure as used for a planetary mixer. Other cutter-mixers have a fixed bowl so they’re washed in place. Here’s a cleaning procedure designed for Stephan, Westglen, and Berkel machines. It’s written in detail for training purposes. However, once learned it’s easy to do.
1. Gather supplies:
• Non-sudsing all-purpose cleaner (e.g., Soilax All-purpose Cleaner)
• Sanitizer and tablespoon for measuring sanitizer
• Nylon pot brush
• Plastic dough scraper
• Clean cloth
2. Set up the pot sink for washing and sanitizing.
3. Assemble the cutter-mixer for cleaning:
A) Attach the cutting shaft if not already on. Be careful with the sharp blades. Screw down the locking nut snugly but not overly tight. For tightening (or removing) the locking nut, use the spanner and peg wrenches.
B) Attach the mixing baffle and plastic inspection cover if not already on.
C) Tighten the locking handle and insert the locking pin.
4. Fill the bowl half full with warm (not hot) water.
5. Add 1/2 pump (or 1/2 oz) all-purpose cleaner (the amount may vary with the brand).
6. Prepare the cutter-mixer for cleaning:
A) Close the lid and lock the bowl latch.
B) Close the plastic inspection cover.
C) Tighten the locking handle and insert the locking pin.
7. Start the cutter-mixer. Do this by the following procedure. Flip the switch handle on-and-off with a single momentary snap (or jog-start the machine). Before the blades stop moving, turn the switch to low speed for 5 seconds, then advance it to high speed for 1-1/2 minutes. NOTE: Turning the cutter-mixer directly to high speed will cause soapy water to spray from the lid.
8. During the last 30 seconds, turn the mixing baffle counterclockwise while the machine is running.
9. Turn off the cutter-mixer.
10. After the shaft stops turning, open and close the plastic inspection cover to remove any water on it.
11. Open the lid.
12. With a long-handled pot brush, scrub the underside of the lid, the lid gasket, and the inside of the bowl. To remove stuck food, use a stiff plastic dough scraper.
NOTE: If necessary, re-run the machine following steps 6 to 12.
13. Put a large tub between the cutter-mixer legs.
14. While holding the bowl latch with your left hand, remove the locking pin and loosen the locking handle with your right.
15. Grasping the bowl latch in your right hand and the cover knob in your left, slowly tip the bowl until the water almost pours from it. Then, with your left hand, position the tub so it will catch the water. Continue tipping and pour the water into the tub. When done, upright the bowl, tighten the locking handle and insert the locking pin. Empty the water from the tub.
16. Rinse and sanitize the cutter-mixer bowl by repeating steps 4 to 10 except substitute one tablespoon (or 1/2 oz) sanitizer for the all-purpose cleaner (the amount may vary with the type of sanitizer). Pour out all the rinse water using the procedure described in step 15. Let the bowl air dry; do not cloth dry.
17. Remove the mixing baffle, plastic inspection cover, shaft locking nut, and cutting shaft. Place them in a dough tray and carry to the pot sink. Immediately wash the shaft locking nut and replace it on the shaft.
18. With a clean cloth dipped in sanitizing water, wash the outside of the cutter-mixer. Thoroughly clean the top of the lid, outside of the bowl, switch handle, legs, and electric cord. Wipe dry with a well-wrung cloth. Also, wipe off the cutter-mixer breaker box.
19. In the pot sink, wash and sanitize the mixing baffle, plastic cover, and cutting shaft. NOTE: Do not leave the cutting shaft (or any sharp object) unattended in the soapy water, as some unsuspecting person might reach into the water and cut their hand.
20. After washing and sanitizing, lay the cutting shaft inside the cutter-mixer bowl; do not put it on the center spindle. Attach the mixing baffle and plastic inspection cover.
21. Push down the lid but don’t latch it. Close the plastic inspection cover.
NOTE: Once a week, remove the rubber lid gasket and wash it. Also, wipe out the gasket groove on the lid. Let the gasket air dry.
22. Put away supplies:
• Rinse the cloth in sanitizer water and hang up to dry.
• Rinse the brush and put away.
• Put away cleaning chemicals.
Spiral
mixers are so named because of their spiral-shaped dough agitator. Another unique
feature is that the bowl revolves during mixing. Although sized more for commissaries
and bakeries, a medium-to-high volume pizzeria can use a small spiral mixer. For
a photo, click here.
Some companies that sell spiral mixers include (in alphabetical order):
• Adamatic – (908) 544-8400
• Bakery Systems – (704) 375-4349; 800-526-2253
• Benier U.S.A., Inc. – (404) 739-0700
• Champion Bakery Equipment Co. – (815) 726-4336
• Hobart Corporation – (513) 332-2410
• Kemper – (203) 458-1745
• Moline Machinery – (218) 624-5734
• Rondo Inc., – (201) 488-0121
• Univex – 800-258-6358
For a full list of mixer manufacturers, contact Baking Buyer magazine (816-756-0494) and ask for their current buyer’s guide issue.
Unlike planetary mixers and cutter-mixers, which are sized according to bowl volume, spiral mixers are usually rated according to maximum flour capacity. As such, models range in size from 30 to 450 lb flour capacity—with most companies producing models in the 100 to 200 lb range. When converted to dough weight, maximum capacities for spiral mixers range from 50 to 600 lbs of dough.
To maximize machine life, some experts recommend (a) reducing the maximum batch size given by the manufacturer by 15 percent when mixing stiffer dough (i.e., dough having 50 percent or less water based on flour weight) and/or (b) running the machine on low speed only.
Most pizzerias likely would use only the smallest size, or a 50 lb dough capacity machine. However, a high volume pizzeria or commissary might use a larger model.
An interesting feature of the spiral mixer is its ability to mix small batches—some models go down to as little as 10 percent of their maximum capacity.
Speed-wise, spiral mixers fall between the planetary mixer and cutter-mixer. Mixing time varies from model to model. On average a spiral mixer will produce a batch of soft dough in 6 to 8 minutes, with some companies suggesting as low as 4 minutes. Generally, when high speed is used a spiral mixer cuts about 1/4 to 1/2 off the mixing time of a planetary mixer used at low speed.
Because of their design they tend to produce a cooler dough than planetary mixers and cutter-mixers.
Spiral mixers come with numerous features, which vary from model to model. Before purchasing a spiral mixer acquaint yourself with several brands. Here’s some of the main features.
Most models come with one spiral-shaped dough hook. However, a couple models come with dual hooks, and some come with shapes other than a spiral (and, as would be expected, claim better mixing and shorter mix times).
At least one model offers optional batter beater and whip attachments that can be interchanged with the dough hook. Some models come with a bowl scraper. This would be used when mixing liquid ingredients, such as a batter.
Most machines come with at least two speeds (100 and 200 rpm). Some also have a reverse gear or a bowl jog, which is used after mixing to position the dough for easy removal.
For safety reasons, all spiral mixers come with either a lid or a wire guard. The advantage of the lid is that it contains splatter and flour dust.
Mixers come with various bowl features. In smaller models the bowl is fixed-in-place. In that case the machine probably has casters. Larger models might have a power-driven tilting bowl, or a removable bowl that can be transported by dolly to another location. For stiffer doughs (having 50 percent or less water based on flour weight) some manufacturers recommend a fixed bowl for maximum durability and machine longevity. Some models also come with an automatic bowl scraper.
All models come with timers; some come with two. Two timers allows the operator to program the mixer to automatically shift from low to high speed. Some also come with revolution counters which shut off the machine after a certain number of agitator revolutions. And some come with electronic programmable controls.
The spiral mixer is a quick-mixing machine, well suited for commissaries and large bakery operations that mix dough steadily for several hours per day. However, the smallest models—which produce a 50 lb batch of dough—are candidates for a medium-to-high volume pizzeria.
Spiral mixers come with numerous features and options that allow them to fit into high-production commercial baking systems.
Proponents of the spiral mixer feel that it produces a superior quality dough. The main drawback, from some pizzeria owners’ standpoint, is that it’s a limited-function machine which can’t be used for blending sauce, chopping cheese, and doing other food processing operations. For that reason the planetary mixer and cutter-mixer is more common in pizzerias.
As with other large machines a spiral mixer must be installed, maintained, and operated properly to insure good performance and long life. Follow the manufacturer’s instructions. For a review of key points, refer to the Installation and Maintenance sections for the planetary mixer and cutter-mixer.
Before the age of automation, bakeries used manpower for dough-mixing. A muscular
man, hovering over a big bowl filled with dough ingredients, would thrust his
arms down the sides of a bowl, push them across the bottom, and then pull up in
the center. By that action bread dough was mixed and kneaded in little bakeshops
around the world. The men who performed the laborious task came to be known as
“groaners”—undoubtedly a description of the sound they emitted.
Understandably, the first mixing machines were designed to simulate the mixing action of the groaner—consisting of two arms that moved back and forth through the dough. Modern versions of those machines exist today—known as reciprocating arm mixers, and also double-, dual-, and twin-arm mixers. As the two arms move back and forth through the dough, the bowl revolves slowly. The result is a gentle kneading, stretching, lifting, and folding action, much like that imparted through manual mixing. For a photo, click here.
Two companies that make reciprocating arm mixers are:
• Adamatic – (908) 544-8400
• Excelsior Industrial Equipment Co. – (201) 967-8222
The reciprocating arm mixer is available in various models ranging from 80 to 700 pounds dough capacity— so it’s a little too large for the typical pizzeria but might be used in a high-volume operation or a commissary.
A reciprocating arm mixer can perform many mixing tasks. Along with bread dough it can be used for sweet goods, rye bread, biscuit, puff pastry, and pie dough. The gentle manipulation of the dough makes it especially good for pie and pastry production.
The slow speed of the mixing arms results in a slow rate of energy input to the dough. So there is very little increase in dough temperature during mixing.
For those who feel that high speed mixing is the worst thing that’s happened to bread since mold, this is the mixer for them. Short of doing it by hand, it takes dough mixing back to its origins. As with the spiral mixer, the main drawback from a pizzeria owner’s standpoint would be that it’s a limited-function machine.
Unlike
other mixers—where the mixing shaft is vertical—in horizontal mixers it’s (yes,
you guessed it) horizontal. It consists of a shaft that extends horizontally
across a mixing chamber or cylindrical bowl. Mixing shafts come in a variety of
designs—each company claiming to have the best. For a photo, click
here.
The horizontal mixer is mainly used in high-volume commercial bakeries and commissaries, and comes in sizes from 100 to 3000 lb dough capacity. Most models are huge machines and, therefore, not suited for pizzerias. A number of manufacturers make them, four of which are:
• AMF Bakery Systems – (804) 355-7961
• ETMW Enterprises Ltd. – (819) 563-3111
• Peerless Machinery Corp. – 800-999-3327
• Shaffer Manufacturing Corp. – (513) 492-4142
For a full list of mixer manufacturers, contact Baking Buyer magazine (816-756-0494) and ask for their current buyer’s guide issue.
At least one company produces a small, economical version of horizontal mixer—which mixes a 50-lb batch that’s suitable for pizzerias. It has two double-action arms that counter-rotate. It’s movable, easy to clean, has a tilting bowl, and can fit under a table when not being used. Its mixing time for pizza dough is 10 to 12 minutes. The manufacturer is:
• Leland Southwest – (817) 232-4482.
In general, horizontal mixers are slower than spiral mixers but because of their large batch size some models can produce up to 10,000 pounds of dough per hour. Like the spiral mixer, they are basically single-purpose machines. Except for the 50-lb model described above, they aren’t feasible for pizzeria use.
In pizzerias using the dough ball method, after the dough is mixed it’s divided
(scaled) into pizza-size weights and then rounded into balls. This process can
be done either manually or by machine. Low-to-medium volume pizzerias would probably
find it economical to do it manually. Commissaries and higher volume pizzerias
(e.g., selling at least 2000 pies per week) might find it worthwhile to install
a divider or divider-rounder combination.
From the pizzeria standpoint there are two groups of dividers and rounders: (1) batch and (2) continuous. With a batch divider, the operator inserts a large piece of dough into the machine, presses a lever or button, and the machine divides the piece into a batch of equal-sized smaller units.
With a continuous divider and rounder the machine produces one unit (i.e., dough ball) every few seconds, and will do it continuously as long as there’s dough in the hopper.
This section describes the batch-type divider; the next section examines continuous divider-rounders.
With a batch divider, a large 8 to 12 lb dough ball is inserted into the machine, usually on a round metal plate or pallet. The machine presses the dough flat and cuts it into equal-sized pieces. The weight of the final pieces are determined by the weight of the initial dough ball. The larger the ball, the larger the final pieces.
Machines can be purchased as a divider-only or as a divider-rounder combination. With a divider the dough is only cut, and not rounded. With a divider-rounder, the dough is cut and then rounded into balls. For a photo, click here.
Dividers come in manual and automatic models.
Divider-rounder combinations also come in semi-automatic and fully automatic. With a semi-automatic machine the dividing is done manually, by pulling down a lever, but the rounding is automatic. With a fully automatic machine both the dividing and rounding functions are automatic at the press of a button.
Some models only produce up to a 4 oz piece—clearly not suitable for pizzerias. However, other machines will produce up to 8 oz and 16 oz pieces, and some go to 26 oz and 32 oz.
For safe, reliable operation, divider-rounders must be used correctly and maintained properly. Follow the manufacturer’s instructions for installation, operation, and maintenance. Generally, it must be lubricated monthly.
Some companies that sell dividers and divider-rounders include (in alphabetical order):
• APV Pavailler Inc. – (514) 631-7592 Canada
• Automation International Corp. – (203) 847-1309
• Dawn Equipment Co. – (517) 789-4500
• Dutchess Bakers’ Machinery Co. – (715) 394-4444
• Gemini Bakery Equipment Co. – (215) 673-3520
• Guyon & Co., Inc. – (215) 634-4600
• L & M Manufacturing Co. – (416) 665-3005 Canada
• Nussex Co., Inc. – (215) 696-3324; 800-345-8092
• Rondo, Inc. – (201) 488-0121
ADVANTAGES. In a high volume operation a batch-type divider-rounder can save labor time and cost. However it’s not labor-free. The initial large dough ball—for inserting into the machine—must be scaled, rounded, and fit to the pallet, and also loaded and unloaded from the machine. To be worthwhile, a pizzeria should probably sell at least 2000 pizzas per week.
Compared to continuous divider-rounder combinations (discussed next), a batch divider-rounder takes relatively little floor space—about 24 inches by 24 inches. (However, there is at least one continuous table model divider and rounder.)
DRAWBACKS. The main drawback is the initial cost. To recoup the investment in labor savings a pizzeria must do a high volume. Before buying a machine a pizzeria owner should compute the potential savings in labor to determine if it’s worth the investment.
In addition, some of the rounding machines are fairly noisy.
Lastly, when compared to continuous-type divider-rounders, a batch-type machine is relatively slow and labor intensive. However, most continuous machines are only suited for high volume operations such as commissaries and large commercial bakeries.
As with other large machines, a divider-rounder must be installed, maintained, and operated properly to insure good performance and long life. Follow the manufacturer’s instructions. For a description of how to operate a batch-type divider-rounder, see the Sample Production Procedure in the Dough-making chapter.
Most continuous-type dividers and rounders come as separate machines. However,
there are a few models—called combination divider-rounders—where the dividing
and rounding units are combined into one. They’re designed to occupy a minimum
of floor space. Before buying a divider or rounder you should understand how they
work. For a photo, click
here.
With a continuous divider a large mass of dough is placed into a hopper and the machine cuts off pieces of desired size. It divides the dough by volume, not weight. There are two basic types of continuous dividers: pocket dividers and extruders.
With a pocket divider the machine forces dough into a cavity or pocket and then cuts it off. As such, the weight of the dough piece is determined by the size of the pocket. So in order to produce different dough weights dividers come with adjustable-size pockets. Also there are single-pocket and multi-pocket dividers. Smaller dividers produce about 2000 pieces per hour. The largest machines do 20,000+ pieces per hour.
With an extrusion-type divider the dough is forced through a hole about 2 to 3 inches in diameter. As it comes out the other side it’s cut off to create a dough piece of desired size.
Depending on the degree of fermentation or rise, dough can vary in volume from batch to batch. So to achieve the desired weight of dough ball the machine usually must be adjusted slightly for each batch. With a pocket divider the pocket size is adjusted. With an extrusion divider the frequency of the knife cut or the rate of extruding dough through the hole is adjusted.
After dividing, dough pieces are rounded. There’s two basic ways that’s done: (1) Conveyor belt with board and (2) revolving surface with raceway. With the conveyor belt with board, the rounding action occurs as the dough piece rides on a conveyor belt while at the same time coming into contact with a board that extends diagonally across the belt.
With the revolving surface with raceway, the rounding action occurs as the dough piece gets pushed up a raceway or trough that is wrapped in spiral fashion around a spinning cylinder or cone. As the cone turns, the dough piece tumbles upward and, in the process, is rounded. When it reaches the top of the raceway it drops off onto a conveyor belt or table. Rounders that use a revolving drum are called drum or cylindrical rounders. Those using a cone are called cone or conical rounders. With some models the point of the cone is at the bottom; with others it’s at the top—in which case it’s sometimes called an inverted cone rounder. Each type and design of rounder has its unique advantages and drawbacks. Become fully informed about the various models before buying one.
Because of their high production capacity and corresponding high cost, continuous dividers and rounders are suited mainly for commissaries and large commercial bakeries, rather than for pizzerias.
For safe, reliable operation, divider-rounders must be used correctly and maintained properly. Follow the manufacturer’s instructions for operating and maintaining the machine. Generally, it must be lubricated monthly.
Even though most dividers and rounders are sized for commissaries and high-production bakeries, there are at least three table models that could be used by a typical pizzeria. ) For a photo, click here. They are sold by:
• Adamatic – (908) 544-8400 (retail bench divider)
• AM Manufacturing Co. – (312) 841-0959; 800-323-6446 (model 1000 divider)
• Nussex Co., Inc. – (215) 696-3324; 800-345-8092 (Eberhard universal rounder - table model
In addition, a very high volume pizzeria or a commissary might benefit from a combination divider-rounder. Companies that sell them include:
• AM Manufacturing Co. – (312) 841-0959; 800-323-6446 & 800-342-6744
• Benier U.S.A., Inc. – (404) 739-0700
• BMD, Inc. – (516) 567-2222
There are many sellers of high-volume dividers and rounders, including the following (in alphabetical order):
• Adamatic – (908) 544-8400
• AM Manufacturing Co. – (312) 841-0959; 800-323-6446
• AMF Bakery Systems – (804) 355-7961
• Benier U.S.A., Inc. – (404) 739-0700
• Champion Bakery Equipment Co. – (815) 726-4336
• Nussex Company, Inc. – (215) 696-3324; 800-345-8092
• Rondo Inc., – (201) 488-0121
For a full list of divider/rounder manufacturers, contact Baking Buyer magazine (816-756-0494) and ask for their current buyer’s guide issue.
ADVANTAGE. The main advantage of continuous dividers and rounders is that they produce large quantities with minimal labor.
DRAWBACK. Except for the table models, they’re too large and expensive for the typical pizzeria.
The conventional
slicer (i.e., with the spinning round blade) was originally designed for slicing
meat into pieces of uniform thickness. However it also can be used for slicing
cheese and vegetables. In a pizzeria it might typically be used for slicing pepperoni,
ham, onions, green peppers and other toppings, as well as sandwich ingredients
such as deli meat, tomatoes, and lettuce. For a photo, click
here.
Some companies that sell slicers suited for pizzerias include (in alphabetical order):
• Berkel Inc. – (219) 326-7000
• Biro Manufacturing Co. – (419) 798-4451
• Bizerba USA – (201) 819-0121
• Detecto – (417) 673-4631; 800-641-2008
• General Slicing – (615) 893-4820
• Globe Slicing Machine
Co. (dba Mozley Mfg.) –
(203) 324-4141
• Hobart Corporation – (513) 332-3000; 332-3095
• Hollymatic Corporation – (708) 579-3700
• Omas U.S.A. Inc., – (313) 421-1061; (716) 297-8275
• Robot Coupe USA, Inc. – (601) 956-1531; 800-824-1646
• Univex Corporation – (603) 893-6191
Slicers come both hand-powered and electric. For occasional slicing of small quantities a hand-powered machine works fine. However, because one purpose of a slicer is to save time and effort, the electric version is mainly found in pizzerias. From here on when we speak of a slicer we’re referring to the electric-powered machine.
There are two types of electric slicers: manual and automatic. To slice with a manual machine a person must push the carriage (which holds the food) back and forth over the knife. With an automatic model the machine does it. However, for short runs it can also be operated in manual mode. When slicing large quantities an automatic machine saves much labor. Generally speaking, a pizzeria that does more than ten minutes of slicing per day should consider an automatic model.
Most automatic machines use gravity feed—that is, the weight of the food holds it in place for slicing. However, a few models also have an automatic-feed or force-feed option. In this case, the food—such as a large piece of meat—is held with clamps and is automatically fed into the knife at a pre-determined thickness. The feature is used for creating uniform, wafer-thin slices of meat. Unless a pizzeria sells a large number of meat sandwiches it probably has little use for this feature.
In addition a few companies make sophisticated, high-production slicers suited for commissaries. Two of them are Bettcher Industries, Inc. (216-965-4422; 800-321-8763) and Berkel Inc. (219-326-7000).
Features vary slightly from model to model.
KNIFE SIZE. The typical knife size for an automatic slicer ranges from 12 to 13 inches diameter, with some a bit less and others a little more. Manual slicers have a 9- to 10 inch knife. A large slicer for a meat processing plant might have a blade up to 18 inches diameter.
MOTOR SIZE. For slicing dense foods like pepperoni and cheese it helps for the knife motor size to be at least 1/3 HP. Some models have a 1/2 HP motor.
SLICING SPEED. Automatic slicers come with either discrete speed controls or variable speed control. Most automatic slicers come with two speeds—low and high—although at least one model comes with only low speed. Slicing speed varies between models. Most have a low speed of 35 slices per minute and a high of 50. One model has a low speed of 45 and a high of 80.
A machine with variable speed control has a range of 1 to 60 slices per minute.
On most automatic models the stroke length is adjustable—short for slicing narrow items and long for wider items.
KNIFE SHARPENER. For a slicer to function properly the knife must be kept razor sharp, which means it must be sharpened regularly. Certain products—such as bread and pepperoni—dull a knife quickly. To make for easy sharpening most slicers come with a built-in sharpener.
KNIFE GUARD. At least one brand of slicer has a knife ring guard that protects the blade after the plates have been removed; thereby making the slicer safer for cleaning.
CLEANABILITY Slicing food is often messy—juice and small pieces of food go everywhere. To assist with cleaning, one slicer model has a lift lever for lifting the machine for easy cleaning underneath. Another one offers optional 4-inch legs. For a short person the legs can raise the slicer to an uncomfortable operating height on some models. In comparing slicers, evaluate how easy they are to dismantle, clean, and reassemble.
WARRANTY. Some companies offer a one year warranty; others don’t mention a warranty.
For a pizzeria the most important accessory is the chute, sometimes called the vegetable chute or hopper. It’s a metal cylinder about 8 inches in diameter and 14 to 18 inches long. It attaches to the carriage in place of the regular slicing platform. It’s used for slicing pepperoni sticks. It can also be used when slicing head lettuce, as for sub sandwiches, and also cabbage, onions and green peppers. For a photo, click here.
Some companies also offer an adjustable fence that fits to the carriage and holds round items like tomatoes and oranges in place for slicing. For a photo, click here.
Another item offered by at least one company is a slaw tray for catching sliced cabbage, lettuce, and pepperoni. In place of the slaw tray a 2-inch high pan (about 12 inches by 12 inches) can be used.
ADVANTAGES. The main advantage of the slicer, as compared to other cutting options such as a 9-inch vegetable cutter, is that it produces neat, uniform slices. Whereas the vegetable cutter tends to hack through food, much like chopping wood with an ax, a slicer slices through, like sawing wood with a circular saw. The result of using a slicer is that there’s less bruising to soft vegetables such as tomatoes and a neater slice when slicing pepperoni and ham. This may or may not be important, depending on how the sliced product is used.
Another advantage in using an automatic slicer for such items as pepperoni is that it requires a little les