Regarding the layering of scraps in your description of the process, I could easily see the expansion rates varying by the age and hydration of the layers, thus encouraging separation upon heating. What I find more intriguing is the fact that you didn't observe any changes in thickness going on with the sheeter adjustments. I wonder if they just keep it dialed as the finished thickness, then just force it through and has more to do with the number of passes? I have tried this on my sheeter and even though the thickness is set the same, I need to pass it ~5 times to make ANY dough come out even at the same thickness. If I only run it through say 2-3 times, it will be a thicker skin.
Like I mentioned, the Manager was "quick". I agree that he "at least" needed to click it down once for the final long sheet. I believe their sheeter was an Annetts single pass.
It didn't sheet as well as the Sommerset or Acme versions I've seen as RT. It did remind me more of my pasta machine, just bigger and a bit more efficient. I never heard the motor strain, but the motor was quite, like at RT.
I played a bit with the pasta sheeter, with the motor attached, and had a similar experience.
What "appears" to be going on is that the primary folding and sheeting are comparable to the "kneading" phase in pasta making. So the dough is folded and sheeted to condition the under developed dough without focusing on creating length, and in this case, our beloved "layering".
So in pasta making this is done on the widest settings, on my machine this is #1 and 2.
If the dough is at a good hydration level and as long as I have the "motor" set on it's higher setting, I can run it through the pasta maker without changing the width. I just need to flatten the trifold a bit. But eventually
it needs to be brought down to the next lowest setting (width) at least once during the" kneading/layering phase" to make a smooth sheet.
I have tried this on my sheeter and even though the thickness is set the same, I need to pass it ~5 times to make ANY dough come out even at the same thickness. If I only run it through say 2-3 times, it will be a thicker skin.
This doesn't seem to be happening with the pasta maker, not even with my low hydration pasta dough. When I do this again, I'll double check.
Can you drop it a bit lower to start with so that you end with the right thickness with the 3 passes?