Accuracy vs. Speed in depositing? You don’t have to choose.
This discussion will focus on lower viscosity materials similar to batter, crème, fats, jam, chocolate, caramel, mallow, etc.: thus, excluding doughs (dividers) and biscuits (wirecut/rotary).
Over the years I’ve worked on many bakery depositing projects. Whether you’re running batter, crème, caramel, jam, chocolate, nut butter, or mallow, the goals are the same:
Consistent, accurate weights
Sanitary design that’s easy to clean (CIP when possible)
Fast changeovers
Minimal unplanned downtime
Control of tailings and drips
One thing to keep in mind: accuracy starts with viscosity. A homogeneous mix, stable temperature, and controlled density are essential for consistent deposits.
DEPOSITING OPTIONS
Broadly speaking, many depositing applications fall into two categories:
Piston depositors (currently more common)
Pressurized manifolds (a competing design gaining traction)
This discussion will focus on pressurized manifolds, with future postings looking into feed rolls, rotary stencil, rotary piston, and sheer plate designs.
PRESSURIZED MANIFOLD BASICS
A typical system looks like this:
Jacketed use tank with agitator (to start with a known temperature and density)
Positive displacement pump, servo-controlled, to set system pressure
Jacketed piping throughout
Optional swept-surface heat exchanger to fine-tune temperature (especially for crystallized fats)
Optional aerator for density control
Three-way valve to divert flow back to tank when not depositing
Distribution plenum and flexible hoses feeding into a manifold with actuator valves and nozzles
Trim valves to balance pressure across nozzles
Note: A design variation would eliminate the distribution plenum and include a single inlet on one end of the manifold with a return on the opposite end. This would require the manual trim or programmable pneumatic valves to be utilized to balance the manifold.
ADVANTAGES OF PRESSURIZED MANIFOLDS
Simpler design, fewer parts than piston systems
Fully enclosed — better for aerated materials
Lower cost
Higher cycle rates (no piston fill/extract lag)
CIP options, plus easy breakdown for offline cleaning
Excellent drip and tailing control
Can “bank up” multiple manifolds for higher speeds or multiple deposit materials (stacked, side-by-side, center-in-shell)
DISADVANTAGES
System pressure is constant; thus, deposit cycle timing must be consistent or weights will drift
“No product – no deposit” functions create weight imbalances across the manifold width
Inclusions are challenging — narrow channels and cutting actuators don’t handle chunks well
More aggressive handling of materials due to higher pressures
More effective for smaller deposits (typically 1–15g)
Note: to assist with disadvantages #1 and #2 there have been attempts to modulate the system pressures to allow variations in deposit cycle timing or the number of active nozzles per cycle:
Addition of pressure compensation vessels (example, Warren Rupp tranquilizer)
Modulating the system pressure at the three-way valve (returning more or less material back to the use tank)
Addition of servo pumps in-line to maintain consistent pressure at the infeed and exit of the manifold
DEPOSIT ACCURACY
Generally accepted benchmarks:
Pressurized systems: ±2%
Piston systems: ±1%
That said, with the right setup and deposit material control, I’ve personally seen pressurized manifolds achieve ±1%.
REAL-WORLD APPLICATION
Think of a high-speed cake line that needs to deposit batter in a range of different pan sizes. A positive displacement system would typically require full changeovers, but a well-designed pressurized manifold with adjustable nozzles installed on a rail system can quickly restart, maintain accuracy, and reduce cleaning downtime. That flexibility can add up to real savings in labor and waste.
CONCLUSION
Pressurized manifolds are a strong option when:
You’re running smaller, high-speed deposits
You need combination deposits
You want a simpler system with fewer moving parts
But the system must be supplied and supported by experienced personnel who understand:
Mixing systems and supplying a homogeneous mass
Correct pump selection
Even/consistent manifold balancing
Viscosity control
New technologies are also reshaping the field. For example, Wiegers Process Innovations has introduced new designs with extreme flexibility, quick changeovers and CIP capable. Early applications include batter, crème, and caramel with excellent results.
If you’re evaluating depositors for your bakery, let’s talk. At LARA Bakehouse we can help you weigh the trade-offs and find the right system for your growth strategy.
– LARA Bakehouse
