Baking+Biscuit 2026-04 digital

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Industry associations AIBI Congress 2026

Fried pastries

Interview with Jorge de Saja – ASEMAC

Berliners are the perfect all-rounders

Finding direction at the crossroads

04 26

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EDITORIAL

The competitive advantage AI company behind the Claude assistant, Anthropic, planned to have “all the books in the world destructively scanned”, according to an internal memo that appeared in court documents. ‘Project Panama’ was meant to secretly have book spines removed, scanned to train Claude, and then destroyed – including old and rare books. Books created before 2022 were preferred, before the ‘corruptive influence of generative AI’, as The Guardian called it.

High-quality input data was the target. Sellers of used books around the world reported spiking sales, with books picked by ISBN, rather than genre or author. The goal was to teach Claude to mimic literary fluency so that it could speak elevated ‘human’ rather than the choppy, recognizable AI language patterns: “It was best to train the LLMs underlying Claude on works just like the ones Authors had written, with well-curated facts, well-organized analyses, and captivating fictional narratives – above all with “good writing” of the kind “an editor would approve of”,” the court decision1 writes.

Catalina Mihu, Editor-in-chief Your commments or suggestions are always appreciated: e-mail: mihu@foodmultimedia.de

Understandably (even by Anthropic, according to their own memo), global outrage ensued over this modern-day version of the Library of Alexandria burning. Images with books having their spines chopped off for scanning and discarding sent shivers down ours, even if some were likely AI-generated.

Even more so, having published our latest book not long ago, a book we’ve been meticulously, passionately building for many months – a new addition to our collection, in the European market research series. On July 20, Anthropic settled the class action lawsuit with a group of writers for USD 1.5 billion, the largest known payout ever, according to Reuters.

At the same time, it is undeniable that AI tools are immensely helpful, transforming academic research, scientific investigations and technology operations. Automating repetitive tasks, quickly analyzing big data, compiling analytics and reducing operation costs are all areas where AI excels – helping people to be vastly more efficient. As long as it is people who remain at the top of the thinking chain, it could be argued, since generative AI content has been routinely found to be biased or distorted, fundamentally unoriginal – and sometimes, downright false.

Anthropic’s case reignites the conversation surrounding AI, how it is used, how it should be used, and what’s the bottom line, especially looking at its price tag. I will leave you with a question recently posed by Lotus Bakeries: ‘What if the biggest competitive advantage in 2026 isn't AI?’ The cookie maker’s answer was: “Creating products people love and building brands over time remains at the center of sustainable growth. We take that to heart.” With big computing power comes great AI responsibility, I would argue. The solution that combines efficiency, margins and ethics has the opportunity to be revolutionary and sustainable in the long run. What do you value as your biggest competitive advantage?

We’d love to learn.

Catalina Mihu

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Bartz v. Antropic, June 2025 - https://copyrightalliance.org/wp-content/uploads/2025/06/Bartz-v.-Anthropic-Order.pdf

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03

CONTENTS

COVER STORIES

HIGHLIGHTS

INNOVATION TELLS A

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Jorge de Saja serves as the General Secretary and Director General of ASEMAC (Asociación Española de la Industria de Panadería, Bollería y Pastelería),

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the Spanish Association of the

© Crown Bakeries

SUCCESS STORY

TAKING THE CROWN

Bakery, Pastry, and Confectionery

Cordia Harrington, the founder of Crown Bakeries,

Industry. In an interview, he offers © ASEMAC

is one of the most successful self-made women in

the insider’s view on an exciting,

America. The key to her success? Passion and

diverse and strong industry.

perseverance. With that, and “a dab of luck”,

14 © f2m

32

AIBI CONGRESS 2026

The 39th AIBI Congress explored the baking industry at the crossroads between tradition and innovation, aiming to discover opportunities in reinventing bakery for the future, while preserving values that are part of our identity.

THE FUTURE IS NOW For the first time, Bimbo Portugal successfully baked bread using a hydrogen-powered oven.

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THE PERFECT ALL-ROUNDER At first glance it seems simple, yet the Berliner is one of the most

HOW CRYSTALLIZATION SHAPES BAKED GOODS QUALITY

challenging pastries to make: the collar formation, striking a

Entirely different corners of the bakery, spanning

balance between fat absorption and airiness, achieving a soft and

texture science, fat technology and frozen logistics,

moist crumb texture, as well as the filling and decoration – all these

share a single, surprisingly elegant root cause:

require experience in preparation.

crystallization.

www.bakingbiscuit.com 04/2026

© Food Shop – stock.adobe.com

26

© AMF Bakery Systems

you can do anything, she believes.

© Stockbym – stock.adobe.com

04

CONTENTS

INDUSTRY ASSOCIATIONS 06

Jorge de Saja, ASEMAC interview: Innovation tells a success story

EVENTS 14

AIBI Congress 2026: Finding direction at the crossroads

WOMEN IN LEADERSHIP ROLES 20

Crown Bakeries: Cordia Harrington and a business earning the crown

FRIED PASTRIES 26

IREKS: Berliners are the perfect all-rounder

BAKERIES 32

Bimbo Portugal: The future of baking is now – with AMF Bakery Systems hydrogen oven technology

SCIENCE 36

ttz Bremerhaven: From chaos to order: How crystallization shapes baked goods quality

ARTIFICIAL INTELLIGENCE 42

KPM: AI helps close knowledge gaps

MARKETS 44

Finland: A baking culture takes root

HANDLING 50

Schubert: Pick-and-place tools for baked goods, always a secure hold

Cover ad: RONDO

REGULARS 03

Editorial: The competitive advantage

54

News

54

Advertiser directory

FOLLOW US ON LINKEDIN

all pictures © ASEMAC

06 INTERVIEW

INTERVIEW

SPAIN

Innovation tells a success story Jorge de Saja serves as the General Secretary and Director General of ASEMAC (Asociación Española de la Industria de Panadería, Bollería y Pastelería), the Spanish Association of the Bakery, Pastry, and Confectionery Industry. In an interview, he offers the insider’s view on an exciting, diverse and strong industry.

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Catalina Mihu: As Spain just won the World Cup last night, congratulations are in order, to start with.

Jorge de Saja: Indeed, it’s the only news on the radio this morning. And the celebrations are still ongoing! Yesterday, everyone was a big football fan.

Mihu: As one of the biggest European bakery markets in Europe, Spain is a very interesting country to study, in addition to its passion for football. Let’s start with its strengths: what makes the industry so resilient that it even enjoys recordbreaking growth, despite the current geopolitical environment?

Jorge de Saja: Thank you for your interest in the Spanish bakery industry! I manage trade associations from different food sectors, one of them being the bakery industry. I have seen a change across the board. Resilience describes the Spanish bakery well.

Exporting is a major factor contributing to its resilience, first of all. Exports have worked well beyond our expectations.

In the past, our industry was focused mainly on traditional production at a national level, which is a big market to begin with. Spain’s population is around 50 million people – a relatively big market, by European standards. But, to change perspective, this year we are going to surpass 100 million visitors.

That’s the full picture of the market. So, while Spain traditionally focused on serving the needs of our nationals, plus those coming from tourism, it’s only the last few years that our members, the country’s market leaders, have had to focus on exports. And it’s worth noting that exports still make up a small share of the market today. It’s clearly growing, and it has helped to support the volatile situation today.

But that’s not the only factor behind our resilience. The combination of traditional products and innovation has been working out well, too: Spain has plenty of local and regional cultures, which, among many other things, have their distinctive pastries, even more than different kinds of traditional bread. Pastries used to be produced in a more artisanal, localized way, and limited to regional distribution.

Our members have been successful at reinventing these traditional pastries and expanding their presence to a national level, at least. Plenty of innovation was also poured into these specialties to facilitate expanding their reach to all national ‘audiences’. With innovation, they’ve been able to reinvent, so to speak, plenty of the ‘nursery’ specialties, and that has helped make more appealing offerings for export as well, out of regional favorites.

The third reason supporting the industry’s resilience would be a relative recovery of bread consumption, after about two decades of decline. Every year we had to face the fact that bread consumption was going lower and lower – fewer grams everywhere. Thanks to innovation and the greater catalogues of bread varieties, we are seeing that not only has the decline stopped, but consumption has even increased over the last two to three years, even if it has been a very slight rebound. For a sector that has seen a decrease for decades, seeing the decline stop and then a slight recovery is already very promising.

The underlying driver is innovation. Most of ASEMAC members are producing much greater catalogs now than they were even five years ago, with high-value products especially expanding. Pastry and bread saw a decline a few years ago, so there was little appetite for investing in new varieties or substantially increasing portfolios, but most of our members have done that in the last years – and it has been a successful story.

Altogether, we were affected by the volatility of raw material markets, which was a big blow, with Spain being a net importer of some commodities. In general, all the driving factors making the European industry resilient apply to Spain, too, but we did some things a bit better than the others.

Mihu: Speaking of exports, what does Spain export and where?

Jorge de Saja: Frozen dough is successful abroad. It may seem an unlikely success story because frozen dough means high energy costs, but it is working well. It started with a few companies that had a more international profile, which, at first, expanded their exports by buying a partner or production capacity elsewhere. The industry leaders made investments in Europe and beyond – as far as the US, Mexico and Brazil, for instance. But now, they are also exporting products made in Spain, starting with neighboring markets, to keep energy costs low. Dulce de leche, for example, one of the most popular pastries, is now exported to the Mediterranean region.

It has taken a while for our members, and there’s still plenty of margin for growth, which stems from the Spanish bakers’ increasing export capacity, while other European competitors might see a decrease in profitability at the same time – but it works, and it shows. We are efficient at keeping industry costs in control while reaching new markets and offering

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INTERVIEW

new types of products, and this has not really been the trend for most of our European colleagues. A substantial number of Spanish companies are successful with this strategy.

Efficiency drives sustainability Mihu: And how are energy prices kept in check? This has been a very hot issue in Europe over the last few years.

Jorge de Saja: Certainly.. For the last 5 to 10 years, I have been looking at the investments carried out by different sectors of the food industry. Over EUR 5,000 million was invested in client-related measures, just by the bakery and pasta industry alone. Basically, our members accepted that energy prices are what they are, and they are starting to make adjustments: plenty of installations such as photovoltaic panels, cogeneration, and heat recovery technologies have been made over recent years.

Our members are trying to optimize in whatever means they have at their reach. They are focusing on making their plants more efficient. They are not fighting against prices.

They are not trying to change their supply, their energy supply lines (even if they could). Instead, they are investing in more efficient technology and are trying to make their processes more energy-efficient to manage related costs.

The increased use of renewable energy in Spain altogether helps. Basically, while working on optimizing their operational costs, they are also lowering their energy footprint.

Keep in mind that many of our energy sources were imported, while now it’s more and more national. That makes our carbon footprint look a little bit better. Even though I believe that energy cost efficiency or energy cost optimization was

SPAIN IS NOT ONE MARKET Spain is a collection of very different

the goal, in the process of doing that on the production chain, their environmental profile is looking better, too. Much better!

Mihu: How do Spanish bakeries approach sustainability?

Jorge de Saja: Whenever I see business strategies, or whenever companies go public, I see now that sustainability is really embedded in the industry decisions taken by our members. They do believe in it. Some of my members have either expanded or built new production capacity. When I visit some of them, I see it. That’s why I enjoy talking with operations directors or production technical directors: while they are showing off their ‘babies’, you can see how they plan, you can see how sustainability is a part of the factory itself, of the production line, or a determining factor in how raw materials are sourced.

“We are efficient at keeping industry costs in control while reaching new markets and offering new types of products.”

Jorge de Saja, General Secretary and Director General, ASEMAC

It’s an integral part of how the frozen capacities are set up, or how the water cycles are optimized. These are all evident changes, while some years ago, the general understanding was to simply comply with regulations (and sometimes, reluctantly). As little as 10 years ago, the industry was conscious of food security over carbon footprint, which was

NORTH • Traditional retail still relevant • Strong regional distributors • Different consumption habits

CATALONIA • Retail innovation & density

• Price sensitivity

• Foodservice highly developed

regional systems.

• International trade gateway • Regional decision makers • Strong purchasing power

CENTRAL (Madrid & Surrounding)

EAST COAST

• National HQs & buying centres • Corporate decision making

(Valencia Region)

• Modern retail leadership

• Tourism & seasonal demand

• Logistics & distribution hub

• Hospitality & foodservice strong • Convenience & impulse retail • High population growth areas

SOUTH & WEST (Andalusia, Extremadura, Castilla-La Mancha)

ISLANDS

• Large consumer base

(Balearic & Canary Islands)

• Strong tourism & horeca

• Tourism driven demand

• Traditional & modern retail mix

• Seasonal peaks

• Important regional wholesalers

• Limited space & logistics • Different consumer profile

Where demand is strongest?

Source: Iberia Food Partner

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Which channels dominate per region?

How purchasing decisions are made locally?

Where initial traction is most likely?

INTERVIEW

more of a technical added benefit rather than an aspect embedded in a whole sustainability strategy. Today, the industry believes in sustainability strategies. When you talk with our members, their concern shows, because they do think that it’s the only way forward. This is the only way for bakeries to become competitive.

We carry out some internal reports on water footprint reductions, for instance. There even seems to be competition in this regard: app companies have a water footprint strategy.

Besides, even if they did not believe in sustainability, food waste is very regulated in Spain, concerning the food industry, so it’s a must regardless.

Co-products are another great example. We didn’t even talk about them 20 years ago; we were talking about the very best by-products or maybe even residues that have to be eliminated from the process.

Mihu: What are some examples of co-products today?

Jorge de Saja: It can start with any product: frozen goods, biscuits or pastes, that fall behind some kind of production standards, or are faulty in any way. Instead of being just discarded, treated as residues, these products are now processed, or bakeries sell them to companies that process them, and turn them into products for the feed industry.

Bakeries are trying to make production as efficient as

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possible, but whenever they have to dispose of some raw materials or some faulty products, the system is designed to directly reach the feed industry.

Mihu: How do they work on minimizing the waste in the production facility? There are several regulations to navigate in this area, national and at the EU level – for example, the PPWR regulation.

Jorge de Saja: Bakeries are still adapting to it. But, to be fair, whatever a European regulation says, Spanish lawmakers are going to go the extra mile, far beyond the minimum required by EU law, and our members are not too happy about it. For instance, we had a legislative proposal to include braille on packaging in Spain. It would make sense to a certain degree: you can implement it for large packages, but not in products that are individually wrapped in plastic.

It eventually did not go through, because the European Commission advised against it.

Bakeries are adapting. Regarding the new packaging regulation, which is still in the process, there is still plenty of national execution to go on. The industry is not happy about it because they don’t see the added value. They see the added value in sustainability, in the circular economy; they’ve experienced the benefit of taking it seriously. It’s the same for water reduction, energy efficiency – all these

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INTERVIEW

make sense, and bakers are very happy to put in the effort.

Regulation starts to become a production over cost in a volatile world in which you really have to work hard to keep your competitiveness.

Mihu: You made an interesting remark: ASEMAC members can already see the benefits of circularity, and the results of taking steps in the right direction. What examples could you share?

Jorge de Saja: Even if production costs may have only slightly decreased, for big volumes, it amounts to a lot. It’s the opposite of a vicious cycle: in a virtuous circle, companies are doing better, so they are investing in new plants or new production lines. All new technologies are built with efficiency and sustainability-minded concepts, which means that, in turn, whenever they are operational, they contribute to lowering production costs, which makes companies even more willing to increase investments. They have seen that it works. Since they are in an expansion process, they are investing more.

That’s when energy optimization always comes into the conversation, for instance. “I am so happy that I installed these new isolating panels. I changed the circularity concept of my own business,” they say. It always comes down to it. Adaptations can be small things, or more sizeable changes, but everyone adapts. These are stories that everyone loves to tell. They are proud to share how they lower energy consumption.

Opportunities ahead Mihu: What opportunities are available for Spanish bakeries?

Jorge de Saja: The artisan segment is growing well. I see plenty of margin for growth there. The separation between artisan and industrial products is much smaller; that is clear.

There are plenty of traditional products in a country where so much value is given to local production, authenticity, and the connection between traditional and healthy lifestyles.

These values, usually associated with traditional artisan bakery, are now applied to industrial baking. Largescale companies have learned to produce these kinds of products, incorporating all the characteristics demanded by consumers.

The artisan craftsmanship is still there, with traditional techniques. Artisan-like products, made at large scale with the same values and the same taste as in an artisan bakery – these are recently developed innovations that do not chip away at the traditional, artisan market, which has stable performance numbers. What large bakeries managed to do is transfer some of the artisan baking conditions into larger, more industrial markets. They’ve expanded some of the qualities of the artisan craftsmanship to the general consumption, and consumers are reacting well. People are able to recognize that this product was not baked by my friendly baker down the street, but that it does look like it, and tastes like it. The fact that plenty of pastries are sold frozen is also good, because it means no additives were

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used, no preservatives, and no other ingredients that would take the product too far away from craftsmanship quality.

Our members already had distribution lines, marketing setup and logistical capacity in place to handle frozen goods, because that’s what they had been using for the more industrial operations. They only had to update part of their production lines, distribution and logistical capacity to be able to use these products.

Mihu: Will authenticity remain key?

Jorge de Saja: It will. And it works, particularly in European markets. There are still plenty of products that are local and artisan and very original, which deserve to be consumed elsewhere. And this is where the existing frozen capacity comes in, as an advantage.

“Regulation starts to become a production over cost in a volatile world in which you really have to work hard to keep your competitiveness.”

Jorge de Saja, General Secretary and Director General, ASEMAC

Mihu: How is the market shared in Spain between large industrial bakeries and small and medium bakeries?

Jorge de Saja: The market is very diverse. Last I checked, there were about 12,000 bakery establishments in operation.

Overall, I would say there is a healthy coexistence between medium and small companies and large industrial groups.

There are not that many large industrial groups, and the market is very diversified. Of course, there are some product segments dominated by our members – everything associated with frozen dough, croissants, pizza, or focaccias, for example. This is a very popular product category in a country with so many establishments for tourists. The majority of this market belongs to industry members. Medium and small companies do coexist in an overall healthy environment, focusing mostly on regional or traditional recipes.

Other products, such as the traditional napolitana, which is, perhaps, the most popular pastry in Spain, are made by everyone – big and small companies, in their own style.

In my European colleagues’ eyes, too, the Spanish market looks more diverse than in other European countries. This might be the key to the Spanish companies’ success story in Europe. In any case, it is clear that different business models, which serve different consumer needs, coexist.

An exciting kaleidoscope Mihu: Let’s explore the market diversity: what does the profile of the Spanish consumer look like? What kind of products do they like?

Jorge de Saja: Businesses are diversified in response to diverse consumers. The Spanish gastronomy culture is a very going-out culture, a very experience-driven culture.

INTERVIEW

Spanish woman selling traditional rosquillas at San Isidro festival in Madrid | picture © tangmo.pa – stock.adobe.com – generated with AI

Spaniards eat something when they are at home, and something different when they are on vacation. They like to eat something different whenever they are eating, every day, depending on the occasion. Eating habits are very much individualized. Family plays a role in Spanish culture, and it definitely makes its mark on Spanish eating out and gastronomy habits. So I would say that Spanish consumers, like all European consumers, are not eating less bakery, but they are being more choosy and careful about what they buy.

The difference in the Spanish consumer compared to other European consumers is that they eat and buy differently in different living situations. There are plenty of regional festivities or moments of consumption in which only certain products are eaten. You only eat a particular specialty whenever you go to your hometown or have a family reunion.

That’s why our members have such a large catalog. They themselves are conscious that whenever they are eating with their families, they eat different types of food than their everyday menu.

And then, there are also plenty of regional products that are only associated with certain celebrations and festivities, and consumers expect those products to be available at the right time. So, while there is a Europe-wide trend for consumers to be more appreciative of certain higher quality products or better-for-you specialties, at the same time, in Spain, they expect to have an enormous array of different products available to them, whenever they are doing different things. This is the key to understanding the Spanish consumer.

Starting from this diversity, our members are trying to make regional or limited-time specialties available more and more. Bakeries are trying to make such assortments popular elsewhere, and they have the capacity to do so.

These days, you can even find in supermarkets, all year round, some products that are traditionally only sold at a specific given time. There are, of course, exceptions,

keeping in mind that Spain is a Catholic country and that much of our culture has traditionally been linked to religious festivities. Some special types of pastry are only consumed on such occasions, for example.

Mihu: Looking at the Europe-wide trend for better-for-you products, what nutritional profiles do Spanish bakers aim for, and what product reformulations?

Jorge de Saja: I believe that the changes in consumer demands and tastes share similar dynamics all over Europe, with some national specificities. And all this nutrient consciousness and this appreciation of healthy lifestyles are happening in Spain, too. We also see a trend for products specifically designed for changes in habits, or smaller families and even single households. All bakeries adapt portions and sizes, and specifically deliver products for them. The reinvention of craftsmanship, authenticity and industrial baking might be more specific to the Spanish market, on the other hand.

Pastries lead the way Mihu: Pastries make a particularly interesting segment of the Spanish market. What are some of the traditional specialties that are present at the national level, and how are they reinvented for young consumers?

Jorge de Saja: ASEMAC members have first exported pastries in the traditional way, and only some of them are expanding further. The markets where we are producing and exporting include, first of all, France, Portugal, Italy, Germany, and the UK. The products that we are selling there tend to be international types of products. There’s always some kind of national innovation based on certain national products, but they wouldn’t be very much different from the popular mainstream offerings, ranging from pastels to Napolitana pastries, and any classic variety, perhaps with a little bit of Spanish flavor.

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“With innovation, they’ve been able to reinvent, so to speak, plenty of the ‘nursery’ specialties, and that has helped make more appealing offerings for export as well, out of regional favorites.”

Jorge de Saja, General Secretary and Director General, ASEMAC

The main priority is to gain ground on the market as much as possible. They are not trying to be ambassadors of Spanish gastronomy, but to be efficient and gain market share. I’m certain that millions of Europeans come to Spain regularly, so they are a bit more familiar with the Spanish production. In principle, they would be open to national products. This could be an avenue, and it may change in the future, but it isn’t the number one priority now. That would be to advance into new markets, when they are still at the beginning of a successful export strategy or internationalization strategy.

ASEMAC supports Spanish baking Mihu: How does ASEMAC work with and for its members, and how do you represent them with the authorities?

Jorge de Saja: Thank you for your interest! We are, as a member, a standalone organization that represents the baking industry, particularly focusing on technical regulatory issues. A great part of our efforts are channeled into working with authorities. We always say that administration is not our necessary evil. We are just a stakeholder, but we are proud to say that we are partners. I really stand by that.

And then, of course, plenty of new legislation has come out in the last 20 years. The Association has played a role in making certain that the industry would adopt new rules, or that regulations would be as industry-mindful as possible.

Regulatory lobby is our main priority.

We’ve also had a number of success stories in working together with health authorities and our members for product reformulation – lowering the use of sugar and salt, for

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instance. Usually, our work has been a part of voluntary schemes rather than seeing new regulation imposed. Industry voluntary agreements have been implemented progressively with the backing of our industry, and that’s where ASMAC has played a substantial role: in getting the industry and health authorities to work together on reformulation, or marketing strategies.

Of course, we do everything else that is expected from the trade regulation. We support our members and give them regulatory information, helping them to adapt to changes.

But I think the distinctive role of ASEMAC has been the capacity, throughout the years, to make industry and administration partners in things that otherwise would have been simply imposed. In this way, authorities could be mindful of the process and the timing that bakeries needed to adapt to new decisions. Making certain that changes would take place at a more reasonable pace and a more industryminded pace has been a significant part of our role.

Mihu: What kind of partnerships do you work in? Who would qualify as a partner for specific projects?

Jorge de Saja: It would depend. We’ve carried out projects with retailers, which are not that many, so the competition is fierce. That means that in such projects, we will collaborate with them one by one.

We worked a lot with consumers’ organizations in the past, but they are not that active in this sector. There are other sectors they prioritize (such as meat). For R&D, we carried out some projects on mycotoxin reduction with different partners.

But most of our members tackle innovation on their own.

I recall a success story from the last few years, when we were able to slightly modify the temperature at which some of our products have to be produced and stored, which was ultra-frozen, while all our European competitors were doing frozen (from -17°C we went up to -14°C). This temperature difference actually meant plenty of money at that time. The Association carried out comprehensive research, proving that the temperature increase did not have any health consequences. That issue was contemplated by other European regulators, which proved that Spanish national legislation was far more demanding and the change actually aligned Spain with the European level.

Mihu: What industry events are in the Spanish bakers’ agenda?

Jorge de Saja: I see a trend among many of our members, which confirms everything we said before: they are not only participating in general food fairs like Alimentaria in Barcelona or Sial in Paris, but they are more and more investing into specialized fairs, like gourmet fairs or exhibitions addressed specifically for retailers. Smaller fairs focusing on hospitality are also interesting. Gourmet in Madrid is a successful story every year, for example.

Mihu: Thank you very much for an insightful conversation!

Jorge de Saja: It’s been a delight. +++

EVENTS

© AIBI

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Finding direction at the crossroads The 39th AIBI Congress explored the baking industry at the crossroads between tradition and innovation, aiming to discover opportunities in reinventing bakery for the future, while preserving values that are part of our identity.

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In the spectacular setting of the French Riviera, the International Association of Plant Bakers (AIBI) and the Fédération des Entrepreneurs de Boulangerie (FEB) hosted the 39th edition of the biennial Congress at the Muratoglou Hotel in Sofia Antipolis. The forces that transform bakery markets worldwide were analyzed together with an impressive audience of over 200 people, including industry leaders, researchers, solution providers, academia and bakery specialists. An agenda spanning two days with the industry’s most important topics was prepared for the event, across seven themed topics, ranging from evolving consumer expectations, nutrition and health, sustainability ambitions, and digitalization to artificial intelligence, and the changing role of bakery.

A market visit, for a glimpse into the region’s colorful businesses, was organized on the day before the conference program. Introduced in Hamburg at the previous edition of the Congress, the market tour returned in full force, doubled in size to meet popular demand.

In parallel with the event’s conference program, the General Assembly meeting gathered AIBI members for the customary leadership transfer and other association-wide decisions.

The French edition bid farewell to AIBI’s President for the 2024-2026 mandate, Jean Manuel Lévêque (France, President – Novepan) and welcomed its new leader, Guido Vanherpe (Belgium, Chief Executive Officer – La Lorraine Bakery Group).

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Kari Meltovaara (Finland, Managing Director – Leipomo Rosten Oy) and Seb Gooding (Germany, UK, Chief Executive Officer – Valora B2B) were appointed as Vice Presidents, completing the leadership team for the next two years.

Latest advances One of the notable changes made over the past two years was to simplify communication. In addition to working with the national associations, which are the backbone of AIBI, the international organization representing plant bakers has established direct access to the bakery companies in Europe. AIBI counts 16 national associations among its members, and “On top of that, we thought we needed to have direct access to the companies, which are more and more pan-European and even extend even further. And this is what has been done by creating a sounding board,” Lévêque highlighted in his welcoming address.

And changes did not stop there: sustainability was deemed the topic transcending the organization’s regular agenda, unifying it. With this new approach, the first tangible program is already underway: the Sustainable Wheat Initiative Europe (SIWE). Established at the symposium in Utrecht in June 2025, the initiative drafted its Manifesto and roadmap towards low-carbon wheat and flour. Its first goal is to reduce wheat and wheat flour emissions by 30% by 2030 compared to 2022 levels, in line with the latest climate science. “As a sector, we want to take our responsibility for helping our

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Cyrille Fillot| photo © AIBI

wheat farmers transition to sustainable agriculture. This is essential to meeting our sustainability goals and to safeguarding the resilience of the European industrial bakery value chain in the face of climate change”, Lévêque explained the importance of the Manifesto. At launch, more than 30 industrial bakery companies, millers, cooperatives, suppliers and value chain actors had already signed the pledge, a shared vision between them.

Industry leaders panel discussion — Jan Hertz (Lantmännen Unibake), Mieke Remans(Puratos), Peter Van Den Berg (Pandriks) | photo © f2m

remains a critical strategic lever in bakery. “Our projection at Rabobank is that we expect the year-over-year food inflation to be somewhere between 5 and 7%,” he anticipates.

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Session: A thriving bakery business: getting acquainted with the latest economic and consumer trends The latest developments in the bakery business took center stage, including firsthand figures and statistics about the sector, as well as insights into the latest consumer trends, in a bid to identify the drivers of the market changes affecting the bakery business.

The industry is at a crossroads of “powerful, often contradictory forces that demand immediate strategic attention,” long-time Congress moderator Cyrille Fillot (Global Strategist – Consumer Foods, Rabobank) underlined. On one hand, macroeconomic headwinds are taking up speed, while consumers go through a profound shift in their journey to health and wellness, fueled by the rise of GLP-1 medication and the rise of everything high-protein to the podium of food choices. Despite inflation-related pressures, premiumization

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The emerging thesis is that premiumization must now be redefined and justified through tangible health benefits, the likes of added protein, or added fiber, rather than relying on indulgence qualities and artisan craftsmanship alone, Fillot noted.

GLP-1 was one of the disruptive factors under intense scrutiny for its potential to bring about an industry-shifting upheaval, with its power to entirely re-map how and what people eat. Puratos offered insights on how exactly the appetitesuppressing drug is changing eating behaviors and what it means for the future of bakery – fittingly over a high-protein

breakfast, to showcase solutions that can unlock new opportunities in bakery. “GLP is not a passing trend. It represents a lasting shift that will reshape the industry,” anticipated Dr. Sara de Pelsmaeker, Group Health & Well-Being Director at Puratos. With oral GLP-1 drugs entering the market in 2026, this trend will only accelerate, as the number of uses will spike, particularly among those wary of needles, which has been the only way to administer the drug so far, she noted. While the leading market for GLP-1 intake has been the US, Puratos sees growing markets in Europe, particularly in the UK, Germany and Spain.

A word from Guido Vanherpe AIBI President, the 2026-2028 mandate “AIBI is about content, first of all: navigating challenges and finding solutions together. But for me, and I hope for you too, it’s even more than that. It’s also about the fun, because we are really in an exciting industry. The Congress has really broadened, and I’m really happy to see more than 200 members in our ecosystem today. That is a fantastic evolution. At the first Congress I attended, 32 years ago, we were around 120 people. At that time, there were even more owners, more CEOs in the room. Our group has developed into a fantastic ecosystem. Going forward, we need to make sure that the owners, the leaders of the bakery industry, attend the AIBI Congress in ever-larger numbers, because they are the passion and they are the fire of our industry.

Actually, the congress from 32 years ago was on the other side of the bay here, in Monaco. My dream would be, in 30 years from now, when it may return once again to Monaco, that some of you will be there and could look at the other side of the bay and say: “ Remember, we were in Antipolis 30 years ago…“ I think that could happen because a lot of the bakery companies are still family businesses. Within our industry, it is important to bring together passion, ownership and leadership in such gatherings because it is very important that, as a bakery industry, we show Europe and the world that we are strong together. So let me end my speech with this adagio: The content and the challenges bring us together. Our passion for the bakery, the breads and the fun do forge good relationships.” photo © AIBI

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Guido Vanherpe at the AIBI Congress gala dinner event, Saint Tropez, May 2026

BORN TO BE HOT

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© f2m

The session’s panel brought to the stage industry leaders: Jan Hertz (Lantmännen Unibake), Mieke Remans (Puratos) and Peter Van Den Berg (Pandriks).

“We see the topics of health and well-being keep coming back, and all the nutritional demands from consumers that are very important, relevant, and will gain a lot of traction onwards – GLP-1 also being a part of that, together with premiumization,” Mieke Remans observed. “For me, it’s always the data that’s interesting,” added Peter Van Den Berg, regarding the assessments proposed by Gira1; “It’s good to know what the expectation is and to learn about all the new developments in the sector. There is more than a single truth to follow” when gathering insights that help build strategies, he said. Looking at the consumer, he welcomed the growth in the bread category. On the other hand, consumer worries need to be accounted for, Jan Hertz observed: “I don't think we have seen a significant change directly since the war in Iran broke out. We could see the consumer sentiment coming down – perhaps 13 percentage points, almost as low as COVID,”, he said noting that the market has already been soft for the last 15 to 18 months.

Industrial scale.

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Session: Nutrition and Health: a matter of corporate social responsibility and industry leadership The growing trend for plant-based food and health-conscious nutrition does not prevent bread consumption from declining – but it does bring an opportunity, if the proposed offerings are interesting enough, with improved nutritional profiles.

AIBI members explored how they could contribute to such improvements.

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Andrew Pyne (UK, Federation of Bakers) presented the success story of UK bakers gradually reducing salt levels

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EVENTS

Nutrition and health panel: Caroline Sluyter (Whole Grain Initiative), Didier Boudy (Emmi Desserts), Nathalie Siccard (Patroba/Institut Pain & Santé), Andrew Pyne (FOB), Mikkel Andersen, Lantmännen Unibake International) | photo © f2m

over 30 years, assessing that the country is now a global leader in salt reduction. This was done through incremental reductions across the entire bakery category. “But you have to take the consumer on that journey,” he underlined. “That journey has to be taken across other sectors where the perception of salt, the preference for a salted texture and flavor is changed within the consumer. We have learned in the UK that some targets can work if they are set to a realistic level, where you can just keep taking a little bit off every few years, and you take the whole of the UK profile taste perception with you,” he assessed.

AIBI in figures 16 – National member organizations 110 bn – EUR in turnover 500 – companies 53.6 – Kg bread/person/year

Didier Boudy, FEB President, shared France’s journey with salt reduction, which started with skepticism around 20 years ago, about the feasibility of any significant advances, and turned out to be enormous improvements by adopting a ‘baby steps’ strategy. For the 2022-2025 program, the target for standard white bread in France was to reduce salt content from 1.7% to 1.4%; it was ultimately surpassed, achieving levels between 1.26% and 1.27%, he revealed, noting that reducing salt in whole grain bread is technologically easier than in white bread.

also pointed out an uneven expansion trajectory, comparing the internationalization of US brands with European companies. “If I measure Europe’s quality, know-how, and variety of products, it’s a mystery that we do not exist outside of Europe,” he pondered. Names such as Starbucks or McDonald’s have a global presence, but “Where are the French patisseries, or the Italian cafeterias?,” he asked.

“I don’t see them. If you go to an airport in the US, it’s impossible to find an espresso. You get a Starbucks. It’s interesting to see that we, the most important market – Europe, are not present. So we should try to think about what we can do all together to become more relevant, not only with products but also with concepts, with ideas, and how to promote our industry,” Angelon reflected.

Session: Addressing the drivers of the bakery business future; how will we reinvent bakery?

Looking at potential scenarios for the 2035 industry, Alessandro Angelon (Italy, Sammontana) described success not being measured by the products sold, but by the ability to curate experiences – especially in HoReCa. In-store bakeries in supermarkets, for instance, are already evolving into visual showcases, with aesthetics, color and product variety driving engagement. He emphasized an essential balance that must be reached: while trends ask for less sugar and less salt, indulgence does remain fundamental. He

For the future, technology – especially AI and robotics – was viewed as transformative in the industry, while sustainability challenges are being addressed. Investment priorities should center on marketing, “Especially in product innovation, on what I would call retro innovation, which means that our future perhaps remains in the past,” as Jean-Manuel Lévêque considers, to refresh traditional products – as long as the cost of new technologies (such as AI) is not passed down to the consumer. A hypothesis and an open conclusion to the Congress that perfectly resonates with the event’s theme: ‘The future is in the past’. +++

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IN THE SPOTLIGHT: WOMEN IN LEADERSHIP ROLES

CROWN BAKERIES

Taking the crown Cordia Harrington, the founder of Crown Bakeries, is one of the most successful self-made women in America. The key to her success? Passion and perseverance. With that, and “a dab of luck”, you can do anything, she believes.

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© Crown Bakeries

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When she was 11, Cordia Harrington started a nursery school. She would gather children from the neighborhood who enrolled, bring them to the family’s backyard, where she organized games and served snacks that she bought with her own money. By the end of that summer, she earned USD 60.

Cordia Harrington wants to encourage others to succeed, too – people who work for Crown Bakeries and people at the beginning of their careers. She is granting scholarships, trying to target students who are also the first in their families to graduate, knowing the change that has brought for herself.

Cordia Harrington has always loved doing business. She worked as a waitress and a lifeguard. She graduated from the University of Arkansas with a degree in home economics, the first in her family to earn a degree. While she had a real estate firm, she started working at McDonald’s – as a prerequisite to becoming a franchisee.

As a McDonald’s operator, she became a member of the bun committee. She wanted to be a baker. Today, if you search for ‘the bun lady’ online, Cordia Harrington is the first result.

In 2026, she received the Horatio Alger Award from the Horatio Alger Association of Distinguished Americans, Inc., a non-profit that honors leaders who have overcome adversity and supports young people in furthering their education. Harrington becomes a lifelong member of the organization, joining 10 other corporate, civic and cultural, as part of the 2026 class of honorees. She supports the Association’s scholarship programs: “For me, education is not so much what you learn in the classroom; it’s the people you meet and the broadening of your world.

College is a time to explore – to learn and to understand.

I am especially encouraging to young people who want to travel as part of their education. Being exposed to different cultures is so valuable. It influenced me in many positive ways,” she underlined.

In 1996, she founded Crown Bakeries. Based in Nashville, Tennessee, the business now operates with nine manufacturing facilities, baking over seven million items daily and employing over 1,800 people. They manufacture a diverse line of fresh and frozen croissants, buns, bagels, biscuits, sweet goods, and dough products for leading foodservice, food manufacturing, and retail customers in the United States. Crown Bakeries is an award-winning business, with recognitions such as the Burger King Supplier of the Year (2022, 2025), Conagra Brands Supplier of the Year (2020), McDonald's Supplier Leadership Award (2012) and Wholesale Bakery of the Year (2010). The company was also named one of the 2024 Best and Brightest Companies to Work For ® by the National Association for Business Resources.

Forbes named her one of the most successful women business owners in the country.

www.bakingbiscuit.com 04/2026

Reflecting on her path and work, she shared her thoughts on the recognition: “Receiving the Horatio Alger Award is deeply meaningful to me because it reflects a belief I have lived by my entire career — that persistence, preparation and hard work can open doors, even when the answer is ‘no’ more times than you can count.”

Last year, she transitioned from her role as CEO to Founder and Co-Chairperson of Crown Bakeries. Yianny Caparos, formerly President, was appointed as CEO. Doug Bame, previously COO, is now President, in charge of Crown’s strategy toward an “exciting future”, as Caparos anticipates.

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IN THE SPOTLIGHT: WOMEN IN LEADERSHIP ROLES

“Trust is a privilege”

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Catalina Mihu: You were recognized as one of the most successful self-made women in America by Forbes in 2021. This year, the Horatio Alger Award is added to your impressive collection of recognitions celebrating your work. What does your day’s work agenda look like, when the work means constantly building one of the most instantly recognizable names in the baking industry?

Cordia Harrington: Thank you for the compliment about Crown. Yianny Caparos, Doug Bame, and the whole team work very hard every day to continually improve on quality, new product offerings, and good value for our brands. It’s a privilege to be trusted to serve our elite customers.

My agenda changes daily – it could include a trip to one of the bakeries for a tour, a Zoom meeting, an American Bakers Association board meeting, or a call with McDonald’s.

The variety is energizing!

Mihu: Challenges aside, what aspect of working in the industry would you consider your favorite? What is the joy in baking as a business, and why is that?

Cordia Harrington: The baking industry is small. We know the families and leaders of our competition. They are all men and women of high integrity, professional and dedicated to quality, making this industry very pleasant to work in. We help each other if a plant goes down for repair, or if there is an emergency. Our suppliers are very dedicated to helping our plants stay online, and go out of their way to help. The Industry is small and very special.

I think it is FUN knowing our products are being enjoyed while families are ‘making memories’. I go to McDonald’s several times a week to enjoy their food… and I am very proud to see moms and dads with their children enjoying our buns or muffins.

Mihu: How do you work to solve current business challenges, with the goal of maintaining your supply uninterrupted?

Cordia Harrington: The baking business, like many businesses, has hurdles from employee retention, training, and having the right products to bake on the available lines!

Baking is a ‘see-saw’ of too little capacity or too much capacity. Crown built a new line to bake for a specific product launch, and the launch did not fill the entire line, so we worked hard to get more sales. Then, once the line was full, the product performed well in the market, and there was not enough capacity! This is a common hurdle.

Mihu: To stay at the top, in a company and as a company in an industry, consistent work is needed to both consolidate foothold and to advance. How have you been focusing on both, as the leader of Crown Bakeries?

Cordia Harrington: It takes top talent to grow and excel in any field. Our partners at Arbor encourage hiring the best, paying them well, and motivating the team. Our new R&D team landed some big wins in the past year with a very large customer who has taken these products to retail nationwide. That was fun! And we have solid products in the pipeline to roll out in 2026. In addition, we are always

“The baking industry is small. We know the families and leaders of our competition. They are all men and women of high integrity, professional and dedicated to quality, making this industry very pleasant to work in. We help each other if a plant goes down for repair, or if there is an emergency.”

Cordia Harrington

The 79th Horatio Holger Award recognized Cordia Harrington this year among the leaders who embody the ‘American dream’ through hard work and perseverance | picture © Crown Bakeries

www.bakingbiscuit.com 04/2026

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IN THE SPOTLIGHT: WOMEN IN LEADERSHIP ROLES

on the lookout to buy a bakery that offers additional capacity and capabilities. In the past five years, we have made six acquisitions.

Mihu: What can you share from the projects in progress this year? What does new product development prioritize?

Cordia Harrington: Crown has many projects in process: a new bun line in Wisconsin, launching a new market. Over 15 new savory and sweet products have hit the retail shelves and there are five others in R&D. Eddie (in R&D) is baking ideation samples daily for our team to present to our large customers. It is a thrill to see the new products be successful with the consumers!

“As we discussed new company names, Crown rose to the top because the technical name for the top of the bun is the ‘crown’. It’s the first thing you see. Crown was a nod to our heritage but allowed us to become known for a wider variety of bakery products.”

Cordia Harrington

Mihu: How would you describe your leadership style? And what values have you instilled in the company’s culture?

How do the people at Crown respond to them?

Cordia Harrington: Culture is key to success. Our culture is based on our mission to ‘Create Opportunities, Make a Difference, and Impact Lives’. We enjoy connecting, encouraging, and supporting growth to be the best we can be, as individuals and as a company. My personal leadership style is an ‘Encourager’.

More than ‘just buns’ Mihu: Having started as Tennessee Bun Company, what did the transformation to Crown Bakeries entail? What was your vision then?

Cordia Harrington: Tennessee Bun Company transitioned to Crown Bakeries because we became more than ‘just’ a bun company. We wanted to expand our offerings to include croissants, bagels, brownies and more. As we discussed new names, Crown rose to the top because the technical name for the top of the bun is the “crown.” It’s the first thing you see. Crown was a nod to our heritage but allowed us to become known for a wider variety of bakery products.

Mihu: And what is your vision for Crown Bakeries now, having transitioned from the CEO role in 2025? How do you work with the company’s new CEO, Yianny Caparos?

Cordia Harrington: Yianny and I have deep trust. We speak often and bounce ideas off each other. Yianny executes and manages the day-to-day operations. We are having a lot of fun!

www.bakingbiscuit.com 04/2026

Mihu: Crown Bakeries supplies major QSR companies with buns, from McDonald’s to Pepperidge Farm and Five Guys.

What qualities must buns have, seeing as they earned you the ‘Bun Lady’ fame?

Cordia Harrington: Our buns must meet a set of 38 exacting criteria when they go through the X-ray machine on each line before they can be packaged. The criteria include symmetry, seed placement, number of seeds on the bun, porosity, and more.

Mihu: Crown Bakeries not only supplies buns, but it is also continuously expanding and reinventing itself. What is your strategy driving this growth?

Cordia Harrington: Our strategy for growth is to simply support our customers’ need for new products and bake them! We aim to be the best at developing the products our customers want.

Mihu: How are new product ideas identified and perfected?

Cordia Harrington: Our new Crown products are created by dreaming with the customer, then presenting samples, commercializing the new products, and the new packaging.

We have the ability to package in bulk and singles, and everything in between.

Mihu: You applied for a McDonald’s franchise, seeing as it would allow spending time with the family, which had become challenging in your real estate business. How do family and work balance in the baking industry?

Cordia Harrington: Family was my driving force to become a baker also. Having a business that allowed me to hire a trusted, professional team gave us a much better work-life balance.

Work-life balance is a priority for our teams; however, when a hurdle arises, it is ‘all hands on deck’ and everyone pitches in. We have a flexible paid time off program and encourage travel and family time.

“Baking is both art and science.”

Cordia Harrington

“Ask lots of questions!”

Mihu: If your life was made into a movie, what moments would be on your list to include, as significant milestones?

And why?

Cordia Harrington: My life has been a dream and is full of blessings. Too many to mention!

Mihu: What would you pinpoint as the biggest challenges in your formidable work as a woman in a baking business?

Cordia Harrington: The baking business was welcoming to me as a woman – surprisingly so! As a woman restaurant

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IN THE SPOTLIGHT: WOMEN IN LEADERSHIP ROLES

Cordia Harrington spoke at a networking event for the women in the baking industry, organized by Dawn Foods at its IBIE 2022 stand | picture © f2m

franchisee, I often felt invisible. I would make a suggestion and be met with ‘crickets’. Five minutes later, a man could say the same thing and have it called a good idea. It was very frustrating.

Mihu: Your recent award celebrates leaders who have overcome adversity and are committed to supporting others.

How do you support young people joining the industry, and Crown Bakeries?

Cordia Harrington: Baking is a fabulous career opportunity for women (and men). When I speak publicly, I encourage young people to consider baking as a future career. I speak at schools and work with counselors to offer internships and summer jobs. This industry is inclusive and warm, and it offers upward mobility to dedicated workers.

“Our buns must meet a set of 38 exacting criteria when they go through the X-ray machine on each line before they can be packaged. The criteria include symmetry, seed placement, number of

Mihu: What advice would you offer young women starting a career in baking?

Cordia Harrington: Say yes! Get involved on committees (like safety), go to industry events, host tours for the community, ask lots of questions, and learn something new daily.

Mihu: What would be an example of a question you would ask today (and to whom would it be addressed)?

Cordia Harrington: “Mr. President, how may I become an Ambassador representing the USA?” Mihu: How should women’s representation be supported to grow in leading roles in the baking industry?

Cordia Harrington: Women should be encouraged to show up and volunteer; they will have visibility and opportunity if they have ways to get more involved in leadership.

Mihu: Please highlight your strategy toward investing in innovation – and the people developing it.

Cordia Harrington: Innovation is a core value at Crown.

Our R&D lab has been rebuilt, and our R&D team has success in commercializing new products. Innovation also spans to our supply chain and packaging.

seeds on the bun, porosity, and more.”

Cordia Harrington

Mihu: What would you consider the most convincing arguments in such presentations you give?

Cordia Harrington: The Baking Industry is a welcoming profession, one where an individual can start at the bottom and become a senior leader in a few years’ time. Drive, determination and dedication pay off in baking. Learning all positions, and working well with others, personal pride in the job and attention to quality… these lead to generous salaries, 401k match, and plentiful benefits. I cannot think of another industry that has such a great upside.

www.bakingbiscuit.com 04/2026

Mihu: How do you see the bakery industry today? What changes should bakers prepare for?

Cordia Harrington: The bakery industry is a staple in the American home. Our products bring nutrition and joy, and we are changing to satisfy both taste buds and nutritional needs, such as gluten-free and other specialized needs.

Who knows what the consumer will want in 10 years – but we will be baking it!

Mihu: In your experience, what is the hardest thing to master to be a successful baker?

Cordia Harrington: A successful baker must have patience, dedication, and perseverance. Putting in the time to really learn is imperative because baking is both art and science. +++

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FRIED PASTRIES

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FRIED PASTRIES

BERLINER

The perfect all-rounder At first glance it seems simple, yet the Berliner is one of the most challenging pastries to make: the collar formation, striking a balance between fat absorption and airiness, achieving a soft and moist crumb texture, as well as the filling and decoration – all these require experience in preparation.

By Simon Knappich, Pastry Chef, Diplomingenieur (graduate engineer) in Food Technology (University of Applied Sciences), Technical Consultant Key Accounts Confectionery Bakery, IREKS, Kulmbach, Germany

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Ingredient selection

The quality of the raw materials, the ingredient proportions, and the respective process steps and parameters determine the outcome when baking deep-fried pastries.

Premixes Baking mixes and premixes can serve as the foundation for consistent and reproducible baking results of the highest quality. The demanding production process requires specially selected raw materials. The primary ingredients used are high-gluten specialty flours with precisely defined qualities that ensure good dough stability, high fermentation tolerance, pronounced subsequent pan spring, the characteristic, stable white collar, and low fat absorption during deep-frying.

Premixes also contain technologically effective ingredients to achieve maximum process reliability, good flavor, longlasting softness, and the desired crumb texture. In addition, they usually already contain the required amounts of sugar, fat, dry milk products, salt, and flavorings.

Eggs Berliners are among the yeast-leavened pastries with the highest egg content. In addition to enhancing the quality of the pastry from the consumer’s perspective, the egg content plays a key technological role in the production process.

Whole eggs

As early as the dough-making stage, the lecithin contained in the egg exerts its emulsifying effect, improving the structure and texture of the dough. The doughs are smoother and more pliable, making them easy to process with

10% whole egg

15% whole egg

20% whole egg

20% whole egg + 5% egg yolk

equipment. Another function of whole eggs in manufacturing Berliners is to reduce fat absorption during the deep-frying process, which has a positive effect on the taste and digestibility of the product. In addition, whole eggs play a key role in volume development and contribute to the formation of the subsequent pan spring as well as to the stabilization of the white collar.

Egg yolks

The deliberate addition of egg yolks improves the crumb structure and color and helps keep baked goods soft. Using only egg whites is not recommended. If the proportion of eggs is changed, the amount of water added must be adjusted accordingly to avoid creating doughs that are too soft and too difficult to process in a machine.

Fats Based on qualitative, technological, or economic requirements, different kinds of fat can be chosen. Generally, the fat content in a baked Berliner contributes to: + A shorter, softer crumb structure + Delayed staling by prolonging softness and freshness + Enhancing aroma and flavor The fat content in Berliner dough is typically 8–12%, based on the weight of milled grain products. However, increasing this content results in a lower volume and increased fat absorption during deep-frying.

Butter

Butter is used primarily for its aroma and flavor. Because butter has a lower melting point than baking margarine, Berliner dough made with butter should be kept slightly

10% whole egg

15% whole egg

20% whole egg

20% whole egg + 5% egg yolk

Different egg content percentages relative to total flour (10 % whole egg, 15 % whole egg, 20 % whole egg, 20 % whole egg + 5 % egg yolk)

all pictures © IREKS

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Gluten stretch test of Berliner dough

Berliner dough pieces and baked Berliners with optimal shape

cooler throughout the entire process. If the pastries are marketed under the name ‘ButterBerliner’, only butter or milk fat products derived from butter may be used. In addition, the dough must be fried in clarified butter, since the deep-frying fat used must be listed as an ingredient in the ingredient list due to the corresponding amount of deep-frying fat absorbed.

been frozen. In practice, the amount or dosage of yeast ranges from 4 to 7%, depending on the weight of the milled grain products.

Margarine

Due to the emulsifiers it contains and its solid fat content, margarine has excellent emulsifying properties. This results in more stable doughs that are less sensitive to temperature variations and have greater fermentation stability.

Vegetable oil

Neutral-tasting vegetable oils are also suitable, as they promote a soft, brief chewing sensation. When used, vegetable oils tend to result in softer doughs and promote increased fat absorption during deep-frying. Therefore, the amount added should not exceed 10% – based on the weight of milled grain products.

Sugar (Sucrose) In doughs for Berliners, the sugar content is typically 6–10%, based on the weight of milled grain products. Sugar contributes to the desired sweetness, enhances the pastry’s flavor, and increases the moisture content of the crumb.

Sucrose and other types of sugar promote the pastry’s surface browning.

Salt Salt is added in the standard amounts of 1.4–1.8%, based on the weight of the milled grain products. It helps both to stabilize the dough and to develop the desired flavor.

Yeast The required amount of yeast depends on the specific fermentation method used and whether the dough has

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The perfect dough piece Berliner doughs are characterized by their elastic and fluffy texture, which makes them easy to work with and well-suited for machine processing. These doughs require intensive kneading, as the formation of the gluten network is delayed by the fat and sugar contents.

Dough preparation Doughs that have been kneaded for approximately 2 + 7 minutes in a spiral mixer exhibit plastic dough properties and a smooth, dry surface. Longer, intensive kneading results in increased subsequent pan spring. The Berliners expand more in width during deep-frying, resulting in a larger diameter. Due to individual operational conditions and processing methods, which can include an automatic divider or a dough-dividing and kneading machine, the amount of water added and the kneading time must be adjusted accordingly. To achieve the most stable dough possible and a target dough temperature of 24–26 °C, it is recommended to use cold water in combination with ice.

The dough temperature, in turn, depends on: + Batch size + Kneading system + Ingredient temperatures + Outside temperature (season) If more than 50% of the liquid is replaced with ice, the mixing phase should be extended, as the ice does not initially contribute to dough formation. Dough that is too warm, or the addition of pre-fermented dough pieces, impairs the moldability of the dough pieces. A proven method for determining the optimal kneading time is the gluten stretch test at the start of production.

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Shaping Shaping is a critical step in the production process that determines the Berliner’s quality. The goal is to produce uniform dough pieces with a smooth surface, even tension, and a closed, flour-free seam. A cleanly formed seam is essential for the Berliner’s subsequent shape retention and ability to absorb deep-frying fat. Gently pressing down on the shaped dough pieces before the proofing phase ensures a flatter pastry shape and prevents them from becoming too round or spherical.

Types of proofing Different proofing methods have become standard in nearly all bakeries.

Direct The dough pieces are placed in the proofing chamber immediately after shaping and are allowed to slightly stiffen when they are three-quarters into the proofing process. To ensure the stability of the dough pieces, it is important to maintain a controlled proofing period of approximately 90 minutes at a proofing temperature of 27–32°C and 75–80% relative humidity.

Proofing interruption The prepared dough pieces are placed in proofing interruption at -7 to -18°C as usual. After a storage period at -7°C, the dough pieces are slowly thawed over seven hours and brought to proofing. The temperature increase during the thawing and proofing phases must be managed in such a way as to prevent excessive condensation from forming on the surface of the dough pieces. Then, when the dough is ¾ proofed, allow the dough pieces to firm up.

When storing unproofed dough pieces in the freezer for several days or weeks, flash freezing is recommended. The frozen dough pieces should be sealed in an airtight container as soon as possible to prevent the surface from drying out.

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Stiffening An essential step before frying is the stiffening of the proofed dough pieces. This process partially prevents the frying fat from penetrating too deeply, thereby helping to reduce fat absorption. In addition, a light formation of skin improves its shape retention, particularly the formation of the characteristic white collar. It is important to note that the dough continues to proof during the skin formation.

Stiffening works best in a cool, dry place and can be accelerated by fans or some form of controlled airflow. However, excessive skin formation should be avoided. If cracks appear during the fermentation test or when light pressure is applied to the surface, this indicates excessive drying, which significantly impairs volume expansion during the deep-frying process.

Deep-frying Fats and oils have a much higher heat capacity than air and can therefore transfer heat to the food more quickly and evenly than in the traditional oven-baking process.

The water present in the dough piece evaporates at the beginning of the deep-frying process and is gradually transported to the surface (mass transfer). Only when no more water evaporates from the surface does the temperature gradually rise from the outside in, resulting in the development of the characteristic fried aroma and flavor, as well as the golden-yellow crust.

Deep-frying fats When selecting deep-frying fats and oils, the following characteristics must be considered, in addition to economic factors: + Long-lasting heat and oxidation stability + High smoke point of at least 210 °C + Low foaming + Neutral taste and odor + Handling and consistency

FRIED PASTRIES

Deep-frying fats are edible fats and are therefore chemical mixtures of triglycerides composed of fatty acids and glycerin.

When heated and exposed to oxygen, their structure changes, resulting in various degradation products. On the one hand, these are responsible for the pleasant fried flavor. On the other hand, they have a negative impact on the quality of the fat. In this context, saturated, long-chain fatty acids are significantly more stable than unsaturated fatty acids with multiple double bonds.

The deep-frying fat changes as it is subjected to increasingly high temperatures. Careful process control helps maintain the deep-frying fat in optimal condition for as long as possible. For example, regular filtration of the deep-frying fat reduces contamination and helps slow down the deterioration of the deep-frying fat by up to 20%. In addition, the ratio of product volume to deep-frying fat volume should not exceed 1:10. The result: an excessive drop in temperature and increased absorption of deep-frying fat.

Deep-frying fats qualities Since some of the deep-frying fat is absorbed into the product during deep-frying and subsequently consumed, consistent quality must be ensured in daily use. In practice, sensory evaluation is the primary determinant. Used deepfrying fats should be considered spoiled if they exhibit clear defects in odor or taste, or physical changes such as: + Stale, scratchy, rancid taste + Pungent and unpleasant odor + Excessive foaming + Increased smoke production at 175°C + Increased viscosity and formation of resinous deposits To corroborate the sensory findings, chemical parameters are also taken into account during the analysis, as deepfrying fats undergo measurable changes over their usage, including:

+ Increase in free fatty acids + Increase in polar components (threshold* ≥ 24%) + Increase in acid value (threshold* ≥ 2.0 mg KOH/g) + Increase in polymeric triglycerides Deep-frying parameters The ideal deep-frying temperature for Berliners is approximately 170°C. The temperature should be carefully monitored at regular intervals. If in doubt, it is recommended to check the temperature using an external thermometer.

On the one hand, too high temperatures cause the surface to brown quickly, which shortens the baking time. This can negatively affect the stability of the collar. Temperatures that are too low, on the other hand, and the resulting longer baking times promote increased fat absorption in the pastry.

For a dough piece weighing 0.045 - 0.055 kg, the optimal baking time is approximately seven minutes, with the following timings: 1. Baking phase........................... 210 seconds, closed 2. Baking phase........................... 150 seconds, open 3. Baking phase............................. 50 seconds, open 4. Baking phase............................. 10 seconds, open To achieve a pronounced subsequent pan spring, the first baking phase should be carried out with the lid closed.

This keeps the surface of the dough piece pliable and elastic for longer, which promotes even volume expansion during deep-frying. As the dough matures, the lid can be opened slightly earlier to regulate excessive volume expansion and support the formation of a stable collar.

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This article is based on a section from the “SIEDE-CHECK” brochure published by IREKS.

*Thresholds: As of July 2025

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© Bimbo Portugal

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The future is now For the first time, Bimbo Portugal successfully baked bread using a hydrogen-powered oven.

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In 2022, hydrogen was proposed as the fuel of the future in bakeries, when the concept was introduced with fully realized tunnel oven technology developed by AMF Den Boer. The modular Multibake® VITA Tunnel Oven effectively eliminated emissions commonly produced by baking ovens by using green hydrogen to activate its burners, for entirely ‘green’ baking.

“The results confirm the feasibility of hydrogen technology as a sustainable and viable alternative for industrial tin and hearth bread production with

burners and operated successfully throughout two weeks of continuous testing.

To run the tests, 12 natural gas burners and controls were temporarily replaced with 12 Hydrogen (H2) burners, each 16 kW (54,000 BTUs maximum output each). The DHF burners were mechanically designed to match typical DGF burners, and were installed in the same locations, for a fast and efficient retrofitting process. As a result, “The complete conversion to H 2 was achieved within two days,” AMF highlights.

With this setup, a maximum output of 192 kW (655,000 BTUs) was achieved. Moreover, the hydrogen DHF burners were

zero carbon emissions.”

AMF Bakery Systems specialists

For Bimbo Portugal, the future is here, now. In collaboration with AMF Den Boer, the bakery successfully carried out industrial-scale bread baking using hydrogen as fuel. The project is in line with Bimbo’s decarbonization strategy and its goal of achieving carbon-neutral operations – and a significant milestone in this direction.

A big step forward A tray oven operating since 1998 at Grupo Bimbo’s Portugal facility was retrofitted with Direct Hydrogen Fired (DHF) burners, in a project carried out by AMF Den Boer, in cooperation with Kiwa Technology. “The baking zone 2 was originally equipped with conventional Direct Gas Fired (DGF) natural gas burners,” AMF explains (pictured below). This zone was retrofitted with Direct Hydrogen Fired (DHF)

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Natural gas-fired blue flame burner in visible light, showing low/mid/high capacity

BAKERIES

Shop testing of the H2 burners (with invisible flame) in the AMF Den Boer Plant in Nieuwleusen, the Netherlands

Mobile hydrogen gas supply connections outside the baker

HMI H2 burner zone monitor and Hydrogen burner

H2 Burners H2 Gas Manifold

Zone 2, featuring 12 retrofitted hydrogen (H2) burners | all pictures © AMF Bakery Systems

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H2 Gas Burners

© Bimbo Portugal

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Natural Gas Burners

also designed to match the thermal capacity and control range of the original natural gas direct gas-fired (DGF) burners.

purging, ventilation, and emergency shutdowns, were successfully validated under real production conditions,” AMF specialists detail.

Once the DHF burners were successfully installed, the baking zone became operational, meaning production could commence, using 100% hydrogen (H2) heat in the baking tunnel. Throughout the two-week trial period, product quality was continuously monitored. In parallel, the hydrogen (H 2) system was closely supervised, including the temporary external gas supply to the bakery and all associated in-house gas safety measures.

Testing results: Green light for hydrogen baking

“The hydrogen’s clean combustion enabled the oven to operate at a lower overall temperature. In addition, the natural gas consumption in the remaining oven zones was slightly reduced.”

AMF Bakery Systems specialists

A wide range of products were baked using hydrogen combustion during these two weeks. Some technical challenges encountered were mainly related to burner ignition – and were solved. Despite these setbacks, the oven zone consistently reached target baking temperatures, without affecting product quality at any point.

Product performance was the first, but not the only result monitored: the baking trials also showed the energy efficiency of the setup, while achieving the temperature set point. “The hydrogen’s clean combustion enabled the oven to operate at a lower overall temperature. In addition, the natural gas consumption in the remaining oven zones was slightly reduced. Safety systems, including leak detection,

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While further engineering improvements are needed before permanent implementation, this project proves that hydrogen baking is technically feasible, offering a promising path toward carbon-neutral ovens.

The successful two-week test proved the concept of bread baking using hydrogen (H2) gas as a heat source. It demonstrated that the process performance is comparable to conventional baking methods with respect to product quality, safety, and sensory characteristics. “The results confirm the feasibility of hydrogen technology as a sustainable and viable alternative for industrial tin and hearth bread production with zero carbon emissions,” AMF concludes.

AMF Bakery Systems has won multiple innovation awards for its Multibake VITA hydrogen tunnel oven by Den Boer, including distinctions at CFIA and Sirha Europain, in 2022, when journalists and professional jury members ranked the hydrogen tunnel oven as the best equipment innovation of the year. “A true future-proof development in bakery equipment that will bring zero-emission baking, with green hydrogen and investment for decades to come,” underlined Eric Tellier, Sales Director France, at the award ceremony.

Today, the DHF burners are patent-pending inovations, (US and International patents).

AMF Den Boer’s R&D develops solutions working closely with customers and suppliers to improve efficiency and achieve sustainable results, the company highlights its approach to new developments. “We are committed to applying groundbreaking solutions in pursuit of our goal: establishing a 100% lights-out, climate-neutral bakery.” +++

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Intricate salt crystal formations

SCIENCE

FROM CHAOS TO ORDER

How crystallization shapes baked goods quality Why does bread go stale even in airtight packaging? Why do some margarines crack during lamination while others fold like silk? And why does a perfectly good frozen dough sometimes collapse the moment it hits the oven?

These three questions seem to belong to entirely different corners of the bakery, spanning texture science, fat technology and frozen logistics, yet they share a single, surprisingly elegant root cause: crystallization.

By Dr. Julien Huen and Frida Köning, ttz Bremerhaven

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Baked goods are mosaics of components that can exist in crystalline or amorphous states, including starch, sugar, salt, fats and, in frozen products, water in the form of ice. How these components crystallize, and how quickly, determines not only how raw materials behave on the production line but also how a product looks, feels and tastes on the shelf weeks later. Far from being a topic confined to physics textbooks, crystallization is one of the most practically powerful, and most underused, levers available to anyone trying to control quality in baked goods. This article explores the thermodynamic principles behind it, and shows how understanding them can turn an

invisible molecular process into a concrete tool for recipe and process design.

A simple case to start: water and ice To understand why crystallization behaves the way it does, it helps to start with the simplest possible system: pure water. Cooled in a differential scanning calorimeter (DSC), distilled water does not freeze the moment it crosses 0°C. Instead, it keeps cooling, often down to around minus 22°C, before crystallization finally kicks in. (Figure 1) This phenomenon, known as supercooling, illustrates a principle that holds for every crystalline component in a baked

Figure 1: DSC curve of distilled water. Cooling from 20°C to -25°C. Effect of supercooling visualized by the crystallization peak around -22°C. © Stefanie Kempel, Julien Huen, ttz Bremerhaven

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© Nurul – stock.adobe.com

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Figure 2: Polarisation microscopy images visualising the crystals in palm oil under different temperature conditions over time. Left: fast cooling creates many small crystals. Right: slowed cooling creates big crystals. The temperature profile over time determines the crystal structure, which in turn affects the rheological properties of the product. | © Julien Huen, ttz Bremerhaven

product: crystallization is not instantaneous. Molecules need time to find their way into an ordered lattice, and close to the melting point, both the liquid and the solid state can coexist for a while before the more stable, lower energy state wins out. (Coupland, 2014) The rate of cooling determines what the resulting crystal structure looks like. Cool quickly, and strong supercooling produces many crystal nuclei and a fine network of small crystals. Cool slowly, and fewer nuclei form, allowing existing crystals to grow large. (Coupland, 2014) (Figure 2) This is precisely why shock freezing, using cold, moving air at around minus 40°C or cryogenic gases such as liquid nitrogen, produces the fine ice crystal structure needed to protect product texture, while slow or fluctuating storage temperatures let crystals coarsen over time through recrystallization, as small crystals dissolve in favour of larger ones, gradually changing mouthfeel and structure. The practical

takeaway is simple but easy to overlook: store frozen products as cold and as steadily as possible.

Fat: a much messier story Where water crystallizes as a single, simple molecule, fats are a different challenge altogether. A typical fat blend contains a large number of different triglycerides, varying in chain length and degree of saturation (Gee, 2007). To complicate things further, each triglyceride can adopt several different crystal forms, known as polymorphs, each with its own melting point (Bayés-García, 2021). The result is a fat crystal network that builds up across multiple length scales, from individual crystal platelets to larger aggregates, ultimately determining whether a fat feels soft and spreadable or firm and brittle (Marangoni, 2020). (Figure 3) This complexity matters enormously for laminating margarines used in croissants and puff pastry. During storage,

Figure 3: Schematic overview of the stages of crystal network formation | graphic is AI generated illustration

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“Because crystallization happens at a molecular and microstructural scale, most of it is invisible to the naked eye, which is why a combination of complementary analytical techniques is needed to capture both the structure and the energetics of the process.”

Dr. Julien Huen, ttz Bremerhaven

crystallization continues. The crystalline fraction increases, crystals recrystallize into rounder and larger forms, and the fat network becomes increasingly interconnected, so firmness rises and the fat can eventually turn brittle (Zhang, 2014) (Figure 2). Tempering studies on industrial sheet margarine make the practical consequence visible: margarine sheets tempered at the wrong temperature crack and tear during lamination, while correctly tempered sheets fold smoothly into uniform layers (Gao, 2022). The manufacturing process for margarine moves the product through a sequence of carefully controlled temperature zones, from blending and emulsification at 50 to 80 °C down to crystallization, kneading and storage around 15 to 25°C, and every one of those steps offers a lever. Choosing fast crystallizing fat blends, applying mechanical work, allowing sufficient time for crystallization to complete, and keeping storage temperature stable all help avoid the cracking and reduced plasticity that plague lamination in practice.

Sugar: crystal, glass or rubber?

Sucrose adds yet another twist. In its pure, anhydrous form it melts at a high 185°C and, unlike water, barely shows a crystallization peak on cooling in the DSC at all.

Cooled quickly, molten sucrose does not recrystallize; it solidifies into an amorphous glass or rubber-like state instead. (Figure 4) Once dissolved in water, the picture changes again. As a two-component sugar water system cools slowly, ice crystallizes first, concentrating the remaining sugar in the unfrozen liquid until it becomes saturated and sugar itself starts to crystallize out. Cool the same system rapidly, and everything solidifies as an amorphous glass before crystallization has a chance to begin, which is exactly the principle exploited in shock freezing of sugar-containing products to avoid grainy, gritty textures from sugar crystallisation. (Sablani, 2010)

Starch: the slow road to staleness The most familiar crystallization story in baking is also the most economically important: starch retrogradation, the molecular process behind staling. Starch granules consist of two polymers, amylose and amylopectin, arranged in alternating crystalline and amorphous regions. (Wang, 2015) During baking, heat and water disrupt this order: amylopectin crystallites melt, amorphous regions hydrate, some amylose leaches out into the surrounding matrix, and amylose-lipid complexes melt as well. The granule swells, while partially retaining its structure. (Figure 5) The reverse process begins the moment the product starts to cool. Amylose, freed during baking, recrystallizes quickly into a three-dimensional network, within hours. Amylopectin recrystallizes far more slowly, over days, but it is this slow process that is largely responsible for the gradual firming and going stale that bakers know all too well, visible under the microscope as a progressive densification of the starch matrix between a freshly baked loaf and one that has sat for a week. (Hug-Iten,1999)

Figure 4: DSC curve of sucrose. Heating from 20 °C to 220 °C (yellow line). Sucrose melt sover 185°C. Cooling from 220°C to 20°C (blue line) of the same sample. No crystallization peaks as sugar solidifies into an amorphous glass or rubber-like state when cooled quickly. © Stefanie Kempel, Julien Huen, ttz Bremerhaven

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SCIENCE

Figure 5: Fluorescence microscopy images of native starch (left) and gelatinised starch (right) | © Ainhoa Ramos, ttz Bremerhaven

Keeping bread soft for longer Because retrogradation is a kinetic, time-dependent process rather than an instant event, it can be slowed, though not stopped, through several complementary strategies.

These include avoiding storage temperatures around 4°C, where recrystallization is fastest, steering clear of a roughly one to one starch to water ratio that favors rapid network formation, adding hydrocolloids, polysaccharides or fibres that physically slow the diffusion of amylose and amylopectin molecules, using enzymes such as alpha amylase or maltogenic amylase to modify the starch chains themselves, and including emulsifiers and lipids that bind amylose into V type amylose lipid complexes, which interfere with crystalline network formation. Each of these is, in effect, a different way of buying time against the same underlying thermodynamic drive towards order.

Making the invisible visible: how crystallization is studied None of the mechanisms described above can be managed on instinct alone. They need to be measured. Because crystallization happens at a molecular and microstructural scale, most of it is invisible to the naked eye, which is why a combination of complementary analytical techniques is needed to capture both the structure and the energetics of the process.

Fluorescence and polarization microscopy make crystalline and amorphous regions visible directly, image by image.

Under polarized light, crystalline structures such as starch granules or fat crystals appear bright against a dark, amorphous background, because their ordered molecular arrangement rotates polarised light in a way that disordered regions do not. (Figure 2). Staining with fluorescent dyes can further highlight specific components, for example

distinguishing intact starch granules from gelatinised, hydrated regions. (Figure 5) This makes it possible to literally watch a structure change, for instance to follow how a starch granule's crystalline core erodes during baking, or how a fat crystal network coarsens during storage.

Differential scanning calorimetry (DSC) takes a different, complementary approach. Rather than imaging structure, it measures the heat absorbed or released as a sample melts or crystallises. The size, shape and position of the resulting thermal peaks reveal not just whether crystallisation or melting is occurring, but how much material is involved, at what temperature and how readily, turning an otherwise invisible phase transition into a quantifiable curve (Figure 1, Figure 4).

Texture analysis closes the loop between microstructure and the property that ultimately matters to the customer: how a product feels. Because crystallisation directly governs the firmness, brittleness or elasticity of fats, starches and frozen structures, mechanical measurements of hardness, spreadability or fracture behavior provide an indirect but highly practical readout of how far a crystallization or recrystallisation process has progressed, and how it will be perceived at the bakery counter or kitchen table.

Used together, these three techniques (visual, thermal and mechanical) provide a fairly complete picture of crystallization behavior: what is forming, how much, how fast, and what it ultimately means for product quality. This combination has, in fact, been the analytical backbone of 15 years of applied research into crystallization phenomena in baked goods and related food systems at ttz Bremerhaven, spanning projects on frozen dough, laminating fats and starch-based products alike.

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Microscopic view of sucrose crystals in polarized light | picture: © Pawel Burgiel – stock.adobe.com

“Baked goods are mosaics of components that can exist in crystalline or amorphous states, including starch, sugar, salt, fats and, in frozen products, water in the form of ice. How these components crystallize, and how quickly, determines not only how raw materials behave on the production line but also how a product looks, feels and tastes on the shelf weeks later.”

Frida Köning, ttz Bremerhaven

One set of rules, many applications What unites ice, fat, sugar and starch crystallization is that they all obey the same handful of thermodynamic rules: nucleation and growth, the trade-off between cooling rate and crystal size, and the long, slow march toward the most stable, and often least desirable, structural state. Once this is understood, crystallization stops being a background nuisance and becomes a parameter that can be designed

for. It can be accelerated where a product needs to set quickly, slowed where shelf life depends on staying soft or workable, or suppressed altogether where an amorphous, glassy structure is the goal. Whether through recipe formulation, selecting raw materials with the right crystallization behavior, or through process control, meaning temperature management, seeding and mechanical working, the lever is the same one, applied to a different ingredient each time.

For bakeries and ingredient suppliers, this shared logic is good news. A quality issue that looks unique to one product, be it a stale loaf, a cracking margarine sheet or a frozen dough that spreads too much in the oven, is very often a variation on a problem that might has already been solved elsewhere in the industry. Recognizing crystallization as the common thread, and having the right combination of microscopy, calorimetry and texture analysis to track it, is what turns recurring quality complaints into a manageable, predictable part of process design. This is exactly the kind of cross-product expertise that institutes such as ttz Bremerhaven have built up over more than a decade of applied research into crystallization behavior across the baking and food industry. +++

References Bayés-García, L., Sato, K. and Ueno, S. (2021). Polymorphism of Triacylglycerols and Natural Fats. In Bailey's Industrial Oil and Fat Products, F. Shahidi (Ed.).

Coupland, J. N. (2014). An introduction to the physical chemistry of food. Springer.

Gao, H., Gao, W., Yang, X., Liu, Y., & Wang, Z. (2022). Effects of different tempering temperatures on the properties of industrial sheet margarine. RSC Advances, 12(36), 23311–23321.

Gee, P. T. (2007). Analytical characteristics of crude and refined palm oil and fractions.

European journal of lipid science and technology, 109(4), 373-379.

Hug-Iten, S., Handschin, S., Conde-Petit, B., & Escher, F. (1999). Changes in starch microstructure on baking and staling of wheat bread. LWT-Food Science and Technology, 32(5), 255-260.

Marangoni, A. G., Van Duynhoven, J. P., Acevedo, N. C., Nicholson, R. A., & Patel, A. R. (2020). Advances in our understanding of the structure and functionality of edible fats and fat mimetics. Soft Matter, 16(2), 289-306.

Sablani, S. S., Syamaladevi, R. M., & Swanson, B. G. (2010). A Review of Methods, Data and Applications of State Diagrams of Food Systems. Food Engineering Reviews, 2(3), 168–203.

Wang, S., Li, C., Niu, Q., & Wang, S. (2015). Starch Retrogradation: A Comprehensive Review. Comprehensive Reviews in Food Science and Food Safety, 14(5), 511–680.

Zhang, X., Li, L., Xie, H., Liang, Z., Su, J., Liu, G., & Li, B. (2014). Effect of temperature on the crystalline form and fat crystal network of two model palm oil-based shortenings during storage. Food and bioprocess technology, 7(3), 887-900.

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ARTIFICIAL INTELLIGENCE

AI helps close knowledge gaps The next step in vision inspection systems is a leap: smart systems can offer comprehensive product readings and can continuously learn how to improve products they ‘see’. Yuegang Zhao, Chief Commercial Officer and President of KPM Laboratory Solutions, offers a glimpse into how the company approaches AI.

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bbi: What are the highlights of your R&D work in AI over the past three years?

Yuegang Zhao: For KPM Analytics, our emphasis on AI is centered on helping bakeries streamline operations, gain deeper insights on process control, ensure product quality and consistency, and amplify food safety efforts. As baking operations have become more automated and fasterpaced, and as more baking experts leave the industry through retirement or other reasons, AI is helping to reduce the knowledge gaps that many bakeries face today.

One area where we’ve invested heavily in our R&D is the development of AI-powered vision inspection applications to inspect products at various process stages. Today’s high-paced baking operations simply cannot rely on human inspectors to spot out-of-spec products, especially since this method is entirely subjective and difficult to control across multiple production lines and shifts at a bakery. Our AI vision technologies incorporate high-resolution cameras, specialized lighting, and powerful software that observe all products on the line for vital quality traits like size, shape, color, volume, and more, and also detect foreign anomalies with accuracies beyond what the human eye can achieve.

KPM is on the leading edge of AI model development for vision inspection systems. We have a dedicated staff of data scientists who are constantly researching and improving models with better detection capabilities and lower false positives. Whether it is counting tortillas stacking into a packaging machine or inspecting easy-to-miss foreign materials, like dough deposits on the bottom of a bun, we have only begun to tap into the potential for AI-powered inspection capability. bbi: In what production areas have you already incorporated AI features into your technology?

Yuegang Zhao: Our AI-powered vision systems have been deployed across various baking lines for a range of different tasks. There are two core categories for vision systems: Vision Process Control (VPC) and Final Product Inspection (FPI).

VPC vision systems cover anything the customer wishes to inspect about their products before packaging. This could range from analyzing doughs leaving the shaper or proofing chamber to measuring topping coverage (e.g., seeds on a

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hamburger bun), before baking. Our AI vision systems are trained to spot even minor product inconsistencies that could signal an issue in the automated production process.

VPC technologies remove much of the guesswork and subjectivity from process control, helping operators make better process decisions that ensure quality and safety.

FPI systems, as their category name implies, function as the final check of products' visible attributes. With the capability to inspect 100% of products on the line, FPI technologies negate the need for routine quality inspection. And because the system never takes a break or a day off, it constantly inspects products to exacting standards while also detecting unwanted foreign materials and hazards.

“The bottom line is that AI models are only as good as the data and the training method. Building a representative dataset, continuous monitoring, and periodic retraining can become expensive and time-consuming, but because production conditions can evolve at random times, this effort is important for success.”

Yuegang Zhao, Chief Commercial Officer, President, KPM Laboratory Solutions

bbi: What are the most frequent requests you receive?

Yuegang Zhao: Vision inspection technology is not new to the baking industry, but requests for more complex, deeper measurements have been driving the development of new AI-based applications. For instance, a hamburger bun producer used to be satisfied with simple attributes like bun shape and color, and with the assurance that it would fit sufficiently into product packaging. However, they are now interested in detailed measurements, such as the shine on the bun or the presence of air bubbles, in their final products. AI vision systems are much better equipped to spot these intricate details, which will simply open the door to even more complex measurement requests going forward.

Another common request trend we’re seeing is the demand

© Chaosamran_Studio – stock.adobe.com

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for top- and bottom-product inspection. Most line inspectors can only observe the top side of the products as they pass by on a conveyor, unless they pull samples from the line.

But pulling a handful of product samples at a time is simply not representative of the production, especially with the high volumes bakeries operate today. AI-based vision systems can be configured with top- and bottom-facing cameras to collect this vital quality and food-safety data.

Then, they are always interested in product rejection methods to automatically remove out-of-spec products from the line.

We’ve worked with companies to develop unique rejection solutions ranging from lifting nosebars to air jets that briskly remove affected products without disturbing other products on the line or impacting process flow. bbi: How is machine learning defined to optimize various production steps in real time?

Yuegang Zhao: Applications of machine learning span the entire baking process. After the mixing and then onto dough shaping, an AI-powered vision system can compare each piece against learned tolerances for shape, size, and other attributes, signaling upstream equipment that may need recalibration.

During proofing, the AI vision system monitoring dough rise and surface texture over time may be able to predict whether proofing conditions (temperature, humidity, and time) are producing optimal volume.

At the baking/oven exit stage, vision systems can monitor crust color, surface uniformity, shape deformation, cracking, and other features. If products fall out of alignment, the system can feed signals back to oven controls to adjust zone temperatures, belt speed, or steam injection, to correct these defects in near real-time. bbi: What are the challenges with AI decision-making algorithms and how are consistent results ensured?

Yuegang Zhao: The bottom line is that AI models are only as good as the data and the training method. In a bakery operation, product appearance can vary based on ingredient quality, seasonal flour characteristics, equipment wear, ambient humidity, and many other factors. If the training dataset doesn’t capture this full range of conditions, the model will reject acceptable products or pass defective ones.

This is why building a representative dataset, continuous monitoring, and periodic retraining can become expensive and time-consuming, but because production conditions can evolve at random times, this effort is important for success. bbi: What opportunities do you see in expanding AI use in bakeries?

Yuegang Zhao: Many bakeries we have worked with have noticed a growing and troubling trend: Over the last few years, many master bakers who have institutional product and process knowledge are leaving the industry, whether by retiring or finding a new line of work. When they leave

the bakery, their knowledge goes with them. It can take years for the next generation of master bakers to learn the equipment, the lines, and the product standards of an experienced master baker, but here is where AI can provide a significant opportunity.

In the case of master bakers, their process decision-making is second nature. They can know by feeling the texture of a dough or looking at the proofing height of products leaving the chamber that an adjustment may be necessary. The problem is – this information and know-how is all in their brain.

Using instrumentation that can help digitize what the master baker is seeing or feeling about their products, and then using that data to train an AI system on those standards so it can assist the next generation of bakers and operators with process decision-making, is a massive opportunity for the industry. An instrument like the Mixolab Universal Dough Analyzer is an emerging tool to acquire digital data as it objectively measures the torque of a dough through a heating and cooling process. Protocols now exist to output dough sample data in as little as two minutes of testing time.

Now, by sampling dough from the line with a Mixolab, and benchmarking its analysis against the AI-powered system, a lot of the master baker’s expertise can be standardized and streamlined. We are certainly still in the early stages of this concept, but something we are exploring with our current customers.

However, it’s important for bakeries to act now and consider these new quality control methods before more master bakers leave this industry. bbi: What does your R&D prioritize in further AI advancements? And how are quality and safety concerns covered?

Yuegang Zhao: We are at the point now where our customers are actually driving a lot of the advancements for our products. Rarely does a day go by where we are not presented with a new challenge or idea to improve the process and food safety efforts of our users. +++

© KPM

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© Julia Kivela

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Baking culture in Finland A baking culture has taken root in Finland – one that is deeply ingrained in regional traditions while being equally diverse and innovative. The market is characterized by traditional artisanal bakeries, a small number of large-scale industrial bakeries, and young start-ups.

By Laura Turunen and Katja Thiele-Hann

+

Rye bread: a part of Finnish culture

Rye bread (Finnish: Ruisleipä) has long been an integral part of Finnish culture – and, since 2017, has even held the status of Finland’s national dish. While Finnish rye bread (made from 100% rye) is historically characterized by a typically dense and tangy profile, consumers today seek out milder, softer – and thus more ‘European-style’ – varieties. As is the case in other countries, there is a distinct trend toward greater softness. Fazer, for instance, has reinterpreted rye bread to align with this trend through its Reissumies product line.

The Finnish fondness for rye bread comes as no surprise, says Johanna Mäkelä, Professor of Food Culture at the University of Helsinki. Rye has been cultivated in Finland for over 2,000 years. Rye possesses the ability to adapt to diverse soil conditions and to ripen during the short Nordic summer. “Finnish rye bread tells the story of a poor country, for there were few ingredients that were consistently available,” notes Mäkelä.

Typically Finnish Other traditional baked goods – such as Finnish ‘pulla’ (yeast buns) – are also undergoing sensory evolution to adapt to new taste preferences. Today, ‘pulla’ is less sweet, fluffier, and often offered in a variety of flavors.

Karelian pies (Finnish: Karjalanpiirakka) – a savory snack often featuring a filling of rice, potato, or traditional barley

– also have a long-standing tradition. Oats are currently viewed as a trending ingredient; they are considered healthy, local, and sustainable. Another typically Finnish feature is the abundance of berry cakes found in local bakeries. While Finland may not possess a distinct cake culture like that of Germany or Sweden, it offers a rich variety of hearty cakes and fine pastries.

The global leader in coffee consumption This, too, is typical for the country’s culture: the rich coffee culture. According to Statista, Finland is the country with the highest coffee consumption in the world (often followed by other Nordic nations). Consumption stands at 10 to 12 kg of green coffee per person per year. This means Finns drink twice as much coffee as Germans, for instance (annual per-capita consumption: 5.5 kg). Mathematically speaking, therefore, every Finn drinks, on average, at least four cups of coffee a day.

Finns do not have a specific term of their own for their coffee culture – unlike the Swedes, who refer to a coffee break as ‘Fika’. But, in principle, there is no difference in people’s love for coffee: + Daily coffee breaks are a standard practice. + Coffee is enjoyed alongside pastries (such as ‘pulla’, cinnamon buns, or ‘munkki’). + Coffee drinking is deeply ingrained in Finnish life, both in the workplace and at home.

About Finland Finland has a total area of 338,450 km², making it one of the largest countries in Europe in terms of land area. The country encompasses approximately 40,000 islands, most of which are uninhabited.

A significant proportion of Finland’s population of around 5.62 million (74%) is classified as urban.

Roughly one in eight inhabitants lives in Helsinki alone.

Major oat exporter Despite its northern location and harsh climate, grain cultivation is an essential component of Finnish agriculture. The most important grain crops are oats, barley, wheat (primarily spring wheat), and rye. Oats are booming: Finland is a major producer and exporter of oats (producing approximately 1.1 million tonnes per year, which accounts for 14% of the total European volume).

Oats are increasingly being cultivated as the primary grain crop, often taking precedence over barley. The annual grain harvest typically exceeds 3 million tonnes. Due to the short summer season (120–150 days), cultivation is concentrated in the southern part of the country.

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cinnamon buns

and bacon

© Julia Kivela

with fish Kalakukko, rye bread stuffed

© Julia Kivela

© Julia Kivela

Korvapuusti, classic Finnish

© Julia Kivela

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Tippalei

tart

© Julia Kive la

Runeberg

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© Kotileip omo Sorsa

© Julia Kivela

Munkkirinkilä, yeast doughnuts, often flavoured with cardamom

© Julia Kivela

© Mi kh ail Oly

© Julia Kivela

ka ine n – sto

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om

Karelian pies

© Elin aM ann ine

n

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Every workspace has its own coffee machine. Many companies even offer established Friday routines: the ‘Perjantaipulla’ (which roughly translates as ‘Friday pulla’).

On Fridays, employees gather in ‘coffee rooms’ to enjoy coffee accompanied by pastries. It serves as an unofficial get-together at the end of the workweek and offers an excellent opportunity to chat with colleagues in a relaxed, informal setting.

When Finns invite friends over for coffee at home, the old adage applies that ‘seven varieties’ must be served. This refers to seven different types of pastries – such as ‘oat peaks’, ‘spoon breads’, or date cake – along with something savory, such as open-faced salmon sandwiches or Karelian pies. And, of course, ‘pulla’ is always on the menu.

‘Bake-off’ on the rise Convenience during shopping is becoming increasingly important to Finnish consumers. This is one reason why in-store bakeries are experiencing a strong surge in popularity within the retail sector. A trend toward premiumization and the use of higher-quality ingredients is also evident.

Furthermore, Finnish consumers are paying increased attention to clean label attributes when selecting food products.

Extensive range of gluten-free products One key growth driver in the Finnish baked goods market is the gluten-free product segment. In terms of both market share and product availability, Finland is considered a European leader in gluteeniton (which is the Finnish term for ‘gluten-free’ ). Whether in small local shops or large supermarkets, the selection is extensive, ranging from bread, pastries, and pasta to beer and ready-made meals.

Many restaurants now also offer gluten-free options. Nowadays, gluten-free products are virtually indistinguishable from their standard counterparts.

Bakeries in Finland

+ Fazer Bakery (Market leader; 2025 net revenue: EUR 446.9 million) + Lantmännen Unibake Finland (with a turnover of EUR 129.4 million and over 350 employees in 2024) + Vaasan Oy (Part of Lantmännen Unibake) + Primula (Part of the Leipomo Salonen bakery group since 2023) + Porokylän Leipomo (Reindeer Village Bakery) + Moilas (Gluten-free bakery) + Uotilan Leipomo (Producer of traditional breads) + Putaan Pulla (Producer of regional specialties) The major companies are experiencing moderate growth, benefiting from exports, the trend toward in-store bakeries, and their own innovations. Furthermore, Fazer Bakery owns numerous small local bakeries throughout Finland, which it continues to operate under their respective established brand names. These include the Oululainen bakery in Lahti and Vuoksen Leipä in Imatra. In addition to these major players (Fazer, Lantmännen, and Vaasan), approximately 600 bakeries are currently operating in Finland, most of which are small businesses. Some regional bakeries even distribute their products nationwide, such as the family-owned Rosten bakery in Turku (which supplies crispbread, among other items), Café Trube from Kuopio (confectionery products), and Linkosuo in Tampere (bread and crispbread). +++

Baked goods vs. eating occasions in Finland + Daily: Rye bread, ‘pulla’ + Coffee time: ‘Pulla’, korvapuusti (cinnamon buns), munkki (doughnuts) + As a snack: Karelian pies, oat bars, small rye flatbreads + Lent: ‘Laskiaispulla’ (Finnish Shrove Tuesday buns) + Christmas: ‘Joulutorttu’ (Christmas pastries), ‘piparkakku’ (gingerbread cookies – which are somewhat thinner than similar pastries in the rest of Europe and are seasoned differently)

+ On February 5: ‘Runebergintorttu’ (Runeberg tarts). These are enjoyed in Finland on February 5, which is the birthday of the national poet Johan Ludvig Runeberg.

+ On May 1: ‘Vappu’ – the festival of spring, students, and workers traditionally features ‘tippaleip’ (funnel cakes/fried pastries) and ‘munkki’.

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HANDLING

PICK & PLACE TOOLS FOR BAKED GOODS

Always a secure hold The automation of packaging lines has greatly increased production speeds. Products used to be placed into trays or boxes manually, but, for decades, agile robots have been performing this task (and many others). As a result, pick & place processes have become not only more versatile but also more challenging. Not every tool is suitable for every product. Product structure, the line environment itself and process speed all play a part in determining which tool should be selected.

By Wolfgang Sedlak, Technical Manager of Tool Design Engineering, Gerhard Schubert GmbH

+

Imagine you’re grabbing a biscuit quickly and somewhat absent-mindedly from its packet. Perhaps it slips out of your hand because of the sudden movement.

Or you grip it a little too tightly because you’re in a hurry – and the biscuit crumbles. This does not happen with pick &

place robots. They do work quickly, however. This makes it all the more important to have the right tools on the robot arm – along with the motion path and speed – to gently pick up and place different baked goods.

As we all know, there is a great variety of baked goods on the market: light, airy pastries such as croissants, biscuits with and without fillings, as well as products with special shapes, such as doughnuts, are all part of the daily packaging routine for many manufacturers. Rarely do they produce just one product. This increases the demand for flexible, interchangeable and product-specific pick & place tools. The tools used to pick up products from conveyor belts, transport chains or robot-based transport modules at high speeds and place them into packaging need to be closely matched to the specific products.

Wolfgang Sedlak, Technical Manager of Tool Design Engineering, Gerhard Schubert GmbH | all pictures © Gerhard Schubert GmbH

www.bakingbiscuit.com 04/2026

Most importantly, they have to operate as gently as possible, so as not to damage products through excessive pressure

INTERVIEW

or the use of an unsuitable tool design. This can quickly lead to rejects, which companies strive to avoid given the high cost of raw materials as well as production and sustainability targets. Tools featuring different technologies and designs are used, depending on the specific application.

TECHNOLOGY MEETS TRADITIONAL CRAFTSMANSHIP.

FOR YOUR PERFECT BAKED GOODS.

Gentle picking via vacuum Delicate products call for an exceptionally gentle approach: robots usually pick up brittle or soft baked goods, such as biscuits, from above using suction tools. These create a controlled vacuum at high flow rates, ensuring that light products with any surface texture adhere reliably to the tools. Instead of a lateral, two-sided grip – which can quickly put strain on brittle or porous baked goods – the vacuum pick-up is carried out from above, making it especially gentle. Once picked up, the products can be placed into their packaging.

To this end, a valve disconnects the suction nozzle from the vacuum source, allowing ambient air to flow into the nozzle. The products are deposited either by their own weight or, aided by the spring-like action of the suction nozzle, are placed onto the discharge surface. Cyclone separators are used in the line for products that contain fat or those with toppings such as jam or nut fragments: they remove dust, crumbs and similar particles from the air stream before the air reaches the vacuum generator. In some cases, separators can be installed on the tool. Alternatively, additional air is deliberately introduced into the system to minimize contamination by increasing the air flow rate.

THE SYSTEM FOR OPTIMIZED PRODUCT QUALITY

However, not all vacuums are created equal: the exact design of the suction tool also depends on the porosity and air permeability of the baked goods, as these factors influence the achievable vacuum force. When in doubt, testing can provide guidance on the most suitable design.

König QualityVac Vacuum Technology With König vacuum technology, breads, cookies and pastries (e.g. Danish pastry) can be cooled and stabilized for further use in just a few minutes. This enables enormously improved product quality in terms of freshness, crispness, volume and stability, immediate further processing of the further processing of the pastry and optimization of your operating processes.

Fingers and clamps for a firm grip A firmer grip is possible in the case of more robust products. Gripping tools hold objects precisely in position and are less dependent on surface texture than suction cups.

Mechanical fingers or clamps hold the products securely on their way to the packaging without damaging them.

Grippers always exert only as much force as necessary.

Pneumatic variants achieve this through precise pressure control, while electric systems regulate current or torque.

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Vacuum-operated grippers are also used, where the negative pressure generates the gripping motion. This allows the force to be adjusted with exceptional precision.

Well-adapted gripper fingers enable a form-fit and are therefore suitable even for delicate products made from puff pastry or for chocolate-coated baked goods.

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HANDLING

“Because grippers are fitted with soft materials such as silicone or other elastomers, they adapt to the product’s geometry, making them suitable even in cases where a suction cup might initially appear to be the obvious choice. ” Wolfgang Sedlak, Technical Manager of Tool Design Engineering, Gerhard Schubert GmbH

Another factor contributing to a secure yet gentle grip is distributed force: with grippers, the force is spread across the product thanks to wide clamps or tools shaped to match the product’s contours, thereby reducing surface pressure.

And because grippers are fitted with soft materials such as silicone or other elastomers, they adapt to the product’s geometry. This makes grippers suitable even in cases where a suction cup might initially appear to be the obvious choice. Small, round biscuits, for example, do not necessarily require a gripper to be transferred safely from the conveyor belt into the box. Unless, however, their surface poses a problem for the suction cup: products with cream fillings can be picked up by suction but are difficult to release again. Quite simply because the cream filling – and with it the biscuit – can stick to the tool.

For highly specific requirements like these, specialized designs are often necessary, such as those recently produced

by Gerhard Schubert: a multi-gripper tool combined with a centrally mounted suction cup, which, without applying a vacuum, serves a stabilizing function. The gripper enables lateral handling, which is essential due to the filling. A suction cup is used because it holds the lighter, not especially robust biscuits in position during the picking process and gently pushes them out of the gripper into the discharge position.

A solution such as this one calls for more than just technical expertise: a wide range of tools and direct dialogue with users support the development process – and demonstrate that rigid categories in toolmaking are often not entirely applicable.

www.bakingbiscuit.com 04/2026

A puncture for a firm grip This is demonstrated by another option which neither uses suction nor gripping, yet still guides the product securely.

Here, the airy structure of some baked goods plays into the hands of technological innovation. Slightly porous, predominantly solid structures – such as those of muffins and cakes – can be pierced with a fine pin, picked up and placed into the packaging without developing any visible indentations.

Handling from above is more practical if products come into contact with each other – for example, on baking trays or feed conveyors. The minimally invasive pick prevents aesthetic defects: the puncture is barely visible; the products remain intact and display no pressure marks. In the unlikely event that a pin breaks, the tools are equipped with safety mechanisms and sensors that detect any change if necessary. Additional metal detectors within the line detect foreign objects.

Baked goods and production processes greatly influence the type of tool selected – and this, in turn, impacts the overall line performance: the heavier a tool, the greater the mass that needs to be accelerated and decelerated.

This results in longer acceleration and braking times, lower speeds – and, put simply, fewer products being picked.

Instead of one-size-fits-all solutions, it always makes sense to take a close look at the product range and your own lines in order to customise the right pick & place tool – one that meets very specific requirements without compromising line performance. +++

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NEWS

Domino's introduces namesake pizza Domino's Pizza introduces the first pizza bearing its name: the Domino. The new Detroit-style pizza made for one can be customized with various toppings. The concept is that “Sharing a meal no longer means having to share a pizza,” Domino’s says.

The Domino is made with premium, buttery-flavored pan dough encrusted with Parmesan cheese. It is baked in a rectangular pan to create a crispy crust and resemble a domino piece, and is cut into two square slices. The Domino is topped with two layers of cheese, customers’ choice of sauce and up to three toppings. It is finished with Domino’s signature garlic seasoning.

“The Domino fills a gap in our portfolio,” said Joe Jordan, chief operating officer and president of Domino's U.S., and incoming CEO. “When everyone wants something different, traditional pizza falls short. The Domino lets every person build the exact pizza they want. It’s fitting that the next generation in pizza is shaped like the logo of the No. 1 pizza company in the world. The Domino is so mouthwatering that we gave it our name!”

In independent testing, consumers who tried the Domino rated it as one of the most delicious products Domino's has ever introduced, the company underlines.

Founded in 1960, Domino's Pizza is the largest pizza company in the world, with more than 22,500 stores in over 90 markets and global retail sales of over USD 20.6 billion in 2026. +++

© Domino's Pizza

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