Peeling Away the Layers

There are many factors to an automated process for manufacturing high quality Croissants, at scale. Each step of the process has an important part to play on the final product. From ingredients and mixing to cooling and packaging, producing an authentic croissant has many different layers.
The dough for croissants is no different, unlike puff pastry it is yeasted. Each thin layer of dough in a laminated sheet for croissants must have a superb gluten structure so that is can contain the gas from the leavening process.
Undue pressure to this structure on such a thin dough will rupture the gluten network and have a detrimental effect on taste, bite, shelf life and that classic open structure of a croissant.
Keeping down stress will mean that less heat is built up in the dough and less free water created. If the croissant then goes through a proofing process and freezing, even with the most accurate pre-chilling and freezing system, some yeast cells will be lost due to breakage under pressure from the freezing of water around them. Therefore, a Stress-Free® system gives the best chance of a good structure to the croissant when the croissant is thawed and baked.
In all croissants, fresh and frozen, thin sheets of butter or lower fat varieties are laminated with the layers of dough.
The layers are reduced in thickness and folded, usually at two stations if fully automatic, with a retarding/cooling stage in between. The retarding allows us to control and chill the temperature of the dough and butter layers but also to give the gluten structure in the dough time to rest and repair.
The croissant relies on the fermentation and initial oven spring from the yeast to form its delicate structure but it also relies on the expansion of steam which occurs between the layers of butter and dough, so keeping a separation in the dough and not melding the butter into the dough through the process is all important and with a Stress-Free® process this can be maintained using the physical principles of engineering and Rheology to achieve this.
A strong dough structure can then maintain that open structure after cooling and you will not be left with collapsed, flat croissants.
Rheon Automatic Systems were pioneers of this system and they introduced the world's first fully automatic croissant line to the bakery market. Their trademark Stress-Free® system has a reputation for working with high quality products.
Rheon’s laminating lines have evolved over the years with their using their patented stretching systems and their current V4 laminating line is a high capacity, fully automatic line for croissants and other pastry dough with a wide range of options for different products.
But Rheon are now moving onto the next generation of laminating line, the new laminating line from Rheon is soon to be introduced to the market. It will produce croissants at high speed, up to 200 pieces per lane per minute, but it has the most Stress-Free® system yet to be devised. The thickness reducing station are truly free of stress on the dough, gone are the typical type of multi-roller system, Rheon will introduce their new patented system, which until its launch is highly confidential.
It will have fewer moving parts and will have less action on the dough, the ensure high quality product and extended machine life.

BUT  you can take a peek below, at the introductory video for the new line