Our Processes
Our machine portfolio primarily supplies our two main divisions of (Pre-)dough and pharmaceutical solids for the production of first-class products. However, the process application of our machines and transfer logistics also extends to much larger fields in the food, fine chemicals, supplements & luxury food and cosmetics industries.
Precise and efficient processes play a decisive role here. From fermentation, kneading and granulation to mixing, pelletizing, drying and coating - every step contributes to the quality and effectiveness of the end product. Our technologies and solutions enable you to optimally control processes and adapt them to your specific requirements. DIOSNA stands for the highest quality standards and supports you in perfecting your production processes.
Fermenting
Mild, strong, juicy-aromatic or sweet? The spectrum for tea flavours is diverse. DIOSNA is a specialist for fermentations and offers you a whole range of different dough cultures to serve different tastes. While the culture "wheat classic" provides a mild to strong taste experience with an optimal consistency of wheat pre-doughs, with "rye sour" you get a juicy-aromatic bread. The thermally produced pre-dough "Aromastück" convinces with its natural sweetness and is the basis for a wide variety of flavour pre-stages. Return dough or leftover bread can also be integrated into your fermentation processes. This has a positive effect for you not only in terms of taste, but also in terms of business management.
In order to maintain a constant and predictable product quality, large bakeries have been relying on our starter cultures for years. DIOStart® starter cultures ensure reliability in your baking processes. This also pleases your consumers. Your baked goods not only always taste the same, they also have the expected properties.
Kneading
Only with the right kneading do your baked goods get the optimum product quality. The mixing stage is already an indispensable component. Thanks to the uniform mixing of the ingredients, the water-soluble protein, salt and sugar dissolve, while pentosans and gluten swell. The starch present also binds the water.
The formation of dough is characterised by the formation of gluten-forming proteins, whereby these form the adhesive skeleton of your baked products. During this time, mixing intensifies, the dough warms up and the swelling processes are driven.
In the last phase, the dough development, the gluten protein is formed until the so-called stand prevails. The gases of the yeast are now evenly distributed and your dough appears plastic - the kneading process is finished. Kneading plants and systems from DIOSNA can handle all types of dough, regardless of the type and quantity. They guarantee safe, economical and flexible solutions for your operation. Even with tight schedules and large dough quantities, you can rely on your individual kneading machine.
Mixing
The character of your pastries is solidified with stirring. And for this, the right stirring tools are needed, ranging from the powerhouse to the whisk. Whereas with heavy cake masses and biscuit doughs, the main focus is on efficient mixing and structure formation, with soft doughs it is important to create a large volume and at the same time a good stability through high air intake.
Depending on the type of dough, soft or heavy, wafer mass or airy sponge dough, filling or cream, different mixers are therefore used, from flat mixers to whisks to combined mixing and beating whisks. Each of the DIOSNA stirring tools mixes all ingredients quickly, evenly and without lumps and ensures even temperature distribution
The DIOSNA planetary stirrers are particularly convincing when stirring your creamy, paste-like masses as well as when beating your foam-like masses. In large bakeries, on the other hand, DIOSNA spiral mixers with their quick-change tools really come into their own. And in fermenters, agitators with scrapers are used or those that induce external and central flow in addition to circular and tangential movement.
Mixing/Granulating
Precise distribution of active ingredients, highest mixing homogeneity, good compressibility or improved flow properties? In order to achieve the desired properties in a solid medicinal product, the granulate must be optimally prepared. To achieve this, the process steps of mixing and granulation must be perfectly coordinated. With the efficient and durable high-shear mixing and granulation solutions from DIOSNA, you are on the safe side in the production of solid medicinal products, even with challenging formulations or under vacuum.
And this from the very beginning: From the project idea to safe operation, from laboratory machines for the smallest batch sizes to production plants with batch sizes up to approx. 750 kg, from professional training on site to safe operation in everyday life. DIOSNA's experts accompany you through each of these steps and support you in developing your ideal process flow.
Drying
In order to obtain an optimal solid with defined residual moisture, the drying process is crucial. DIOSNA offers different plants that are not only flexible, but also do not lose sight of your economic efficiency.
In the fluidised bed process, the solids are fluidised by air flow in the process tank. This achieves very short drying times of the granulate at gentle temperatures.
The vacuum drying process, on the other hand, removes moisture by supplying thermal energy via the bowl walls while creating a vacuum. The vacuum allows a lower boiling temperature and is therefore also a gentle drying process. Here too, DIOSNA impresses with very short process times, which are very suitable even for your temperature-sensitive products.
The DIOSNA process experts support you in choosing the right drying solution and this from the very beginning. Whether as a laboratory version, pilot plant or dryer for large throughputs: DIOSNA ensures that your product is optimally treated.
Coating
Coating gives tablets, pellets and granulates the finishing touch. In addition to colour and gloss, a coating not only guarantees the tablet's stability, but also protects it from moisture or harmful exposure to light. The coating also ensures targeted release of the active ingredient, for example in the case of intestinal medicines. In addition, coated tablets are easier to swallow.
The flexible and modular DIOSNA coating machines fulfil every one of your wishes and ensure short process times and optimal results. Especially in research and development, you benefit from the versatile and flexible coaters on a laboratory scale. And this is completely independent of whether this is done with a drum coating or a fluidised bed process or whether a sugar coating, aqueous coating or even a coating with organic solvents is desired. Refine your processes with the support of the DIOSNA experts and make an appointment at the DIOlab in Osnabrück.
Pelletization
Healthcare, beauty care and fine chemical production rely on the pelletizing process to produce preparations in efficient and user-friendly dosage forms. Uniform pellet size and shape are crucial for the precise dosing of APIs and targeted release of active ingredients.
Prior to pelletizing, the starting materials are homogeneously mixed dry in the DIOSNA laboratory high-shear mixer granulator (P 1-6) and granulated wet. The granulate is then pressed into uniform extrudates using an extruder. DIOSNA's modular P 1-6 can be converted to the DIOSNA Spheronizer in just a few minutes by changing the bowl without tools. Thanks to its fast rotating friction plate, the Spheronizer produces flawless, spherical and smooth pellets of uniform size from the extrudates, which can then be dried and coated.
