baking+biscuit 2020-01 digital

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Cookie perfection baked into every batch Presenting the new GenesisPro Series Wirecut Machine from RBS

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Interview

Research

Production

A Lifetime in the Baking Industry

Baking with ohmic heating

Solutions to produce toast-bread

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EDITORIAL

Willingness and resources Many bakeries – both big and small – were forced to file for insolvency in 2019, or even close.

There were also changes, crises, takeovers and mergers in the supplier industry and in plant construction. A company often suffers a creeping demise. The reasons in the baking sector are no different to those in other sectors. Firstly, there is increasing competitive pressure, and secondly the baking industry continues to consolidate.

Moreover, consumer behavior is changing, and new players try to earn money with baked products. The baking sector has observed this shift for a long time, however, and the recommendations are always the same: stand out from competitors, be different and individual or play the regionality card and find one’s own niche.

PosiDrive Spiral™

++ Bastian Borchfeld, Editor-in-Chief Your commments or suggestions are always appreciated: phone: +49 40 39 90 12 28 borchfeld@foodmultimedia.de

None of these ideas is new, nor are they suitable for every business. The important thing is what the customer wants. Not every consumer can or wants to buy the latest trendy snack or bread roll. As well as this, there are topics such as sustainability, bureaucracy, waste reduction and climate change. Hot summers are a particular affliction for the baking sector. Customers no longer satisfy their hunger with baked products.

The scarcity of specialist skilled staff, the minimum wage and the ageing population are additional challenges.

Once a company has run into difficulties and a restructuring concept has been established, it’s a question of resolute implementation. However, even the best strategies and investment planning lead nowhere if restructuring was started too late or the concepts are only half-heartedly implemented.

As I said, downfall is often slow and painful. However, self-deception also plays a big part in distressing situations. No-one likes to admit that his or her business is no longer functioning, or that the idea, the bakery, the sales outlet facilities, the IT or the vehicle fleet is outdated. There are no successors or investors who want to carry on the (life’s) work. The hope that there will be a rescuer to resolve the investment backlog, invest fresh capital in the business and tackle the situation vigorously is kept alive by many entrepreneurs until very little of the business remains. All that is left is the road to insolvency or closure of the business.

To stay alive in the market, there must be willingness and resources. All the participants must find solutions cooperatively, especially when there is a handover to another owner, or even within a family. No-one will buy or take over a business if the price is not right and/or its resources have been exhausted.

Proven Solution For: • High Tension • Heavy Loads • Greasy Products • Product Movement Call for System Audit +31 20 581 3220

As Sir Thomas More is said to have remarked: “Tradition means passing on the flame, not preserving the ashes.” No-one is obliged to perpetuate a tradition any longer nowadays. However, if the conditions (willingness and resources) are right, the baking sector provides numerous opportunities to manage a successful business.

Best Regards, Bastian Borchfeld

www.ashworth.com

CONTENT

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© Handtmann

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© Burford

Interview 06

Trade Fairs 08

interpack 2020: Fully booked

WP BAKERYGROUP: An intelligent mixer

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Varimixer: New protective screens

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REGO HERLITZIUS: A power-pack with a recipe assistant

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VEMAG: Portioning and molding

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RONDO: Sheeter with four individual drives

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DEBAG: A plug-in fully automatic proofer

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Benier: The new L’Artisane baguette line

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Handtmann: A system solution to produce toast-bread

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Sacher: An accident makes history

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Research 20

BOKU: Baking with ohmic heating

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Puratos: The Space Bakery Project

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Production facilities 24

FactoryXperts: Better baking in existing premises

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Fortisa: Rebuilding during ongoing production

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Management 38

Geiping: Using algorithms for better planning

Market 41

Innova Market Insights: Top Trends for 2020

Regulars 03

Editorial

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News

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Trade fair calendar

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News

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EDITOR-IN-CHIEF Bastian Borchfeld +49 40 39 90 12 28 borchfeld@foodmultimedia.de

ADVERTISING DEPT. International sales director Dirk Dixon +44 14 35 87 20 09 dixon@foodmultimedia.de Advertisement administration Susanne Carstens +49 40 38 61 67 94 carstens@foodmultimedia.de

Production 12

PUBLISHER Hildegard M. Keil +49 40 380 94 82 keil@foodmultimedia.de

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Fred Springer: A Lifetime in the Baking Industry

cover photo: © Reading Bakery System

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• Pressing and punching machines for cakes, pies, quiches and tortelettes.

• Pizza bottom and topping machines, application specific dispensers and strewing.

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INTERVIEW

A Lifetime in the Baking Industry After more than 46 years, Fred Springer left the Burford Corp. to take well-deserved retirement.

He is an extraordinary man and has been a supporting pillar for the baking industry in the US and internationally. He talked about his experiences and plans with Hildegard M. Keil, Editor of baking+biscuit international.

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Keil: Fred, you started working in the baking industry in 1973, when you entered the Burford Corp. after finishing your education at the University of Oklahoma where you studied business administration. More than 45 years in the same company and the same industry, always carrying out your job with passion. This nowadays is quite unusual.

Can you tell me why you stayed with the same company, your story and what has motivated you for all of these years? + Springer: I have always loved challenges and no more so than when the outcomes are successful. When I started at Burford, there were many challenges. We didn’t have automation and so everything was carried out by hand or through an outside service. We were actually the first company in our area to get an in-house computer for accounting, inventory and engineering design. There were so many opportunities to learn and to grow in all areas. People were all so eager to be educated and to work on new projects. I was fortunate to be in a position to grow within the company. We also had the culture within to support industry associations where additional customer contacts could be made.

farming equipment. In 1961 Earl and Charles Burford invented the first "twist-tie" machine to close bags, which subsequently became very famous in the baking industry and made Burford a well-known supplier. Following this, Burford started building other types of equipment for the baking industry. How important is closing equipment for Burford today? + Springer: Closing equipment is still an integral part of the business and represents approximately 40%.

+ Keil: Which invention, not including the twist-tie, has been the most important for Burford from your point of view? + Springer: The topping applicator for applying sesame seeds and other toppings to rolls and buns.

© Burford

+ Keil: The company originated in the 19th century with Fred Springer graduated from the University of Oklahoma in Business Administration in 1973, which was the same year he started working at the Burford Corp. as an Assistant Controller. This was to lead to positions as Controller, VP Finance, Executive VP and from 2000 he served the Company as President & CEO, Corporate Secretary until November 2019. From 2011 to 2017 he was also Managing Director, Burford Bakery Solutions.

Fred Springer’s voice is well known in the industry and everybody in the industry listens, when he speaks. He has served the industry as Co-Chair of BEMA Tech 99, President of the Allied Trades of the Baking Industry (2001 – 2003) Chairman of the Board BEMA (Bakery Equipment Manufacturers & Allieds) from 2001 to 2002 and was Chairman of the Board of American Institute of Baking (2008 – 2010). For more than 7 years he was a Committee Member of IBIE, and he was and is member of Mid-West Allied Trades of the Baking Industry and Texas Allied Trades Associations and is Privy Council Member of the Wild Yeast Organization. The American © Burford

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Society of baking honored him in 2013 with the Robert Fischer Distinguished Service Award, and he was presented with the BEMA 2018 Lifetime Achievement Award. +++

www.bakingbiscuit.com 01/2020

INTERVIEW

baking industry and it certainly isn't the same as it was when you started. When you look back – what events, developments and/or inventions have changed the baking industry the most during this time? + Springer: Automation in conveying speeds, servomotors, and electronics have certainly been major developments ensuring that equipment has evolved in all areas of the industry.

+ Keil: We have seen a lot of consolidation in the baking

industry. Do you think in the mature markets such as the US and Europe that there are still opportunities for newcomers and new ideas? + Springer: I think there will always be room for newcomers.

You only have to look at companies such as The Bakery Cos (Cordia Harrington), Sister Schubert’s Rolls, Dave’s Killer Bread and Canyon Bakehouse producing gluten free baking.

All of these companies were created within a very mature industry, but each had their own niche product.

+ Keil: Today, Burford delivers baking equipment all around the world - how big is the export market and how do you organize services outside of the US? Do customers from elsewhere have different requirements? + Springer: Burford’s international business will vary from 25% – 40% of total sales. We have a subsidiary in the UK that has a warehouse for spare parts and an office for our Service Technicians and Sales Manager that handles the majority of Europe and some of the Middle East. The Middleby worldwide offices also support Burford. + Keil: Are there any special

occasions in your business life that you particularly remember, anything that has happened to you that was unexpected, any stories you would like to tell our readers? + Springer: The most fulfilling occasions were developing new equipment and getting to see the first installation, as well as the success and subsequent sales of something that had been designed and built from scratch. These are certainly occasions that have been very rewarding and ones that you will never forget! Also, receiving the BEMA Lifetime Achievement Award 2018 and then having it named after me was an all-time special occasion that my family and me will certainly never forget. Additionally, being surprised by receiving the Robert

Fischer Distinguished Service Award from the American Society of Baking in 2013.

+ Keil: You have worked hard over the years, not only for Burford, but also for BEMA, AIB, ASB, ABA and ATBI for example. You have been honored with several awards for your tireless work. Not everybody in the industry is willing to sacrifice so much time. What has been your driving force and are you satisfied with the results? + Springer: Yes, I have been very satisfied with the results.

The amount of time and extra work was so gratifying due to the relationships built with customers and their families as well as other allied suppliers and their families. Also the accomplishments that were made in serving in the associations, for example, seeing the Bakery Equipment Manufacturers Association grow and becoming a dominate partner to the industry. I’ve always felt that it was important to give back to the industry and to try to make it better than before.

+ Keil: Fred, you are leaving the company and going into

well-deserved retirement - the industry will certainly miss you, will you miss the industry? Will we see you sometimes, somewhere? + Springer: I will absolutely miss the industry and the relationships I have made over the last 46 and a half years. I plan to stay active in some of the associations and who knows what the future holds.

+ Keil: Thank you very much, Fred, and I wish you and your

family all the best for the new phase in your life. God bless you. + Springer: I consider you a very good friend and have always enjoyed meeting up with you and I will always remember your trip to Oklahoma. God bless you. +++

© Burford

+ Keil: 1973 – 2019 – there have been many changes in the

www.bakingbiscuit.com 01/2020

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T R A D E FA I R S

interpack 2020 fully booked The Messe Düsseldorf reports that the interpack 2020 trade fair is fully booked. The event is regarded as the most significant international trade fair for the packaging sector and related process industries, which also include the baking, cookie and confectionery industries.

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The interpack 2020 trade fair is fully booked. At the same time, the Messe Düsseldorf provided a far larger area on the trade fair site this year. The event organizers expect around 3,000 exhibitors from about 60 countries.

They will again occupy all 18 halls and large parts of the outside area from May 7 to 13, 2020. The “components – special trade fair by interpack” arranged in parallel, with offerings from the packaging technology supply industry, is also fully booked and is being held for the third time entirely in parallel in the temporary Hall 18. One ticket allows entry to both trade fairs.

With its solutions relating to packing and related process technology, the target groups at which the interpack trade fair is aimed include foodstuffs, beverages, confectionery, baked products, pharmaceuticals, cosmetics, non-food consumer goods and industrial goods. Exhibitors with corresponding offerings now form more sharply focused segments to save long walking routes for visitors from these sectors. Thus the suppliers of processes and machines for pharmaceuticals and cosmetics packing now form a cluster in Halls 15 to 17; visitors to the interpack 2020 trade fair will find labelling and marking machines, the packaging production area and integrated packaging printing in Halls 8a and 8b.

Confectionery and baked products Exhibitors within a cluster have also been structured more clearly to simplify orientation there as well. Offerings relating to specific process steps now exhibit in close proximity.

As well as the areas mentioned above, this is also true for the segment comprising processes and machines to pack foods, beverages, consumer and industrial goods in Halls 5, 6 and 11 to 15, and also for the offers focusing on

www.bakingbiscuit.com 01/2020

© Messe Düsseldorf / ctillmann

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processes and machines to pack confectionery and baked goods in Halls 1, 3 and 4.

The packaging and packing materials area has been positioned centrally around the North Main Entrance in Halls 7a, 7, 8a, 9 and 10. According to the event organizers, there is a large potential for synergy in Hall 8a, where machine suppliers in the packing materials production, converting, package printing and labelling areas meet corresponding suppliers of the corresponding packaging and materials.

South Entrance Shortly after the interpack 2017 trade fair, demolition of Halls 1 and 2, whose basic substance still dated from the nineteen-seventies, created space for the Düsseldorf Messe’s architectural figurehead: the “New Messe South”, consisting of the new Hall 1 and an entrance area with a foyer directly in front of it and a tapering canopy 17 meters high made from translucent glass fiber fabric with integrated LED lighting. It now offers interpack 2020 trade fair exhibitors state-of-the-art architecture and technology, and about 500 m 2 of additional space. The building also contains six conference rooms and is linked directly to the South Congress Center. +++

SAVE FOOD The SAVE FOOD topic is being themed at the interpack for the first time, with various campaigns relating to reducing food losses and wastage in the city of Düsseldorf, and thus it directly involves the general public.

Program details are still currently being worked on in consultation with the official agencies. +++

MIXING SOLUTIONS for bread, pastries, cakes and snacking industries

NEWS ++ NEWS ++ NEWS

++ Frederic Dangel Appointed Regional Account Manager at AMF Bakery Systems AMF Bakery Systems (AMF) announced that Frederic Dangel has joined the company as Regional Account Manager for Southern Europe. Frederic has over 10 years of experience in the industrial baking sector, having working across several continents. His goal is to develop new business and to grow the complete AMF portfolio in Mediterranean countries, focusing on Portugal, Spain, Italy, Greece and Turkey.

++ New company spokesperson for the Stuttgart Trade Fair Stefanie Kromer has managed corporate communications for the Messe Stuttgart (Stuttgart Trade Fair) since January 1, 2020. In this function, she is at the same time the company’s spokesperson and reports directly to the Executive Board’s spokesperson. The 31-yearold is from the ranks of the Messe Stuttgart. After completing her degree course in Rhetoric, she started her professional career in the company’s Communications Department. In addition to Corporate Communications, Kromer’s area of responsibility also includes the Media Service and the trade fair’s Press Center. +++ © Messe Stuttgart

© AMF Bakery Systems

His experience in sales and business development is extensive, having worked in Mexico, USA, Spain, Portugal and many European countries. Frederic lives and works out of Mulhouse, France and speaks four languages, including Spanish and Italian. He holds a degree in Industrial Maintenance and a Bachelor of Arts in English, which he used to teach.

Prior to joining AMF, Frederic Dangel had worked for Mecatherm and VMI and most recently for Fritsch. +++ ++ American Pan UK Launches eCommerce Program

American Pan UK, Skelmersdale, has launched their new eCommerce website (www.shop.americanpan.com), allowing bakeries within the United Kingdom to purchase stock bakeware items online. Jordan Hughes, Key Account Manager for American Pan UK states, “We are excited to be able to provide customers with the convenience of purchasing our industry leading bakeware on our new website. This service will allow our customers to order products at any time of the day and access valuable information on the product features and use and care.” American Pan UK offers bread tins, baking trays, baguette trays, bun and roll trays, muffin trays, cake tins, and pizza trays. All bakeware is designed to be used on a 762 mm x 457 mm (30” x 18”) rack. American Pan UK is a division of Bundy Baking Solutions, headquartered in Urbana, Ohio USA. +++ www.bakingbiscuit.com 01/2020

++ IREKS: CEO Jürgen Brinkmann has retired Jürgen Brinkmann retired on December 31, 2019 after more than ten years of service as the CEO of IREKS GmbH. Brinkmann has been responsible for the corporate investment management of the IREKS group of companies, the ice-cream business of the LUMEN Group and the Controlling and IT departments since 2009. According to the company, he accompanied various subsidiaries of IREKS in numerous national and international supervisory board mandates and achieved their considerable advancement. In addition to his area of responsibility, in late 2015 Brinkmann took over the corporate group’s international baking ingredients distribution operation, which looks after more than 20 national companies and a total of 90 foreign markets.

Under Brinkmann’s leadership, the Controlling and IT departments underwent further development, and increasingly undertook tasks for the whole of the company group. © IREKS

Frederic Dangel: “I am excited to be joining this growing team and to bringing my energy and motivation to AMF. AMF is a market leader in the industry, with complete system solutions for industrial bakers and rising bakeries around the world. I look forward to meeting and working alongside these customers.”

© American Pan

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+++

++ Sales revenues growth for Bread Holdings In the twelve months to the end of February 2019, the British company Bread Holding, consisting of the Bread Factory and the chain of Gail's branches, which operate mainly in London, achieved 23% growth in its stores’ sales revenues, which now stand at GBP 47.4 million. The success was based not least on ten new Gail's branches, of which there are now more than 60 in total. As a wholesaler and delivery bakery, Bread Holding recorded growth of GBP 68.3 million, and has thus now passed the GBP 100 million mark. The group also plans to open at least ten more branches in the current year. Bread and foodstuffs can also be ordered online and via the Ocado delivery service.

Gails's own shop can be found at www.gailsbread.co.uk.

+++

RONDO Industrial Solutions • More than 30 Years of Experience • More than 3000 Installations world-wide • Swiss Precision Engineering • Highest Performance and Capacity • Ground-breaking Hygiene Standard (ASTec)

Visit us at booth 3E54 in hall 3.

www.rondo-online.com

RONDO Industrial Solutions RONDO Burgdorf AG, 3400 Burgdorf/Switzerland, Phone +41 34 420 81 11, info@rondo-online.com RONDO Schio s.r.l., 36015 Schio (VI)/Italy, Phone +39 0445 575 429, info@rondo-online.com

PRODUCTION

++ The mixer is available in sizes designed for 160, 200 and 240 kg of dough/batch

An intelligent mixer The KRONOS mixer from the WP BAKERYGROUP promises consistent mixing results independent of the personnel and fluctuating raw materials properties.

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Continuously consistent and thus standardized dough quality – that’s what bakeries aim at when mixing. To achieve this, many mixers can be controlled via fixed mixing and kneading times. However, changes in the surrounding conditions and/or temperatures, together with fluctuating raw materials qualities and the “human factor” or specialist knowledge and experience, play a big part when producing an optimally mixed dough, and need to be taken into account.

Many mixer operators intervene in the mixing process based on their own judgement and expert knowledge. There are no longer any individual influencing factors with the WP BAKERYGROUP’s KRONOS digital because, as the company promises, the mixer autonomously determines the optimum full kneading time based on measured facts alone, independent of the personnel. The mixing process is terminated automatically. Any required under- or over-kneading can be defined at the same time, depending on the recipe.

The right moment The KRONOS digital is equipped with sensors to record data, directly in the dough or indirectly via the controller, during the entire mixing process. These data give information about the state of the dough based on, among other things, the temperature profile, viscosity, elasticity and stiffness of the dough. This knowledge enables the mixer to automatically adjust mixing and kneading times to the dough’s properties and to changed raw materials properties and environmental parameters. Based on the flour and water temperatures,

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among other things, the mixer recognizes the correct moment to automatically switch over from the mixing phase to the kneading phase. Finally, as WP explains, the plant uses the development of the gluten compound as a reference value to terminate the kneading process when the dough has reached its desired optimal condition.

Data base The KRONOS digital is easy to operate. The required recipe must be chosen, after which the entire mixing and kneading process runs fully automatically under recipe control. The

© WP

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++ The mixer records various data and ensures consistent mixing results. Under- or over-mixing can also be defined when required

PRODUCTION

interpack

© WP

PROCESSING & PACKAGING

batch size and/or filling quantity and the required degree of kneading can be included when the recipe is saved. The KRONOS digital makes an unbroken digital record of various data, e.g. energy absorption or the temperature of the surroundings and of the dough. This simplifies retrospective quality control, and makes sources of error in the production process traceable. The wide data base also leads to greater process know-how, which in turn helps to optimize operating procedures and to intervene at an early stage if quality deviates from the required level and there is a threat of rejected product. For example, the mixer also detects incorrect dosage. In this case the mixer stops the process automatically and sends an appropriate message to the relevant person.

The KRONOS digital is compatible with all bowls in the KRONOS, PRESIDENT and TITAN series, and can be used with existing bowl tippers. The bowl trolleys have rubber rollers to ensure quiet operation. The mixer can be used as a stand-alone mixer or in the KRONOS LINEAR SYSTEM. It is available in sizes designed for 160, 200 and 240 kg of dough/batch. +++

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According to the company, the KRONOS digital is suitable for all wheat and wheat mixed doughs with a TA (dough yield) from 145 to particularly soft doughs. Like all WP Kemper’s spiral mixers, the KRONOS digital also operates on the 3-zones mixing principle. This involves incorporating a large amount of energy into the dough through rapid, intensive blending of the ingredients. It also says the input of a large amount of oxygen ensures stronger gluten formation together with an increased absorption of water by the dough. This is intended to result in fluffier doughs that are easy to process.

Messe Düsseldorf GmbH P.O. Box 10 10 06 _ 40001 Düsseldorf _ Germany Tel. +49 211 4560 01 _ Fax +49 211 4560 668

www.messe-duesseldorf.de

PRODUCTION

New protective screens The protective screens for Varimixer’s planetary mixers are now made of stainless steel. Elongated viewing windows give a clear view of the condition of the batter. rotation speed, are quickly and stably whipped using the whisk. Use of the stirrer enables crèmes, sand cake batters and fillings to be homogeneously blended. For this purpose it is advisable to use a scraper to additionally scrape batter from the bowl wall and guide it back again in the opposite direction to the rotating tool, thus ensuring an optimum result of the stirring.

The manufacturer offers the ERGO series to produce larger batches of batters and fillings. ERGO models 60 L,100 L and 140 L are used in the pastry and confectionery departments of larger artisan businesses, and in large and industrial operations.

© Varimixer

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++ The planetary mixers’ new protective screens are now made of stainless steel. The two protective screen halves are opened horizontally for cleaning, and are removable with a single hand movement

+

Since the firm was founded in 1915, the Danish company Varimixer – part of the American Middleby Group – has specialized in constructing mixing machines operating analogously to the planetary system. On planetary mixers well-known under the name BÄR, the stirrer tool rotates anticlockwise around its own axis, while the stirrer head operates in the opposite direction. The accurately matched ratio of tool to bowl enables complete coverage of the batter without the tool touching the bowl wall.

As a result of the planetary movement pattern, egg white, crèmes, sponge cake batters and cream, which require a high

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Ergonomic handling The stirrer tool on the ERGO series of models can be clamped into the freely accessible shaft of the stirrer head at an ergonomic working height by means of a bayonet fixing. A bowl trolley is used simply to move the bowl into the gripper arms, which lock it firmly and raise it to working height by a lift system. Shortly before the bowl reaches the final stirring position, the stirrer tool turns slowly and gently into the batter. When the mixing process is complete, the bowl is automatically lowered and can be taken out of the machine again without previously removing the clamped-in tool.

Batters can be poured into the filling machine by using various bowl tippers that are matched to the bowl system.

Process operation is frequency-controlled via an inclined display with piezoelectric pushbuttons. The panel has an impervious stainless steel surface, is easy to clean, and is dustproof and waterproof. Mixing programs are simple to store by using the Remix function: after the mixing program has ended, the process, with all the movement operations and pauses, can be saved as a program.

New protective screens The plant’s new protective screens are now fabricated from robust stainless steel and, according to company’s information, have a long lifetime in daily production operation.

Elongated viewing windows give a clear view of the condition of the batter at the same time. The company also says the two protective screens are simply opened horizontally for cleaning in a dishwasher, and are removable with a single hand movement. ERGO models conform to Protection Class IP53. As an option, the mixing machines are also offered with a water-tight stirrer head and additional seals in accordance with Protection Class IP 54. Different versions of the whisk and stirrer are available, depending on requirements.

The machines have a small footprint and, the company also says, run quietly even at high speeds. +++

Advanced hydration technology is here.

Introducing Hydrobond from Exact Mixing Want superior hydration without adding excess heat to your dough? New Hydrobond technology delivers.

Not only does it blend dry and wet ingredients with unmatched efficiency, it also: • Requires no additional floor space • Reduces your total mixing time • Cleans quickly and easily • Reduces heat attributed to mixing energy • Allows you to mix more dough with same size continuous mixer

EXACT MIXING

BY READING BAKERY SYSTEMS

A Markel Food Group Company

VISIT US Hall 1, Stand B70

Perfect your mixing process with new Hydrobond technology.

Visit exactmixing.com for details.

PRODUCTION

A power-pack with a recipe assistant Plants in the REGO HERLITZIUS manufacturer’s PM series promise fast, precise processing of batters and doughs.

Recipe reproducibility is indispensable for confectioners and bakers. Machines in the PM series thereby support users in the context of their extensive standard equipment. According to the company, the mixing and kneading process for the recipes have been optimized under laboratory conditions, and the shapes and curve or radius transitions of the mixing arms are designed to guarantee excellent dough blending.

IUS

All REGO HERLITZIUS planetary machines have an electronic controller and a memory computer with thirty-seven 20-step programs and continuously variable electronic rotation speed regulation. The machines’ automatic start-up program is also computer-controlled, which also protects the tools and the machine. The features mentioned above, like the digital time and rotation speed displays, help to ensure accurate recipe production and reproduction.

www.bakingbiscuit.com 01/2020

A comprehensive range of accessories The standard equipment of the PM series includes a bowl trolley, three tools (a whipping or stirring whisk, a flat stirrer and a kneading spiral) and a set of accessories. All the tools are made from rust-free stainless steel. According to the company, the stirring and whipping whisks are shaped in such a way that the consistency of a recipe yields a stable batter that does not “collapse” and lose volume so quickly.

Scrapers, cruciform stirrers and other tools are available as options for the machines.

The high-efficiency drive of the PM series is matched to the IE-2 Class and, according to REGO HERLITZIUS, ensures optimum efficiency. It also says that the wear and noise emission of the planetary gears have been examined under laboratory conditions, and improved based on the knowledge obtained.

© REGO HERLI TZIUS

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With its PM series of planetary, stirring and mixing machines, the bakery machine specialist REGO HERLITZIUS, Wuppertal, Germany, provides artisan confectioners and bakers with a machine portfolio with bowl sizes from 12 to 200 liters, designed to make processing easier, more precise, faster, more hygienic and more pleasant.

© REG O HER LITZ

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++ All REGO HERLITZIUS planetary machines have an electronic controller and a memory computer with thirty-seven 20-step programs and continuously variable electronic rotation speed regulation

PRODUCTION

40 liters and above, electronic bowl height adjustment allows the bowl to be removed without dismantling the tools. The machines’ low-noise drive also makes working with the PM series pleasant from the acoustic point of view.

The bakery machines specialist REGO HERLITZIUS, with more than 100 years of experience, represents modern products that combine function and design. The manufacturer’s product range extends from whipping, stirring and mixing machines to slicing machines and strip

Hygiene All the machine frames in the PM series were designed based on Hygienic Design aspects. Externally, for example, this is visible at details such as adjustable feet and the novel onepiece protective cover with a filling window over the bowl.

All the covers are simple to remove and easy to clean. The film panel emphasizes the orientation to the highest hygiene requirements and to DIN EN 454. The shafts to accept the tools are made entirely from stainless steel with a quickchange system.

bread molding plants. According to the company, the quality standard of the product is very high, as proved by the long lifetime of the machines in use. As well as successful product marketing in the German market, intensive export activities have ensured that the brand is as well-known in Asia today as it is in North America or Europe. +++

Optimized fabrication processes and materials combinations were used to develop a low-maintenance, stable planetary gearbox with maximum smooth running even at the highest operating speeds. The drive from the motor to the planetary gearbox was optimized via a load-dependent, frequency-regulated controller and ensures good running characteristics in any load situation. Integral vibration elements absorb and reduce vibrations transmitted to the frame. The company also says all of the measures mentioned above increase the lifetime of the machines. The plants are equipped with a quick tool-change system. At a bowl size of

Uwe Paass, CEO of REGO HERLITZIUS, explains: “We have put together a total package for confectioners and bakers in the shape of our PM series of planetary machines that on the one hand work very precisely due to their complex computer controllers, while at the same time operating powerfully and durably as a result of their robust drive and gearbox designs.

The extensive standard series equipment including accessories also make the planetary machines economically attractive, and their many other features render them very user-friendly in operation.” +++

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17

18

PRODUCTION

Portioning and molding VEMAG promises customized solutions to accurately portion and

© VEMAG

mold snacks, fine pastries & confectionery and protein and fruit bars.

Whether it’s licorice, doughs for fine baked goods and cookies, marzipan, fondant or batters for fruit and energy bars – according to the company’s information, the plants deliver portions as bars, balls, blocks or the like, each with an accurate weight and exact molding of the materials used. The company also says large number of modular attachments ensures that the food portioners can be used for numerous products, flexibly, seasonally and with a high output capacity.

The core elements of VEMAG machines are the delivery flow curves that transport doughs and batters on the

© VEMAG

+

At the ProSweets trade fair, VEMAG showed various plants to accurately shape and portion fine doughs as well as pasty, pumpable batters with gram accuracy. It presented the flexibly usable Robot500 portioner with the ASV811 cutoff device, an HPE series filling machine with the MMP223 portioner, and the MTL280 multi-tray loader for depositing and placing products into packages. Also presented was the HP20E portioner with a 32-way filling stream, divided to multi-row dispense a wide variety of batters.

++ At the ProSweets trade fair, VEMAG showed various plants to accurately shape and portion fine doughs as well as pasty and pumpable batters

double-spindle principle, gently and without crushing.

According to the company, even fillings in large pieces such as nuts, dry fruit and chocolate for stollen, fruit bread and other special baked products can be divided.

According to its own information, the VEMAG Maschinenbau GmbH company based in Verden/Aller is one of the leading manufacturers of machines for filling, portioning, dividing, molding and depositing pasty foods, doughs and batters.

The range extends from artisan solutions to highly-industrialized applications and modular production lines. The company employs around 670 staff, operates worldwide and records an export ratio of more than 80%. +++

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RESEARCH

Baking with ohmic heating Ohmic heating is a process in which a product is connected in an electrical circuit like a resistance and is heated as a result. At the BOKU in Vienna, this technology is being tested for bread baking,

© BOKU/Bender

specifically for gluten-free bread.

+

++ Ohmic heating equipment available at the Institute of Food Technology at BOKU

Up to now, ohmic heating has been used in the food industry mainly for sterilization etc. It functions in seconds, but depends on various product properties, including water and salt content, pH etc. A team of researchers at the BOKU in Vienna/Austria (University of Natural Resources and Life Sciences) has tackled the question as to whether it makes sense to use it for baking bread, specifically gluten-free bread. An interview with Regine Schönlechner and Denisse Bender.

+ Hildegard M. Keil: What motivated you or your research

group to use this heating technique for bread, which as a general rule undergoes a process during baking, namely oven spring, that is part of the development of its structure and crust? What advantages could ohmic heating provide compared to heat transfer via contact or convection? + BOKU: Gluten-free doughs need a larger water content compared to doughs containing wheat, and are thus a challenge for bakeries simply due to this different texture: liquid/pumpable dough (similar to cake dough) for gluten-free doughs, compared to firm, “free-standing” doughs for wheat doughs.

However, this pumpable, more fluid dough texture is exactly the ideal precondition for ohmic baking. That’s why we tested it quite spontaneously, in a simple experiment, and this initial attempt astonished us: the volume of the gluten-free bread heated in this way was many times greater than that of the www.bakingbiscuit.com 01/2020

© BOKU/Bender

20

++ Ohmic heating of a piece of dough between two electrodes in an ohmic baking chamber

same breads baked in a conventional oven. Subsequently, therefore, we worked on determining the parameters (power, time etc.) more precisely.

One of the advantages of ohmic heating is that the dough heats volumetrically. Heat is uniformly distributed within the bread (there are only minimal temperature differences within the product), and the baking process is accelerated.

+ Keil: In your most recent study, you concentrated in pro-

ducing gluten-free breads based on buckwheat flour and starch. What idea lay behind it? + BOKU: Most of the gluten-free breads available on the market are based on very starch-rich raw materials, or on pure starch, and therefore contain relatively low levels of dietary fiber, minerals and vitamins. Our aim in the research into

RESEARCH

+ Keil: If I have understood it correctly, the baking process consisted of three stages in which the heat was reduced in a stepwise manner. Could you please explain to us where the advantages lie compared to a single unvarying heating process? + BOKU: The stepwise reduction in the electric power (not the heat!) is necessary because otherwise the doughs/breads would burn in the ohmic oven. The initial high-power step is the actual baking step: a dough temperature of more than 90°C is reached within a few seconds and the bread is baked right through, the dough expands and the crumb of the bread is formed. After these few seconds, however, the bread crumb is still rather too moist; the water content is still too high and/or the bread crumb is still too moist, chiefly at the margins (at the zones of contact with the pan). Further heating is still needed here, although burning must be prevented at the same time. This optimization was one of the biggest challenges, and we succeeded through a stepwise reduction in the power. + Keil: How long does a baking process of this kind last, and

to what extent does it depend on the weight and volume of the dough? + BOKU: The total duration of the entire baking process is between 25 seconds and 2 minutes, and depends mainly on the water content. Weight and volume have scarcely any influence on baking time, as long as the total amount of energy flowing through the dough is held constant. I.e., if an increased weight of dough is required, only the power needs to be adapted/increased to arrive at the same baking time.

+ Keil: How did the volume, color, structure and crumb

moisture content of the breads develop during the baking process? + BOKU: A crumb structure formed very quickly as a result of using the ohmic heating process (in about 30 seconds to 2 minutes). At the same time, the final bread volume was larger than for breads baked in a conventional oven. The crumb was very open, and also dry as a result of holding for a slightly longer time at a lower energy input. This means the breads were ready to eat after a very short time. In contrast to bread baked conventionally, however, the baked bread does not develop any crust.

+ Keil: Is there any way of producing a Maillard reaction and thereby the usual crust?

+ BOKU: A crust can be produced, for example, by a short

exposure to infrared radiation afterwards. Alternatively, the breads can also be pushed into an oven for a short time.

© BOKU/Bender

gluten-free products was always to make them more nutrientrich. Using wholegrain flours and/or using nutrient-rich, gluten-free flours offers a good opportunity to achieve this.

Flours made from pseudo-cereals (amaranth, quinoa and buckwheat) or varieties of millet are good examples of this, and we have studied all of these. Since buckwheat flour is also an indigenous product in this country, however, we gave preference to this flour for many of the experiments.

++ Crust and crumb of a gluten free buckwheat bread baked with ohmic heating (left) and obtained from conventional baking (right)

+ Keil: Does the process affect the ability to bind water, and

thus to the impression of freshness and/or retrogradation of the breads? + BOKU: Breads produced using ohmic baking are unbelievably light and succulent. However, there is still a need to carry out accurate studies of the shelf life and storability of the breads.

+ Keil: Were you able to define an optimum baking process,

and/or a complete optimum production process? + BOKU: As a result of numerous experiments, we succeeded in defining an ohmic baking procedure in which the breads were optimally baked all through without burning.

+ Keil: What is your estimate of the comparison with regard

to costs between heat transfer through ohmic heating vis-à-vis contact/convection? + BOKU: The baking process consumes at least 50% less energy than a conventional baking process. Moreover, ohmic heating needs no preheating as in the case of a usual baking oven, which takes at least 15 minutes to reach baking temperature (180°C).

+ Keil: Are the results transferable to all gluten-free products, irrespective of their raw materials basis? + BOKU: Basically, this process is applicable to all doughs and batters that have a similar recipe, i.e. sufficient fluidity and viscosity (defined mainly by the water content). It is important that the batter has sufficient electrical conductivity, although this is ensured by adding at least 0.5% of salt (relative to the flour). Breads usually contain at least 1.5% of salt. + Keil: Many thanks for our discussion. +++ www.bakingbiscuit.com 01/2020

21

PRODUCTION

Sheeter with four individual drives RONDO Burgdorf AG has launched new electronic sheeters with individual drives. The user can operate the plants via a smartphone-style i-Touch controller.

+

The Swiss bakery machine manufacturer RONDO has launched a new electronic sheeter onto the market; the Compas 4.0. According to the company, it is the first and only sheeter with four individual drives. This enables stress-free roll-out of all dough types. The company promises that the Compas 4.0 ensures double-digit percentage increases in efficiency. The plant is controlled via a smartphone-type operating interface.

In contrast to other electronic sheeters available on the market, which have only one central drive and a gearbox, the Compas 4.0 is fitted with four individual drives for the conveyor belts and rollers. This concept is absolutely new, and a patent has been applied for. The decisive advantages are: + The Compas 4.0 rolls every dough out stress-free – the precondition for uniform dough sheets, and ultimately for baked products that always have identical weight and the same size. + Separately adjustable entry, exit and roller speeds allow the sheeting process to be optimally matched to the dough type. Thus the Compas 4.0 can be used to process even very difficult doughs that could only be handled manually in the past.

Maximum efficiency A sheeter’s efficiency increases significantly if it can process large blocks of dough. According to the company, with a 700 mm working width, a belt speed of up to 130 cm/s and a roller gap of up to 65 mm, the Compas 4.0 has no problems

when coping with dough blocks weighing up to 20 kg.

Thanks to the four individual drives, the plant is also said to work considerably faster and at the same time more gently than conventional sheeters, thus reducing operating costs.

Overall, so the company reports, this yields demonstrably increased efficiencies in the double-digit percentage range compared to sheeter machines available nowadays.

Operation like a smartphone The i-Touch operating interface makes working with the Compas 4.0 very easy from the start, even for inexperienced operators. All information is presented in clearly understandable tiles on the big touchscreen. The way operation takes place is the same as everyone is accustomed to from his or her smartphone – intuitive, reliable and fast. Assistance systems and a “Program Wizard” not only make working with the Compas 4.0 easy, they also prevent operator errors.

The new Compas 4.0 can also be equipped with newly-developed functionalities in the future. The plant’s safety and hygiene properties have been tested and certified by independent agencies.

In addition to the Compas 4.0, RONDO is launching another electronic sheeter: the Rondostar 5000. This plant has the same i-Touch controller as the Compas 4.0 and combines high performance with robustness. Its predecessor model, the Rondostar 4000, passed its practical test long ago, with several thousand units sold. +++

++ The Compas 4.0 is an electronic sheeter with four individual drives

do

++ i-Touch control simplifies working with a sheeter

© R on

22

www.bakingbiscuit.com 01/2020

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24

P RO D U C T I O N FAC I L I T I E S

Better baking in existing premises FactoryXperts, baking industry consultants from Switzerland, uphold this motto in the sustainability sense as well. According to the advisers, although new building is an option, a meticulous analysis

+

of the business is needed first of all.

The company has been in the business of upstream planning for redeveloped and new buildings for large, medium and small bakery businesses throughout Europe for many years. According to CEO Roger Bless, who is himself a professionally trained baker and has decades of experience in the baking industry, the consultants’ expertise in this situation starts at the planning stage and is by no means finished when building starts.

A salutary look at the big picture According to Bless, an expert knowledge of the trade, product range, working conditions, lines and logistics is what decides success. In an ideal case, even before an architect begins planning, experts undertake an in-depth study of the existing business situation – across the board, over every operating area. Explaining the normal rationale, Bless says: “Our aim in the first place is to understand what a client does, why he does it and where he wants to go with it. Only then do we begin the drawings.” Not infrequently, the end result is a jointly developed objective to increase efficiency that necessitates a package of measures quite different to the new building originally envisaged. He says the core of consultancy is a profound analysis leading to a written formulation of the target definition. The analysis reveals what optimum solutions might look like, to clear away inefficiencies and planning mistakes ahead of the actual master plan.

No fear of redevelopment Bless says: “In most cases, the wish to grow is what drives the decision in favor of a new build.” But, as he also says, an in-depth analysis at the outset helps to recognize that closing down inefficient processes and introducing innovative ideas into the existing business can, in most cases, develop just as much potential for growth and financial success. Often, simply questioning the product range or the existing plant technology A D V E R T I S E Motiv4 MENT KOENIG NTS 91x53.qxd

12.02.2007

11:10 Uhr

Quality-brand and freshness with long tradition

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How to make a new build and a building redevelopment efficient, sustainable and successful.

1. Formulate a definition of the goal! In writing! Not just verbally. Anyone who fails to make an in-depth analysis, and just thinks “what do I want to achieve with the new/rebuilt structure?” will remain aimless and will run the risk of creating for himself a medium-term financial problem.

2. Never lose sight of the specific features of the market! Be aware of the market in which you are operating, exactly why your customers come to you, and how much growth potential is at all realistically possible. You must also ask yourself the question as to what influence growth will have on the product price and production costs.

3. Select the team carefully based on competences and experience! The chemistry must be right.

Anyone who intends to collaborate successfully over a long period of time must also be a likeable person.

That’s worth more in the long run than a 3% cheaper offer at the outset. +++

and production processes is sufficient to realign a business to future needs. Redevelopment in the existing premises?

It’s an approach that terrifies many developers. After all, safeguarding the ongoing business during building work is a big challenge. But, according to Bless, with the right planning, time and experience, this is an entirely feasible way forward.

According to Bless, the classical comprehensive product range is often what stands in the way of growth. “One can expand with a full product range, but it doesn’t always make sense.”

From the business management point of view, it may be Seite 1 better to buy in certain products from other specialists, particularly if these are difficult to surpass in price and quality terms.

The Nut specialists

E-Mail: info@koenig-backmittel.de • Internet: www.koenig-backmittel.de

Three tips from the experts

Automation; yes, but only when it makes sense According to Bless: “Our approach to process automation is to let everything depend on a single question: what added value arises for me and my business?” Trends and movements back to classical artisan operation are a recurring subject of critical discussion. Pushing rack trolleys from the freezer to the cold store, and doing it hundreds of times a day, doesn’t improve product quality. Quite the contrary. This is a situation where machines could ensure more hygiene and better traceability, and thus ensuring process reliability. But if it involves

P RO D U C T I O N FAC I L I T I E S

Time well spent Based on a knowledge of the individual stages of the supply chain and the various processes necessary for the operation, a consultancy contract finally leads to the development of a master plan, whereupon the optimum dimensions of a building can be defined. An approach from the opposite direction forces the operating facilities to be subordinate to the existing space. Permanent inefficiency may then already arise in the planning phase, which in turn costs the client hard cash.

Bless is confident that approx. three months of intensive analysis beforehand is well worth while. Based on a few key figures (not including the typical business management figures), the consultants clearly show where fine tuning is needed.

After the analysis, work on the master plan starts with a meaningful final report containing costs, layout, functionalities and deadline dates. This gives the developers certainty and the decision criteria on which to base the following planning phases. Since early in 2019, FactoryXperts can rely for this task on the ATP architects engineers and its workforce of more than 900 staff. Beforehand, FactoryXperts undertakes the building planning, analysis and process technology planning and develops a master plan, with building know-how support from ATP (Available to Promise). FactoryXperts operations

FactoryXperts The FactoryXperts team based in Eschlikon/Switzerland comprises around 35 specialists from all the baking sector disciplines: from logistics and operational engineering, architecture, construction planning and overall project management to controlling, change

management

and

strategic corporate development. The integrated design

© FactoryXperts

refining a recipe, or testing a special dough processing method, the human factor may certainly be what brings about the desired added value.

company ATP architects engineers has been a FactoryXperts shareholder since early 2019.

Web

site:

https://factory ++ Roger Bless, CEO of

xperts.com +++

FactoryXperts

planners assist in planning the material flow, machinery layout, logistics and production technology, and supervise the installation and commissioning. Integrated building design then takes place based on digital planning technology (BIM; Building Information Modelling) and with the experience of ATP gained from decades of working for the food industry.

+++

Dictionary of Bakery Engineering and Technology

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25

P RO D U C T I O N FAC I L I T I E S

+

© Fortisa AG

Fortisa: Rebuilding during ongoing production

Fortisa AG is the market leader in Switzerland for buns and small breads for the convenience segment. During the company’s development, together with FactoryXperts, the management developed various expansion options, and finally decided in favor of extending and redeveloping the existing location in Zuchwil.

Fortisa AG

In an in-depth operating concept, FactoryXperts planned a complete modernization of the production lines. In the past five years, all the plant components were replaced, enlarged or improved. Project implementation, including all the building activities, took place in parallel with ongoing production, and was achievable without interrupting production for a single day, thanks to meticulous planning.

the retail trade, branded article producers, the sand-

A completely new internal production flow was designed for the operation. This involved inserting an intermediate floor into the ground floor of the existing building to create space for a new, fully automatic reusable containers handling robot for McDonald’s trays. The operation was also expanded by adding cooling spirals and a packing line (for pillow-packs)

on the ground floor, and two tubular bag packing lines (flowpacks) for frozen baked products on the intermediate floor.

Fortisa AG, Zuchwil/Switzerland, produces burger buns, hot dog buns and sandwich breads that are offered as fresh goods or frozen products. The company has produced the entire bun portfolio for McDonald’s Switzerland for more than 30 years. Other customers include wich industry and food service distributors. The company operates a six-day week around the clock. According to the company’s web site, the proportion exported is 20%. Fortisa is privately-owned, and maintains a partnership with Grupo Bimbo, the world’s biggest bakery group. +++

In the new production flow, burger buns are now taken from the basement floor (existing production lines), via the newly-

++ Cooling spirals www.bakingbiscuit.com 01/2020

© Fortisa AG

26

P RO D U C T I O N FAC I L I T I E S

installed cooling spirals, for packing either on the intermediate floor or on the ground floor. Thus the buns, produced under hygienic conditions, can be fully automatically cooled and conveyed to the packing lines by means of cooling spirals.

After packing, the buns packed in bags are automatically placed in distribution containers. A shock-freezer was installed as an additional option, allowing the packaged products to be frozen for delivery as frozen products. The entire new

process comprises goods reception for the containers, the crate washing plant, and storage and transport of the newlyfilled containers for outgoing delivery to customers. A consistent hygiene zones concept completes the new procedure. Since the work took place during ongoing operations, implementation of the project was carried out stepwise during two years. Commissioning was achieved on schedule in the fall of 2019. +++

© Fortisa AG

++ Fortisa’s head office in Zuchwil/Switzerland

++ The tray washing line

© Fortisa AG

© Fortisa AG

++ Packing buns in pillow-packs

++ Tray storage www.bakingbiscuit.com 01/2020

27

PRODUCTION

A plug-in fully automatic proofer The fully automatic proofer from the plant constructor DEBAG is called the TEFI. The plant can be used to control both proofing and cooling processes, e.g. to always allow proofed dough pieces to be baked off in a branch. supplies the TEFI ready to plug in. A normal (230 V) socket outlet is sufficient to operate it. Thus the user can bring the fully automatic proofer into operation immediately after delivery. With its external dimensions (792 × 2,120 × 715 mm or 792 × 2,120 × 1,021 mm), the TEFI easily fits into, for example, a retail sales outlet.

Energy losses are prevented by insulation. It also guarantees sustained cooling even if the electric power supply fails. The equipment has an automatic restart, so the proofing process is continued. The company says the TEFI is easy to clean and has a self-closing door with a fulllength handle. The door optionally opens to the left or right.

The push-in magnetic seal can be changed if it becomes dirty.

Adjustable feet allow the plant to be adapted to the floor situation. ++ The TEFI fully automatic proofer has space for up to 20 trays (580 × 780 mm) or The construction material of the 40 trays (400 × 600 mm) and can be set up in a branch outer walls is brushed stainless The TEFI fully automatic proofer (TEiglingssteel. Internally, the plant is cladded with bright-rolled stainFrIschhaltung = keeping dough pieces fresh) from the less steel. Condensate is drained away via a built-in drain supplier DEBAG Deutsche Backofenbau GmbH, Bautzen/ system. The temperature range of the plug-ready, fully autoGermany, enables optimally proofed dough pieces with an matic proofer is between -20 and +40°C. +++ oven-ready final proof to be produced and stored in a sales outlet. This allows the fully automatic proofer to be loaded with dough pieces on the previous evening, for example. The dough pieces then mature overnight. Next morning, staff can immediately start the first baking process, e.g. in an instore oven. The fully automatic proofers allow both proofing and cooling processes to be controlled. DEBAG promises perfectly cooled, temperature-adjusted, air-conditioned goods. The oven-ready dough pieces are also said to have an optimum state of maturity and a high proofing tolerance. Furthermore, dough pieces can be processed at a low temperature for a prolonged time. The advantage, it is said: pre-matured dough pieces can be stored in the cell and baked off over a longer period of time. © DEBAG

+

Small and flexible The TEFI has an intelligent controller to calculate the process time. The equipment has space for up to 20 trays (580 × 780 mm) or 40 trays (400 × 600 mm). DEBAG www.bakingbiscuit.com 01/2020

© DEBAG

28

++ Temperature sensors and an intelligent controller help to determine the optimum proofing point and to store the dough pieces for a prolonged period of time

MIXING

MAKEUP

|

DIVIDING

|

|

SHEETING

BAKING

|

|

PAC K AG I N G

L A M I N AT I N G

|

|

P O S T- PA C K A G I N G

DEPOSITING

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D E C O R AT I N G

Through innovative, precision engineering informed by our master bakers’ expertise, AMF designs integrated production solutions for a variety of baked goods, from bread and buns to pizza, cakes, pastries, and beyond. Our team of dough process experts works alongside yours to determine the most optimal makeup solution for today with the flexibility needed for future growth.

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PRODUCTION

The new L’Artisane baguette line The L’Artisane baguette line is destined to change the world of industrially produced baguettes.

As a result of Benier’s new system, the baked products are designed to achieve high quality without

© Kaak

final proofing.

© Kaak

++ The baguettes have an open structure. It is also said that the proportion of yeast can be reduced and the TA (dough yield) increased

+

Benier Nederland B.V., a company in the Netherlandsbased Kaak Group, has developed a new plant to produce large quantities of baguettes without final proofing.

Benier Nederland B.V. reports: “We are proud to present our new DrieM L’Artisane baguette line. This line is the only industrial baguette line that produces your perfect artisan baguette.” According to Benier, the proofed dough is made up gently and no longer needs final proofing.

Moreover, the concept is capable of integration into

existing industrial baguette plants. The patented process is said to allow the production of up to 15,000 baguettes per hour. It is also said that L’Artisane creates a traditional baguette by adhering to the original traditional recipe with small amounts of yeast and a large proportion of water.

This also means lower costs and high profitability. The Editors are attempting to discover more information about the new system, and to present it in more detail in a forthcoming issue. +++

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www.bakingbiscuit.com 01/2020

March 26-29, 2020 Istanbul/Turkey IBAKTECH www.ibatech.com.tr

April 20-23, 2020 Barcelona/Spain Alimentaria 2020 www.alimentaria.com/en

March 31 - April 2, 2020 Las Vegas/USA/Nevada International Pizza Expo www.pizzaexpo.com

May 7-13, 2020 Düsseldorf/Germany Interpack – International Trade Fair for Processing and Packaging www.interpack.com

April 14-16, 2020 Kiev/Ukraine IFFIP 2020 - International Forum of Food Industry and Packaging http://ifw-expo.de/exhib/iffip-2020-international-forum-of-food-industry-and-packaging-2/

July 21-24, 2020 São Paulo/ Brasil FIPAN 2020 http://fipan.com.br/?lang=en

© rclassenlayouts – 123rf.com

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WAVE SSP 800 GENTLE HIGH SPEED BUN EXTRUSION WITH INDIVIDUAL PUMPS

The Wave SSP 800 introduces the latest innovation in our high speed extrusion bun divider, providing the ultimate in lane control. Scaling is done via a Servo Sine Pump per each lane.

Wave SSP

Our large diameter polymer double screws rotate slowly, and prevent dough sticking. The result is higher quality product, truly round dough balls, with lower shear and substantially lower pressure than our competitors.

FEATURES & BENEFITS • Servo Sine Pump per each lane provides unparalleled scaling accuracy • High speed, up to 150 cuts per minute • Available in 6 lanes and 8 lanes • Hygienic divider design and easy access to all assemblies • Lower formula cost (scaling weight & dough conditioners) • Toolless design reduces time for clean up & changeover • Lower maintenance cost • Visually inspectable product path • Output center lines of manifold can be customized to fit existing equipment.

+1 972 422 - 5808 | stewart.sales@stewart-systems.com BAKERY

PRODUCTION

Dough mixing/ kneading

Dough division SE 442

Round molding + transfer to an intermediate proofer

Long-roller, Molding

Deposition into pan clusters

Piece

A system solution to produce toast-bread Albert Handtmann Maschinenfabrik GmbH & Co. KG, Biberach/Riss, offers various solutions for the industrial production of toast-bread.

+

©H

The modularly constructed plant offered by Albert Handtmann Maschinenfabrik GmbH & Co. KG, Biberach/Riss, Germany, offers various solutions for industrial toast-bread manufacture. The portfolio comprises dough dividing and portioning machines for the baking sector with various performance ratings. When combined with molding/ cutting and metering attachments, these dough divider and portioning machines create flexibly usable machine solutions.

The company also says all the systems are interfaceable and can be integrated into complex line solutions. Toast bread is produced industrially using a system solution consisting of a VF 800 portioning machine and a SE 442 cutting unit.

++ The toast-breads that are produced have a typical fine-pored, fluffy crumb structure

Process steps The industrial production of toast-bread is an intermeshing chain of various process steps. Handtmann technology is used for accurate weight dough division in the manufacturing process framework (monoline). In this respect, the interfaces can be described as feeding dough into the cone of the VF 800 portioning machine and transfer of the dough piece from the SE 442 conveyor belt to a conical rounder. According to the company, the main feature when using Handtmann technology in toast bread production is the high weight accuracy achievable in 24/7 operation. This allows deviation values of 0.5% for a 600 g dough piece in continuous operation. The precondition to attain such highly accurate weights over a long production period is the coordination and exact interplay of important details, e.g. the synchronized feeder curve and the conveyor vacuum in the VF 800, which guarantees a down-feed of dough into the conveyor. Uniform, continuous filling of the individual conveyor compartments with dough can thereby be ensured during the entire production process.

In this respect, the sliding vane conveyor is the decisive component and is the basis of accurate portioning. Dough piece capacities of 6,000 portions/hour are achievable with a 600 g dough piece, with minimal overfilling (giveaway).

© Handtmann

32

++ High weight accuracy is achievable. For example, deviations of 0.5% for a 600 g dough piece can be attained in continuous operation www.bakingbiscuit.com 01/2020

The toast-breads produced using this technology have a typical fine-pored, fluffy crumb structure. The oil-free portioning principle allows oil consumption in the production unit to be reduced, which can lead to financial savings in production costs, and improved crumb structure quality of the toastbreads. The company also says this reduces holes caused by oil inclusions and oil adhesions.

and

tm

ann

PRODUCTION

Baking process

proofing

Cooling +

Depanning

Packing

slicing process

++ Diagrammatic illustration of the toast-bread manufacturing process using the VF 800 and SE 442 in an overall process

© Handtmann

Hygienic Design Changing the product and dough fill amount are possible in real time, due to the piston-free functioning principle, by entering them on the monitor controller of the VF 800 without any conversion or dismantling. After production has ended, all the parts and components in contact with the product can simply be removed from the machine and cleaned in a washing machine. The VF 800 and SE 442 are mobile, and can be moved quickly out of the production area and into the wet area. Due to its hygienic design, the machine body can be cleaned using a water jet, which contributes to a reduction in cleaning costs. As a result of its high level of interfaceability, Handtmann dough divider technology is usable in almost every existing toast-bread line. +++ The toast-bread production process using a VF 800 dough divider-portioner machine and SE 442 cutting unit can be viewed via this link: www.youtube.com/watch?v=zrvECM4Xf24

++ The VF 800 portioning machine combined with a SE 442 cutting unit is a system solution for industrial toast-bread production

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Production

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Baking with ohmic heating

Solution to produce toast-bread

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Dictionary of bakery terms

THE EUROPEAN BAKERY MARKET 2019

Dictionary of bakery terms Dictionary of bakery terms

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Wörterbuch der Bäckereitechnik

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33

PAC K AG I N G

Approaches to increased sustainability Biscuits, baked goods or pizza are commonly packaged in plastic flow wraps. When it comes to

© Syntegon

sustainability, however, there is room for improvement.

++ In the case of films made of mono-material, the optimum interaction of the three sealing parameters is essential: pressure, temperature and time. The perfect seam can only be achieved if these parameters are perfectly aligned

+

In the field of packaging, a number of approaches already balance the requirements of sustainability and product protection. Here, the main focus is the development of recyclable materials as well as waste avoidance.

Sustainability approach 1: waste prevention At the production stage, the use of thinner films can reduce material consumption, thus minimizing waste. Using thinner films at constant processing speeds requires the packaging machines to be adjusted to the film properties. In general, film consumption can be reduced by optimally adjusting the roll width and take-off length. A further reduction in material use can be achieved by using narrower sealing seams. Even if this only involves a few millimeters of film per product pack, it can pay off in the long run and result in considerable savings. For example, reducing roll width and take-off length by two and five millimeters per pack, respectively, can result in material savings of over 130,000 square meters at an output rate of 200 packs per minute in 23-hour operation over a period of 50 weeks – equivalent to an area the size of 19 soccer fields. Alternatively, material savings can be achieved by changing pack styles, such as switching from twist wrap to flow wrap packaging. Similarly, the effectiveness of the packaging machines contributes to waste avoidance too; the greater the process stability, the fewer products are rejected.

www.bakingbiscuit.com 01/2020

Sustainability approach 2: recycling/recovery Very few procedures are currently capable of separating and recycling composites. Furthermore, for health and safety

++ Syntegon, formerly Bosch Packaging Technology, is continuously working on technical developments in order to process mono-material films and paper in the high-performance range

© Syn teg on

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PAC K AG I N G

Bosch Packaging Technology is now Syntegon Syntegon Technology is the new name among the market leaders in the processing and packaging industry. Known as Bosch Packaging Technology until late 2019, the former

the company gaining full independence at the turn of the year. +++

Bosch division today presented itself as an independent enterprise at the company headquarters in Waiblingen (Germany). Syntegon Technology’s business focus is on intelligent and sustainable technologies for the pharmaceutical and food industries. Extending the service range is a priority for the company. Syntegon Technology employs 6,100 people at more than 30 locations worldwide. It posted 1.3 billion euros in sales in 2019. Bosch disclosed its plans to sell the packaging machinery division to a newly incor© Syntegon

porated entity managed by CVC Capital Partners, a leading private equity and investment advisory firm, in July 2019.

The transaction was completed according to plan, with

Films made from mono-material Since the different layers are made of the same type of plastic, mono-material films are fully recyclable. Cookies, crackers or bars are usually wrapped using polypropylene (PP).

Depending on the packaging application, this can be either CPP (cast polypropylene) or OPP (oriented polypropylene).

The transition from composite to mono-material films is not straightforward. Mono-material imposes high demands on sealing technology, especially in the high output range. The sealing window is much smaller because the temperaturesensitive outer layer will be damaged if the sealing times are too long. At the same time, insufficient energy input results in inadequate sealing. With heat-resistant composites this is unproblematic; but in the case of heat-sensitive monomaterials this can easily lead to defective seals and damaged products.

In order to create the perfect seam using mono-material films at different film speeds and constant energy input, the three sealing parameters of pressure, temperature and time need to be coordinated optimally. What’s more, these technical challenges have to be mastered for a range of different mono-materials. This can only be achieved through the continuous development of sealing technologies in order to adjust the fin and cross sealing tools to the new conditions.

Paper as an alternative Since paper is made from renewable raw materials as well as being recyclable and biodegradable, this material is very

popular with manufacturers and consumers alike. The demand for flow wrappers made from paper as an alternative to plastics is currently increasing. Paper packaging also has the advantage that consumers can recognize the character of the paper from the way it looks and feels.

Horizontal flow wrapping machines use heat or cold sealing technologies. With paper packaging, heat sealing poses a significant challenge: paper is a good insulator. This means the material is not suitable for high output packaging, as sealing times have to be as short as possible. As a result, cold sealing is the common choice for high output quantities.

This process ensures reliable seals without the application of heat. A very thin plastic barrier layer provides the necessary product protection. Despite this layer, the paper packaging can be recycled.

Whether paper or mono-material films are the right packaging material strongly depends on the product properties and the required seal integrity. For example, for sensitive products, such as cookies and other baked goods, mono-material film with heat sealing is recommended, unless the product itself is heat-sensitive. Every product and every process is different.

For this reason, it is worth investigating all the parameters and conditions in detail to make sure the packaging solution takes brand targets, product protection and sustainability into account. +++

Author Christoph Langohr, Syntegon Technology GmbH (formerly Bosch Packaging Technology), Project Manager Sustain© Syntegon

reasons, the use of recycled materials for foodstuff is limited and is only permitted in certain cases, for example as a middle layer in composite films. For products that cannot be recycled, the last option in the waste hierarchy is thermal recovery.

Current developments are moving towards alternative packaging materials that are fully recyclable: paper packaging and films made from mono-material.

ability Horizontal Packaging, Email: Christoph.Langohr@syntegon.com

www.bakingbiscuit.com 01/2020

35

PRODUCTION

An accident makes history

© Sacher

The secret of the Original Sacher-Torte

+

“Oh, that he may not discredit me tonight!” – This admonition marked the beginning of the story of the Original Sacher-Torte in 1832. We have an historical accident to thank for this success story. One day in 1832 the court of Prince Metternich wanted a dessert to be created for discerning guests. It just so happened that the chef de cuisine was ill at the time and apprentice Franz Sacher filled in for him. The young man created a cake that left nothing to be desired.

This night marked the birth of the Original Sacher-Torte – and a moment of glory for epicures.

how the Original Sacher-Torte became a piece of Austrian contemporary history – best enjoyed with unsweetened whipped cream.

A secret kept throughout the generations The successful manufacturing of an Original Sacher-Torte depends on more than the blend of ingredients, the right temperature, and the relative humidity within the bakery.

Equally important is the precise sequence of 34 individual steps up to the packaging of the torte in its exquisite wooden box. The Original Sacher-Torte is made exclusively from fresh, free-range eggs and various kinds of premium chocolates produced especially for the hotel. And even after more than 185 years, the Original Sacher-Torte is still made by hand today. Since 1832, its recipe has been passed down from generation to generation and kept securely locked away in a safe.

Within a matter of years, the Original Sacher-Torte had gained international popularity. Even figure-conscious Empress Sissy could not resist the torte of Franz Sacher, his son Eduard, who opened the famous Hotel Sacher Wien, was also purveyor to the Imperial and Royal Household.

As ruled by a court of law in 1962, only a torte produced at the Sacher is entitled to be designated “Original”. That is

A culinary masterpiece from Austria Today, the Original Sacher-Torte is beloved and known across the globe. About 360,000 tortes a year leave our Original Sacher-Torte Manufactory for shipment worldwide.

Since 2009 it is probably also the only torte with a charitable bend. Hermann Nitsch, Xenia Hausner, Arnulf Rainer, Heimo Zobernig and Gottfried Helnwein are among the outstanding Austrian artists who have already artistically enhanced the wooden box into unique artworks for the Sacher Artists’ Collection. The net proceeds of the sales of this limited edition are donated to charitable causes.

Facts concerning the Original Sacher-Torte

+ The largest Original Sacher-Torte ever was made for the ++ More details: www.sacher.com

www.bakingbiscuit.com 01/2020

© Sacher

36

Vienna Festival in Ljubljana, Slovenia. It was 3.5 meters in diameter.

37

© Sacher

PRODUCTION

+ Anywhere from 5,000 to 8,000 eggs are separated by hand daily for torte production. During Christmas season, that number rises to anywhere from 15,000 to 21,000 eggs. + The Original Sacher-Torte was awarded the Tourism ADVERTISEMENT

Prize by the Vienna Economic Chamber in 2005.

+ Only the family, the head pastry chef and hotel manager and director of the Original Sacher-Torte Manufactory, Reiner Heilmann, know the original recipe. +++

MANAGEMENT

Using algorithms for better planning The more accurately baked products sales can be forecast in advance, the lower are the returns losses. The Geiping Bakery relies on self-learning software to push down the proportion of returns,

© f2m

while also discovering sales opportunities that remain unused.

© f2m

38

+

++ The Geiping Bakery’s latest flagship store opened in the summer of 2019

Much has changed since Geiping started using self-learning software. The proportion of returns fell by 2 – 3 percentage points, but much more importantly: the software helps cope with the increasing complexity with 220 different baked products, because data are decided in the order management system, not by gut instinct. Greater clarity has been achieved in and about the product range. However, it is hard to put a figure to the exact financial benefit.

working time per branch, i.e. 23 hours/day with 46 locations.

For a very few products, Geiping’s production unit needs a 2-day lead-in time. They quickly began searching for suitable software to solve the orders problem in the best possible way. “We quickly gave up the idea that a fully-automatic forecasting tool exists.” Volker Hollenberg is certain that this

Data discipline is one condition to allow the analysis tool to function, and a centrally organized ordering system is another.

No obstacle for Geiping. Volker Hollenberg, who as Sales Manager is the “Numbers Master” in the company, and the interface between sales and the bakery, says “We centralized our orders management four years ago,” and he reports that “We switched over on foot at that time, still without any IT Controlling.” He says they recognized that it was possible to operate with considerably greater accuracy from the center, with IT backing, than from the branches. It was a real cultural change, and needed considerable tact. After all, they didn’t want to give those responsible in the branches the feeling that they were being virtually “disenfranchised”, and so they have retained an influence on ordering. The switchover yielded another benefit: it was possible to save ½ an hour of

FoodTracks is a cloud-based, intelligent controlling

What is FoodTracks? solution for bakeries. The Geiping Bakery has used the “Turnover & Customers” module for branch controlling, and the “Branch Tuning” module for ordering, since March 2019. “Branch Tuning” indicates the branch-articleweekday combinations for which the order should either be reduced or increased. The core of the tool is a ranking in EUR of the biggest returns losses and the biggest sales revenue opportunities. The “Sales Revenue Opportunity” is a novel key figure for which the algorithm estimates, for zero returns, how many more articles could have been sold. The number can be multiplied by the selling price, and the missing goods are displayed as a value in EUR. +++

MANAGEMENT

The Geiping Bakery The W. Geiping GmbH & Co KG bakery, with lead manager Michael Geiping in the fourth generation of the family, has operated at the company’s headquarters in Lüdingshausen near Dortmund, Germany, since 1998.

With around 500 employees, the company produces up to 220 different baked products, seven days a week.

Bread and snacks (topped bread rolls, flatbreads or flutes etc.), which are prepared centrally in our own snack kitchen, are among the growth drivers just as much as confectionery and cakes. Of the total of 47 branches (in a radius of around 45 km), 23 are bakery-cafés, and another five are operated as food service locations, including with a salad bar, fresh pizzas prepared on the spot, and a Sunday buffet breakfast. In addition to its own branches, Geiping supplies B2B customers such as hospitals, canteens and restaurants.

The company generates around EUR 25 to 30 million per year.

Handling returns In addition to the actual branches, Geiping operates four previous day shops. The majority of the goods from the branches are sold at half-price on the following day. The bakery then makes anything still remaining available to community food outlets. Whatever these do not take is used by a local farmer as animal feed.

© Geiping

+++

© Geiping

++ Four of a total of eight Miwe rack ovens

© Geiping

++ The fully-automatic multi-deck oven is emptied via this outfeed belt

++ The dispatch building, where baked products for the branches are order-picked with support from an IT-controlled distribution system

is not practicable, at least not in the current situation. FoodTracks works differently. “It’s a recommendation tool, virtually an intermediate stage, that assists us in the ordering process but does not automate orders.”

How Geiping works using the analysis tool In the first place, FoodTracks (or more precisely the “Branch Tuning” module) actively informs staff in Central Customer Service about conspicuous issues. “Actively” means a daily E-mail tells them which articles in which branches have caused which amount of returns loss on the previous day or, to put it the other way around, where a turnover opportunity was missed, and for which articles. Recommendations about what that means for future orders are also provided at the same time. For example, such a recommendation may say: “Please check croissants in branch XY next Sunday.” In the Geiping bakery, FoodTracks obtains all the data it needs for its analysis from Goecom’s Marvin merchandise management system.

Secondly, the tool creates branch rankings sorted by sales revenue in EUR. From these rankings, staff in the center select the five Top and Flop branches on each occasion (i.e. those with the biggest returns), and evaluate them. What was the trend in the branch in the past six weeks? What was it on each weekday, for each product group and for each article?

That all costs time. Two employees and two trainees each work with FoodTracks for two hours daily. Because the system cannot take all the effects into account, manual substantive checking is also included. For example: a branch could drop down in ranking because a building site is deterring customers from making purchases. The weather also (still) does not enter the algorithm. According to Hollenberg, an If-Then relationship between weather forecast and purchasing behavior is as complicated as it is location-dependent. Weather data are included in the Food-Tracks graphics, however, as information. Finally, after an assessment and substantive check, the center prepares the order for each branch for the corresponding weekday. It is forwarded to the branches once a week (on Thursdays) for a final check-up, and is adjusted as necessary.

The next steps The Geiping Bakery played a major part in developing “Branch Tuning”. Volker Hollenberg reports that “We prepared a catalog of requirements stating, in our opinion, how and which data such a controlling solution should deliver. FoodTracks developed it, we improved it, FoodTracks developed it and we improved it. That went on for weeks until a tangible result existed.” He thinks the next step lies in developing ordering recommendations expressed in real figures. Moreover: “One of our aims would be to enable staff deployment planning to be carried out based on expected turnovers. So, in a first step, we need turnover forecasts.” That’s exactly what the software developer is currently working on, and is sending initial test programs which, according to Hollenberg, are already quite close to reality. +++ www.bakingbiscuit.com 01/2020

39

NEWS ++ NEWS ++ NEWS

++ Organisational Changes at ARYZTA North America ARYZTA AG announces, as part of a planned organisational evolution, that Tyson Yu has been appointed as CEO of ARYZTA North America effective 1 February and as a member of the Group Executive Committee, reporting to Kevin Toland, Group CEO. Dave Johnson assumes the role of Non-Executive Chairman of ARYZTA North America.

John Heffernan has been appointed as President and Chief Commercial Officer North America, reporting to Tyson Yu. Tyson Yu (37) is currently Chief Operations Officer of ARYZTA North America and has been with ARYZTA for 10 years in various roles, previously as President of Canada, Head of Strategy North America, Head of Strategy and Acquisitions of Fresh Start Bakeries before taking up his current position as North America Chief Operations Officer two years ago. Prior to this, Tyson worked in private equity and investment banking and is a graduate of Georgetown University with a Bachelor of Science in Mathematics and Economics.

John Heffernan (49) is currently Group Chief Strategy Officer ARYZTA AG and has been with ARYZTA since March 2018.

He will remain on the Group Executive Committee. Prior to joining Aryzta John had senior positions as Chief Development Officer in daa plc, as founder and CEO of Clearpower and AER, in private equity with Boundary Capital and worked with McKinsey and Company. John has a Bachelor of Commerce from UCD, a MSc from LSE and an MBA from Insead. In his new role as President and Chief Commercial Officer John will be responsible for Commercial, Innovation and Strategy for North America. +++

beverage industry and worked for many years for Allied Bakeries and Twinings, both parts of the ABF Group. +++ ++ Finland: Fazer acquires Vuohelan Herkku’s bakery Fazer Group continues executing its growth strategy and investing in growing product categories by acquiring Vuohelan Herkku’s bakery and mill businesses. Vuohelan Herkku is one of the forerunners of gluten-free baking in Finland and has a new gluten-free bakery in Lahti. Through the acquisition, Fazer becomes the market leader in glutenfree bakery products in Finland.

According to Fazer the demand for gluten-free and bellyfriendly products increases Gluten-free products represent approximately 3 % of the total bakery market in Finland. The market is estimated to grow significantly in the coming years. Around 2 % of the Finnish population is affected by celiac disease and at least one out of ten Finns suffer from IBS (Irritable Bowel Syndrome). In addition to those suffering from celiac disease, many people with sensitive stomachs have experienced that a gluten-free diet is suitable for them and relieves their stomach symptoms. Vuohelan Herkku Oy in brief: + Net sales 8.6 M EUR (2018) + Employs approximately 80 people + New, modern gluten-free bakery in Lahti and mill in Joutsa + The biggest product category is fresh bakery products.

Produces also frozen products and flour mixes +++ ++ British consumers are confident Anyone who believed that the tug-of-war around Brexit had diminished British consumers’ confidence in their personal future consumption is on the wrong track. According to GfK UK’s monthly survey in December, trust in their country’s economic future among the British is trending upwards as robustly as has not been seen since 2016. A similar situation holds true for their own financial situation and for the retail trade’s turnover. +++

++ Axel Beck appointed as Executive Vice President ITW Axel Beck has been appointed Executive Vice President of the Illinois Tool Work FEG Segment, comprising leading brands like Hobart, Foster, Bonnet, Elro, Traulsen, Avery Berkel. The 54-yearold German national will be responsible for the $ 2,2 billion Food Equipment Group, which produces dishwashers, cooking, refrigeration and food processing equipment and provides technical service for the Food Equipment Industry worldwide. +++

++ Switzerland is the winner of the European Pastry Cup Team Switzerland, composed of pastry chef Jean-Sébastien Guinet and chocolate specialist Nicoll Notter, have won the latest Pastry Cup during the Europain trade fair in Paris. Team Sweden (also “eco responsible prize”) and team Russia achieved 2 nd and 3 rd place. The 3 teams will meet again on January 24 & 25, 2021 for the next world final of the contest that will be held in Lyon, France, as part of Sirha trade fair. +++

++ John Jenkins, the new CEO of Müller Milk & Ingredients UK The German dairy group Müller has brought in Jon Jenkins, previously CEO of Allied Bakeries, to occupy the executive chair of its British subsidiary Müller Milk & Ingredients, regarded as one of the island’s biggest private dairy companies, where he replaces Patrick Müller from Switzerland, who will manage Müller’s Milk&More home delivery business in future.

Jenkins began his career with Mars, then moved to the

++ Christian Johansson appointed CFO of Lantmännen Christian Johansson has been appointed new CFO of Lantmännen and will be part of the Group Management Team. He has previously been CFO of Gunnebo and most recently held the position as Senior Vice President & CFO at SKF. In addition to that, Johannsson has held leading positions within Volvo and ABB - where he acquired a solid international experience from global positions as well as from working and living abroad. +++

© HOBART

40

www.bakingbiscuit.com 01/2020

MARKET

Top Trends for 2020

+

Increased consumer interest in the stories behind their food and beverage products and their notable influence on purchasing decisions has resulted in companies increasingly paying attention to storytelling in branding strategies. The top five trends for 2020 are: 1 Storytelling: Winning with Words Although ingredient provenance has always been important, consumer interest in discovering the story behind their foods has risen further and increasingly influencing purchasing decisions. Consumers' attention is piqued by opportunities to learn more about how products are produced, which promotes an understanding of product benefits and helps build all-important trust in the brand.

As a result, manufacturers are increasingly focusing on ingredient provenance platforms in order to highlight the taste and quality of their products, as well as their uniqueness and sustainability efforts. Provenance platforms can communicate a whole range of messages to the consumer, including flavor/taste, processing methods, cultural and traditional backgrounds, as well as the more obvious geographical origin.

2 Plant-Based Revolution Plant-based innovation in food and beverages continues to flourish as a result of consumer interest in health, sustainability and ethics, which ties into the broader consumer lifestyle trend towards cleaner living. As the use of the term “plant-based” moves more into the mainstream, the industry and start-up companies in particular, are taking up the challenge to deliver more clean label meat and dairy alternatives with improved nutritional profiles.

3 The Sustain Domain Consumers increasingly expect companies to invest in sustainability, with Innova Market Insights research indicating that 85% of, on average, US and UK consumers

© Rawpixel.com – Adobe Stock

Storytelling: Winning with Words leads Innova Market Insights’ Top Trends for 2020.

expected companies to invest in sustainability in 2019, up from 64% in 2018. In the area of food waste, upcycling is the new recycling, as companies strive to follow a zero-waste approach by creating value from by-products. Meanwhile in packaging, the focus is on using less of it, as well as developing sustainable alternatives.

4 The Right Bite Stress and anxiety are key concerns in modern life as consumers manage careers, families and social lives while striving to maintain healthy lifestyles, both physically and mentally. Responses to this vary, although the majority of consumers aim to balance the benefits and costs of busy lifestyles. This, in turn, raises the demand for nutritious foods that are easy to prepare, convenient and portable.

Indulgent treats play a role in relaxation and enjoyment.

5 Tapping into Texture Last year’s leading trend “Discovery: the Adventurous Consumer” is still prominent, with consumer demand for something new and different being reflected in more product launches with textural claims. Consumers increasingly recognize the influence of texture on food and beverages, allowing a heightened sensory experience and often a greater feeling of indulgence. According to Innova Market Insights research, 45% of, on average, US and UK consumers are influenced by texture when buying food and drinks, while 68% share the opinion that textures contribute to a more interesting food and beverage experience.

The other top trends for 2020 identified by Innova Market Insights are: 6 Macronutrient Makeover 7 Hello Hybrids 8 A Star is Born 9 Eat Pretty J Brand Unlimited +++ www.bakingbiscuit.com 01/2020

41

RESEARCH

The Space Bakery Project How can bread be baked on Mars? This is the challenge facing the Space Bakery Project; a consortium led by Puratos, comprising seven Belgian organisations.

+

However, before their research is used to help feed the first people to land on the red planet later this century, the project aims to have a clear impact on Earth today. It will focus on how we can produce food in a more sustainable way and will help to provide nutritional staple food for regions across the globe. The consortium started its research on 1 January 2020, which will be continued for a period of two-and-a-half years. In order to fund the research, the seven partners will invest a total of 6.3 million euros.

Four large interconnected containers have been installed at Puratos' headquarters near Brussels, Belgium. From the outside, they may look ordinary, but inside it’s a different story with the containers housing a closed organic plant cultivation system and bakery, where researchers have already begun their work.

Using the plant cultivation infrastructure, the researchers will learn how to create the ideal environment for the efficient production of wheat crops, as well as other plants that could be included in bread to increase its nutritional value. But, why focus on bread? The reason is simply that bread is highly nutritional and is consumed all over the world, making it an ideal candidate as a staple food for space exploration.

Filip Arnaut, Upstream R&D Director at Puratos when asked about the project, said: “With this consortium, we are bringing together various knowledge banks and expertise in order to answer the very important question of how we can further improve the nutritional value, sustainability and efficient use of energy to produce food? Here, we are looking at bread, which today is one of our main specialties, but which will also be important tomorrow in more challenging environments.”

The environment on Mars is very different from that on Earth; the lack of atmosphere, cold temperatures and dust storms are not conducive for providing the right conditions for crop growth. So, for this reason, research will take place in the containers, providing a closed and self-sustainable

www.bakingbiscuit.com 01/2020

© Puratos

42

system in which the climate can be adapted to make it suitable for crop growth, with optimal use of resources.

Working in parallel with the research on crops, the consortium will also study many other aspects involved in the entire food production cycle, such as the use and recycling of resources, the monitoring of a microbial climate, the influence of radiation, and pollination through automated drones.

Members of the consortium: 1. The consortium is led by Puratos, an international producer of ingredients and solutions for the bakery, pastry and chocolate sector.

2. Urban Crop Solutions, a provider of solutions for vertical farming, developed the infrastructure for plant growth and engineered a biosphere with a variable climate in a hermetically sealed building in which different climatic conditions can be simulated.

3. Magics Instruments, a technology company specialising in the development of semiconductor chips and machine learning-based smart sensors, will focus on the automation of pollination and work with Urban Crop Solutions to investigate how artificial intelligence can optimize crop growth.

4. SCK•CEN, the Biosciences research group, will study the effect of microorganisms on the release of nutrients to plants and monitor the overall microbial climate in the closed environment.

5. Ghent University, through its applied plant eco-physiological research at the Faculty of Bioscience Engineering, will create a 3D model of wheat growth and development using functional-structural plant modelling and data from innovative plant sensors.

6. The University of Hasselt, with its center for environmental science, will analyze how the waste of the wheat plant can be used to make the closed biosphere system circular by reusing organic matter.

7. Flanders Food, the agri-food spearhead cluster and supporter of the project, will focus on collaboration across the food value chain. +++

The European Bakery Market 2019 Subscribe now to baking+biscuit international and you will get a digital copy of the book for free Please contact: Viktoria Usanova via E-mail: usanova@foodmultimedia.de

COnTENT ++ 7 Country portraits: Hungary, Poland, Romania, Slovakia, Sweden, Switzerland, United Kingdom ++ Expert Interviews: The European out-of-home market ++ Market Research: Trends and market dynamics ++ Company reports: Profiles of major suppliers to the bakery market Hard copy • 272 pages • EUR 49 incl. VAT + delivery costs fotolia.com © lukiv007

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