Some ingredients take longer to prepare than others during the mixing process. That’s why prehydration has become a much-discussed concept in recent years, especially with the addition of seeds, whole grains and other better-for-you ingredients in premium breads and rolls.

“Prehydration is a relatively new concept in the dough mixing world,” said Jim Warren, vice president, Exact Mixing, Reading Bakery Systems. “Some advantages include extra time for ingredients slow to hydrate, even distribution of ingredients, flavor development and even moisture distribution. It is also possible to reduce mixing time. The return on investment can be based on improved product consistency and quality, but the more likely justification could be higher throughput with the same size mixer.”

Prehydration is beneficial for ingredients such as flour, vital wheat gluten, enzymes, dough conditioners, yeast, salt, sugar, milk powders, hydrocolloids, fiber, bran, whole grains, seeds and protein powders, noted Shawn Hasley, director of food system sales and service, Zeppelin Systems USA.

“Hydrating these ingredients before mixing enhances gluten development, improves dispersion, boosts fermentation and ensures uniform incorporation, leading to better dough strength, consistency and final product quality,” he explained. “It is especially useful in high-hydration doughs, artisan breads and formulations requiring precise ingredient functionality, ultimately improving texture, moisture retention and overall baking performance.”

Despite these advantages, he added the extent of implementing prehydration varies widely across bakeries and is influenced by factors such as production scale, product types and investment capabilities.

This article is an excerpt from the April 2025 issue of Baking & Snack. To read the entire feature on Mixing, click here.