baking+biscuit issue 2022-01

In-store ovens Bake smarter, not harder!

In the spotlight Pierre Tossut, Puratos CEO

H2 technology Therese Mölk to bake CO2-neutral bread

www.bakingbiscuit.com

01 22

// Packed with the goodness of whole grains, spelt, buckwheat and quinoa // Better for you // Artisanal taste and texture // Guilt-free indulgence

EMBRACE NATURE’S BEST GRAINS

A RICH & VERSATILE MIX, EASY TO USE

With our Dawn Balance® Ancient Grains Mix Multipurpose you can create deliciously tasting sweet baked goods, while offering a new texture experience and leveraging the benefits of whole grains, spelt, buckwheat and quinoa to meet consumers’ conscious lifestyle preferences.

Contact us at www.dawnfoods.com

Start creating your own Ancient Grains / muffins Ancient Grains / cakes Ancient Grains / cookies

EDITORIAL

“The great life refresh” Every year, market analysts announce the findings of extensive consumer studies in a bid to anticipate emerging trends and changing behaviors that will support the consumer goods industry, to better meet them. Euromonitor announced the top 10 trends identified by its research a few weeks ago, trends providing insights into consumer values while also exploring how recent shifts impact businesses around the world. One of them was appropriately named ‘The great life refresh’, and outlines how passion and purpose drive action. We’ve heard of ‘the great resignation’ professional wave, but this goes beyond it. Triggered by the pandemic, like most new changes, this trend sees the emergence of drastic personal changes, as well as “a collective reboot of values, lifestyles and goals.” This is a once-in-a-generation moment, which should be met with goods, services and experiences that resonate with it, coupled with marketing that acknowledges and embraces the upheaval,” Euromonitor recommends. The biggest change in attitudes measured in this trend was that the responders felt they could make a difference to the world through their choices and actions.

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

This profound, positive change makes it one of my favorite trends to watch – and live by – this year. We’ve seen essential parts of our ‘former life’ be diminished to a standstill, and then reemerge to be even more meaningful. Traveling is one of them: navigating various forms, tests, and other safety checks has turned the selection of our next trip into a more meaningful goal. Directly connected to (and largely affected by) this are trade events. I followed ISM and ProSweets returning to in-person formats; the same observation became apparent and, despite a lower head-count of visitors, those who attended came with the active intent to do business. It’s a refreshing start, as we anticipate and book for upcoming events.

We are also stepping up to meet this trend through changes of our own. We like to say, “Stay relevant with us”, and we are aiming to always do so ourselves. In this regard, I am happy to announce our new and quite literal refresh, which has been a long time coming: our brand-new website is live and ready for visitors, with an updated content structure, a reader-friendly layout that we designed to make your reading experience a pleasant, informative and effective one. We stepped up to make our website a truly modern, device-responsive experience. And we couldn’t be more proud to invite you to browse it at www.bakingbiscuit.com. Together with it, we also launched our bi-monthly English language newsletter, Bakery Mirror, for an essential and unique newsfeed; follow the ‘subscribe’ button to receive our newsfeed. More things to greatly refresh our professional life are coming soon, so please look out for them! In the meantime, we hope you enjoy our first magazine for this year, in a brand-new, revitalized design.

Catalina Mihu

03

CONTENTS

COVER STORIES

HIGHLIGHTS

IN THE SPOTLIGHT Puratos has been guiding its strategy in line with the findings of its ‘Taste Tomorrow’ study, an extensive undertaken every two years.

26

It is now regularly updated

06

as findings guide decisions to fast-paced consumer changes, the company’s new CEO, Pierre Tossut,

PRODUCTION

shared with us.

From viennoiserie to Danish pastry, and any number of hybrid,

© RONDO

consumer research program

© Puratos

new creations, laminated dough is the path to the sought-after airy, light layers. Gentle dough stretching and folding is a a must. However, there is by no means a one-size-fits-all approach to the process. Tried and tested laminating methods and line

14 © MIWE

30

IN-STORE OVENS Smart devices are quickly becoming an indispensable part of life inside the baking shop as they

RAW MATERIALS

are on the outside.

With consumers wanting simpler ingredients to make a come-

© Dawn Foods

setups can accommodate flexibility and consistency in results.

back, it is still important to them that their favorite baked products should also maintain all the convenient benefits they have learned to rely on, including long life and great taste. R&D cre-

32

42

H2 TECHNOLOGY From February 2022 onwards, Therese Mölk will be using green hydrogen (H2) for the first time, for

BAKERIES

thermal utilization, and for baking bread. By doing

The Polish bakery NOWEL set its sights high in 2020 and, in

this, the bakery subsidiary of the Austrian food

the midst of the pandemic, invested in a line that transferred

retailer MPREIS is probably breaking new ground

the concept of artisan bakery production into a fully automated

worldwide.

process.

www.bakingbiscuit.com 01/2022

© NOWEL

ates the balance allowing bakery fillings to check all the boxes.

© Therese Mölk Bakery

04

CONTENTS

Media to the global baking industry

IN THE SPOTLIGHT 06

Interview: Pierre Tossut is the new CEO of Puratos

PRODUCTION 14

In-store ovens: Smart in-store baking with ovens by MIWE, WP Bakerygroup,

Food2Multimedia is a publishing house operating at an international level and specializing in researching and editing technical information for the baking sector.

DEBAG, WACHTEL and WIESHEU 20

Snacking: Flexible options with Mecatherm’s MECAFLEX

24

Reading Bakery Systems: New pita chip line for healthy snacks

26

Laminating: All the means to a laminated end

RAW MATERIALS 30

Dawn Foods: Long-life and cleaner label fillings

baking+biscuit international Our specialist journal concentrating on production professionals in large companies in the industrial and chain-store sectors.

Published six times a year in the English language.

H2 TECHNOLOGY 32

Therese Mölk: On the way to CO2-neutral bread

36

Survey: Baking with green hydrogen energy?

MARKETS 38

Commercial Baking: Clean labels give bakeries a clean break

BAKERIES NOWEL: “The best products take time”

f2m Food2Multimedia GmbH

SUBSCRIBE

AUTOMATION – SCIENCE AND TECHNOLOGY

Hardcover edition: ISBN 978-3-9824079-0-6 PDF: ISBN 978-3-9824079-1-3 f2m Food2Multimedia GmbH Schoolkoppel 27 21449 Radbruch Germany www.foodmultimedia.de

FOLLOW US ON LINKEDIN

Publishing house · baking + biscuit international · brot + backwaren (German) · brot + backwaren (Russian)

f2m food multimedia GmbH Ehrenbergstrasse 33 22767 Hamburg Germany

03

Editorial: “The great life refresh”

46

News

46

Advertiser Directory

Cover photo: © L ANDMAGD Collage, ovens clockwise: Wachtel, MIWE, WP, Wiesheu, DEBAG

www.bakingbiscuit.com

Dictionary of bakery terms

Price: 49 € incl. VAT

REGULARS

AUTOMATION SCIENCE AND TECHNOLOGY

f2m food multimedia

42

Dictionary of bakery terms English

ENG

German

DEU

French

FRA

Glosario de términos sobre tecnologías de panificación

Spanish

SPA

Термины хлебопекарной индустрии

Russian

RUS

Ordbog over bageriudtryk

Danish

DAN

Japanese

JPN

Dictionary of bakery terms

Wörterbuch der Bäckereitechnik Dictionnaire des termes techniques pour la boulangerie

Our Review series provides in-depth analysis of clearly defined issues. This involves market analyses and is a comprehensive, informative presentation of the state of the art in process engineering.

The f2m dictionary translates bakery terms into a mulitude of different languages.

www.foodmultimedia.de

www.foodmultimedia.de

IN THE SPOTLIGHT

Taste Tomorrow, every day Puratos has been guiding its strategy in line with the findings of its ‘Taste Tomorrow’ study, an extensive consumer research program undertaken every two years. It is now regularly updated as findings guide decisions to fast-paced consumer changes, the company’s new CEO, Pierre Tossut, shared with us.

+

Catalina Mihu: Congratulations on your new role.

Please share your thoughts on taking on the CEO role at the beginning of a new year in an unprecedented global business environment.

Pierre Tossut: As Daniel Malcorps was preparing to step down from his CEO role (Malcorps led the company for 20 years, until the end of 2021 – eds.), we had started a transition process two years ago, so I could step in starting from the beginning of January this year. Cédric van Belle also took on the role of Chairman of the Board at the same time; we have been working together for the past two years in preparation for taking over the new assignments.

© Puratos

06

www.bakingbiscuit.com 01/2022

Mihu: What has the transition entailed?

Tossut: When we first communicated the plans internally, two years ago, we had initially envisioned a transition in which we would travel to all the countries where we work, to meet our colleagues. We had worked intensely on reviewing and updating our strategy. But then COVID-19 came; we had to reconsider all these plans, and we set up a crisis team instead. I took over the management of the crisis team for two years, as the situation progressed, starting from Asia, then with infections spreading throughout Italy and Europe, followed by the Americas. There were many unknowns managed by the crisis team, about how the situation would evolve, when (and if) it would end and what the impact would be.

The upside to this situation was that we were forced to review everything we were doing. Our first priority was, of course, protecting our people in factories and making sure they didn’t get sick. But then we also reassessed our ongoing projects to make sure we were focusing on what consumers need. Early in the crisis, we did a study to see what was changing at the consumers’ level, which helped us shape the product portfolio that we needed to have in order to please them. We saw, for instance, people increasingly looking for health and wellbeing products, for foods helping to boost their immune system and products with less fat. We had to modify our product focus and make it even sharper during this time. A great deal of that effort went towards trying to make processes lean, focusing on

IN THE SPOTLIGHT

aspects that were truly relevant in the moment. We did that created a dedicated business unit with a specially-appointed for a period of two years. There was an impact on sales in team for this trend alone. the beginning, but then we started to recover as we made Looking into well-being, we observed that people have sure to return to some kind of normality, at least in as far been looking for products with less sugar and more fruit. as sales were concerned. It We have reviewed our offerwas an entirely new range ings including fruit in re”In product ranges, we increased the focus on of activities during this timesponse and have reduced everything that is plant-based to match the big frame and an incredible sugar while increasing the learning curve as we had to fruit content up to 85% in movement that we see – I would call this trend reconsider many aspects some cases. almost a tsunami in magnitude, which started on within the company.

We also continue to invest We had to review our strategy in digital. We had started the West coast of the U.S. and then spread all over in a more structured way, online sales back in 2015, the world.“ Pierre Tossut, CEO, Puratos while we carried out what but we saw e-commerce bewe coined as ‘the new norcoming prominent as a result mal exercise’ and we looked at all the changes that came of COVID-19 measures. Consequently, we accelerated our with COVID-19 and what would stay after that. We were efforts in this direction and we now see triple-digit growth in then able to redefine the purpose of the company and ree-commerce. We also invested in virtual reality, because align everything with the company’s strategy. We started to there is a growing number of customers that our technicians implement many things in the past two years and we are can help remotely with tools such as smart glasses. We ennow continuing with this work. visage that we can help more people all over the world in this way. We have also been working on AI: we have brought Mihu: What key aspects from the last two years in business experts on board who are researching how we can use AI will be reflected in your management of the company? to work on new product development, for instance.

Tossut: The consumer study was the starting point. We There are several things on which we have been working used to do our ‘Taste Tomorrow’ study every two years, but and which we will continue to develop. we decided to do it on a much more regular basis. We took some of the findings from the study to adapt our plans. In Mihu: You bring a comprehensive knowledge of the company product ranges, we increased the focus on everything that to its helm, gained from 26 years with Puratos. How does is plant-based to match the big movement that we see – I such intimate knowledge in many areas starting from R&D would call this trend almost a tsunami in magnitude, which to marketing and product management translate in your started on the West coast of the U.S. and then spread all approach to product development going forward? over the world. Meat was first to be replaced and then milk; Tossut: Although I have spent many years in R&D and seen the trend has since evolved to encompass alternatives for numerous developments, I still think I know very little. The best flexitarian lifestyles. I think this is now the target, to provide learning experiences I get are going out and speaking options for people who want to follow fully plant-based with specialists and customers, because that is where you diets for a certain number of days, and less frequently also learn what their needs truly and specifically are. I try to consume meat, cheese, or other animal-based products. spend a lot of time meeting with and listening to customers, We have been intensively working on this approach, we have to understand both the needs that they actually recount, as

Meet Pierre Tossut Pierre Tossut has been in charge of the

role he also held in parallel with other

late, to gain a profound understanding of

company’s R&D, marketing, product man-

roles. One of the latest such tasks included

what the customers need, how the ingre-

agement and sales divisions. He is behind

setting up the channel structure, special-

dients work, and what the consumer

the group’s health and well-being approach

izing the sales force from the perspective

wants. “Our work at Puratos over the past

and, as of January 1, Puratos’ CEO. With

of the different channels in the baking

12 years goes much deeper into consumer

a background in agriculture engineering,

industry. “I had the privilege of working in

understanding, which influences how we

Tossut joined Puratos 27 years ago, as a

many aspects of the business, but always

develop innovations, in that we make

sourdough R&D specialist at first. He has

with the customer in center-focus, and

sure the work we are developing for the

since managed different business units and

how to be relevant to the customer,” he

client is also relevant to the consumer.

perfected product and process develop-

emphasizes. He has traveled around the

This has fueled the Group’s innovation

ment throughout his career. For 16 years,

world many times to learn all the subtleties

pipeline, which was my responsibility,”

he was the head of the Group’s R&D, a

in breadmaking, in patisserie and choco-

Tossut shared.

www.bakingbiscuit.com 01/2022

07

08

IN THE SPOTLIGHT

well as needs that are, sometimes, not clearly expressed or for sensory analysis at the point of purchase. We collect and even identified. I am not alone in doing so; the innovation analyze all of this data. In addition, we gain insights from driven by our ‘Taste Tomorrow’ insights is based on the client observations, all of which we funnel in for analysis. close observation of the customer as a priority. We identify We select the best ideas based on their potential and the relevant trends this way and what we need to develop, differentiation considerations (e.g., can we protect it with a respectively. This is, obviously, a subjective assessment – patent?). This is a good workflow, but it can take time. We sometimes, the choices prove to do fast-track some ideas, skip be correct and sometimes, not. certain steps and use a simpliThese are risks in any innovative fied stage-engage sequence to company, and, while success is bring the products to the market never guaranteed, this is our faster. In any case, we supervise PURATOS’ TURNOVER innovation pipeline. I believe the workflows to make sure we Puratos is a fantastic company continuously improve them and TARGET BY 2030 because we have a long-term that we can measure their effivision. Courage is one of our main values, as well as vision. ciency. We systematically track the sales of the innovations, We are always asked what comes next; now we have for example, we use a very interesting and innovative tool COVID-19, what comes after? This is what drives us to envi– the Puramid* – that helps us measure the different kinds sion what is going to happen, to stay innovative and stay of innovations that we launch on the market. We even ahead of the trends. share it as a best practice in universities. It is based on the Sometimes, you can be too early and develop something concept that existing and historic products in a portfolio for which the market is not yet ready for. But, you have comneed to be renovated all the time. If you stop renovating, pleted it, you have mastered it and you can quickly have it you lose touch with what consumers want, which will affect ready when the time comes. For example, we had worked product sales. There are also different levels of innovaon a number of things that we implemented when COVID-19 tions: some that are a bit more incremental and the more came along. We had been developing health and well-being, radical ones, which create a breakthrough in the market. sugar-reduction solutions for 12 years although they were We have set up and are measuring the growth rates for not always gaining traction. However, when the need for different kinds of innovations that have to feed the growth these was accelerated by COVID-19, we were ready because of the company itself. we had envisioned the trend and we were prepared. This is the way we do things and we aim to continue to do better.

Mihu: What local sources of inspiration does Puratos Innovation is not a theory, it is a journey and you learn by find, considering its global presence? Can you share an doing it, with new methodologies always coming out to be example? inspired by, to be faster and leaner. You have to explore, Tossut: What we know as ‘bread’ is the Western type of try things, sometimes fail, pivot, do something else when bread, loaf bread, toast bread, or baguette. When you needed, and continue. This requires a mindset that we are travel around the world, you see other traditions. In the lucky to have embedded in the DNA of our company. It is Middle East, people prefer flatbread and baklava-type not a forced process, on the contrary – sometimes, we need products; in Asia, bread is steamed. We go into bakeries to tone down the stream of ideas and re-center around the and observe how people work. Ciabatta, for example, was portfolio. This is a fantastic way to work, where ideas conlaunched just before I joined Puratos. We thought it was an tinuously effervesce thanks to the creativity in the company. incredible kind of bread because you can freeze it, chill it The challenge is to select what is truly relevant and will be as needed and it is always good once’s it’s baked. We successful in the market. launched the first ciabatta mix – typically, a long-fermentation dough that requires a lot of water. This is an example of a Mihu: So this is where the expertise comes into play, in product originally from the North of Italy, which we launched addition to the beginner’s mindset that you consider to and then it spread across markets all over the world, by always be an important asset. developing a complete mix to consistently manufacture it.

Tossut: Yes, we have experienced people and processes in place to try to select the best ideas and then to bring Mihu: And how should ideas that are ahead of their time them to the market. be treated? How do they become trendsetters?

Tossut: Back in 1998, I remember we patented a technology Mihu: With this stream of ideas for new opportunities, what to soften grains and seeds, starting from a tradition we saw are the strengths, values and R&D workflows at Puratos that somewhere in Germany, which gave the bread an incredible you are aiming to preserve and build on? taste, especially wholegrain bread. We tried to launch it Tossut: Understanding the consumer is an important first then, but it was a bit too early. A few years ago, however, step. ‘Taste Tomorrow’ is key, but we also have the Sensobus we brought it back to the market, as we felt it was the moment

EUR5BN:

www.bakingbiscuit.com 01/2022

10

IN THE SPOTLIGHT

for wholegrain to shine. We saw a spike in sales that showed us the market was indeed ready for it.

particular. Fermentation is also an important topic for us because it is an incredible source of innovative ingredients. We also work on fruit to make sure that we have the best possible quality raw materials for fillings. We are looking into vertical integration in this regard, up to the level where we work with farms to select new varieties and to ensure fertilizers are not overused, for example.

We are also developing innovative technologies to prepare the fillings.

Mihu: Please share details about the company’s EUR5bn target by 2030.

Tossut: To arrive at this figure, first of all, we looked at the historical performance of the company. The market of finished goods (breads, patisserie products and chocolate) is expected to grow in value by 3-5% in the coming years, according to our estimates. We plan to continue to have a complete product assortment of what bakeries, patissiers Mihu: What do you consider the core innovation drivers at and chocolate makers need to make outstanding finished Puratos? products. innovations will focus on health and well-being, Tossut: Understanding the market perfectly is the start. You responsible products, plant-based alternatives, and clean can have an incredible invention, but, if it is not relevant labels. In addition, we have to consider the portfolio of to what the customer and the consumer need, it is never geographies. We want to going to work. Innovation is continue to complete our an invention that succeeds ”Innovation is not a theory, it is a journey and you geographical coverage, to at generating change in learn by doing it, with new methodologies always be close to customers everythe market, and is at its where where there are marcore the ability to undercoming out to be inspired by, to be faster and kets for breads, patisserie stand what the customer leaner.

You have to explore, try things, sometimes and chocolate – which means needs and to develop the not only adding salespeople invention that fulfills those fail, pivot, do something else when needed, and and technical staff but also needs. Local innovation is continue.“ Pierre Tossut, CEO, Puratos production units, which we one of the great strengths aim to have close to cusof our company; local R&D tomers for fast deliveries. To reach this goal, we will also expertise helps to adapt the technology to the process continue to digitize our internal processes and use digital and the recipes. We are lucky to be an entrepreneurial tools to help our customers be even more successful in company and the culture of innovation is embedded in our their businesses.

DNA.

From local inspiration to global innovation Mihu: What is the ratio between products available globally and solutions dedicated to specific markets?

Tossut: That is s tricky question. What we develop for certain countries is very local as we always aim to adapt to different local tastes. In Belgium alone, for example, three main types of bread are baked. We bring centrally the technology that we develop, however, such as new enzymes for clean-label products. They are then implemented in the countries following local recipes, which is why a clear-cut answer is difficult to share. Everything should be adapted to local preferences to entice people to buy the products, from legislation down to tastes and labeling. A lot of the work that we do has to be adapted to local needs.

Mihu: How would you summarize R&D at Puratos and its priorities? How are health and well-being supported?

Tossut: We set clear goals regarding health and well-being: we work on not only improving the nutritional features of our products but also on introducing gut-health solutions.

We believe bread fiber to be an incredible substrate to enhance gut micro-flora and we are investing in resources to work on that. A new team that we set up a few years ago is dedicated to health and well-being, and gut health in

www.bakingbiscuit.com 01/2022

Mihu: And how is change generated in the market? Could you share an example of work you have done in this regard?

Tossut: Let’s look at brioche buns, for example; they normally get their shiny crust by using egg. We developed an eggwash alternative called Sunset Glaze for consumers who prefer plant-based diets. First of all, you need to convince your sales team that it is an interesting change to make, then you have to convince your customers to buy it, and eventually to make minor adjustments to the process in order to be able to spray the glaze on an industrial line or even manually.

For all these small steps, you need to generate a change, and these are steps leading up to innovation. Once people learn it, it becomes a routine in daily production.

Mihu: Because the plant-based trend is enjoying such growth, how do you think it is likely to influence the baking industry in the long term?

Tossut: I don’t know if it is going to transform it; there is a part of the market that wants to avoid animal-origin food, including flexitarians and vegans. We see this trend growing and we want to capture a part of it in several categories, from egg, to butter and milk chocolate, for example. We have egg-free cake mixes and plant-based, dairy-free whipped cream; this trend is opening new opportunities.

Proven Quality & Durability

to keep your bakery moving forward Invest in bakeware that has proven its value in bakeries around the world for over 40 years. Achieve maximum product quality and consistency while minimizing your cost per bake by partnering with us to select the right design, coating, and pan refurbishment schedule for your tins and trays.

STOCK & CUSTOM BAKEWARE Select from our stock bakeware or create a custom pan designed for your bakery’s exact needs and specifications to maximize throughput and increase efficiency.

PAN COATINGS Work with our experienced team to select the optimal silicone or long-life coating to reduce the use of oil and provide clean release from your bakeware.

BAKEWARE REFURBISHMENT Maximize pan life and product consistency with a refurbishment program personalized for your bakery’s product, pan usage, and production requirements.

WE ARE

HERE

Jesper Albertsen |

EUROPEAN SALES DIRECTOR

Tel: +45 23 68 51 85 | jalbertsen@americanpan.com

MANUFACTURING & SERVICE LOCATIONS: ROMANIA | SPAIN | SWEDEN | UK

IN THE SPOTLIGHT

© Puratos

12

Mihu: What other market trends do you anticipate and which are you preparing for?

Tossut: Carbon neutrality is an important point – how we can bake bread with low CO2 emissions, starting from the production of the wheat to milling, baking, shipping and waste handling, considering that every step contributes to a certain extent to the emission levels behind a single loaf.

Understanding how CO2 is generated throughout the value chain provides clues into how to minimize it. This is a major project that we are developing for the future and is also the aim of our ‘Mission to Mars’ project – working on more sustainable finished goods looking at emissions as well as resource efficiency. There would be no baker’s yeast factory on Mars, for example; this project helps inspire us for the future.

Another important project is integrating the supply chain, along with other exciting topics such as gut health, which is also a very complex one. New products will soon come to the market.

Mihu: How soon can we expect them, and what type of products will they be?

Tossut: This year, we are introducing an innovative sourdough, inspired by the Mars project. More information about our other projects will come soon!

Mihu: What possible paths are there to continuously improve on sustainability?

Tossut: We have big projects lined up. One of them is to be carbon-neutral by 2025. We also want to lower our water consumption and ensure the water we dispose of is perfectly treated. Beyond water analysis to demonstrate compliance, we also put fish in ponds to signal the water is entirely safe to permit aquatic life. We also have our bakery schools where we provide training to help the community. In 2022, we are having 350 permanent students enrolled in our schools. Currently, we have seven bakery schools, and we will continue to invest in providing this type of training to help the youth, with the eighth school opening this year.

Through this program, we also support our students in finding jobs when they finish school.

We also have an ongoing program on sustainable cocoa through which we try to have a more fair distribution of the revenue between the cost the consumer is paying for the chocolate and the cocoa price paid to the farmer. We have improved the farmers’ revenue by around 25%, for the time being. It is an ongoing process, as we help them to improve the quality of the cocoa. We run the fermentation for them, to ensure it is well done and we develop chocolate that is valued by the consumer. We distribute the generated revenue towards the farmers. It is an interesting project, as the impact in the field can be clearly seen.

Mihu: Thank you for an insightful conversation!

+++

References * The Puramid (Puratos Innovation Pyramid) has been designed to better drive implementation of innovation and renovation projects; the Puramid is also used to help Puratos’ teams to balance efforts and resources on strategic innovations, local and international innovations and renovation of regular products (historical products of the group). Each strategic business unit (SBU) has its own Puramid; regions and countries also have their Puramid, in line with their market realities. www.bakingbiscuit.com 01/2022

IN-STORE OVENS

Bake smarter, not harder Smart devices are quickly becoming an indispensable part of life inside the baking shop as they are on the outside.

For in-store ovens, smart tools are being developed to make them more efficient and easier to operate for consistent results. Some of the industry’s leading technology suppliers share their solutions.

+

Baking in-store not only brings the entire process in view of the consumers but also invites a warm connection. High-quality results will, naturally, only consolidate this relationship. To achieve this, there is a long list of requirements that in-store ovens should meet.

Sophisticated equipment makes baking simple: MIWE Smart tools take the process of baking in-store to the next step of simplicity and efficiency. For example, the MIWE TC touch control system takes into account that a variety of people, with different training levels, operate in-store ovens.

User feedback also shows that energysaving features such as MIWE eco mode and MIWE auto-start are used each day, allowing energy savings while the oven is on standby and ready to bake quickly when needed.

The oven specialist also provides digital solutions allowing access to all incoming and outgoing information, for comprehensive monitoring and reporting. “Connecting in-store ovens to intelligent network systems helps in many ways, e.g. for a master baker to test, optimize and release new baking programs,” MIWE illustrates. ”On the deck oven side, the MIWE condo shines with the optional MIWE TC feature, the touchscreen control, the MIWE TC-U, one unified control for all decks, different accessories and many optional functionalities,” the specialists add.

The MIWE TC can maximize baking safety, by adjusting certain user roles in the interface and using predefined baking programs. It can also help coordinate multiple ovens by connecting them to the MIWE shop baking suite,

www.bakingbiscuit.com 01/2022

© MIWE

14

which enables access to data coming in and going out. “Interconnected baking stations can be integrated into the MIWE shop baking suite software package, making analyzing data, changing and adding programs easier.

The MIWE TC will even notice abnormal oven functionality and adapt or correct them,” MIWE explains. The awarded MIWE go! interface provides easy-mode control settings for everyday operations, and an advanced mode for authorized users to set and monitor all baking parameters.

“User feedback shows that energy-saving features such as MIWE eco mode and MIWE auto-start are used each day.“ MIWE specialists

In addition to software, the ovens themselves are equipped with sensors to avoid handling mistakes and to take product consistency one step further.

For example, steam is not released when doors are open; alerts will also notify when they are not properly

closed. As the MIWE TC ‘knows’ the exact parameters the oven is supposed to have, it provides helpful feedback anytime values step outside the presets.

Flexible equipment For traditionally challenging, premium products that are in demand, baking settings will always be adapted to the oven system and the characteristics of the baked goods, to match expectations. To simplify this process, MIWE ovens come with pre-programmed settings, which can easily be adjusted.

“In the field of in-store baking, customers look for reliable and easyto-handle ovens with a small footprint and as many features as possible.

MIWE conquers these challenges with a variety of convection and deck ovens and even oven systems, like MIWE backcombi or the MIWE cube system, combining the best of each,” the company says. The latter is designed to be an essentially versatile ‘bake-andsnack’ station, packing a convection oven, a deck oven and an oven for specialties such as pizza, hot snacks, or pretzels, which can all be flexibly combined on the same base.

IN-STORE OVENS

The big (process) picture Smart features help to entirely transfer during the day work that was usually done with night shifts; a game-changer when finding staff is a long-term issue still to be solved. In this regard, the software used by MIWE ovens also helps with the (user-friendly) optimization of the baking processes, to maintain consistent product quality despite potential staff fluctuations. Moreover, connectivity features assist in optimizing workflow.

Sustainability also rapidly ranks higher among baking priorities; MIWE ovens are engineered to combine small footprints with high energy efficiency.

“Of course, there is more to that, as far as sustainability efforts in stores go. Baking at the point of sale has many advantages, such as boosting sales, simplifying logistics and the ability to flexibly adjust to customer demands, which reduces waste,” the specialist outlines. MIWE technology combines hardware and software features to help improve sustainability, from heat-insulated glass in the door, to intelligent software. For example, the automatic stove preselection suggests the right deck in the MIWE condo that is closest to the temperature needed.

MIWE easy clean also contributes to the store’s sustainable baking – it helps

reduce water consumption and cleaning expenses.

Baking premium, in-store: WP BAKERYGROUP An in-store oven should always be able to bake fresh dough pieces into products of consistent quality, similar to those baked in the central bakery, WP BAKERYGROUP notes. On the software side, the oven control system must have the possibility of storing baking programs that – after a simple selection procedure – will automatically control all parameters during baking. Once the recipes are stored in the baking program control system (by a trained baker), the baking programs can be used to bake with the same quality results time and time again.

“The energy required for

© WP

In-store ovens made by MIWE can bake the full range of bakery goods, from heavy rye bread to rolls and every convenience stage. Some ovens, such as the MIWE gusto, even come with a ‘gastro’ functionality for snacks.

They offer many choices in functionalities, with options to create complete baking programs with up to eight steps, each with its own temperature and steam settings. In addition, the ‘eco mode’ can be enabled to save energy after a pre-defined time interval, while the ‘autostart’ feature ensures the oven is ready to bake when needed. “These are some of the features that come in very handy for in-store baking to be as flexible as demanded,” the MIWE specialists point out.

baking depends only on the baked product itself, not on the oven.“

Dr.-Ing. Christoph Adams, WP Lebensmitteltechnik GmbH

The user interface takes into account that even non-professionals should easily use it; the desired baking program must be easy to select and displayed via product photos, for example. It should also include information about the status of the oven, whether it has reached the baking temperature, and then display the remaining baking time once baking starts. The end of the baking process should also be clearly signaled, the specialist details. Other useful options include the possibility of programs starting during the night, as well as the automated shutdown when the oven has not been used for a pre-defined, extended period of time.

The most frequent product quality variations occur when dough pieces are introduced too early for baking, before the optimum baking temperature has been reached. “This should therefore be clearly shown on the display, e.g. in the form of a traffic light,” the specialist highlights.

Most inquiries for in-store ovens the company receives are for deck ovens, to bake premium products. In this category, the MATADOR ® oven was designed around one core requirement: uniform baking results, consistently, which it achieves with an intelligent heating system. It runs with the WP BakeryControl software, which helps control baking sequences according to the oven’s capacity utilization, contributing to extending shelf-life at the same time. It also includes features for recipe management, baking sequence optimization, monitoring and (remote) diagnosis. “The oven control system must be able to bake all baked products, in principle. This requires a sufficiently large baking program memory that makes the required baking technology available at any time,” Dr.-Ing. Adams summarizes.

Another option available in the WP NAVIGO II PROFI-CONTROL is the WP INTELLIGENT ENERGY CONTROL feature, which helps to minimize the energy loss the MATADOR ® could have in between baking batches, via the ‘stand-by’ function.

www.bakingbiscuit.com 01/2022

15

IN-STORE OVENS

Premium results For traditionally challenging, premium products that are increasingly popular, the leading role belongs to the master baker, to identify the process that best serves the recipe and product demands.“The oven manufacturer has to provide a professional oven on which the baker can set and program all baking parameters accordingly. The control system ensures reproducible quality, even if the operator is not a trained baker,” he adds.

Looking to the future of smart in-store oven technology is, without a doubt, looking into sustainability and optimizing the efficiency of the process.

“The energy required for baking depends only on the baked product itself, not on the oven,” Dr.-Ing. Adams points out. However, the oven must provide the required heat energy from the available energy sources, be it electricity, oil or gas. “Since electricity is used in most cases in the in-store area, efficiency is particularly high here, at 100%, since all the electrical energy supplied is converted into heat via the heating elements (electrical resistances),” the expert argues. Losses that might occur as the heat dissipates from the oven can be countered with good insulation.

Working with steam, which is absolutely necessary for baking quality, also entails energy losses, since water evaporation requires a lot of energy and the generated steam eventually leaves the oven again. “Therefore, by reducing the volume of steam step-bystep, an attempt should be made to steam as little as possible so that the desired baking quality is just achieved,“ he recommends. The energy required for baking depends, for the most part, on the baked product itself and only for a small part on the baking oven.

Smart baking is green baking: WACHTEL WACHTEL considered the must-have technology features in modern bakeries and incorporated them into its in-store oven, the PICCOLO PRO®.

www.bakingbiscuit.com 01/2022

© Wachtel

16

It incorporates the IQ TOUCH control system as an integrated panel or as IQ TOUCH MULTI, which operates multiple ovens. The IQ TOUCH can save and run up to 999 automatic programs, with up to 10 steps each. Its utilization is intuitive, similar to that of a smartphone; baking programs can be automatically synchronized across multiple ovens. It is built with a ‘power pilot’, a feature that limits kW consumption for capping peak usage.

The IQ TOUCH can also be connected to third-party software, such as ShopIQ.

“Baking has always been an energy-intensive business, with in-store bakeries making especially high demands – an in-store baking oven often accounts for 40-45% of the electricity bill for the retail outlet.“

WACHTEL specialists

To ensure product quality, WACHTEL’s in-store ovens are equipped with its IQ TOUCH control as standard. It features an energy manager and it can be paired with the WACHTEL REMOTE tool to connect all ovens in all the branches. The specialist explains: “With the WACHTEL REMOTE software, the most important operation and consumption data (e.g. energy consumption) can be

read and analyzed deck- and ovenspecifically. Consequently, this management tool sees itself as an essential building block for pivotal, future-proofing process optimizations within the operation.” The WACHTEL REMOTE also offers a service and maintenance tool that provides the baker with an overview across the business of all significant cycle-led maintenance parameters, error messages, life cycles, and version updates. “Information about a pending or recommended service is given automatically. The right spare parts can be ordered directly with the software as required with just a few clicks of the mouse,” WACHTEL details.

With the trend for green electricity on the rise, WACHTEL focuses on optimizing electric ovens for this market segment, with improvements to temperature control, steam generation and insulation technology. More than 80% of the ovens made by the company are electric deck ovens, to answer demands for sustainability.

“Baking has always been an energyintensive business, with in-store bakeries making especially high demands – an in-store baking oven often accounts for 40-45% of the electricity bill for the retail outlet,” WACHTEL underlines.

This was the driver for its R&D to focus on optimizing energy consumption.

The PICCOLO PRO ® has several ‘eco-functions’ helping it save energy, including ‘smart start’ (automatic

IN-STORE OVENS

preheating), ‘standby eco’ and ‘eco safe’ – which automatically decreases the temperature when it detects unplanned interruptions to the baking program.

as EUR2,500 can be saved every year, per oven, respectively CO2 savings of 3,210kg.

The result: the PICCOLO PRO® earned WACHTEL an energy-saving certificate from the independent certification body VDE. “We became the first and, so far, only oven manufacturer to be awarded a VDE energy-saving certificate for our new PICCOLO PRO® in February 2021,” the company shares, as its multi-zone baking technology can save up to 33.6% electricity, compared to previous-generation ovens.

The VDE certification means that the oven is eligible for any subsidies available in Germany.

To effectively meet distinct, unique sets of requirements from diverse in-store bakeries, DEBAG has bundled all its smart technology features, onto one platform, the e.BAKE.solutions. It comprises several sub-platforms: + e.ASSISTANCE – assistance systems for the automation of baking processes + e.CLEAN – solutions to help make oven cleaning simple and resourceefficient + e.CONNECT – intelligent software for connected ovens, with features supporting energy optimization + e.CONTROL – tools for intuitive oven controls

Depending on the type of product, baking program and throughput, as much

The smart answer to individual needs: DEBAG

“Under each of these, you will find several useful concepts, software but also hardware solutions to exactly meet all individual requirements,” Georg Schulze, head of International Sales at DEBAG, explains. He offered a comparison to illustrate different possible applications, taking the case of two different retailing chains, one in busy urban areas, with shops in city centers, and the other operating in sparsely populated, rural areas. “Assuming that the one in urban areas struggles with peaks of electricity consumption, here we can offer a solution, the PCM (Power Control Management), a combination of software and hardware enabling optimized baking capacity along with certain energy restrictions,” he explains. The Performance Control System (PCS) synchronizes and controls a group of ovens via a processor unit. The

ADVERTISEMENT

Specialists in food processing equipment

The magic of stress-free laminated dough

Premium dough quality Efficient production process Hygienic Design Fast & easy cleaning Ask for a demo: info@rademaker.com

www.rademaker.com

+31 345 543 543 www.bakingbiscuit.com 01/2022

17

IN-STORE OVENS

is show-baking,” he reminds us, “so a clean and hygienic oven is mandatory.

We can assist in this area with our fully automated, liquid-based cleaning solutions.” Other smart solutions in the e.ASSISTANCE suite include the automatic program start function, automatic switch-on, door opening and softclose systems, re-bake function, and e.Fresh – controllable fresh air inflow.

© DEBAG

18

software assigns resources for the linked ovens, limiting power peaks from the outset, which helps avoid the power supply overload. Alternatively, a rather rural chain would have vast distances between the shops. “Here, I see a mandatory connection of all ovens via the internet as a good idea.

Imagine how much time and other resources can be saved if, for example, a new baking program is introduced and can be instantly replicated elsewhere with a simple click from headquarters,” he adds.

SmartBake should be noted: this is part of the e.ASSISTANCE systems where the software detects the batch quantity and automatically adjusts the baking process parameters to it. “No matter if there is one baking tray with croissants or five, the color and crispiness will remain unchanged. I believe the consistency in quality – and I measure quality in evenness – is what helps our clients position their brands within the product category,” he adds.

This is especially visible when running several shops, as consumer trust drives sales growth. In addition, “Shop-baking

www.bakingbiscuit.com 01/2022

One of the requests DEBAG frequently receives is to connect and remotely access ovens, we learn. This is possible, and it is currently being carried out with the company’s next-generation FilialNet, its oven networking software that can connect an unlimited number of ovens, to help with the baking program management and control within the branch network, based on the in-depth data analyses it performs.

FilialNet also helps connect other types of equipment in a similar way, including refrigeration units and airconditioning systems, for example.

Remote maintenance can be performed for all networked devices, which can be accessed via computers and mobile devices.

“Imagine how much time and other resources can be saved if a new baking program is introduced and can be instantly replicated elsewhere with a simple click from headquarters.“ Georg Schulze, Head of International Sales, DEBAG

The DECON (DEBAG CONvection Oven) is DEBAG’s newest, multifunctional and smart in-store oven. Equipped with the optional cooking function and core temperature probe, it can bake, cook and refresh products, using 8.5% less energy consumption compared to similar technologies, the company shares.

This award-winning in-store baking oven is built for efficiency in operation and control. Its new one-touch interface

can save up to 99 baking programs; it has a programmable timer and integrated proofing chamber operation.

The DECON networking and remote maintenance can be done via FilialNet.

Network-connected ovens: WIESHEU Connectivity is among the must-have technology features in a modern bakery and its in-store ovens, respectively, to ensure the best-possible baking outcome. Today, it is not only common that bakeries and cafés offer free internet access for their customers, but also that the technical equipment used is networkcompatible and connected to a database, WIESHEU observes. This allows the operator to collect, control and evaluate data in order to ensure consistent quality in the store or across several branches.

The company has developed an oven network to manage ovens across stores, the Wnet. It works as a maintenance and service tool as well, and can be connected to an existing database and optimize data management.

It also allows the transfer of firmware and configurations for convenience.

One of the tools developed by the company to support this is the automatic load detection system, the Intelligent Baking Control (IBC). It recognizes not only the quantity but also the temperature of the loaded product, adjusting the baking settings accordingly for consistent results and energy savings (compared to standard machines, without IBC). Each product type will only require one baking program, regardless of the quantities baked – half-load programs are not necessary and such options have been removed. The simplified operation reflects on the reliability of the results of the baking process. Excessive browning or having pastries dry out are avoided, regardless of the fill level. Because the IBC optimizes the temperature curve during the baking process, the baked goods also stay fresh longer. “IBC is definitely a tool that simplifies daily work – the

IN-STORE OVENS

The construction of the oven itself allows the company to create the perfect baking program sets for all types of dough.

Intelligent baking control Baking results are finetuned with software; WIESHEU ovens can record and automatically reproduce previously defined settings for even results.

“Changes can be made via our connectivity software Went and easily transferred to ovens in other branches,” the specialists explain the options. To ensure the desired baking result, the oven settings should be adapted to the load of the oven and the condition of the baking goods (fresh dough, frozen, thawed). They should also be removed from the oven as soon as the baking program concludes, they add. For challenging premium products, including certain breads, rolls or pastries, WIESHEU recommends baking the bread at around 240°C and rolls at 220°C,

“Handmade baked goods, in particular, have individual characteristics and the heat, time, air circulation and steaming must be matched to their requirements.“ WIESHEU specialists

with high temperature and static heat.

For pastries, e.g. croissants, the temperature should be 175-180°C with circulating air.

The Dibas, E3 and Euromat oven ranges are equipped with the IBC automatic load detection: “If the oven is only half loaded, the baking goods do not get too much heat and, as a positive side effect, the energy consumption is reduced as well,” WIESHEU details.

Several other software features help to support the process, including the automatic opening of the door at the end of the baking program, and a cooling function.

Several settings ensure WIESHEU instore ovens are energy-efficient. The specialists illustrate: “The functions range from stand-by settings for display, temperature and lighting to limiting the duration of preheating and maintaining a high temperature.” In addition, IBC

© Wiesheu

operator does not have to make any adjustments if they need to bake less or if the products have a higher starting temperature than normal.” The reference baking program should be selected, and the oven adapts the program according to the actual load and condition detected.

19

is not only ensuring product quality but is also an energy-saving tool that can save up to 25% of the energy needed per baking process (depending on the product and load level; evidenced by measurements).

Besides efficient baking solutions, the specialists recommend smart rendering of the baking process as the key to efficiency, making use of all the technical features that avoid energy waste, and baking batch-after-batch whenever possible, to avoid frequent preheating. +++

ADVERTISEMENT

Sharp. Strong.

Quality Blades.

Providing high quality blades for 85+ years.

Partner with our experience to optimize your slicing.

++1-563-386-1131 • sales@hansaloy.com • www.hansaloy.com

SNACKING

The flexibility in MECAFLEX On-the-go or in home offices, nothing seems to be able to slow snacking down. Snacks are also increasingly the preferred option over regular mealtimes. Together with the hunger to snack, however, the demand for more diverse, healthier and tastier products also grows. Flexible technology is needed for the task.

© Mecatherm

20

By Catalina Mihu

+

The demand for healthier products is growing throughout all product categories in the food industry.

One iteration brings clean labels to the forefront, which encompasses the general expectation for healthier and more natural products. Three-quarters of all food manufacturers are currently reformulating their products to be aligned with these new trends, according to Mecatherm. Opportunity is thriving for snacks, as bakeries innovate to propose new experiences, special and personalized products to meet consumers’ preferences. This is illustrated by a spectacular increase in new product development in bakery, up by 60% in the last 10 years (Mintel).

A technology solution designed for continuous production updates is Mecatherm’s MECAFLEX automated line. Built for product diversity, it is able to run a comprehensive range of snacks, from croissants, buns, and hot dogs, to pains au lait, muffins, ciabattas, Kaiser rolls, or chocolate croissants.

In addition, baguettes and larger products such as toast breads, brioches or loaf cakes can also be added into production on this line. “To be relevant and viable, product diversification has to be done without making any compromise on product quality, industrial performance, and sustainability. This wide range of products is made possible thanks to the compatibility of several different make-up lines, using different technologies to process the dough,” explains François Retailleau, Line Product Manager at Mecatherm. For products with different shapes and doughs,

www.bakingbiscuit.com 01/2022

different make-up technologies can be placed in parallel, to cover molding, sheeting, rounding, or just batter dosing, as needed. “For this entire solution, the layout has been thought of so that the line remains compact and footprint efficient.

For a fully-automated MECAFLEX Advanced, the floor space required is less than 2,000sqm,” he illustrates.

Downstream, the line follows the main process steps shared by the majority of bakery and pastry products, i.e. proofing, customization, baking, depanning and, optionally, cooling and freezing. The technology specialists included generous space for customization areas before and after the oven, allowing for either manual or robotic operations. Many processes can be customized, from scoring and seeding to flouring or egg spraying – before baking. There are multiple options to choose from for processes after baking as well, from topping to cutting, decorating, or packaging, for example. Choices have expanded to include solutions from Mecatherm’s sister company, ABI Inc., meaning a whole new range of additional robotic customization solutions is available such as scoring, cake cutting, cake decoration or brand printing.

Another flexibility feature, confirming the name of this line, is its compatibility with different types and sizes of trays, pans, or straps. This is possible thanks to the MECAFRAME system – universal grills that can convey any type of bakeware, offering a gateway to industrial production. “With MECAFRAME, we give the possibility to industrial bakers of using any existing tray, strap or pan at an industrial scale.

SNACKING

It is particularly adapted to mid-size bakers, who already have an existing wide range of products and therefore trays, typically small that can easily be handled manually,” details Retailleau.

©M

The (fastest) way around all products and production volumes Adding to the product ranges, the MECAFLEX line can also adapt to high variations in production volumes. The same baking system can produce anywhere from 750 brioches per hour up to 18,000 buns per hour, for example. However, there are guidelines that should be followed to maintain efficiency: one of the key priorities in this regard is to manage very precisely both the batch sizes and the changeover times between them.

This is where Mecatherm’s simulation software, the M-PLAN, comes in to help establish the optimal production sequence.

It is designed for a double role, to help production managers to accurately size production gaps and to properly sequence product batches. Sizing production gaps accurately will help eliminate missed changeovers, avoiding potential line downtime and, potentially, significant emergency manual handling. Alternatively, finding the best sequence for the production is key. “We often use an example showing the sequence of three products manufactured on one line. The

ADVERTISEMENT

F2M BOOK COLLECTION Title: AUTOMATION, SCIENCE AND TECHNOLOGY Language: English Hard copy: 180 pages Price: EUR49,00*

ORDER YOURS NOW *Including VAT, for the hard copy or e-copy. Shipping costs are not included.

Food2Multimedia GmbH

21

Contact: Viktoria Usanova, usanova@foodmultimedia.de

eca

the

rm

difference between the best (brioche – buns – focaccia) and the worst (buns – focaccia – brioche) sequence makes up for 6% of additional line availability over one day of production, with the exact same quantities produced on the line,” Retailleau explains. The time savings can even go as high as 10%, by chaining the production batches in optimal order.

Choose your own automation level The MECAFLEX line comes in two versions that can each be sized to meet individual production needs.

The MECAFLEX Essential make-up is intended for mid-size semi-industrial bakers as a core solution built around the M-TA oven, a piece of flexible equipment by itself, and the modular M-UB proofer. It features the MECAFRAME system, meaning any existing tray, strap or pan can still be used with no changes to the production workflow. Further customization, and cooling and freezing steps remain manual with this version.

The M-UB handling system is made to support easy changeovers between products. The MECAFLEX proofer does that with its six M-UB modules, which can each be bypassed, dividing the proofing process and timings as needed. This proofer is also equipped with two independent thermal zones, each one managed by a separate air handling unit.

“This makes the thermal transitions more efficient,” Retailleau details, “as it is no longer necessary to empty the whole proofer to switch from 35°C to 22°C, but only half of it. “It is also very interesting to be able to adjust very precisely the proofing temperature to exactly what the product requires,” he points out. The M-UB system also ensures gentle product handling. It uses a pusher-free transfer system to do so.

Mecaflex Advanced is the complete and fully automatic solution, which covers automated customization, cooling, and freezing steps, as well as an automatic tray changeover.

The Advanced version uses dedicated trays to help increase the efficiency of a fully-automated process: in this way, complex handling operations that would be necessary to load and unload existing small trays from a MECAFRAME system are reduced to a minimum. “This solution is intended to mature industrial bakers, but is also available as an

www.bakingbiscuit.com 01/2022

© Mecatherm

SNACKING

© Mecatherm

22

upgrade of Mecaflex Essential, which was designed to allow upgrades and the integration of additional modules,” the specialist explains. The switch from MECAFLEX Essential to MECAFLEX Advanced can be easily made thanks to ‘bridges’ available between these two options.

Mindful efficiency This versatile line accommodates the processing needs of a wide range of baked snacks and staple products by taking agility to the drawing board to cover an extensive checklist: it is aimed at shortening the time to market, to provide versatility for any semi-/industrial setups, process efficiency and agile monitoring. Production parameters can be set each step of the way, from make-up to packaging, the optimum baking supports can be employed and any needed circuit can be adapted. New products can be tested and developed on this line directly, and they are ready to market as soon as the R&D is completed.

In addition, “The MECAFLEX supports the ramp-up of production volumes thanks to a good capacity potential. When a product becomes a best seller and volumes are getting high enough, it then makes sense to invest in a dedicated production line and keep using MECAFLEX for other products with lower production volumes,” Retailleau details.

Sustainability was also an important aspect of the design of this line. Resource efficiency starts, naturally, with the oven, which is why Mecatherm equipped the MECAFLEX with its latest-generation technology, incorporated in the M-TA oven. Not only it is the flexible oven choice for a line that should excel at baking vastly different products, but it is also available in a more sustainable version – with fully electrical heating. And, even with conventional heating, the convection-based technology integrated into the M-TA oven can circulate air at lower temperatures, meaning less energy waste. There is also an option to assist users in setting up the chimney valve opening to an optimum level. The target is again to prevent any energy waste by limiting the flow of rejects to the minimum required.

The MECAFLEX aims to meet both current and future product diversity and can optimally plan their parameters and order. +++

INGREDIENTS OF YOUR SUCCESS

More than 7% fibres.

The Kornspitz® has been delighting bakers and consumers in over 70 countries around the world for more than 30 years. Pure enjoyment, thanks to high-quality raw materials and a high fibre content.

More at www.kornspitz.com

24

SNACKING

More healthy snacks, please!

With a growing trend for health-conscious eating, product innovation relies on flexible equipment to perfect bakery products. Now snack manufacturers have that flexibility in a new automated solution to make pita chips, developed by Reading Bakery Systems (RBS).

+

Consumer preferences for nutritional and dietary snacking options are always changing and expanding. Over the past two years, these dynamics have only gained in amplitude, with people seeking health benefits, nutritional balance, immunity support in addition to unique taste experiences. Product development follows suit, with plenty of options to explore, combining various types of healthy ingredients. “This means system flexibility is an absolute must for snack manufacturers,” said Joe Pocevicius, European sales manager for Reading Bakery Systems. Pocevicius also observes there is a growing need to transform manual or semi-automated production processes into large-scale industrial processes as businesses are scaling up. “This is exactly what we’ve accomplished with our pita system,” he explains, “we have transformed a manually-made product into a reliable, high-quality industrial process.” The system is aimed at providing a turnkey industrial production system for pita chips, a staple among healthy snacks, while also being able to run different types of crisps.

The drawing board The newly-launched system to produce pita chips is based on the multi-crisp technology that was designed and customized for this product by RBS. It

www.bakingbiscuit.com 01/2022

is a modular system with a capacity of up to 1,000kg/h, depending on the number of oven zones.

The pita and crisp doughs are more sensitive than traditional wheat-based cracker doughs and need more flexible sheeting and baking parameters, which this system provides. “This combination of sheeting, baking and drying technology is what makes this system unique and exclusive to RBS,” Pocevicius explains. The system comprises Thomas L. Green sheeting and gauging equipment, a rotary cutter, followed by a SPECTRUM multi-pass proofer. This is

“Oven manufacturers will increasingly use electrically driven solutions.“ Joe Pocevicius, European sales manager, RBS

a special addition to the standard equipment line-up of the multi-crisp technology, designed to develop the pita chip dough. A SPECTRUM convection oven is next, for which the heat application process was optimized for this product. Post-bake slicing has been added, performed with a pita dicer, to expose the inside of the pita.

RBS explains: “During baking, the pita product expands into ‘pillows’, after which our pita dicer is used to cut

these ‘pillows’ into pita chips. The dicing machine can create various rectangular shapes and sizes.”

The system is designed to be able to also accommodate other types of crisp snacks, by simply bypassing the proofer and dicer used for pita chips and directing the products from the rotary cutter straight into the oven. A variety of crispy snacks can be produced, made from wheat, potato, rice, corn masa, and other ingredients. The system can work with both batch or continuous mixing, depending on the level of automation needed by the snack manufacturer. RBS always recommends continuous mixing whenever possible, for a more consistent product, and more efficient process.

The SPECTRUM Multi-Pass Dryer performs the final production step. Its role is to reduce the moisture in the product’s core, which improves its overall quality and storage characteristics as it prevents the occurrence of hairline cracks that can subsequently cause crisps to break (the ‘checking’ issue).

The post-bake dryer also makes it much easier to control the product’s color.

© RBS

SNACKING

Compared with previous technology, the new line is the first flexible system that can automate the production of pita chips, as well as multi-crisp products. Pocevicius summarizes: “The beauty of the line is its ability to produce a variety of crisps from different dough types, including potato, wheat, multi-grain, rice, corn masa, or other flour-based doughs. Product-wise, this means baked potato crisps, other gluten-free crisps, wheat and cheese crisps, in addition to pita chips. Interesting flavors can, of course, be added to any product. It’s a game-changer for manufacturers that want to innovate their snack portfolio and maximize production capabilities.”

A new, multi-pass proofer The new, environmentally-controlled multi-pass proofer specifically addresses the needs of the pita chip dough and is instrumental in its correct development. It controls the temperature and humidity, which affects the flavor, color, and texture of the final product.

The key benefit of this new equipment is achieving product consistency. It also counts towards improving process efficiency, with high throughput

in a significantly smaller footprint: “We achieve 42 meters of proofing in a 9-meter long enclosure with an automatic PLC-controlled environment,” RBS explains. It is designed to optimize the process, as it features a full enclosure around the machine, for better chamber efficiency. Moreover, maintenance is made easy thanks to multiple enclosure doors to clean and inspect the equipment.

Flexibility, sustainability and more Additional products can be easily added into production: the new recipe is selected and the rotary cutter die is changed – if a different shape is required. RBSConnect helps streamline changeovers, incorporating recipedriven systems that make controlling the line easy. For sheeted crispy snacks, the product possibilities on this line are endless. However, the specialist notes, more traditional, laminated and sheeted crackers cannot be produced on this line. These types of snacks would need Direct Gas-Fired oven zones and additional layering equipment. RBS can assist snack manufacturers to develop new products for this system and to improve their production processes, at its Science and Innovation Center.

also incorporating sustainability into our own manufacturing and business processes. “ These sustainability efforts can be seen in the new pita chip system, as well. For example, the oven and dryer have been designed for a reduced operational footprint, for lower operational energy costs, and for cleaner exhaust emissions. “We can even offer this line with zero emissions by offering the oven and dryer with fully electric heating,” RBS notes. Together with its ovens, the company delivers the SCORPION ® 2 Oven Profiling System, which allows manufacturers to maximize their operating efficiency by measuring the oven and dryer’s temperature, air velocity, heat flux, and humidity.

Automation is also an important part of sustainability; automated systems are simpler to operate and easier to maintain. To achieve this, the RBSConnect control systems provide data analysis and diagnostics to ensure the line is running within optimum parameters.

The new production process made possible with this pita line aims to meet the need for equipment flexibility, designed to specific needs, to deliver consistent product quality with a reduced footprint. Interesting product development opportunities are ahead.

+++

Process optimization also plays an important role in increasing sustainability, for pita chips and any type of snacks. It is an important aspect for RBS, too: “Not only are we designing equipment and processes that help our customers reach their sustainability goals, such as energy-efficient and low-emission ovens, but we’re

www.bakingbiscuit.com 01/2022

25

PRODUCTION

All the means to a laminated end From viennoiserie to Danish pastry, and any number of hybrid, new creations, laminated dough is the path to the sought-after airy, light layers. Gentle dough stretching and folding is a must, however, there is by no means a one-size-fits-all approach to the process. Tried and tested laminating methods and line setups can accommodate flexibility and consistency in results.

+

Precision and consistency are required to turn blocks of dough into thin, delicate sheets. The big challenge lies in the correct distribution of the dough reduction steps while avoiding any unwanted tension in the dough. Inconsistencies in the reduction steps will significantly impact the structure of the final product. Keeping rework dough under control is another important aspect, according to the reduction plan chosen on the line, Rademaker experts point out.

Three methods with Rademaker Rademaker developed three different laminating methods, to closely match different types of dough, production capacities and processing needs. “Every dough type and end product require a specific application and laminating method. It is also possible to apply inline laminating, as it knows no restrictions regarding laminating widths of up to 1,600m,” Rademaker explains. The three methods are: + Lapping: The dough sheet runs vertically within a guiding system that moves back and forth. This symmetric lamination method is unsuitable for soft dough and has a maximum lamination width of 600mm. + Horizontal laminating: The belt with the dough sheet moves back and forth above the next conveying belt.

This is an asymmetric lamination system suitable for soft dough with no restrictions regarding the laminating width. + Cutting and stacking: A guillotine cuts the dough sheet into rectangular sheets that are then stacked on top of each other. This flexible, symmetric system lays both even and uneven layers. It is suitable for soft doughs, with no restrictions regarding the laminating width.

Rademaker laminators are developed to produce many varieties of laminated dough for mid-sized to industrial bakeries, combining process and recipe information to optimize flour usage and for a fast start-up. It is the end product with its requirements that ultimately dictates the best process and associated solution. To develop customized

www.bakingbiscuit.com 01/2022

laminating solutions, Rademaker uses its standardized units in the construction of a complete line: “We build a line and adapt it to the desired situation. In addition, for each recipe, we can define our own parameters needed in the processing of the various doughs and/or fats,” the specialists explain.

This flexibility allows for a wide variety of configurations, from a block processor to a fully automated laminator, with working widths varying from 600 - 1,600mm. The laminators can be designed in different shapes (L-shape, U-shape, Z-shape etc.) and laminating belts can also be set up straight in-line. “Thanks to this flexibility, the line can be optimally configured to meet customer-specific applications, resulting in the best possible production efficiency,” Rademaker explains.

“Process control utilizing intensive data handling and communication is becoming increasingly more important in industrial production processes. “ Rademaker specialists

To integrate them with existing technology, a signal exchange is possible with the upstream equipment, but is less necessary. This is strongly recommended, however, with the equipment downstream of the laminator. Rademaker stresses: “In case of stops, for whatever reason, in the downstream flow, you will also want to stop production on the Rademaker line. This feature is provided in our production lines.”

A light touch, automated as needed Dough-friendly processing is key for light, airy products with laminated dough. Rademaker designed its dedicated equipment, “to focus on efficiently handling the dough with the utmost care, at the required capacity.” Then, depending on how the dough reacts in the starting phases such as the reduction step, the next steps are mapped out for the appropriate production setup. Laminated doughs with

© Rademaker

26

PRODUCTION

margarine, for example, can be processed without cooling and resting; conversely, cooling becomes a necessary step after layering the fat when softening butter. This involves not only temperature control, but also that of the humidity of the ambient air. “An incorrect relative humidity can cause dehydration as well as condensation, which certainly makes it a point of attention,” Rademaker points out.

Its laminators range from semi- up to fully-automatic production lines. Manual processes can include taking laminated dough blocks off the line for cooling or proofing, and placing them back onto the line, for example. “For a fully automatic process, we have transferred the cooling and resting traditions into an industrial process solution. In this way, we can offer a fully-automated laminator with capacities of up to 10,000kg of dough per hour,” adds the specialist.

The cooling and resting system can be optionally added, especially for the continuous processing of laminated and sheeted dough. Cooling ensures that the integrity of the layers remains intact and that the fat and dough layers are consistent, resulting in a significant improvement for further processing of the dough sheet. Resting directly influences taste and shape/volume, the combined result of dough relaxation (stress reduction) and controlled yeast activity.

The outcome of this process is the development of mono sugars and CO 2. “With our Cooling & Resting system, operating with indirect air coolant for accurate temperature control, we have transferred the artisan traditions of the past into an industrial process,” Rademaker explains. The cooling principle of the system consists of tubes positioned underneath the belt, creating an active air coolant while minimizing unwanted vaporization. Because no air is directly blown onto the dough sheet, the dough will not dehydrate.

With this system, a minimum coolant temperature of -17°C can be achieved.

Automation features are incorporated to make the Rademaker laminating line adjust to parameter changes it detects: when deviations are measured, either in the dough or in the process, the line course-corrects the process flow using its automatic speed adaptation (Cascade control). The specialists elaborate: “The advanced control system features fully automatic speed adjustment and enables the different sections to operate independently.” While the last dough part of the production run is processed towards the last section of the line, the first section of the line is ready for cleaning or to start the production of another product. The operator receives a notification when the next recipe can be started on the machine.

In addition, smart features are built in to closely control the operation. “Process control utilizing intensive data handling and communication is becoming increasingly more important in industrial production processes. Our control platform

enables OMAC based data exchange with neighboring (third party) equipment as well as LMS, MES, or ERP systems,” Rademaker highlights. Moreover, the equipment can be monitored and optimized online for efficiency, thanks to advanced data processing.

SoftProcessing technology: FRITSCH The answer to challenges in laminating dough perfected

by FRITSCH is its SoftProcessing technology, which helps avoid any unnecessary tension and compression. It is featured in the company’s laminators to produce uniform dough sheets. It should be noted this range of machines was renamed to cluster them according to end-product groups and performance spectrum: LAMINATOR 900, 1100, 1300 and 1500 are part of the industrial range, and the LAMINATOR 700 is specialized in mid-range production.

The numbers indicate the table width of the LAMINATOR. The operating principles of the FRITSCH SoftProcessing technology are as follows: the pre-portioner of the dough band former (the FRITSCH TBP) works with two rollers that constantly fill the TBP with dough so that the amount of dough contained always remains the same.

“The dough is therefore constantly spread under the same pressure. The TBP forms a thick dough band using a five-roller dough sheet former,” the specialist explains. In the next processing step, the FRITSCH satellite head and the cross roller ensure that the dough band is clearly defined and calibrated to the desired dough thickness. Fats (e.g., butter or margarine) are then applied with a fat pump, to ensure that it is evenly discharged onto the dough band and that a clearly defined ratio of dough to fat is maintained. “Our industrial LAMINATOR can optionally be equipped with a water separator, which is placed just before the nozzle of the fat pump,” FRITSCH adds, so that it can be drained off when butter is used, and therefore not reach the dough band and impact its quality.

Product and process flexibility The industrial LAMINATOR can use various folding units with layering units being the primary choice for high-volume production. They ensure precise laminating as it places layers accurately on top of each other to form dough blocks. The table under them is height-adjustable, to minimize the drop height of the dough. The layering unit can process a wide variety of types of laminated dough, such as croissant, yeast, puff pastry and brioche dough. It can achieve various amounts of layers and foldings, respectively, including odd numbers of layers. The fold width and number of layers can also be adjusted automatically.

Numerous parameters can be set and components adjusted on the LAMINATOR to produce an optimal dough band for each product. The newly-developed FRITSCH Operating System (FOS) is key to having the equipment adapt and

www.bakingbiscuit.com 01/2022

27

PRODUCTION

Coming soon FRITSCH is working on further technology updates and is preparing to introduce a new innovation this year, the company shared with us: the FRITSCH Smart Production Insights (SPIs). “The FRITSCH SPIs are a dashboard that grants our customers a live insight into their production, enabling complete process transparency. With the continuous capture of data and visualization of key performance indicators in real-time, it will be possible to achieve further improvements still in overall equipment effectiveness,” the company anticipates. The data provided by the SPIs can pinpoint the exact cause of disruptions or malfunctions, and take actions accordingly, to prevent such unplanned downtimes.

© FRITSCH

28

adjust to process variations. “With the new FOS, the system is controlled according to performance. With the new control panel, numerous basic programs and corresponding performance parameters are available for different products, where only a few parameters, such as the rolling gap and number of layers, need to be readjusted to achieve the desired result,” the company details. The FOS uses predefined programs, which simplifies the use of existing recipes and the introduction of new ones, in which case only a set of defaults have to be set such as the line output, the number of folds and the roller gap, and not all data points from scratch. “This significantly reduces the time needed for setting up a new product. The software checks whether the desired change in output is feasible. The drives coordinate with each other in terms of their performance and, if necessary, regulate themselves to that of the smallest drive,” FRITSCH explains the steps.

In addition, components on the line can be started automatically when needed, for efficiency. For example, flour dusters or cross rollers will only be switched on when they are currently being used in the production process. “This is a standard feature of our industrial laminating lines (LAMINATOR 900, 1100, 1300, 1500),” FRITSCH underlines.

The LAMINATOR can also be equipped with a cooling chamber for additional benefits, including: + An even and faster cooling process, to control the yeast activity + Uniformity for downstream processing steps + Consistent quality + Humidity and contact cooling control – meaning that the dough will not dry out and there will be no skin-building on its surface. Contact cooling is a feature unique to FRITSCH technology, with a significant influence on the quality of the final product

www.bakingbiscuit.com 01/2022

”The FRITSCH SPIs are a dashboard that grants our customers a live insight into their production, enabling complete process transparency.“ FRITSCH specialists

Cameras added to the line’s set-offs are another new feature, added to make it easy to observe hard-to-see places during production, such as the cooling tunnel, for example.

The FRITSCH LAMINATOR can process a wide range of doughs. “Depending on the desired end product, our LAMINATOR can easily process up to 8 tons of dough per hour in industrial use,” the company highlights.

It's all in the dough band: RONDO To maintain consistency in production, with many variables starting with changing dough and fat consistencies, RONDO prioritizes minute process supervision and control. It takes an encompassing assessment of the manufacturing process: “Even if the RONDO MLC laminator can handle different dough conditions and variations of the dough’s consistency, the mixing process upfront must be kept as constant as possible,” observes Alexander Weissbach, head of Technology, Product Management and Dough-how Center. The laminating process itself must be gentle enough regardless of these variations, to preserve the dough structure. “Any impact brought to it will be reflected in the final volume of the products, and it will be especially visible on sensitive products such as pre-proofed frozen croissants. If the gluten network is damaged, ice crystals will start to grow around these points during storage, which will, in turn, damage the network even more, resulting in freeze burns and low volume products,” the specialist explains. Similar considerations apply to the fat used in laminating, as the volume and the structure of the final baked product will depend on its functionality and lifting effect. “Therefore, the composition and the structure of the fat must not be damaged during

PRODUCTION

the fat band forming and the laminating,” Weissbach concludes.

The quality of a laminated dough band or block starts with the dough band former MIDOS, the dough structure is maintained even for pre-proofed and rested doughs. “The four-roller design and the single drives allow settings to form a perfectly even dough band quality, shape and weight accuracy. The MIDOS is the only dough band former on the market which can form a dough band without the use of additional flour or oil, resulting in a better physical lift of the baked goods,” RONDO’s specialist explains.

To ensure even fat layering, the fat pump designed by the Swiss company is equipped with a two-stage feeding process to preserve the structure of the fat in the process. Butter or margarine blocks are fed to an eccentric cavity pump, which then feeds it to a nozzle where that fat band forming will take place. “This process combines two major points, a shear-reduced fat band forming to keep the butter structure and continuous feeding to reduce the weight variations. If the shear rates are too high during the fat band forming, the structure of the fat will be negatively influenced, and consequently the volume of the baked goods,” Weissbach says.

29

just one fat layer. By folding the dough manually, the number of layers can be increased. “With this starting line, the work intense dough dividing, scaling, and manual sheeting is eliminated. The result is a constant and homogenous base for the block laminating,” he illustrates. The MLC can later be equipped with additional components to increase its automation features and capacity. “Even after several years, the MLC can be adapted to the current needs by adding or even removing components,” adds Weissbach.

A full range of automated processes can be set up for this line. Its control system is also designed in a modular scale.

IIoT components can also be added in stages, to permit the MLC’s integration into an MES system, for example. All production parameters can be exchanged with the superior MES system. In addition, predictive maintenance can also be enabled with IIoT features. RONDO is also offering a retrofit to update the controls and the electrical components of older models to the newest generation.

With the families of RONDO MLC Laminating lines and ASTEC laminating lines, Rondo is covering a production volume ranging from 200 to 5,000 kg/h. Now in its fifth generation, the RONDO MLC line for laminating, feeding and make-up was designed for diversity, for any product variations in ranges including pastries, yeast pastries, artisanal breads, pizza, donuts, and more. Its make-up line, for example, can incorporate any tools needed for filling, folding, cutting, decorating and rolling up by plug and play, allowing configurations to upgrade easily. It comes in several versions: + The Block standardized lines: For the production of dough blocks ranging from 4 to 400 fat layers + Feeding line: For the continuous feeding of make-up lines + Laminating lines: For the production of dough bands with capacities from 10 and up to 100 fat layers – continuous feeding included

”The four-roller design and the single drives allow settings to form a perfectly even dough band in quality, shape and weight accuracy.“ Alexander Weissbach, Head of Technology, Product Management and Dough-how Center, RONDO

The modular design of the MLC allows it to grow together with the production needs. The smallest laminating line can produce a continuous and constant dough band with

© RONDO

Possible configurations

The MLC’s dough band formers are designed to keep the quality of the formed dough band as constant as possible, even if the characteristics of the dough vary. In this way, the settings of the line will only need a minimum of adjustments while operating. This helps to reduce the manpower on the line, the specialist from RONDO explains.

Moreover, by combining the RONDO MLC laminating line with the RONDO Smartline, the options of product categories that can be produced becomes close to unlimited, highlights Weissbach: “Laminated dough bands are precisely formed and sheeted to the desired width and thickness with the MLC. On the Smartline, dough bands for the production of bread, pizza, yeast dough, thin doughs and even gluten-free doughs are formed, without stress and damage to the dough structure. This combination is unique on the market and enables producers to react immediately to variations in the market demand.” +++

www.bakingbiscuit.com 01/2022

FILLINGS

Live long and prosper!

With consumers wanting simpler ingredients to make a comeback, it is still important to them that their favorite baked products should also maintain all the convenient benefits they have learned to rely on, including long life and great taste. R&D creates the balance allowing bakery fillings to check all the boxes.

+

The balance between having better-for-you, cleanlabel products with simpler ingredients and, at the same time, the benefits of a long shelf-life can be found in compiling cleaner fillings, minimizing the use of preservatives and additives, while at the same time maintaining shelf-life properties, and most importantly, not compromising on taste. While fruit fillings have the benefit of using natural extracts and the fruit’s own acidity instead of preservatives, cream-based fillings do not have any natural preservatives in their composition and also require a stabilizer for the water and fat emulsion on which they are based.

To further complicate formulating, removing preservatives impacts secondary shelf life: “Once a filling container is opened, it needs to be used completely in one production run or to be stored chilled if some is left unused. Bakers need to work in a very ‘clean’ way in this case, as there is more risk of the product going bad quickly,” explains Christopher Ries, Category Marketing Manager Wets for Europe & AMEAP at Dawn Foods.

Clean-label, versatile options Products with clean-label claims often use natural flavors and colors, such as fruit extracts, and natural preservatives, for example - vinegars. In this category, Dawn Foods’ recent editions of cocoa- and fat-based fillings in its Delicreamrange are designed to work in both fresh products and bakery products with a longer shelf life. And they are all made with only non-hydrogenated fat. Creating or updating recipes to earn clean-label status starts with a clear image of what it entails. For Dawn Foods, it means reducing

www.bakingbiscuit.com 01/2022

© Dawn Foods

30

additives and working with ingredients that are as natural and label-friendly as possible. “We always look at both the product category and its functionality. How are our customers using the products? And what would best suit their needs?

How can we make a product cleaner, while still answering the production requirements of our customers?”, Ries details.

In addition, versatility is an important quality driving the choice of fillings for baked goods. It amounts to several properties, starting with a good viscosity, so they can be easily dosed, but without ‘running out’. Fillings that are suitable for bakery products are, of course, expected to also be bake-stable, freeze-thaw stable, have an appealing color, and (if they are made of fruit) have fruit pieces.

Out of all types of fillings, “Jams are the most technical, and need to be adapted the most. For example, viscosity needs to be changed to the customer’s specific dosing machine and the temperature of the application needs to be factored in. It is also important to know the level of water activity in both the jam and the product hosting it to avoid water migration,” R&D illustrates. And that’s not all: if the jam is applied before baking, bake-stability becomes a requirement. “Our Confibel for frangipane is completely different in make-up when compared to a Confibel for zebra cakes.

This is why we mostly customize our Confibel range (jams) for our industrial customers, based on the specific requirements of their production process and the application they are using it in,” Ries adds. The recipes vary according to the water activity of the bakery application, the shelf-life requirements and the required viscosity.

FILLINGS

Preserving flavors and textures unchanged after processing and throughout their shelf-life is particularly challenging for fillings made with raw natural ingredients. Consequently, Dawn Foods' guidelines refer to production time and process, temperature, and packaging: the faster a product is made, the less damaged it will be and the longer it will last.

“Extreme temperatures harm the organoleptic qualities of the product, while killing any bacteria; it is often about finding the right compromise between stability and quality,” explains Dawn Foods. Sturdy, tight packaging contributes to delaying product staling; moreover, packing circumstances (the cleanliness of the environment, the temperature and the duration of the process) are also critical for stability. “At Dawn Foods, we can produce fruit fillings in metal tins. Due to the more ‘gentle’ production process, the texture of the fruit is better maintained, as well as its color and flavor.”

Stability across temperature extremes Dawn Foods specializes in developing products with improved bake stability. “Working with a comprehensive range of ingredients, such as various texturizers, sugars, starches, salts, and simultaneously accounting for different pH-levels – it all translates into an infinite number of combinations possible that will result in bake-stable fillings. This makes it interesting to develop and to find the right balance and combination

for each product and the respective other functional requirements,” the R&D elaborate.

Conversely, to achieve freeze/thaw stability, the process at Dawn Foods starts with selecting the right ingredients going into the filling; some starches, for example, are not freeze/ thaw-stable and gelatine may not always give goods results.

The product for which the filling is developed is also a factor, as it must adapt to the intended application in terms of water activity and viscosity and avoid migration.

Delicious now Dawn Foods extensively and continually researches dynamics in consumer trends, from exciting, new emerging flavors, to how established preferences fare against various factors. For bakery fillings, the company observes that classic variants such as apple and cherry still dominate among flavorfavorites, along with other berries such as strawberries.

“This year, we have introduced a Superfruit filling, made up of fruits like cranberries, pomegranate and blueberries, which is appealing to the health-conscious consumer,” Ries shares. For creamy fillings, the all-time-favorite flavors – chocolate or chocolate and nuts – are still highly in demand, as well as up-and-coming flavors including caramel and salted caramel. +++

ADVERTISEMENT

■

ideal e+

All around champion.

Multi-deck oven MIWE ideal with loading unit MIWE sherpa: ideal for baking the entire product range, from heavy rye breads to small wheat rolls. ▶ true hearth-baking ▶ great, consistent baking results ▶ cost-effective, fast production ▶ reliable and robust

More information: miwe.com/ideal Contact us: Phone +49 9363 68-0 · contact@miwe.de

31

H2 TECHNOLOGY

The electrolysis plant

THERESE MÖLK

On the way to CO2-neutral bread © MPREIS

From February 2022 onwards, Therese Mölk will be using green hydrogen (H2) for the first time, for thermal utilization, and for baking bread. By doing this, the bakery subsidiary of the Austrian food retailer MPREIS is probably breaking new ground worldwide.

By Helga Baumfalk

+

Therese Mölk’s aim is nothing less than decarbonizing bread production. Ewald Perwög, who heads the Sustainable Energy Solutions business area of MPREIS and who has decisively advanced the hydrogen initiative on which the company has been working for six years, says, “We want to make our baked goods without burning fossil energy sources, thus not only showing that this is possible but also making a significant contribution to climate protection.”

The foundation stone for the project’s ‘centerpiece’ – the electrolysis plant designed to supply green hydrogen – was laid in March 2021. Building work is now complete. According to Perwög: “We are now in the commissioning phase. We plan to start generating hydrogen in February 2022. Immediately after that, hydrogen will be used for the first time for thermal purposes and for baking. The H2 refueling station for our logistics fleet is currently being built and is scheduled to start operation in calendar week 14/22. The first three logistics trucks with hydrogen-fuel-cell drives will then begin operating.”

When the plant is running, Therese Mölk’s eight ovens will be supplied with thermal energy via a heat-transfer oil system.

The project manager says: “When we convert hydrogen into thermal energy in our H2 burners, all the ovens that need heat will be supplied with CO2-free heat from green hydrogen.” He goes on to explain: “In our project, hydrogen is converted into thermal energy using an innovative dual-fuel burner that burns H2 and natural gas, and can switch

www.bakingbiscuit.com 01/2022

© Therese Mölk Bakery

32

Ground-breaking ceremony for the hydrogen plant with (left to right) Ernst Fleischhacker (Green Energy Center), Peter Paul Mölk and Julia Mölk (MPREIS), Deputy State Governor Josef Geisler, Stefanie Graber (Therese Mölk Bakery), Erich Ruetz (Mayor of Völs), and far right Ewald Perwög (MPREIS Sustainable Energy Solutions)

H2 TECHNOLOGY

between these media while it is working. We operate several burners/boilers. The new combined burner/boiler in our coupled system is intended to ‘take the lead’ and is not supplied by our oven builder. Integrating the control technology into the existing cascaded burner/boiler operational management will be implemented together with our oven builder. Therefore, the necessary consultations with the latter here relate only to adaptation work to integrate our innovative dual-fuel burner into our combined boiler/burner (in which energy is supplied to the heattransfer oil).”

THE Peelboard

The Therese Mölk bakery The Therese Mölk bakery is a production unit newly built for the MPREIS company in 2013. Bread is baked without addi-

Suitable for all industrial baking lines.

tives according to the philosophy: “Nature. Craftwork. Time.

Nothing else.” The bakery prepares around 12,000 tonnes of bread and baked goods per year, which is supplied to MPREIS supermarkets and specialist outlets under the “Baguette” brand in Austria and the Italian South Tyrol.

Sustainability is the company’s fundamental principle.

1

Excellent non-stick effect

1

Perfectly hygienic

State-of-the-art technologies enable a 40% energy saving, it operates its own combined heat-and-power plant, and a photovoltaic installation captures more than 800,000 kWh/year of solar energy. More information at: www.therese-moelk.at

No adaptations to the existing premises were needed.

Perwög says: “Fortunately, our boiler-house was built with an extension area for a third heat-transfer oil heater. We are now using this free space. There was no need for adaptations on the ovens as a result of using hydrogen. The gas warning installation (CH4) that was present in our boilerhouse, in any case, is being enlarged and equipped with an H2 sensor system. H2 is supplied to the burners at a maximum pressure of 5 bar, so there is also no need for changes in the Ex-protection concept of our operating plant.”

1

Stable & durable

As mentioned, the burner is a novel design. For Therese Mölk, it was important to be able to operate the baking process independently of the presence of hydrogen. As Perwög reports: “That was why we wanted a new combined burner/boiler that can also burn natural gas. It is impossible for us to retrofit our existing boiler with an H2 burner because the physical properties of CH4 and H2 are too different in this respect.” He explains that CH 4 and H 2 differ with regard to flame velocity, energy content and viscosity, among other things.

bakeware & coating ADVERTISEMENT

Green hydrogen is intended to be used in parallel to both ‘refuel’ heavy goods vehicles (HGVs) and to fire ovens.

The two uses go hand-in-hand. He says that heating will be the first step, and the HGV refueling station is intended to follow shortly thereafter. Perwög also has policy

Kempf GmbH | Carl-Benz-Straße 3 | 85296 Rohrbach ++49 8442/9669-0 | www.kempfgmbh.de

www.bakingbiscuit.com 01/2022

H2 TECHNOLOGY

© MPREIS

34

expectations: “In fact, green hydrogen is ‘green’ because it is obtained from regenerative electricity by using a CO2free production process (electrolysis). Now, even though natural gas prices have undergone an unparalleled price increase in recent weeks, electricity is still a considerably more expensive energy source. Currently, therefore, it is not yet possible to replace natural gas with electricity for economic management reasons. To achieve decarbonizing in this area as well, we need rules that make the emission of CO 2 from natural gas so much more costly that green hydrogen produced using renewable electricity can compete on price.”

Regarding prices, MPREIS has also found a solution: “We utilize the fact that we market our electrolysis plant on what is called the ‘controlled energy market’ and take so-called ‘surplus’ electricity there from the grid. From the cost price point of view, this electricity is considerably cheaper than

the electricity we purchase on a regular basis. Hydrogen generated by using this electricity can even compete with natural gas in terms of cost, and it can then be used to bake CO2-neutral bread.”

EUR13M IS THE VALUE OF THE INVESTMENT For MPREIS, the goals are clear. Perwög reiterates: “As a company, we are keen to reduce our CO 2 footprint and to bring it to zero. That’s why, for us, generating industrial process heat is just as important as finding substitutes for diesel as an HGV fuel. In our view, there is no such thing as green CO 2. Emission of CO 2 must be avoided if we want to achieve the Paris climate goals.” +++

The MPREIS hydrogen initiative MPREIS is a trailblazer. Nothing comparable existed, so the food

(from hydroelectric power). The project’s investment volume is

retailer took it into its own hands to create a hydrogen initiative

around EUR 13 million and is being supported by the European

with the aim of reducing its CO2 footprint to zero in the long term.

Commission, the Austrian federal government and the Swiss

They brought FEN Systems onboard for strategy and project

Confederation.

development, the TIWAG/TINETZ electricity network for electricity

MPREIS plans to use the green hydrogen for process heat to

purchase, and ILF for technical implementation – all from Austria.

supply Therese Mölk’s ovens with CO2-free heat, and for trans-

The electrolysis technology originates from Switzerland (the IHT

port mobility. The initial intention is for three H 2-fuelled HGVs to

company).

begin using hydrogen, and the whole fleet will be gradually

The plant, which will come into operation on an area of around

converted to H 2 vehicles. With the hydrogen initiative, MPREIS

1,000m2 close to the Therese Mölk bakery, is run by PAE elec-

has its sights on a new business case. In the final expansion

trolysis (pressurized alkaline electrolyzer). It is 9m high and

stage, the electrolysis plant will be able to supply twice as

designed to produce green hydrogen from green electricity

much H2 as the company needs.

www.bakingbiscuit.com 01/2022

EAT. ENJOY. AND REPEAT. KEEP CUSTOMERS COMING BACK WITH A VARIETY OF BAKED SNACKS ON ONE FLEXIBLE SYSTEM.

LEARN MORE

With innovation as the key ingredient, RBS can help take the future of your snack operation to a healthy new level.

Our advanced baking technology offers you the flexibility to make different types of healthy baked snacks on one line.

Change shapes. Swap ingredients. Give your customers the variety of healthier snack options they’re looking for. To find out more about the RBS Multi-Crisp Baked Snack System, call (01) 610-693-5816 or visit readingbakery.com.

A Markel Food Group Company

H2 TECHNOLOGY

Baking with green hydrogen energy?

“What is your position on the use of hydrogen technology to fuel ovens in bakeries?” This is the question we put to oven manufacturers in Europe and the USA. The WP Bakerygroup, Reading Bakery Systems and the Bühler Group came back with their statements.

By Helga Baumfalk

Hydrogen (H 2) is basically a perfect fuel, since its combustion with oxygen (O2) generates no carbon dioxide (CO2), but only water (H 2O). Hydrogen can be obtained from methane (CH4), although that does produce CO2 again.

Another method is the electrolysis of water (H2O). This involves passing a direct electric current through water Dr.-Ing. Christoph Adams between two electrodes immersed in the water. Two gases, hydrogen and oxygen, are evolved at the two electrodes – separated from one another – but no carbon dioxide. In conjunction with electricity generated from wind or the sun, this allows the ‘storage’ of a large amount of the electrical energy that is generated.

So, when considering this energy chain – the generation of hydrogen from wind or solar energy, and the production of the energy needed in the baking oven from hydrogen – this really forms no CO2 in the entire process.

However, using hydrogen is not entirely problem-free on safety grounds. There is a good reason why a mixture of two parts of hydrogen and one part of oxygen is called detonating gas: it is highly explosive!

www.bakingbiscuit.com 01/2022

An added factor is that although hydrogen burners already exist, they are available only for 600 kW and above, i.e. for rather large plants. Developments are also ongoing for burners up to 40 kW. Currently, in the baking ovens area, there are still no practicable solutions with burner powers in the range between 60 and 200 kW. As soon as these become available, everything really favors the use of hydrogen in the baking ovens area. The costs required for this remain to be seen.

Dr.-Ing. Christoph Adams, Technical Director at W&P Lebensmitteltechnik GmbH (Werner & Pfleiderer), Dinkelsbühl, Germany

“Oven manufacturers will increasingly use electrically driven solutions”

© RBS

“Basically a perfect fuel, but not entirely problem-free”

© Wp Bakery Group

36

Joe Zaleski

While a 30% hydrogen/natural gas mixture could be considered a bridge technology to a more sustainable green fuel in the future, burning pure hydrogen gas in ovens has the challenges of a more complicated combustion process and high-pressure on-site storage systems. The energy vector required to produce hydrogen, transport it to site, pipe

37

it to combustion equipment then burn it to create heat makes the process only 60-70% efficient. Because compressed hydrogen gas has one of the highest energy densities of all potential fuels, mass transportation may be the most suitable use for the hydrogen. Oven manufacturers will increasingly use electrically driven solutions of induction, radio frequency, ultrasonics and resistance heating as the zero greenhouse gas fuel of the future.

Joe Zaleski, President of Reading Bakery Systems, Robesonia, Pennsylvania/USA

“We are closely monitoring developments in this sector”

© Bühler Group

“Bühler Group aims to save 50% water, 50% waste, and 50% energy in its customers' value chains by 2025. This is how we are combating climate change with our innovations,” says Sonja Jeßberger, Head of Product Management Business Unit Wafer at Bühler. “Based on these goals, we are continuously testing various technologies to reduce energy Sonja Jeßberger consumption, replace fossil fuels, and avoid CO2 emissions. The next few years will show whether hydrogen technology is suitable for our

applications to reduce the consumption of fossil fuels.

We are closely monitoring developments in this sector.”

Pietro Aresta, Director of Product Management Business Unit Biscuit at Bühler, adds: “Hydrogen as a heating power still not only raises different questions today in terms of use, maintenance, and safety, but also in terms Pietro Aresta of effective CO2 reduction. The path to green hydrogen is not yet immediately tangible.”

However, Sonja Jeßberger makes it clear: “We are continuously working on further alternative heating technologies for our wafer baking ovens. In doing so, we are focusing both on our sustainability goals and on increasing overall equipment effectiveness for our customers.”

© Bühler Group

© PhotoGranary – stock.adobe.com

H2 TECHNOLOGY

Sonja Jeßberger, Head of Product Management Business Unit Wafer, Bühler Group, -Leobendorf/Austria, and Pietro Aresta, Director of Product Management Business Unit Biscuit, Bühler Group, Skovlunde/Denmark

KOENIG Motiv4 NTS 91x53.qxd

+++

12.02.2007

11:10 Uhr

Seite

ADVERTISEMENT

Quality-brand and freshness with long tradition

The Nut specialists Almond- Hazelnut- and Peanut-Products, roasted, sliced, diced and slivered.

Hazelnutfilling and Multi-Crunch.

Please ask for products meeting your specifications.

KOENIG BACKMITTEL GMBH & CO. KG • Postfach 1453 • D-59444 Werl Tel. 02922/9753-0 • Fax 02922/9753-99 E-Mail: info@koenig-backmittel.de • Internet: www.koenig-backmittel.de

www.bakingbiscuit.com 01/2022

38

CLEAN LABEL

A clean break for bakeries How clean-label goods with simple ingredients are maintaining popularity and profit.

“I’m going to start eating cleaner.”

Author: Liz Goodwin

+

It’s a common mantra at the turn of a year or when summer approaches, and the word ‘clean’ is one that consumers focus on in multiple ways. ‘Clean label’, the food movement that preaches products without artificial chemicals, continues to rise in popularity with shoppers, and it’s proving that short ingredient lists (especially with names the common person can pronounce) pay off. But as trendy as the movement is, it still has many questions surrounding it, including the most basic: What exactly is a ‘clean label’, and who decides whether something is ‘clean enough’ to make the cut?

Although there is no universal rulebook on what is required for a product to be considered clean label, a general rule of thumb is that the ingredient list needs to be short and relatively simple. This usually means nixing preservatives and artificial colors and flavors, while still keeping the same taste and texture consumers love. Although it’s a tall order for bakery producers, it’s a force to be reckoned with in the grocery aisles: 48% of global consumers say they make proactive health and wellness choices on a regular basis, according to NielsenIQ, and 77% of consumers expect product labels to be more specific and transparent.

Gone are the days when uber-clean products were a niche market; it has been propelled into the mainstream and is now more of a standard than a specialty.

Jennifer Halliburton, Corbion Global Bakery Insights senior manager, has spent much of her career figuring out how to conquer clean label.

She said that in a world where the rules are ambiguous, it’s best to let bakers and snack producers create their own path in the clean label space.

“I approach it as partnering with customers to understand how they want to look at the label for their own differentiation,” she said.

www.bakingbiscuit.com 01/2022

“A big trend in formulating is ‘choice goal,’ and clean label is huge at choice goal, though I don’t put a hard definition out on the topic.”

A choice goal is a consumer behavior concept that is critical to pinning down ways to get your product noticed. IGI Global defines a choice goal as a benchmark that people want to attain during product selection, which can in turn determine their satisfaction with the decision-making process. For example, if a consumer has a goal to be more conscious of ingredient lists in their snack choices, a clean label product would gain the attention (and the dollar) of that shopper. They will feel good about the purchase because it met their goal, and hopefully, come back for more.

A common way for brands to get themselves into many consumers’ choice goal categories is by being open about what’s in their product. Despite the ambiguity around clean label’s true definition, one thing is crystal clear: A straightforward label strengthens the chances of a consumer deciding to press ‘add to cart’.

“For some, clean label is just about transparency,” Halliburton said. “They want to know where products come from and what they do. They don’t want to feel like they’re being tricked or that there’s something heavier in there.”

One brand that taps into the ‘transparency tactic’ is Waterville, ME-based Maine Crisp Co. The clean label and gluten-free crisp brand uses buckwheat flour in its products, allowing for a balanced taste that doesn’t require extra flavoring agents.

“Our product’s clean label helps us successfully straddle the gluten-free market, where our flavors stand out, and the artisanal crisp market, where our gluten-free certification is a differentiator,” said Karen Getz, founder and president of Maine Crisp Co. “We’ve recently found that store buyers, customers, and nutritionists look at our label and are happy to see that we use buckwheat flour instead of rice, starches, and gums as binders, so we will continue to emphasize that in our marketing strategy.“ While ingredient openness is becoming gospel for so many food producers, one retail outlet is often deemed the pioneer of the clean label movement: Whole Foods. The health food giant that offers an organic option for nearly everything has a list of more than 230 ingredients — including hydrogenated fats, high-fructose corn syrup, and sweeteners such as

CLEAN LABEL

2026, the natural sweetener market is projected to reach USD 28 million — up USD 5.5 billion from 2020. Popular options include stevia, monk fruit extract, agave, honey, tapioca syrup and brown rice syrup.

aspartame, sucralose and saccharin — banned from the products on its shelves.

When it comes to developing a clean label product, earning a place in the aisles of Whole Foods’ serves as a golden ticket.

Two key categories that Whole Foods focuses on, which are particularly relevant to the baking industry, are preservatives and sweeteners. The grocer states on its website that preservatives undergo consideration on a case-bycase basis, “weighing the benefits and the drawbacks.”

The company allows things like citric acid and cultured dextrose but bans benzoates and three sorbate varieties: calcium, potassium and sodium, all common preservatives in baked goods. Without these elements, shelf life is shortened, so bakers have to figure out how to either go without preservatives and make a shorter shelf life profitable or replace them with clean label options.

“We’re truly better-for-you, and that is what we aspire to be. It can’t be solely defined by eliminating the bad stuff. There’s got to be a corollary that we are including the good stuff, which is really at the core of our concept.“ Jeff Posner, CEO, Wholesome Goodness

According to a report from Allied Market Research, the natural food preservatives market is predicted to reach USD 1.07 billion by 2026, growing at a CAGR of 3.7% from 2019 to 2026. The top contributors to the market included salt, an ancient and cost-efficient preservative, and citric acid, found naturally in citrus fruits and widely used as an acidifier in foods. Even seaweed and other algae-derived ingredients have been popular contenders in the natural preservative market for antibacterial and mold-inhibiting qualities.

The other category ripe for clean label innovation is sweeteners.

Consumers are increasingly turning to natural sugars rather than chemical ones; in fact, Statista reported that by

Riceworks, a clean label brand owned by the company Wholesome Goodness, is no stranger to clean sweeteners.

The parent company has banned 158 additives and chemicals and uses only non-GMO ingredients. The brand makes savory rice chips and omega-3 bars, the latter of which brings a sweet taste without any added sugars like fructose.

In general, if it ends in a ‘tose’, it doesn’t belong on a Riceworks ingredient label.

“Not all sugars are created equal,” said Rick Letizia, Wholesome Goodness’ co-founder, president and COO. “We use natural sugars in our bars such as natural fruit. And now you have a new category [on the ingredient label] that says ‘added sugars’ because you have naturally occurring sugar in items like a tomato or something. So now, you really have to look at what kind of ingredient is driving sugar content.”

These kinds of formulation challenges can be tough, but can also present opportunities. “It can present some confusion, but it also allows bakeries to figure out what’s really going to be the most compatible with consumers in a purchasing event,” he said.

Once a bakery has nailed down the right formulation, the other (sometimes equally challenging) piece is marketing the product. Since there is a lack of clear guidelines on how to define clean label, front-of-pack claims can be a bit tricky. Even the word ‘healthy’ has hurdles to navigate.

In a statement published by the FDA in May 2021, the organization announced it was beginning to update the ‘healthy’ nutrient content claim for food labeling, something that has a big impact on the clean label movement that falls under a health and wellness halo. The updating process is part of an overall plan to provide consumers with more information about what they are eating, otherwise known as the Nutrition Innovation Strategy.

This is one of the many regulatory concerns that food producers face when navigating the clean label space. Letizia knows firsthand how important these factors are when deciding

www.bakingbiscuit.com 01/2022

39

CLEAN LABEL

what to put on the packaging of a product. “There are a lot of regulations coming out that are getting very restrictive with what you can put on the front of a package,” he said.

“The FDA is really trying to stop what they believe is misleading labeling. A lot of the language is changing, so the FDA is cleaning that up and we are following along with that, only putting the major type of ‘clean’ claims that you can make on the packaging.”

Letizia and his colleague Jeff Posner, the CEO of Wholesome Goodness, are navigating this by focusing on what they include rather than what they exclude. This allows them to make those more ‘clean-cut’ claims such as gluten-free, celiac-friendly, free of cholesterol, non-GMO ingredients and 0 grams trans-fat, but they also put a spotlight on the inclusion of better ingredients. Other highlights include 15 grams of whole grains, a simple callout of ‘better-for-you’ attributes.

“We’re truly better-for-you, and that is what we aspire to be,” Posner said. “It can’t be solely defined by eliminating the bad stuff. There’s got to be a corollary that we are including the good stuff, which is really at the core of our concept that is nutritional density. So you have to think about how you will communicate that to a consumer.”

One way that the brand sets its baked omega-3 bars apart is with its signature ‘O3MG powered’ branding.

The registered acronym stands for omega-3, multigrain and gluten-free, and the symbol helps set the bars apart from the competition.

“It was done for consumer communications marketing purposes, and our analogy was like how a computer is powered by Intel,” Posner said. “Our bars are nutritionally powered by O3MG. And that’s something on which we can really build brand equity. It speaks to the consumer, and we are considering a line extension of our chips to be O3MG as well. So that means adding ingredients whether they be quinoa, chia seeds or flax. We think omega-3 is where the consumer is going.”

And as consumers increasingly shop online, it’s critically important for a brand to differentiate itself against the plethora of options.

“With omnichannel and online, this idea of having front-ofpack callouts and how you can find products is becoming more important,” Halliburton said. “How do you talk about the function or the elements of a product differently so that it does show up when traditional shopping is changing?”

As clean label enjoys its time in the culinary limelight, all signs point to even more acceleration for the market.

Emerging alternative ingredients that can help bakeries make cleaner products appear to be rolling out almost daily as baking companies increase their demand for clean, label-friendly ingredients.

“It’s a space that is going to continue to evolve,” Halliburton said. “It’s going to be important to consumers when they think about what they need from food and food security.”

Content provided by Commercial Baking magazine (Avant Food Media)

© alexandra-golovac – unsplash

40

www.bakingbiscuit.com 01/2022

© carl-heyerdahl-unsplash.com

THE INTERNATIONAL NEWSFEED YOU NEED. Subscribe to the Bakery Mirror newsletter, delivered to your inbox every other Wednesday. www.bakingbiscuit.com

© NOWEL

BAKERIES

“The best products take time” The Polish bakery NOWEL set its sights high in 2020 and, in the midst of the pandemic, invested in a line that transferred the concept of artisan bakery production into a fully automated process.

+

Helga Baumfalk: NOWEL’s main products are bread rolls. In the past, you have produced more than a billion bakery products annually. Have you found that the pandemic has changed your sales channels and/ or regional markets?

Elżbieta Zajezierska: It would be difficult to identify an area of the economy that has not been affected by the pandemic. COVID-19 has redefined the existing perception of business and made numerous companies leave their comfort zone after years of stabilization. For us, the first wave of the pandemic last year was like a test of our procedures and our readiness to make rapid and profound changes. Working closely together during the crisis has strengthened relationships with our business partners and improved our understanding of our common needs.

Michał Zajezierski: What is important to mention, despite the experience of the last year, we not only maintained production, but we also did not slow down the planned investments and expansion of production lines. In just a few weeks, we have created the first consumer brand in almost 100 years, ‘Home Bakery’, which is frozen and packed bakery products for home baking. It was an almost immediate response to consumer concerns, especially important in the first months of the pandemic. We also invested in a new production line for premium stone-baked © NO WE L

42

www.bakingbiscuit.com 01/2022

products. In February 2021, the products were launched in Lidl shops all over Poland with the ‘Baked on stone oven’ campaign. We were also able to open up new markets. Meetings took place from our desks, in the company office or from our home offices.

Baumfalk: You produce bread rolls and bread with the ‘clean-label’ promise and organic baked goods. Did sales in these two categories increase during 2020?

Karolina Zajezierska: Currently, almost all NOWEL products carry the ‘clean label’. In some product ranges, we have taken it a step further and also stopped using enzymes. These baked goods are based on just three to four ingredients.

On the one hand, this quality is our trademark, and on the other – increasingly, our consumers expect it, not only in Poland but throughout Europe. Following these trends, each year we are increasing the number of organic products that we offer. However, we predict that despite the growing popularity of this group of products, it will still remain a niche market. This is particularly due to high operational requirements in stores – retail chains must ensure that there is no contamination between organic and non-organic products.

Baumfalk: NOWEL is a manufacturer and supplier to retailers, but is not well known to consumers. Did the idea of launching a consumer brand come as a result of the pandemic?

Elżbieta Zajezierska: We have had plans for a consumer brand for some time. COVID-19 has given new impetus to our efforts to launch 'Home Bakery'. Will this product continue

BAKERIES

to be popular after the pandemic ends? Or will customers return en masse to the stores and choose fresh bread rolls straight from the oven? Time will tell!

Karolina Zajezierska: ‘Baked on stone oven’ is our second brand that is ‘visible’ to the customer – it is the brand under which our new products are sold all over Poland and on European markets. The products are the result of several months of work and tests. Our goal was to create an original bread flavor that we remember from our childhood or our parents' or grandparents' generation. The intense, deep flavor and longer freshness of the baked goods result from a precisely determined maturing time and a multi-stage fermentation process. The products owe their crunchiness, golden-brown crust and rustic character to baking on granite volcanic stone from the Italian region of Val D’Ossola.

Baumfalk: Up until now, you have achieved about 30% of your sales in exports to about 15 countries. Has COVID-19 impacted these figures?

Karolina Zajezierska: We have succeeded in maintaining the export share at a similarly high level. Seven further export nations were added in the past two years. Today, we are present with our products in 22 countries. We have noticed that customers are more open to new flavors. Buyers are more and more often looking for novelties and going beyond domestic suppliers, which significantly increases our export opportunities.

Baumfalk: Does this mean you will focus even more on exports in the future?

Karolina Zajezierska: Strengthening NOWEL’s position on key European markets and further international expansion is our long-term and consistently implemented development strategy. Our products can already be purchased on the

largest markets in Europe as well as in the USA and Canada.

In the coming years, we want to offer our latest product lines, including ARTISAN. We will also work on introducing NOWEL bakery products to other European countries as well as on strengthening our position in those already acquired.

Baumfalk: From 2013 to 2019, NOWEL invested more than EUR 60m in the development and acquisition of production equipment. How much did you invest in 2020?

Michał Zajezierski: We started with a very extensive investment plan worth EUR 22m, which we managed to implement despite the pandemic, largely thanks to good organization and exemplary cooperation on the part of bakery equipment suppliers. The first project was a line dedicated to the production of tin bread, mainly rye or wheat-rye, produced on the basis of our own sourdough. We implemented this project in cooperation with WP, Newcap, JBT and Diosna.

The second project, which I see as the crowning achievement of our bakery and which, is also unique on a global level, as far as I know. We have managed to translate the artisanal process of producing bakery products into fully automated industrial production. Assuming that the best products take time to develop their full flavor, we designed the line so that the entire production process – from the start of wheat acid fermentation, through the maturing of the dough and further processes – takes over 40 hours. The products, made on natural wheat sourdough, with a long maturing time (over 12 hours), have a deep flavor, an open texture and also stay fresh for a few days after the final baking. Regarding this line, we would also like to thank our partners, namely Mecatherm, Diosna and Rademaker for developing together pioneer production solutions with us, and for the proper management of the installation process during such a difficult period.

NOWEL Sp. z o.o.

NOWEL produces frozen bakery products (breads, bread rolls) for bake-off at a plant in Legionowo (about 30km from the Polish capital, Warsaw). In addition to supplying leading Polish retail companies, the wholesale baker also supplies food retailers and discounters in other European countries, such as the Netherlands, Germany, Czech Republic and Hungary. Other export markets include the USA and Canada. The export share is about 30%. With approx. 500 employees, NOWEL generated a turnover of about PLN 247m (around EUR 53.94m) in 2020, which makes it one of the top five bakery companies in Poland according to its estimates. In its home market, NOWEL is considered the market leader in the Kaiser bread roll and Wachauer (torn open) bread roll segments as well as in some mixed and wholemeal breads.

The Zajezierski family are majority owners of NOWEL. The owning family includes Elżbieta Zajezierska (center, President of NOWEL Sp. z o.o.),

© NOWEL

Michał Zajezierski (VP of NOWEL's Management Board) and Karolina Zajezierska (Commercial Director). Less than 30% is held by the Polish investor Credit Value Investments (CVI).

www.bakingbiscuit.com 01/2022

43

BAKERIES

expanded their ranges and took over parts of the basic supply including bread. BP and Orlen also offer snacks.

Although there was no scientific evidence that SARS-CoV-2 could be contracted through food, consumers were initially concerned about buying snacks and eating them without additional heat treatment. As a result, a significant part of this segment in Poland was at a standstill. However, after a period of hard lockdown, it was reintroduced, which was met with enthusiasm, because in difficult times customers appreciated the convenience and the possibility of eating out.

© NOWEL

44

Baumfalk: In autumn 2019, you opened a modern research and development center in Poland. Do you work with universities?

Michał Zajezierski: Yes, the center is also a platform for cooperation and exchange of knowledge with academic units. Together with them, we are conducting research and technological tests based on a completely new approach to bakery product consumption. This is a topic for our next meeting, but it will be a real revolution.

Baumfalk: Before the COVID-19 crisis, the out-of-home market was considered extremely dynamic and almost unstoppable. The pandemic changed that. What is the situation in Poland?

Karolina Zajezierska: Indeed, during the first wave of COVID-19, after many years of growth, food producers in Poland saw a slowdown in the economy. The introduced trade restrictions and the appeals to stay at home also had a significant impact on the bakery industry, both on the domestic market and in the context of exports. Economic uncertainty, as well as a big increase in interest in home baking presented huge challenges. Fortunately, demand returned to normal relatively quickly. However, it is worth looking at the market situation in the long term.

The convenience sector had been growing very quickly before the pandemic. Polish people had fallen in love with stores that provided them with necessities and were located close to their homes. Today, now that customers are accustomed to the difficult situation created by the pandemic, we may find that the convenience sector is one of the main growth drivers for many manufacturers. As shopping centers and supermarkets closed, small outlets and petrol stations

www.bakingbiscuit.com 01/2022

Baumfalk: What are the main problems facing Polish bakery producers at the moment?

Elżbieta Zajezierska: The main challenge faced by food producers is the rising production cost. Climate change directly affects, for example, the costs of raw materials and energy prices are rising as well. Companies are also paying more and more attention to sustainable development – elimination of greenhouse gas emissions and reduction of waste. These actions are inevitable and urgently required to save the planet, but are associated with higher production costs.

Baumfalk: How is the Polish bakery market currently developing?

Michał Zajezierski: In Poland, the consumption of bakery products per person has been declining for some time.

However, interestingly enough, the bake-off bread category has been gradually growing for several years. Of course, the pandemic will slow down this growth, but we do not expect changes in this aspect in the long term. It should also be emphasized that every year, the bakery industry in Poland is growing more and more intensively – mainly due to considerable investments in new technological solutions.

As a result, the competitiveness of Polish companies on the international market is increasing significantly. What is more, the domestic market is becoming more and more saturated, which directly translates into an intense price fight. Each year, the Polish bakery market is becoming more and more difficult for companies, and the COVID-19 pandemic has further escalated the challenges.

Elżbieta Zajezierska: The Polish market is very competitive, and also in terms of inter-industry sectors. It is not only the producers of bakery products that fight for customers. The younger generation is not consuming bakery products as frequently, but choosing substitute products. A traditional breakfast, which a few years ago would always be accompanied by a slice of bread or a fresh bread roll, often looks very different today. We are certainly dealing with very rapid growth in the sector of quick snacks and ready meals.

Customers are also paying more and more attention to the variety of flavors and quality.

Baumfalk: Thank you very much for your time.

+++

THE ONLY BAG CLOSURE THAT’S HOME COMPOSTABLE.

TO LEARN MORE, VISIT:

KWIKLOK.COM

© Bühler

NEWS

A healthy, carbon-neutral snack

© Central Association of the German Bakery Trade

46

Germany’s Bread of the Year 2022 The ‘Bread of the Year’ 2022 has been decided: The Scientific Advisory Board of the German Bread Institute selected wood-fired bread as the BREAD of the Year. According to the Central Association of the German Bakery Trade, it is a traditional type of bread that is becoming increasingly popular again today. It was officially cut by the German Federal Minister of Food and Agriculture, Cem Özdemir, on February 1, together with Association President Michael Wippler and Managing Director Daniel Schneider.

Every year, the Scientific Advisory Board of the German Bread Institute chooses a particularly traditional, popular and highly-nutritional, quality type of bread as the ‘Bread of the Year’. The aim is to improve the knowledge among German consumers regarding different types of bread and to strengthen the German bread culture as a recognized cultural asset of the country. +++

IMPRINT baking+biscuit international is published six times a year.

Single copies may be purchased for EUR 15. Subscription rates are EUR 75 per annum. Students (with valid certification of student status): EUR 40. (All rates include postage and handling, but not VAT).

Cancellation of subscription must be presented three months prior to the end of the subscription period in w ­ riting to the publishing company. Address subscriptions to the above stated distribution department.

Claims will not be accepted for any copies not received or lost copies due to reasons being outside the responsibility of the publishing company. This magazine, including all articles and illustrations, is copyright protected. Any utilization beyond the tight limit set by the copyright act is subject to the publisher’s approval.

Online dispute resolution in accordance with Article 14 Para. 1 of the ODR-VO (European Online Dispute Resolution Regulation): The European Commission provides a platform for Online Dispute Resolution (OS), which you can find at http://ec.europa.eu/consumers/odr Valid advertising price list: 2022

www.bakingbiscuit.com 01/2022

PUBLISHING HOUSE Food2Multimedia GmbH Schoolkoppel 27 21449 Radbruch, Germany +49 4178 244 9797 www.foodmultimedia.de EDITOR EMERITUS Hildegard M. Keil hildegard_keil@t-online.de PUBLISHER James Dirk Dixon dixon@foodmultimedia.de EDITOR-IN-CHIEF Catalina Mihu mihu@foodmultimedia.de

Austrian start-up Selectum partnered with Bühler to provide a new, healthy and CO 2-neutral snack. Selectum launched Paddies, crunchy wafer pillows with a creamy dip inside at the end of 2019. Bühler contributed with induction baking technology to make their production entirely free of CO2 emissions. Paddies are made with a combination of rice and chickpea flour and are available in three flavors – cheese, toffee, and peanut butter. +++ ADVERTISER DIRECTORY American Pan.......………………………………………….....................11 AMF Bakery Systems……………………………………….................13 Backaldrin………………………………………………..........................23 Dawn Foods...………………..………………………….............................2 Hansaloy.........…………………………………………..........................19 Kaak...........................……………………………………………............48 Kempf................................………………………………………........33 Koenig, Werl.......................................……………………...............37 Kwik Lok...........................................…………………………………...45 Mecatherm................................……………………………..9 MIWE................................………………………………………..31 Rademaker...............................………………………………….17 Reading Bakery Systems...............……………….......................35

SUBSCRIPTIONS Viktoria Usanova usanova@foodmultimedia.de DISTRIBUTION vertrieb@foodmultimedia.de ADVERTISING Dirk Dixon dixon@foodmultimedia.de SOCIAL MEDIA Annie Dixon annie.dixon@foodmultimedia.de LAYOUT/GRAPHIC DESIGN LANDMAGD Design aus der Heide Linda Langhagen, design@landmagd.de

EDITOR Helga Baumfalk baumfalk@foodmultimedia.de

PRINT Leinebergland Druck GmbH & Co. KG Industriestr. 2a, 31061 Alfeld (Leine), Germany

COPY EDITOR Annie Dixon annie.dixon@foodmultimedia.de

IT IT Consulting BRUNK Felix Brunk, felix@brunk-net.de

KEEP UP TO DATE STAY RELEVANT

Your connection to insights into: + Bakery technology + Market trends + Science and Research www.bakingbiscuit.com

Subscribe: usanova@foodmultimedia.de

From silo to truck

Solutions for your bakery kaak.com

Whether you need a single machine or turn-key line

Best Lead Time 24/7 Support Hygienic Design Line Integration Sustainable Development Goals