baking+biscuit 2024-01 digital by landmagd

01 24 Visit Savoir faire at Savimex, in Bulgaria

Production Chocolate is the answer

Breads Baguettes, ciabatta, rolls

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EDITORIAL

Find your joy! Blue Monday, the most depressing day of the year, was on January 15. The year is well on its way now. It can also fall on the first or second Monday of the month. The science behind this defamatory evaluation of a given Monday in January? There isn’t much, although the Internet will unearth an ‘equation’ behind it: Cliff Arnall, a tutor at an education center linked to Cardiff University, reportedly calculated the day (and then made a hasty departure from his role as a result). Arguably, social media use patterns could provide some clues today, but they would still be a matter of defining and interpreting the entire world’s shared data. However, the concept caught on, in what became a creative and lucrative marketing campaign. The UK’s Sky Travel first used ‘the most depressing day of the year’ concept to sell its holiday packages in 2005. Almost 20 years later, this smart marketing idea has been firmly planted and is here to stay; we have several ‘retail therapy’ invitations in our inboxes to prove it, meant to ‘cure’ the infamous Monday blues. A ‘made-up’ occasion is still a great occasion for a feel-good moment. Two years ago, Dutch volunteers baked 3,000 cakes for care homes and shelters in Amsterdam. This year, Catalina Mihu, Editor-in-chief Your commments or suggestions are always appreciated: e-mail: mihu@foodmultimedia.de

Bread Ahead gave Londoners 100 free donuts, on Blue Monday morning, and 25% off everything for the day. Bakers like to bring joy on bad days, too! Aside from making good days great, of course; after all, this is the industry for culinary joy, guaranteed. Celebrations, big and small, are a great reason to imagine, make, promote, sell and enjoy a treat. We will indulge in a crispy fresh croissant because it’s simply delicious and, perhaps, in the right company, and not because the nutri-score evaluation will persuade us. Speaking of special occasion days and fruitful marketing ideas, January 30 marks World Croissant Day. And up next, the day of all things red and heart-shaped, in February! Krispy Kreme is one of the companies that believes in Valentine’s Day joy, for example. Its ‘Dough-notes’ collection of themed donuts has already been available since the last days of January. Finding the right occasion and matching it with a great product is a good recipe for business. However, there is joy in sharing moments and pairing them with the treat of choice, any day of the year. Just as consumers treasure these small moments, the bakers working to offer them do, too. It takes a careful approach to perfect the flavor of a new snack until it tastes great. I was lucky to have the opportunity to see this for myself a few weeks ago, when I visited Savimex, an innovative producer of pretzels, crackers, twisted breads, buns and pasta. You can read about it in this magazine. We hope you enjoy reading it! Catalina Mihu

CONTENTS

COVER STORIES

HIGHLIGHTS

“ALONE, YOU GO FASTER; BUT, TOGETHER, YOU GO FURTHER!”

Thomas Lesaffre is the newly

appointed President of the Federation of European Manu-

facturers and Suppliers of Ingredients to the Bakery, © Fedima

SAVOIR FAIRE AT SAVIMEX, IN BULGARIA Savimex has been thriving on disruptions; those

Confectionery and Patisserie Industries – Fedima.

that came its way and those that it is boldly innovating. The cracker and pretzel producer has made a name for itself in Europe and beyond, with its own brands including Savi, and private-label offerings.

THE ART OF BREAD An enticing range of breads is carefully crafted to

UPSTANDING OVEN TECHNOLOGY

answer the consumer’s unwavering love for a slice

MECATHERM unveiled its latest oven in October last year, at iba.

of wholesomeness, whether it’s an artisan-style

Since then, the M-VT vertical oven has also been presented at

bread or roll, ciabatta, focaccia, or a baguette. It’s

Gulfood Manufacturing, which makes two/two for this piece of

their time to shine, in all creative interpretations,

equipment in terms of trade shows attended vs. awards gained.

with the technology ready to reliably back up

28 CHOCOLATE IS THE ANSWER!

With chocolate as the answer, the only question that remains is how to deliver its optimum

AN AUTOMATED EYE FOR DETAIL

properties in any shape and state required

Automated inspection systems are able to guarantee top product

by its host product.

quality and safety – no exceptions allowed.

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production.

CONTENTS

INTERVIEW 06

Thomas Lesaffre, Fedima President: “Alone, you go faster; but, together, you go further!”

VISIT 12

Bakery: Savoir faire at Savimex, in Bulgaria

BREADS, BAGUETTES, CIABATTA AND ROLLS 16

Artisan-style: The art of bread

MARKET 22

Puratos: Plant-based materials rising to dough-mand

SUSTAINABILITY 24

Reading Bakery Systems: Save your energy!

CHOCOLATE 28

Part I – Production: Chocolate is the answer!

OVENS 34

MECATHERM: Vertical oven technology for sustainable baking

INSPECTION 38

KPM Analytics: An automated eye for detail

RESEARCH 40

Grainar: Around the world with flatbreads

Editorial: “Find your joy!”

News

Advertiser directory

Cover: © f2m – VISIT Savimex in Bulgaria

REGULARS

INTERVIEW

“Alone, you go faster; but, together, you go further!” Thomas Lesaffre is the newly appointed president of the Federation of European Manufacturers and Suppliers of Ingredients to the Bakery, Confectionery and Patisserie Industries – Fedima. He shared his views on the role of the association in defending the industry and the work ahead, in support of the organization’s members, their customers and the consumer.

Catalina Mihu: You have recently taken on the role of Fedima President. What is your view on the association’s role as it mirrors the pace of the industry and its changing priorities? Thomas Lesaffre: Fedima aims to be the European platform for baking ingredients and to support the growth of bread and pastry markets. We want to shape a favorable environment for our members, to ensure that this growth is achieved through solutions that are both sustainable and innovative. Ultimately, we aim to promote and protect our industry, especially in the current environment. Presently, we are living with a lot of uncertainties, and new regulations are shaping up in Europe. I often say that for example North America is good in innovation and creates new concepts, while Europe is very good to regulate innovations. Just think about AI: Europe is the first to take steps towards regulating this field, while America and China are prioritizing focusing their efforts on innovation and new developments based on this new technology. This is why Fedima, a European federation based in Brussels, comprising national associations, aims for a joint approach, with a shared vocabulary, so that we can defend our interests both locally and on European level. In light of growing uncertainties, we strongly believe that it is important for our industry to be reactive and proactive in anticipation of all the new regulations that are coming – and this is where Fedima plays a key role. Mihu: Safety and sustainability are among today’s core trends. What is your view on optimizing the efforts of Fedima’s members in this regard? And how is this best conveyed to the consumers? Lesaffre: To these, I would add one more key topic: cost optimization, in light of the huge inflation currently facing Europe at the moment. Safety and sustainability are two of the main trends, but cost optimization has also been a big focus over the past two years. Fedima is organized into three committees: the marketing and communications committee, the technical and the sustainability committees. The latter is in charge of everything related to sustainability matters and is channeling its work into supporting our membership so that they can, in turn, support the customers to develop concrete actions.

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We developed a vision paper on sustainable packaging, which was endorsed by all our members, who all agreed that the active involvement of various stakeholders along the supply chain is a necessity for sustainable food packaging. Fedima is committed to the transition to a circular economy at an EU-wide level, for which we proposed four main courses of action: to reduce the packaging used where it is feasible, to increase the reuse of packaging materials, to use recyclable packaging materials with the goal of increasing recycling rates, and to call to action the key stakeholders in packaging material supply, collection, sorting as well as in recycling of emptied packaging. Fedima is also focusing on responsible sourcing. This is key for us as ingredient providers who also aim to offer functionality, by driving our providers to offer new solutions. In this regard, we can take action taking into consideration fair working environments along the supply chain, effective packaging and waste management, as well as the preservation of human and animal rights. The recent European Commission proposal for a corporate sustainability due diligence directive brings just that into focus, showing that Europe is currently prioritizing this. This is why we want to be proactive and not simply wait for the new regulations, but push our industry to already propose solutions to our customers, in line with these new regulations. We also put together a Code of Conduct for responsible sourcing, which is currently in the endorsing phase, among our national associations and their member companies. The goal is to plan coordinated actions toward responsible sourcing, to be able to hold the supply chain to account. By communicating, engaging with stakeholders and advocating for our sector, we do our best to mitigate these issues, through this Code of Conduct. Mihu: What are the main points in the Code of Conduct? Lesaffre: It focuses on a fair work environment in the supply chain, effective packaging and waste management, and preserving human and animal rights, among other aspects.

Fedima means community Mihu: What is your unique perspective on spearheading Fedima, following your experience as a Fedima member and considering your previous roles as a Board member

INTERVIEW

and Chair of the Marketing and Communications Committee (MCC)? Lesaffre: As the Marketing Director of the Lesaffre Group, I have a good sense of the importance of communication. I have also been a member of the MCC for some years and a Chair of this committee for a few years more, which was a role I accepted because I am convinced that communication is one of the pillars of Fedima, communication towards the consumer, the baking industry, as well as the national associations and two distinct bakery sectors. Communication with different European institutions is also a part of this, with efforts to better communicate the risks and opportunities for the bakery industry, concerning various regulation changes. I am also a Board member of COFALEC, the Confederation of European Yeast Producers, which is not a Fedima member. But, Fedima is working with COFALEC on a common project – the ‘Bread Initiative’, as an example of communication with other organizations. I value the community aspect of Fedima; the more we are, the stronger we are. Mihu: Fedima’s work with AIBI also comes to mind. What are some of the organizations already in Fedima’s established collaborations? Lesaffre: Looking at different stakeholders, first of all, we want to work closely with our customers and all the bakery associations in our ranks. Regarding other institutions, we work with the national and European ingredient associations to collect market needs and draft common actions. Then, there are national and European authorities to promote our sector and drive decisions in our interest and organizations throughout the value chain, as well as any other European professional associations linked to the baking industry, such as AIBI, COFELAC, CAOBISCO, AMFEP, CEBP, and more.

Mihu: Can we expect that, in the coming years, a common way of communicating will be built so that transparency can be increased? Lesaffre: That is one of my goals. As a member of the COFALEC Board, for example, I can steer collaborations with Fedima. I am looking forward to opportunities to work closely with AIBI, as I am in contact with its President. I know quite well the President of CEBP, as well.

INTERVIEW

With my new role at Fedima, I will try to strengthen these networks and work together with these organizations on some concrete actions that bring value to everyone. We have also recently established a connection with the American Bakers Association, to tackle issues that go beyond the borders of Europe.

Resilience is a skill Mihu: Because we are talking about responsible sourcing, it’s imperative that we look at the entire supply chain. How have recent disruptions reshaped the ingredient supply chain? Lesaffre: Living in an increasingly more volatile time is reflected in the supply chain. Only last year, while the baking sector was still feeling the strong impact of the COVID-19 pandemic, the war in Ukraine added its own consequences, including the energy crisis. Suddenly, it felt like everything had been coming from Ukraine, because ingredient shortages started – from flour and sunflower oil to energy. In fact, this doubled with another crisis, one affecting logistics and transport, itself caused by the existing crises. Among the main problems affecting Europe last year was the increase in the cost of living, doubled with increased risk of shortages. We have experienced quite turbulent and confusing years recently, which have had a significant effect on the bakery sector as well. Our association comprises very large companies, but also small to medium businesses and each has felt the impact of the recent socio-political developments differently, depending on their size. The agility to adapt to new constraints and perpetual changes in the environment has been key for all our members. The ingredient supply chain has been reshaped by these crises, first of all, in terms of agility and adaptability. Then, we have to consider the impact on the consumer and the trends concerning their purchasing behavior, dictated by factors such as inflation and its impact on the cost of living. Important trends show how retailers and bakers have also been affected, including the cost of raw materials and disruptions in logistics and transportation. All the businesses in the bakery sector must adapt in order to be able to retain their customer base. We have seen unexpected trends: for example, at the beginning of the pandemic, when people were on lockdown, they would visit retailers and buy heavily, causing strange shortages. When everyone started venturing out, one of the first visits that they made was to return to their craft baker, especially in France. Worries and purchasing power aside, this has shown that consumers still want to eat and enjoy bakery and pastry products. Despite all crises, the sector keeps growing, demonstrating its resilience. Another key trend, which was evident even before the past few years, is traceability, which encompasses clean label trends and ethical trends. It is linked to the product’s origin and, again, to responsible sourcing, and environmental preservation. Consumers are behind this trend, as they

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Position paper on nutrient profiles Fedima is strongly committed to improving transparency and the provision of clear, factual and relevant information while providing nutritious products to be consumed as part of a balanced and sustainable diet. Fedima welcomes the opportunity to contribute to the development of a nutrient profiling system and supports a simple, harmonized,

fit-for-purpose

and

science-based approach in that sense.

want to know what they eat and they increasingly want to be well informed. This is where Fedima and we, as ingredient producers, play a big role in better informing and educating consumers regarding the use of ingredients, their purpose and their origin. Mihu: You mentioned cost optimization. It is an important point, especially at a time when we have seen bakers posting their astronomic energy bills. How can Fedima support with topics that, although not directly related to ingredients, still have a big impact on its members? Lesaffre: Despite the inflation, we have seen that consumption did not decrease. Quite the opposite: it is very interesting to see the price increase and consumption doing the same. We are witnessing a positive price elasticity. It may seem strange, but, it can make sense: when people have less purchasing power, they will perhaps buy less meat or fewer premium products. However, they will increase spending on vital, basic products such as bread. One might cut spending on pastries, for example, a segment that has, indeed, been much more impacted than bread. A lot of bakeries have been posting their energy bills in front of their shop to show consumers why they needed to increase prices. I fully support this move. In France, craft bakers have received government support regarding energy costs. On this topic, our member companies can individually support the bakery sector by proposing new ways of working and new ingredients that could help reduce kneading or baking times, for example. Fedima can help by giving all national associations a common voice to speak clearly and loudly to relevant institutions and ensure that we can support the bakery sector, locally and at the European level, as was the case in France with the support for craft bakers. We are also working with national associations so that Fedima can better provide support and help exchange ideas. For craft bakers, several ideas could help. Having in-shop eating spaces and serving coffee could help increase revenues, as well as services. Why not start again delivering, too? So consumers could have fresh bread and pastries delivered to them first thing in the morning.

Source: Fedima, June 2022 (www.fedima.org)

INTERVIEW

In addition, working as a complete chain is something we can improve and a priority I would like to focus on for the coming years. By this, I mean not just Fedima’s work on its own, but also its work with bakers’ associations, enzyme associations. Alone, you go faster; but, together, you go further! By working together with all relevant national and European associations, I am convinced that our voice will carry much more weight in front of different institutions in our dialogues.

Communication is key Mihu: Fedima has organized several promotional and awareness campaigns. Drawing from that experience, what would be a good avenue to communicate with consumers about these, in a very clear and straightforward way? Is it through a label, a nutri-score, or campaigns? Lesaffre: I think it can be a combination of these. There are also new regulations coming soon regarding front-of-pack nutrition labeling, by which our industry will indirectly be affected.We will have to find ways to help improve the nutrition labeling for the bakers, through our ingredient solutions. However, we have to pay attention to not overcomplicate things and end up lowering the product’s quality to improve the nutritional label. For instance, if I go to a bakery and buy a croissant, I will not do it because the nutritional value on the label is convincing, but rather because I want to enjoy a tasty pastry, which will make me happy. I don’t think consumers will be happy to eat products that compromise taste for a very good nutritional label. We need to welcome innovations, to develop solutions to keep having excellent products with an improved front of pack nutrition labeling. We also need to explain the ingredients. For example, preservatives are mostly perceived by consumers as bad for their health. But, what about waste management? Without preservatives, some products will immediately generate more waste, because their shelf life will be diminished. There are a lot of contradictions coming from consumers: they want products without preservatives and, at the same time, they want to reduce product waste. They want organic products because they feel they are better for the planet; but, what about organic wheat that is coming to Europe from Peru? It is not sustainable. This is where I strongly believe that Fedima should play a big role, in explaining such different perspectives to the consumer, to increase awareness. Lastly, we have two types of businesses, industrial and craft bakers. Craft bakers do not package their bread; meaning, they do not have to label it – no front-of-pack nutriton label such as the nutri-score for instance, no ingredient lists. Industrial bakers, however, have to do all these things. Interestingly though, consumers trust craft bakers much more than they do industrial bakers, at least in Europe. In this case, we could support the industrial sector to defend its position, because they have many more constraints in their manufacturing process, including audits, certifications, quality

controls, and packaging and labeling restrictions. Communication can change this perception of the industrial sector, with more information and transparency toward consumers. Mihu: Could consumer perception lead to developments such as products that are both clean label and long life, for instance? Lesaffre: Absolutely! We can improve the shelf life of the product by using only clean-label ingredients, even without a fixed definition of clean labels, which means that the perception of what they are can vary from one country to another. In Europe, they may be understood as ‘cupboard ingredients’; but, in other parts of the world, cupboard ingredients might not be the same as what we commonly group in this category. Mihu: Could Fedima propose a working definition of clean labels, shared by its members in different European countries? Lesaffre: It could be tricky, in the absence of regulations regarding such a definition. What we can do at Fedima is aim for a common position in this regard. We draft position papers in which we propose a common understanding of the concepts so that we ‘play’ by the same rules. These papers are reviewed and endorsed by all our members. Fedima can also play an important role in supporting our customers on how to label and navigate the alternatives available to them in terms of labeling. This is a key priority for our work this year. Mihu: We went over some of your priorities. What can we share from Fedima’s 2024 agenda? Lesaffre: In 2024, we are taking the time to reflect on our messages and bring them to focus, so that they can be heard in the ongoing discussion and shaping of the next EU agenda. The upcoming European elections this year might hold opportunities for us – or pose a risk. The main topics we have planned for the Technical Committee are to prioritize ingredients with a focus on multifunctional ingredients: we want to have a harmonized EU-wide approach, with a clear definition and criteria to be considered when KOENIG Motiv3 91x53.qxd

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INTERVIEW

“We want to help build better regulations by maintaining a single-market principle and avoiding different interpretations in each country and we will work on policy impact assessment.” Thomas Lesaffre, Fedima President

determining their regulatory statute. Now, it is not always clear whether and when one should be declared as an additive, for example. Contaminants are another priority of the Technical Committee, such as mineral oils. We want to make sure that our members are aware of all the developments, the potential impact and how to minimize it. In this regard, we are working on an association position on limit levels for mineral oils, so we define them together and submit our joint proposal to the EU. Another priority is enzymes and their safety. We already have worked on enzyme handling research and best practices, to share with our members and customers and avoid the occurrence of any respiratory issues when mishandling them and we will continue raising awareness and educating and educating our workers on this. Labeling is another priority on this committee’s agenda, including allergen management and EU-wide alignment on risk assessment. We want a better management approach and analytical methods for the presence of potential allergens due to contamination. As an industry, we are not waiting for election results to draw our plans and act, however. One of the first actions we want to advocate for is to have adequate support for sustainable agriculture, packaging and food ingredient systems. We want to make a push for innovation and sciencebased principles to reduce bottlenecks and support digital initiatives. We are also looking into New Genomic Technologies (NGT) for microorganisms. We also want to help build better regulations by maintaining a single-market principle and avoiding different interpretations in each country and we will work on policy impact

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assessment. In addition, we need to boost trade and secure supply, for example, regarding cocoa. Essentially, our actions aim to support the industry and our bakers’ interests. Mihu: What does Fedima’s support entail for craft bakers and for industrial bakers, given their different challenges? Lesaffre: We defend both equally. I don’t want to consider these two market segments in opposition; I much prefer to see them as complementary: you don’t buy a toast bread for the same reasons you buy a baguette. Or, looking at the growing trends for long-fermentation, sourdough bread: good as it may be, you will not feed the entire planet with sourdough bread alone, or only with organic flour. A segment of the population is ready to pay a premium for these specialties, but, what about the rest of the world? This is why these two segments should not be opposed, but considered complementary. Together, they complete the full picture of the market! We do understand that their problems are different, so this is where we could potentially support each, by addressing specific problems. For example, labeling-related issues and solutions mainly apply to industrial bakers. A common sourdough definition, by comparison, is a topic that concerns all bakers equally. This is a good example of our recent work. Similar to clean labels, the absence of regulations or general definitions leaves space for risks. This is where Fedima has an important role, to harmonize and ensure that between us at least, we agree on a common definition. Another topic that can offer support to both sectors is the Bread Initiative, a project we intend to continue. +++

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VISIT

Savoir faire at Savimex, in Bulgaria Savimex has been thriving on disruptions; those that came its way and those that it is boldly innovating. The cracker and pretzel producer has made a name for itself in Europe and beyond, with its own brands including Savi, and private-label offerings.

In his travels, Danko Savov is an avid seeker of new and different snacks: the second-generation owner of Savimex looks for unusual and exciting finds at snack aisles in supermarkets around the world. Each destination means one additional suitcase full of local product samples for the return trip. Bread sommelier training builds expertise for master bakers in Germany; in a similar way, he has been researching and tasting snacks. From the samples he collects, the owner of Savimex selects, step by step, features he believes are best and have the best potential to develop new products that will enjoy market success. Savov’s curiosity for new experiences in tastes, flavors and textures and his instinct for consumer response to new offerings have led Savimex to successfully introduce snacks previously unknown in Europe. Broken pretzels are among them, a well-known snack to American consumers, but virtually unknown on this side of the Atlantic Ocean. Savimex now successfully exports this premium product, which is particularly enjoyed in Germany and the UK. With headquarters and production facilities in Dobrich and seven warehouses throughout Bulgaria, Savimex exports its crackers, pretzels, sticks, burger buns and pasta to over 30 countries, including major supermarket chains in Italy, Denmark, the UK, Germany, the Netherlands, Japan, South Korea, China, Jordan, Saudi Arabia and South Africa. The

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company also provides airlines with snacks. In this process, it passes rigorous quality checks and unannounced inspections with flying colors – one of them, on the day of our visit. An international ‘library’ with Savimex-made product ranges is set up in a meeting office. It holds hundreds of packs on display, with packaging in various languages, from Bulgarian to Korean. An acknowledgment of its organic sticks from Sial China completes the collection, along with quality certifications. In its home market, Savimex sells salty sticks, pasta and bread.

“At first, we developed our own machine to break pretzels, while we were also working on perfecting the recipe and the process.” Danko Savov, owner, Savimex

The company is getting ready to celebrate 33 years in business on February 6, 2024 – and it does so at full operating capacity. There are plans for several new investments that will see new lines installed in almost each production hall, including a new snack line and a soft bun line. Even the warehouse, which was only two months old in January, is in the works to become a manufacturing space. Then, a new storage facility will be built. At the beginning of 2024, around 270 people were working here, 200 of them in

VISIT

production. And 50-60 new teammates will join in the following months, to support the expansion. To work around labor shortages, people from outside of Bulgaria are welcome. “It takes up to five months to hire new people from other countries such as Uzbekistan, via an agency. They receive training, accommodation and transport to and from work,” Savov explains. The company’s main steps forward since 1991 have not been small. Out of its portfolio of hundreds of unique products, the main segments at Savimex today are crackers and pretzels. It was a completely different picture two years ago, when the main part of the business consisted of the production of fresh bread, with large volumes of bread sold every day. That was indeed one of the recent disruptions that saw Savimex turn the tide and focus on the promising segment of snacks. “Market price caps wouldn’t allow a price increase to reflect the inflation we experienced. We had old equipment for bread production, that would have required massive investments for a product with low profit and complicated logistics. We needed to have bread trucks at the door of the supermarkets throughout the whole country, before opening time. This also limited the extent to which we could grow,” Savov explained the radical change of direction. His instinct was right: Savimex achieved the same turnover in 2023 without making bread as it had before, but with a higher profit.

Broken pretzels: making of a successful snack Broken pretzels, thin pretzels and twisted sticks (pastry) are some of the ideas-turned-successful-line-products at Savimex so far. First came the broken pretzels: “The US is the best source for snacks, followed by Asian markets,” Savov recalls. In 2013, he tried broken pretzels during a trip and tried to reach a distribution agreement. The prices were too high, though. Days later, the team was carrying out tests on how to break sticks and what recipes would work best for seasonings. They developed their own machine to break them while perfecting the recipe and the process. For high-volume production, Savimex quickly found the only solution available for their needs was a pretzel system from Reading Bakery Systems (RBS), for this product and more. “It was simply the only technology available on the market, which was suitable for more interesting products

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and, importantly, came with a dryer and a soda bath, in addition to the oven. Placing an order from the US was a first for us,” Savov detailed, as the company considered new variables such as transport costs, spare parts and service. Savimex took this step, and the low-pressure extrusion line for pretzels has been working in the facility in Dobrich since 2018. There are now plans for a second RBS system to expand production by the end of 2024. “Savimex stands out because of the new and unique mentality regarding highend products,” highlights Joe Pocevicius, EMEA Regional Director, RBS. Mixers of up to 900 kg capacity/batch are used to prepare the dough for snacks. The line now produces flat pretzels and the broken variety. Pretzels require no proofing, so the dough can be moved directly to the RBS line for production, which carries out baking, drying, seasoning, and cooling automatically, followed by packaging. The final moisture content of pretzels should be around 4%, which is one of the parameters consistently recorded in the control room, where samples are also kept. Two people are required at the start of the line, to run and supervise operations. To ensure product safety, products with cheese are conveyed on a dedicated conveyor. An advantage of using the line is that no scrap dough is generated. Floor space savings were also important, along with consistent product quality. Dough for crackers, by comparison, will require proofing. Crackers are made on an adjacent line, running in parallel. Roller dies are used to produce crackers of different shapes, meaning that scrap dough will result in the process. Profit margins are somewhat lower for this segment, compared with pretzels, so Savimex is looking for products that stand out. A third line, a new RBS system, is expected to join the two in this production hall, which will bring new product ranges, along with a capacity increase. “This is why, in the near future, we want to start looking into new products , sweet and salty, with different shapes, seasonings and unique shapes,” Savov anticipates. One of the upcoming big plans at Savimex is to increase its efforts in developing its own brands. New, interesting snacks should be available as soon as 2025, including filled and twisted products and sweet snacks. +++

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An enticing range of breads is carefully crafted to answer the consumer’s unwavering love for a slice of wholesomeness, whether it’s an artisan-style bread or roll, ciabatta, focaccia, or a baguette. It’s their time to shine, in all creative interpretations, with the technology ready to reliably back up production.

It cannot be stated enough: a relaxed dough makes the best bread! For artisan breads of European inspiration (and beyond), dough need not only to be stress-free during the process, but also well-hydrated, in many cases.

care of the first curling of the dough piece, and the motordriven molder board does the final step to deliver product in a pan, or on a peel board. With this system, the dough is not only stress-free but also sheeted at high speeds. Its design has eliminated falling heights so that thickness reduction is carried out without bringing any tension to the dough band. “Incorrect reduction factors, including inadequate speeds, can bring too much tension and stretch the dough sheet unnecessarily, damaging its structure and even causing it to tear,” AMF Bakery Systems points out.

Flexible, high-speed lines: AMF Bakery Systems The stress-free sheeting technology developed by AMF Tromp is at the heart of the processing line for any artisan bread product. The technology was developed around maintaining the quality and integrity of the traditional craft, according to the company. Several features have been built to meet specific manufacturing demands, including the possibility for oil-free sheeting, and dedicated make-up options for cut, rounded and molded products. The in-line molding section de-gasses dough for better and finer structures in the final product. Adjustable mesh belt take

“The dough sheet can be set up to follow various processing steps, which include cutting it into triangles, squares or strips, or preparing pieces for molding and rounding.” AMF Bakery Systems specialists

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The Tromp Stress Free Artisan (SFA) Breadline is designed to be highly versatile; it supports a variety of products, including baguettes and demi-baguettes, pave, petit pains, boules, sourdough bread, whole wheat bread and hard rolls – in entry-level configurations as well as for high-volume capacities. It can adapt to different types of dough, from wet to dry, and including many pre-fermented doughs. The same flexibility is applied to product shapes and sizes: the line can process products ranging from small rolls up to large, rounded breads, baguettes, ciabatta, or tin bread. From the same sheeting station, “The dough sheet can be set up to follow various processing steps, which include

The art of bread

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cutting it into triangles, squares or strips, or preparing pieces for molding and rounding,” AMF’s specialists illustrate. When volumes are of the essence, the SFA line is designed to handle large-scale operations: “Our solutions reach up to 4,000 kg dough per hour, so industrial capacities for high volume lines can be guaranteed,” AMF details. Half of this or even smaller volumes can also be prepared efficiently, with no resource waste, thanks to the built-in flexibility of the line as well as its modular design. Smaller operations, as well as changes in volumes required, can be accommodated in this way. Adding to its flexibility features, the AMF Tromp line features top and bottom flour applicators and customizable seeding options that bring diverse seed varieties to certain sides of a bread. Decorative scoring with water jets can add even more variety to the product lineup. Special care is taken of baguettes: a pointer can help shape “true artisanal baguettes” with pointed ends, AMF underlines. Its flexibility does not come at the expense of process efficiency, either. The line is designed for minimum dough band trim and efficient waste management, which includes scrap return systems to sustainably re-introduce dough into production. A dough centering unit (gently) helps keep the dough sheet in the middle of the conveying belt, to lower the amount of scrap dough on the sides. To minimize downtimes, changeovers are streamlined: “AMF Tromp designs its sheeting and breadlines to avoid long downtimes and keep productivity up. No tooling is needed for changes, and c-frame units can be wheeled in and out. Our custom trolleys per line assist with bringing product parts such as rollers, or cutters as close to the line as possible. It’s also easier to wheel them to the cleaning room afterwards.” Sanitation is also factored into the machine design: the AMF Tromp Breadline can be washed down.

Automation is also ensured so that a team of one or two can manage the process. They set up the line, select the recipe, and then only need to supervise the production, as almost every step of manufacturing artisan-style breads with AMF equipment can be automated. The AMF Tromp line can be upgraded to support new product ranges. A system that makes cut products, for example, can easily add molded or rounded varieties, using the same sheeting line. Robotics can also be brought to the line anytime, for a step up in automation. Integration with AMF mixing, proofing, baking and cooling systems, can be made seamlessly, using the same software and process controls by AMF.

A new IMPRESSA for bread, by FRITSCH Making its debut on the best stage for a first impression, at iba, the new, compact IMPRESSA bread line developed by FRITSCH for industrial production manages to save 20% of the floor space – about 5 m. This was accomplished, in part, by new sheeting technology incorporated in the revised Soft Dough Sheeter (SDS) and the new Soft Dough Roller (SDR). A sensor in the SDS monitors the dough level in the hopper; when it falls below a certain threshold, new dough is brought in on another conveyor belt. “This allows for greater precision and more even weight distribution when producing the dough sheet,” the specialists point out. Next, the SDR gently rolls out the dough, a uniform dough sheet with very well-defined edges, obtained with no separating agents and without applying shearing forces to it. In this way, dough scrap is reduced to a minimum throughout the process. Moreover, thanks to its fold-up conveyor belts, the SDS flours the dough sheet on all sides, thereby eliminating the need to use any oil at all when rolling the dough out. Both technologies were already components of the

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PROGRESSA bread and have been adapted to industrial processing. “Depending on the thickness of the dough, a conventional satellite head can be dispensed with in many cases,” FRITSCH explains. Moreover, the make-up section can be configured to include only the required modules. Its modular design also means that the IMPRESSA bread can produce a wide variety of specialties by swapping out individual components, without having to prolong the line. “A baguette coiler, for example, could quickly be swapped out for the newly developed Dough Twisting Unit (DTU), which produces twisted breads. Before this module existed, such products could only be produced by hand,” FRITSCH adds. Dough make-up steps can include several processes such as longitudinal cutting, spreading, cross-cutting, decorating, twisting, round-moulding, and long-moulding.

“Fold-up knife edges, like those on the feed table of the calibrating head for example, ensure good accessibility for cleaning, even in relatively tight spaces.”

FRITSCH specialists

The line’s open design allows modules to be easily swapped as well as ample access for cleaning. This is because the design is now flatter, making many components easily accessible from the side. Another design revision was made to the handling concept of the longitudinal cutter: the roller can now be accessed by opening the hood. If the hood is raised above a certain point, the cutting roller is released and can be changed quickly. A counterpressure roller ensures the appropriate power transfer during cutting. The design of individual components also favors hygiene: it features smooth surfaces, watertight covers on threaded connections, and rounded corners where no dirt can accumulate. Some components, such as the conveyor belt table of the SDS and the SDR are now mobile and can be cleaned in the washing area. In addition, “Fold-up knife edges, like those on the feed table of the calibrating head for example, ensure good accessibility for cleaning even in relatively tight spaces,” FRITSCH specialists illustrate. The drives on the line are also new - on the so-called ‘omega drives’, the belt

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can be completely relaxed in a matter of seconds, which makes cleaning under belts a quick and easy process as well. Depending on the product and the width of the line, this line has a dough throughput of up to 8,000 kg per hour. Among the products highlighted at iba were a rustic bread roll and a twisted bread roll. To produce the rustic bread roll, one piece of dough is folded over the other after the guillotine. The two pieces of dough are then folded in with the coiling mat, which gives the product its artisan look at the end. For this product, no special equipment is required. The new Dough Twisting Unit used for twisted bread rolls achieves an output of 60 cycles/min and row. The new IMPRESSA bread also comes with FRITSCH Smart Services, a family of digital solutions such as the Smart Production Insights (SPI) and the newly developed ‘Watchdog’ for drive monitoring. The smart tools help monitor the key performance data of the line in real time. The aim is to achieve complete production transparency, in addition to insights supporting predictive maintenance. The SPI service was established to give production and shift managers real-time insights into the most important performance data of the line on a clear dashboard. FRITSCH explains: “Even minor malfunctions that occur intermittently during production are recorded by the SPI and reported on. This data can be inspected to determine what is causing the faults, and the appropriate measures that can be taken to prevent unplanned line stoppages.” The ‘Watchdog’ digital service monitors the motor power and the temperature of every drive on the line. “As soon as an algorithmically calculated value deviates by a specified amount from the set target value, a warning is sent to a defined group of people, so they can react accordingly before the drive unit becomes damaged or even destroyed,” adds FRITSCH.

Rademaker: automated production of cut breads, rolled products Rademaker designed its bread line for production efficiency, for a diverse range of breads including small baguettes, baguettes, triangle buns, square buns, hexagonal shaped buns, decorated/stamped buns, ciabatta, focaccia, pave, bagels and for a large variation of rounded products. It processes different types of dough, ranging from green

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doughs to highly hydrated doughs. Overall, any specialties in the categories of products that require the dough to be either cut, molded, or rounded can run on this line. Flexibility is ensured by its modular build, as well as fast changeovers.

“When the recipe is set and production starts by bringing the dough in the Double Chunker Stress working.”

Free System (DSS), the dough tracking is already Rademaker specialists

Efficiency features are designed for every process. The sheeting section consists of quick reducers, cross roller and gauging stations to optimize dough sheet width and thickness. After sheeting, lane cutting and spreading, the dough is transported to the make-up section. Next, the make-up section will include units that help produce either cut, molded, or rounded products, with or without seeds. Throughout each step, the dough is tracked to ensure consistency at the desired parameters: “When the recipe is set and production starts by bringing the dough in the Double Chunker Stress

Free System (DSS), the dough tracking is already working,” Rademaker illustrates. Dough tracking ensures the process flow is carried out as intended. For example, it can monitor if the flour sifters are switched on in time so that the dough always has flour when it arrives at the conveyor. It can also switch on a flour brush or a cross roller when required. Process accuracy is also an important component of the overall efficiency of a line. Rademaker’s bread line ensures product size consistency by relying on its in-line weighing system, which was engineered to improve weight accuracy for continuous production. “This sophisticated weighing

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system is versatile, capable of accurately measuring all types of dough and accommodating various product lengths,” says Rademaker. Dedicated software enables automatic weight correction, while maintaining a consistent guillotine stroke rate. The result: uniform product lengths and optimized weight control. The weighing process can be applied to cut, rounded and molded products. The cutting itself is done with a Rademaker guillotine unit or a box motion cutter unit, depending on the product. With the box motion cutter unit, six different cutting modules are incorporated into one dough-cutting machine, the specialist explains. Cutting and separating are carried out on a belt transfer, for better alignment and product separation. Cutting and stamping are made on a cutting table, with or without seal time technology. For fast changeovers, tools are designed to slide sideways onto a tooling trolley. The role of Rademaker’s own Double Chunker Stress Free System (DSS) pre-sheeting system in achieving the quality of the final product is essential. It is here that the dough batches coming from the kneader begin their journey as one continuous sheet of dough. “The DSS features two sets of chunker blades. The unit has a dynamic hopper that transports the dough in a controlled manner, keeping the shape of the dough chunks linear and constant. Landscape sensors and separate belts carefully guide the chunks in the sheeter, ensuring size and weight accuracy. The weight and length of each chunk are exceptionally accurate, which leads to a more stable and consistent dough sheet and eventually high-quality baked products,” Rademaker explains the operating principle of the technology. The latest version of the DSS replaced the oil its predecessor used to prevent dough from sticking to the hopper with wax, while also reducing the amount to a quarter compared to the oil it used to require. This is great news for the production of some of the most sought-after 'artisan' breads, which require high levels of hydration or need (long) fermentation times making the dough inherently sticky, such as ciabatta, focaccia and pinsa. With the new DSS, cleaning is easier, “Cost-savings are considerable and the wax distribution system has a ROI of only 1 – 1.5 years. Equally important, the DSS using wax is more accurate on dough chunk weights due to the dynamic belt principle and, therefore, performs better overall, when compared to the oil DSS,” Rademaker explains. (Both oil and wax operating versions are available for the DSS, while the DPS is only available in the setup using wax) The DSS and the corresponding dough sheeting section are designed to transport dough with minimal height differences, to preserve its homogeneity and structure. It also features easy access for cleaning. Moreover, it has a hygienic design and, with its wider belts, combined with advanced flour strewing and optimized waste bins, it supports clean working. Wet doughs are only one of the ranges that can be processed with the Rademaker line; it accommodates a wide

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variety of recipes, including highly hydrated, low-salt, organic, gluten-free, pre-fermented such as Levain, mother dough, biga, and sponge dough. “This extensive range of recipes opens up a world of possibilities, for a wide array of bread products and crumb structures,” the technology specialists underline. Hygiene is universally among the first production requirements in bakeries and this bread line is designed to meet all Rademakers’ Sigma hygienic design standards. The concept includes eliminating any recesses, cavities and dead corners and prioritizes round edges, tubes, ducts, angled surfaces and smooth finishings. In addition, an open design supports easy cleaning while maintaining the operator’s safety. “To keep the rollers of the reduction stations as clean as possible, they are fitted with wear-resistant roller scrapers,” Rademaker says. The modular architecture of the Rademaker bread line makes it flexible for various configurations as well as changes over time.

Breads and rolls in the Verhoeven Bakery Equipment Family

The companies in the Verhoeven Bakery Equipment Family, BVT, NewCap, Vacuum Cooling and Bakepack, together design turnkey solutions, which can range from mono-lines for bread specialties, for example, baguettes, to multi-bread lines for a multitude of products including artisan breads, rolls, buns, baguettes and many more. There are numerous possible setups to choose from when establishing the design of these custom-made systems. Resulting production volumes, depending on the specialties made, can range from 600 to 12,000 kg per hour, considering that process times are product and bakery-specific. For example, for long-processing specialties, climate control systems can automate dough proofing and storage up to 48 hours. “The setup is always different! We have more than five different extruders, depending on the type of dough, from a press extruder to the NED extruder, where we only cut dough pieces and put them on top of each other. The rest of the line is also customized according to the different end products you want to make,” the Dutch specialists explain. For the on-trend, highly hydrated doughs, Verhoeven Bakery Equipment Family offers two types of stress-free extruders to choose from: one for doughs of up to about 175 TA, and the other is the NED extruder, which processes dough without bringing any stress to it.

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To identify the appropriate sheeting solution, the specialist looks at two possible scenarios: an operation that produces a certain product/products and is looking to scale up production efficiently, with no changes to the product characteristics; and small-volume production facilities wanting to increase their capacity and level of automation, following a growing demand. In each case, “The starting point remains the end product,” the company underlines.

“Links are made between computerization and automation systems that monitor and utilize real-life data. This information helps in the context of maintenance and preventive maintenance and provides data for traceability.” Verhoeven Bakery Equipment Family specialists

For product shaping, relevant equipment supports all possible techniques, from cutting, shaping, molding, and rounding, to depositing fillings and more. In addition, manual and artisanal functions can still be implemented, to preserve each intended unique, signature characteristic of the product. Features frequently requested in the design stage are related

to efficiency and food safety. “Links are made between computerization and automation systems that monitor and utilize real-life data. This information helps in the context of maintenance and preventive maintenance and provides data for traceability,” in Verhoeven’s experience. In addition, the specialists also observe that hygiene is high in demand. The answer can be wash-down capabilities for systems. Designing a solution with the Verhoeven Bakery Equipment Family brings together the list of tasks that the equipment is required to perform with the experience of the baker together with that of the equipment specialist. The line setup undergoes thorough testing to be completed. “Customer requests are often specific product requirements that need to be scaled up in production, for which they need advice regarding technical issues and support on the technology for the process. We have in-house specialists in the field of product management on lines and formulation of recipes,” the specialists at the Verhoeven Bakery Equipment Family say. With technology providing all conceivable process-related answers, the science is here to support optimized, largevolume production. Then, it’s all down to the art of creating a unique creation, with a generous array of artisan inspiration – from ciabatta to baguette, round bread, rolls and anything in between. +++

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MARKETS

Rising to dough-mand In recent years, numerous food categories have expanded their plant-based offerings – and the bakery sector is no exception. This is not just a fleeting fad; it represents a profound transformation in the way people view and choose food.

By Laurent Thomé, Business Unit Director, Plant-Based Solutions, Puratos

Shoppers are increasingly reaching for plant-based bakery options, driven by a complex interplay of health consciousness, environmental concerns and ethical choices. For bakeries of all sizes, understanding and responding to these purchase drivers will be the key to growing plantbased sales.

Cutting a sustainable slice Puratos’s latest Taste Tomorrow research has recently unveiled a staggering 63% of consumers believe plantbased food has a positive impact on the environment. This perception comes down to factors such as resource consumption, greenhouse gas emissions, land use and more. However, there is still more to be done in educating people about their own environmental footprints and how they can contribute to a greener planet. The key takeaway for bakers here is to make sustainable ingredients more visible – both on packaging and in-store. Bakers using Puratos’s Mimetic plant-based specialty fat, for example, have the opportunity to signpost the fact that this ingredient has an environmental impact three times lower than dairy butter .

Going the extra mile Second on the consumer agenda when purchasing plantbased foods is animal welfare. In fact, two-thirds of Taste Tomorrow respondents say animal welfare is a priority when buying food. A prominent ingredient in baked goods, eggs play a significant role in this movement as concerns arise around caged chickens. To cater to these concerns, over 20 years ago, Puratos created Sunset Glaze, a plant-based glaze and an egg wash alternative, which also offers an environmental impact 59% lower than pasteurized eggs. These are two attractive selling points for consumers looking for both cruelty-free and environmentally friendly products.

Agrees plant-based has a plant-based impact on the environment

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Wellness wins But it is not just about ethics. Taste Tomorrow data shows that 58% of consumers believe plant-based food is healthier than animal-based options. This means there is a whole demographic of health-conscious individuals who would find more plant-based options beneficial. Plant-based muffins, cakes and cookies are also often lower in saturated fat and cholesterol when they include Puratos’s Mimetic butter alternative for example, making them an attractive choice for these consumers. As the plant-based market is largely driven by the growth in flexitarianism, it’s important to offer nutritional transparency in both standard and plant-based bakery products so that these consumers are offered choices.

Rise of the mature consumer Although sustainability, animal welfare and health are the top motivations for switching to plant-based products, what do consumers want once they are in this space? Interestingly, and contrary to popular belief, many consumers are not looking for plant-based alternatives that mimic traditional items. Instead, people enjoy offerings that are fulfilling in their own rights. Bakers could consider switching up recipes to create something unique as opposed to a traditional alternative. Inclusions such as fruit, vegetables, seeds and grains are an effective way to achieve this while adding to the product’s health credentials. Looking ahead, it’s essential for bakers of all size to recognize the evolving drivers behind plant-based growth and the role that every ingredient and partner along the supply chain has to play in responding to this demand. Using and calling out high quality plant-based ingredients with known origins and backed by Life Cycle Assessments (LCAs) will provide consumers with the transparency and trust they have come to expect. +++

Agrees plant-based is healthier than animal-based food

Thinks plant-based is made in a natural way

Source: Puratos

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S U STA I N A B I L I T Y

Save your energy! The conversation around increasing manufacturing sustainability will unavoidably start with analyzing ovens, for any baking operation. Visible results are a necessity.

An oven that bakes more sustainably should make use of energy efficiently and emit fewer greenhouse gases in the process while producingbaked goods of excellent quality. The variables are obvious; achieving the perfect balance requires expertise in technology and processes. Today, there are several options to choose from, each a possible fit according to individual and regional circumstances.

Sustainable technology options From an energy efficiency standpoint, the conversion of electricity to bake is 1:1, making it 100% efficient. The added bonus is that emissions are 0%, in this case. Electric oven zones are also simple to operate and maintain. These are only some of the reasons why Reading Bakery Systems (RBS) sees the baking industry moving to electric ovens in the future.

The company first conducted tests and verified that the baking results when using electricity exclusively were the same as when using gas, in terms of quality, texture and taste. “RBS conducted hours of tests and R&D work that shows there are no significant oven performance differences between gas and electric power sources. Today, our electric penthouses allow RBS to offer all-electric versions of our latest Convection, Emithermic, and Emithermic XE oven zones,” the specialists explain. The electric penthouse offers one electric element per plenum, with dual blowers, allowing bakers to control top and bottom air speed and temperature independently. These ovens can be installed now with a gas-powered penthouse, and can easily be converted to use electric power in the future. Since a process line is used for three to four decades, machines acquired today will still be running in 2050. “Either buy

RBS Electric Oven

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S U STA I N A B I L I T Y

green energy ovens now, or make sure you have a plan to convert it in the future,” RBS concludes.

“Knowing where the heat goes helps RBS design more energy-efficient ovens, something our engineers have been working on for decades.” Reading Bakery Systems specialists

Electricity has been gaining ground as a preferred energy source. RBS has been using electricity for heating for many years; now, it is being applied to larger oven systems and dryers, specialized in baking cookies, crackers and pretzels. For example, RBS describes the Emithermic XE, designed to replace the traditional direct-gas-fired (DGF) oven, as a game-changer for cracker bakers: “DGF cracker ovens are costly, difficult to maintain and often deliver an uneven bake to the product. These problems come from the large number of ribbon burners down the entire length of the oven (up to 300 feet long) that must be maintained and adjusted to deliver consistent heat to the product.” The DGF burners, placed above and below the baking band, supply low- and high-level radiation to heat the product and the traveling baking band in an environment with little to no convection currents. “This unique atmosphere allows baked goods to develop and expand while retaining the necessary moisture to create the product’s flavor and texture profile,” RBS explains. RBS designed the new Emithermic XE Oven zone to bake via electric radiant heat elements, high radiant Thermatec Panels, and convective heat, eliminating all ribbon burners. It replicates the DGF baking process with a matching oven heat trace, by using a centralized penthouse to circulate and impinge heated air on thermal plates above the product and onto the baking band below the product. High-intensity

electric radiant burners then provide the highlighting blisters and colors on the top of the product. On a gas-heated oven, the Emithermic XE zone has two electrically controlled gas-to-air burner systems, down from around 40 burners that can be included in a DGF oven. In this way, the Emithermic XE oven zone also delivers a more balanced heat to the products. Greater flexibility and control are also built into it, with a humidity-controlled product zone. “The unique feature of the Emithermic XE oven zone is the ability to emulate either the still air environment of a DGF or Cyclothermic oven zone, or the convection air zone of a dryer. The baker can configure and store zone settings of product formulas that require either more humidity for product development or less humidity for product shape setting and drying,” RBS recommends. The flexibility of the Emithermic XE oven zone makes it best positioned as the first third of a tunnel oven of three or more zones. Retrofitting existing RBS gas-powered ovens to use electricity is a straightforward, simple swap of the penthouses. Electric radiant elements can also be added to any of its ovens, to be used for a toast effect and product coloration before they exit the oven.

Improvements, every day The latest RBS oven designs include several energy-saving advances, all of them backed by extensive R&D, testing, and data, the company underlines. “Knowing where the heat goes helps RBS design more energy-efficient ovens, something our engineers have been working on for decades,” the specialists explain. New developments to increase efficiency have also been made to the control systems, which now include downtime software that automatically reduces the fuel consumption of an oven. “The software works by automatically setting

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S U STA I N A B I L I T Y / N E WS

the exhaust dampers to a minimum, lowering the belt speed to the slowest setting, and forcing all burners to the minimum firing rate or turning off burners once the cutting system on the production line stops. When additional dough is loaded in the hopper after a shutdown period, the extrusion or sheeting process can trigger the restoration of all production settings,” RBS explains.

Planning for the future New technologies need to be invented in order to switch to green energy and be more efficient. For example, such advancements would enable ovens to pull the water vapor out of the exhaust air while returning the heat back into the oven. And, rather than heating and re-heating steel belts in

tunnel ovens, the belt can return inside the oven and be inductively re-heated just before the product is loaded. “These are all areas where we are working with universities and trade organizations to improve technology which we can implement on new oven designs, RBS shares. Ovens are undeniably headed into a sustainable future; but, this requirement is only the beginning of the features they need to incorporate. The specialist anticipates ovens with simpler control systems as we move into the future. “As the labor force moves around more freely in the job market, oven controls need to be more intuitive so that new operators can understand how to produce great-tasting products more consistently.” +++

Kwik Lok promotes Bas Reijndorp to global distribution role Kwik Lok Corporation promoted Bas Reijndorp into the role of Global Distribution Sales Manager for Europe and the Middle East. He will develop, execute, and grow Kwik Lok’s distribution and original equipment manufacturer (OEM) network in Europe and the Middle East. “Bas has been a strategic member of our Kwik Lok Sales Team for almost two decades. He has developed strong partnerships throughout the region and has a deep knowledge of our solutions. He is the perfect person to lead our Distribution and OEM growth strategy,” said Chief Revenue Officer, Blair Chastain. The European and Middle Eastern team also adds Eugene McLaughlin, who joined Kwik Lok as a Regional Sales Manager. He will be responsible for executing Kwik Lok’s regional sales strategy. “I am excited to bring my energy, commitment and experience to Kwik Lok and look forward to working with Bas and the rest of the team,” said McLaughlin. +++ © Kwik Lok

Koenig Group makes management changes Norbert Hübler is the new Global Sales Director of Koenig, as of January 1, 2024. The Board of Directors of the Helmut Koenig Private Foundation and the Management of the Koenig Group announced organizational changes in the company concerning future challenges, including the new appointment. In this newly created position, Hübler is tasked with the strategic management and alignment of the global sales network of the entire Koenig Group. He will lead the Sales Managers of all subsidiaries and mentor and develop its sales partners. Franz Sommerauer was also appointed on January 1, as a proxy of Koenig Maschinen GmbH, in addition to his role as head of Sales and Marketing. “With confidence in the decades of sales experience of Mr. Hübler and Mr. Sommerauer, we see ourselves encouraged to secure and further expand our existing market success for the future,” CEO Hannes Stelzer explains the decision. +++ © Koenig Group

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Vegan, Plant-Based or just delicious Pastry? To support you in answering the growing demand for plant-based baked goods, we have added 3 new innovations to our range of vegan ingredient solutions: Dawn Balance® Sponge Cake Mix Vegan, Dawn Balance® Delicream Caramel Vegan and Dawn Balance® Fond Neutral Vegan, which was awarded with the Broodway Innovation Award 2023. Creating fully vegan applications is a piece of cake with our comprehensive vegan range. All easy to use, tolerant and robust ingredients that deliver consistent and delicious results. We are Dawn, your partner for bakery success. Discover how we can be your partner, contact us at dawnfoods.com/eu

C H O C O L AT E

Chocolate is the answer! In all its iterations, from dark to milk, from ruby to white, chocolate is the undisputed consumer favorite for any moment of indulgence, and a trusted ingredient for a world of bakery offerings. With chocolate as the answer, the only question that remains is how to deliver its optimum properties in any shape and state required by its host product.

PART I

By Catalina Mihu

Technology is not only tasked with processing chocolate so that its properties are preserved, but it should also reliably deliver end products, often in premium ranges, of any type, shape, or packaging. The goal is to achieve products that are beautiful on the outside, when coated in chocolate using enrobing technology, and on the inside, when chocolate chips are incorporated in recipes – and perfect all over, in stable, consistently high-quality products.

Enrobing with Aasted Nielsen Perfect tempering, to stabilize chocolate, is a must for efficient enrobing in large volumes. Aasted has been developing solutions for the chocolate and bakery industries since 1917. The Aasted Nielen line of equipment is designed to handle various types of chocolate, including dark, white, and milk chocolate. The newest Aasted Nielsen chocolate enrobing machine in this patented, energy-saving range brings a number of improvements for large-scale operations, addressing all common production problems, in a functional design: it enables reduced downtimes, precise control of chocolate temperature, easy access to the conveyor belt, safe unit transfer via a rail system, and fast component changeovers. A bypass conveyor can also be easily installed on this line when it is needed for quick product ranges. “These features contribute to less build-up and increased efficiency and productivity,” Aasted specialists explain. The Aasted Nielsen Enrober offers three configurations, each representing a tailored solution that caters to specific production nuances: + Energy enrobing – This is an energy-optimized solution designed for the sustainable production of chocolate. In this configuration, the machine precisely controls the chocolate temperature to prevent unnecessary tempering while maintaining the high quality of the finished products. It uses a patented mix of reused and freshly tempered

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chocolate, by partially returning it to the tempering unit. It is used in combination with the Aasted StellaNova tempering machine.

“The Energy Enrobing Concept, which involves a direct injection of tempered chocolate into the feed pump, enhances output, extends product shelf life, and provides significant energy savings compared to traditional tempering machines.” Aasted specialists

It optimizes energy consumption by directly injecting freshly tempered chocolate into the feed pump. “This ensures a stable thickness of the enrobed layer, providing a beautiful gloss and a good break for the product,” Aasted explains. The technique enhances output, extends product shelf life, and provides significant energy savings compared to traditional tempering machines, according to the specialists.

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supports production environments where versatility is required, for an extended number of portfolio entries.

Fig. 2: Direct enrobing principle

Source: Aasted

Fig. 3: Compounnd enrobing principle

Source: Aasted

Fig. 1: Energy enrobing principle

Source: Aasted

The Nielsen line

+ Direct enrobing – In this setup, the Aasted Nielsen Enrober focuses on delivering a consistent flow of temperate chocolate. To prevent build-up and blockages, freshly tempered chocolate is continuously flushed. It then makes a full return to the tempering machine, for optimum process efficiency. + Compound enrobing – This compound-optimized solution does not utilize a return system, as tempering is not required in this configuration. In this way, it supports the production of a wide range of products, with fast and easy changeovers of the enrobing band unit and the pumping and tray unit, for minimum downtime. With the compound enrobing setup, the Aasted Nielsen machine

The production volumes using the Aasted Nielsen enrober (with bandwidths of 850/1,050/1,300/1,600 mm) will vary depending on the changeovers needed, and the operating efficiency. Increasing or decreasing production capacity may be influenced by factors such as the type of products being enrobed, the size of the products, and the speed of the production line, Aasted specialists elaborate. With a band width ranging from 850 to 2,600 mm, the Nielsen Master is designed to provide an efficient, costsaving enrobing solution that can operate 24h/day. “With a unique detachable lower section, you have rapid and flexible changeover between any enrobing material,” Aasted describes. Its hygiene features start with its sanitary steel design, which is easy to clean and maintain. Numerous auxiliary equipment options are available for this model, to customize solutions to various production needs. These include by-pass conveyors, cleaning wagons, down pressing systems for various products, decorating systems such as stringers, sprinklers, tempering machines for direct enrobing (Stella) tempering machines for energy enrobing (SuperNova Energy) chocolate tanks, pumps and pipes. Licking rollers (also called coating or enrobing rollers) are also an option, used to cover products such as candies, biscuits, or nuts with a uniform layer of chocolate or compound coatings. The layer’s thickness can be controlled. In addition, the Aasted enrobers can also be used in tandem with Alice extruders, Stencil depositors, tempering and cooling tunnels. The XXL version was designed for large-scale production. This model is designed for 24-hour production at high speed. To ensure high-quality enrobing, the curtain box provides two layers of enrobing. Furthermore, it features two bottoming systems – designed for the bottom enrobing of products such as doughnuts and biscuits, with an optional turning device – as well as two blowing systems, to perfect the appearance and texture of the finished products.

Chocolate chip production with IPCO IPCO specializes in chocolate forming equipment, with systems designed for the production of industrial ingredients – chips, chunks, drops and blocks – and decorative products such as shavings, rolls, pencils, and blossoms. In the industrial production of chocolate chips, chunks, or drops, controlling the chocolate solidification process is key. Every stage, from heating and depositing to cooling and handling, requires precise control. “This is particularly the case with decorative products – often consisting of different colors – which have to be rolled, scraped and shaped,” IPCO’s Mitchell Paquaij, Global Product Manager, Food, points out. Advanced molding lines are required in this endeavor.

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C H O C O L AT E

From its portfolio, the company is highlighting its Rotoform HP chip production system and its piston depositor – both part of IPCO’s trade show solution roster at ProSweets 2024.

Rotoform: HP means High Performance The Rotoform rotary drop depositor is at the heart of all IPCO’s high-capacity solutions, the company underlines. The latest model in the series is the Rotoform HP (High Performance), which is specifically designed for forming chocolate chips. It was specifically designed to handle bakestable (low-fat) chocolate but is also capable of handling and processing lower-viscosity products. Compared to the standard Rotoform technology, the Rotoform HP is built with a significantly larger product distribution channel coupled with an increased outer shell diameter. “This, together with multiple pressure steps inside the system, ensures even product distribution across the full width of the cooling belt for optimum pastille uniformity,” Paquaij explains. As showcased live at the Cologne trade fair, the Rotoform HP depositor features a pump that brings the molten chocolate to the system via heated piping. The Rotoform itself consists of a heated stator – which is supplied with liquid chocolate – and a perforated rotating shell that turns concentrically around the stator to deposit drops of chocolate onto a continuously running steel belt. A system of baffles and internal nozzles provides uniform pressure across the whole belt width, ensuring that the chips created are uniform in shape and size. To ensure that the drops are deposited without deformation, the circumferential speed of the Rotoform is adjusted to match that of the belt. Cool air is then blown onto the product and the belt itself. The cooling process needs to be quick, so that only small volumes of oxygen manage to penetrate the product. The formed chocolate chips are free-flowing for easy handling, storage and dosing. Chips of vastly different sizes – from 30,000 to 300 pcs/kg – can be produced by simply changing the shell.

the product, resulting in perfectly circular wafer products. The system also makes use of an automatic ‘craning’ system to lift the depositor from the molding line, eliminating the need for manual input.

“Our piston depositor delivers a number of unique benefits and features an innovative D-motion to deliver chocolate or compound directly onto a moving belt without any linear movement. The depositor travels at exactly the same speed as the belt. ” Mitchell Paquaij, Global Product Manager, Food, IPCO

Piston depositing innovation IPCO observed a distinct gap in the market for high-end piston depositing technology; a gap it has filled with its latest depositor. Its goal was to provide a solution combining high productivity with a high-quality end product, while also being easy to operate and low maintenance. The IPCO Piston Depositor is the company’s first solution of this kind and incorporates a number of new advances. This system comprises a 1,500-mm wide depositor that uses a D-motion to deliver chocolate or compound directly onto a moving belt, rather than the traditional belt-to-depositor movement. The speed and height of the depositor is software controlled and driven by four servo motors, to ensure that it precisely travels at the same speed as the belt. This precision control, combined with the D-motion, means a variable deposit can be applied without any distortion of

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The depositor travels longitudinally along the belt and then completes the D-shape by returning to its starting position. “The design of the system means this is achieved using only rotational movements. The fact that no linear bearings are used in the unit means significantly less wear and tear, resulting in lower maintenance requirements,” the process systems specialist explains. While production volumes will vary according to the type of product and installation details, Paquaij explains when to make the most of each: “Our Rotoform rotary depositor is very good at producing small chips at very high speeds, while the piston depositor is the best solution for producing easy melts, with throughput capacities of up to 4 t/hr,” he recommends. Throughput rates for decorative products can range from 65 kg/hr – 1,000 kg/hr.

C H O C O L AT E

The piston depositor can be installed alongside existing equipment on IPCO Chip and Chunk Molding (CCM) triple pass steel belt cooler lines. In this way, three depositing systems – piston, Rotoform and chunk extruder – can be integrated on a single line for maximum production flexibility.

By having them together, it is possible to produce chips, drops and chunks on a single line. “This system gives you the highest capacities on one line – up to 2,800 kg/hr for chip production; up to 4,000 kg/hr for wafer production; and up to 3,200 kg/hr for chunk production – with minimal downtime,” Paquaij illustrates. Finally, the piston depositor can also be installed as an upgrade to older CCM lines, or as a standalone system on new lines. IPCO’s systems are designed to handle all types of chocolates and compounds, of any viscosities.

3D printing chocolate with Print4Taste Startups are a great source of new ideas. This is the case of Print4Taste and its 3D printing chocolate solutions – one of the new businesses showcased in a dedicated space at iba 2023. It manufactures a ‘complete family of chocolate printers’, including units that cost less than EUR 1,000 and can be used by bakery and confectionery shops, as well as caterers and hotels. The plug-and-play machine provides the tools to create unique product interpretations that can set these types of businesses apart, the company believes. For example, the Procusini 3D chocolate printers allow the production of individual lettering or logos for a single cake as well as for

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C H O C O L AT E

a larger corporate event of 250 guests, the company illustrates. The international market launch of the new Procusini 3D chocolate printer showed promise; it is suitable for larger quantities and dedicated to the catering and hotel industry target group. The launch of the Procusini mini 3D chocolate printer should also provide new opportunities, Print4Taste anticipates. Gerd Funk, CEO, explains the company’s approach to the challenges of 3D printing chocolate: “First of all, chocolate is the most challenging product when we talk about 3D food printing. It requires a deep understanding of its characteristics, which are very different from plastic, which is commonly 3D printed.” This is why elements such as overhangs, which can easily be printed with plastic, have narrower limits when using chocolate. “This is the reason why most of our team members have a background in food technology or are a pastry chef,” he adds.

“When using a plastic 3D printer, deep diving into settings is usually required. We are going in a different direction to 3D print chocolate.” Gerd Funk, CEO, Print4Taste

A unique benefit of 3D printing, compared to using molds, is that the process makes sense, creatively and businesswise, starting from a quantity of one. “3D chocolate printing does not require the large quantities that industrial production does. On the contrary, its strength lies in smaller quantities, as it convinces with intricate filigree and individual shapes,” the specialist underlines.

Printing instructions The printing itself may appear similar to plastic 3D printing; but, Print4Taste developed its solutions to be easy to use: “When using a plastic 3D printer, deep diving into settings is usually required. We are going in a different direction. Our target group is highly creative and, at the same time,

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Tempering temperature ranges

+ Milk chocolate – melting: 45°C, cooling: 26°C, and reheating: 29°C

+ White chocolate – melting: 40°C, cooling: 25°C and reheating: 28°C

our customers face challenges like time and cost pressure and problems in finding staff,” Funk says. This is why the Procusini printers are designed following the plug-and-play philosophy, they work without any programming and are quick and easy to clean, in under five minutes. The chocolate 3D printers can be operated either using a Procusini chocolate compound or using other preferred kinds of chocolate. The machine is preset for the Procusini chocolate compound; for other formulations, temperature, speed and flow rate can be adjusted for best results. To be suitable for 3D printing, chocolate requires high viscosity. Print4Taste recommends using dark or milk chocolate with a fat content between 28 % and a maximum of 39 % and a cocoa content of at least 30 %. During printing, it is recommended that the environment does not become too dry and an ambient temperature of 20 – 22°C. The machines come with about 1,000 design templates and more can be made using the ‘Procursini Club’ online platform. Self-made STL-format files can also be uploaded. On request, Print4Taste can also provide design services. With the latest Procusini 3D chocolate printer, 100 – 300 chocolate objects can be produced in a reasonable production time during ‘mise en placed. Several units can be used simultaneously for larger volumes, if needed. Unique hotel eating experiences The company based in Freising, Germany, observes a strong tendency for the hospitality industry to personalize products creatively, especially in terms of chocolate decorations, which can build lasting memories thanks to what their customers called the ‘wow effect’. “Our catering and hotel customers doing events mention that their customers are more and more demanding – they especially ask for differentiation,” Funk reveals. Creating personalized, creative chocolate objects meets these demands: “It is possible to create the motto of a customer’s project for special events, or a company logo and creative hollow molds for the dessert,” he illustrates. It is an experience five-star hotels are able to provide using 3D chocolate printers. With options such as coatings, inclusions and unique decorating elements, the chocolate is the limit to the appeal of new bakery snacks. +++ Part II, to be published in the next issue, will focus on chocolate trends and material innovation.

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OVENS

SUSTAINABLE BAKING

Upstanding oven technology MECATHERM unveiled its latest oven in October last year, at iba. Since then, the M-VT vertical oven has also been presented at Gulfood Manufacturing, which makes two/two for this piece of equipment in terms of trade shows attended vs. awards gained.

The M-VT is the latest entry in MECATHERM’s new generation of ovens designed around sustainability. It combines several new features to support a sustainable baking process for a generous range of products, from crusty to soft, from breads to pastries and patisserie specialties, from cake to brioche. It does so while occupying less space on the production floor, as its baking process is designed to literally aim high.

Going low: energy consumption and carbon emissions The M-VT was made to answer today’s most stringent requirements, from lowering energy consumption, greenhouse gas emissions and overall production costs, and it adapts to changes in portfolio while simplifying work, especially timely given the ubiquitous shortage of staff. To check this to-do list, flexibility was one of the requirements for the drawing board of the M-VT development team, along with the equipment’s ability to support energy transition and high industrial performance. Xavier Gotti, Ovens Product Manager at MECATHERM, explained the company’s perspective on developing the M-VT oven: “In a context of unstable energy prices and therefore production costs, our customers are challenged on the industrial performance of their equipment; they also need to be supported on the issue of energy transition. We have therefore worked to offer them the most compact and sustainable oven on the market, ensuring optimal efficiency, precision and regularity of baking while consuming up to 30% less energy than a standard tunnel oven, for the same production volume.”

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Several aspects contribute to achieving this level of energy savings, starting with its vertical build, which makes it about a fifth of the length of a tunnel oven. This design is instrumental in reducing energy loss, since it minimizes the surface of contact with the outside world. In total, it has an 80% smaller wall surface, so significantly less energy can be lost through the walls. Moreover, by having the tray elevator entirely

OVENS

enclosed inside the oven, any heat loss usually observed when conveying outside the baking chamber is eliminated. Besides using convection heating, which also means the M-VT oven requires lower temperatures when baking, the new heat exchanger reaches 91% efficiency to achieve more energy savings, Gotti explained.

too). The elevator can handle trays of up to 50 kg each. When baking, this means that the intrinsic quality of the products will be preserved, especially in the stage before doughs or batters of various viscosities have baked and solidified. In this way, even notoriously fragile formulations can be baked with the M-VT.

Gotti highlighted an issue in need of quick solutions, with urgency: transitioning between energy sources – for new and existing ovens. This is why the M-VT is electricity-ready, so it can be used with renewable energy. The benefits of an electric power supply are immediately visible when comparing the costs between resources. What’s more, when an oven runs on electricity alone, it does not emit CO2 or smoke. In this mode, energy consumption can be further lowered, by up to 10%, MECATHERM calculates.

It was used to bake cakes during a technology preview event for the press, held at MECATHERM’s Barembach Demo Center ahead of its official launch – a new type of product for an oven of this kind, demonstrating it is able to keep up with the bakery’s trends for “variability, seasonality and quality” while precisely following the required baking curve for the product, Marie Laisne, Marketing Manager at MECATHERM, pointed out. The pilot version of the oven (the M-VT has already received upgrades since this started working, in 2023) running in France features three baking zones, functioning as three independent ovens. The air velocity control can ensure speeds ranging between 10 to 30 m/s (measured at the nozzle).

Energy is also recovered from baking vapors. MECATHERM installed a double heat exchanger on the upper part of the oven, to recover the energy produced by the baking vapors and reinject it, both into the oven itself as hot air, and into the rest of the line, thanks to a hot water circuit. Vapor energy recovery can reach up to 19% of the oven’s energy consumption, according to testing carried out by MECATHERM.

“The big challenge for this new vertical oven is to guarantee an identical energy level for all products. To achieve this, we worked on several parameters including adjusting the speed of the

A new air circuit also contributes to the precision of the baking process – with different requirements for various products. Each module can be independently adjusted so that exact baking curves can be set. Gotti explains: “The big challenge for this new vertical oven is to guarantee an identical energy level for all products. To achieve this, we worked on several parameters including adjusting the speed of the turbine, significant air renewal in each module, and the addition of a flow of hot air under each stack of the oven to homogenize the temperature in the entire baking

turbine, significant air renewal in each module, and the addition of a flow of hot air in the lower part of the oven to homogenize the temperature at the oven entrance with that of the rest of the baking chamber.” Xavier Gotti, Ovens Product Manager, MECATHERM

The oven’s industrial performance is ensured by a new, smart airflow design that can ensure a Δ BCU (Baking Contrast Unit for the product’s color) of around 0.2. The regulated flow of steam injection also contributes to it, thanks to a new steam header for even steam intake.

The M-VT convection oven is designed around new kinematic principles, having its shock-less conveyors with swings that smoothly rotate – a tall carousel with motions so fluid that a glass with water placed on it will not lose drops or even have the liquid reverberate while it completes the circuit (and the accuracy remains the same with heavy loads,

Going high: literally

OVENS

chamber. Thanks to all these developments, our new M-VT oven delivers very homogeneous products.”

What is hygrometry? Hygrometry control is a new, patent-pending feature developed for this oven. Aside from temperature, baking time and airflow, humidity is another variable that can perfect product quality. The Hygro Control System manages the humidity level of each baking chamber. It automatically regulates the opening of the steam damper, the entry of dry air and the management of steam in the baking chamber. By minimizing fresh air entry and steam injection into the oven, this new feature contributes to optimize energy consumption during baking. Precise management of hygrometry results in more precise control of certain product characteristics such as its crust thickness, softness, or water loss, MECATHERM explains. It ensures high baking homogeneity, with a guaranteed hygrometry setpoint regardless of fluctuations that might occur in production. The Hygro Control System is not exclusive to the new M-VT, as it can also be retrofitted on existing ovens. “This is a new parameter, which could not be set up before. Hygrometry rates can be adjusted to each module, to control product characteristics such as crustiness, product softness, or water loss,” Laisne explains.

The M-VT oven user guide For easier cleaning and maintenance operations, the M-VT provides ample access: everything that needs regular checks has been positioned on the lower part – including the conveyor motor and the steam system. Parts with fewer maintenance needs are placed on the oven’s sides. There is no need to climb on the roof of this tall oven for any maintenance procedures, so its space requirements do not move from the floor vertically. With a footprint of 31 sqm for two modules, it has an available baking surface of 115 sqm; it is simply a compact machine. Depending on the number of modules which can go up to seven, the total baking surface can go as high as 400 sqm. It can work with pan sizes of 1,200 x 800 mm and 2,000 x 800 mm. The M-VT has four large doors – a new feature – which allow full access to the internal conveying system. The swings can

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Energy consumption along the baking line

+ Dividing and forming......................................................... 1% + Proofing................................................................................ 3% + Baking and steaming...................................................... 60% + Cooling............................................................................... 12% + Freezing.............................................................................. 20% + Pan drying........................................................................ 3.5% + Scoring, depanning, pan brushing, storing, conveying.......................................................................... 0.5%

be easily removed from the conveyor and cleaned outside of the oven. The baking chamber was also designed for easy cleaning. Its bottom is flat and slightly curved, featuring draining ducts. Optionally, a stainless-steel version is also available so that the oven can be washed down. The oven management is automated so that it independently adjusts actuators to reach the optimum balance for minimum energy consumption, based on presets for all four baking parameters (temperature, baking time, air speed and humidity rate). Moreover, as a new piece of equipment should, the M-VT oven is fully connected to manage production data, consumption monitoring, as well as preventive and predictive maintenance through the Mecatherm interface. It comes with several digital tools that streamline its day-to-day use and gain important insights into its operation. It is equipped with sensors on a large part of the actuators, so that it collects data, compiles performance reports, and monitors its energy consumption. The oven also helps minimize waste, by automatically detecting and adjusting to the load introduced for baking. By recirculating the air in the oven every 5 seconds, the trays entering production first after changeovers will only be minimally affected by the flash heat effect, so the quality will remain consistent, with no need to discard products. After its official launch at iba, the M-VT entered the pre-series sales phase, a limited number of installations with selected partners. Following some adjustments, the series sales will be open soon. +++

Source: MECATHERM

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INSPECTION, MONITORING

An automated eye for detail All information is valuable information in the realm of inspecting products throughout the entire manufacturing process, through to packaging. Automated inspection systems are able to guarantee top product quality and safety – no exceptions allowed.

By Yuegang Zhao, Chief Commercial Officer, KPM Analytics

In-line vision inspection technologies comprehensively inspect 100% of the products throughout the entire manufacturing process. This can be achieved with two types of systems: Vision Process Control systems (VPC) and Final Product Inspection systems (FPI). Vision inspection was initially developed for FPI systems applications to verify final products for visual traits and brand standards before packaging. While these technologies streamline inspection by taking and analyzing objective measurements, baking companies now have several options to deployvision inspection to help them close the loop on quality control. VPC systems can be installed at key production process stages – before or after baking. Using multiple VPC systems makes it possible to monitor different production phases in real-time and, if necessary, fix issues causing non-compliant products, minimizing waste and ensuring product safety, with no exception. Combining VPC with FPI means total control of the manufacturing process is available, with the tandem of systems providing actionable data and an overview of the process capabilities of the production facility. This is a step toward a smart factory environment.

Integrating vision systems Every baking operation is unique. Similarly, vision inspection integration is an iterative process that will uniquely match each respective setup. For companies considering vision inspection in their operation, the best route is to begin focusing on the most critical individual traits of the most important products in the production portfolio. It may be the baked color of a type of cookie, the uniform diameter or height of a bagel, or the distribution of toast marks on a tortilla; whatever those one or two features may be, this is where to begin the journey.

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It is also essential to engage the Quality Assurance and production teams early and often through the integration process. Aligning everyone’s expectations will contribute to the development of a solution that suits all the operation’s specific needs. This leads to the design of a vision inspection solution with reasonable tolerances for quality and consistency.

“Combining VPC with FPI means greater control of the manufacturing process is available, with the tandem of systems providing actionable data and an overview of the process capabilities of the production facility. This is a step toward a smart factory environment. ” Yuegang Zhao, Chief Commercial Officer, KPM Analytics

Camera configurations are among the details established based on specific production needs. There are several factors that contribute to selecting the most beneficial camera configurations, including whether it takes 2D vs 3D measurement, the camera itself (its resolution), and its placement – whether it is a top vs bottom camera, or installed in parallel across the conveyor belt. The choice of camera configurations is optimized for cost and performance for each production line. Rejection mechanisms are also uniquely set up around the production environment. When selecting the best sorting/ rejection technology to pair with a vision inspection system, there are several important considerations that should be factored into the evaluation. These include the physical properties of the products being inspected, the operating speed (e.g., throughput) of the production line, the production line

INSPECTION, MONITORING

configuration, material handling requirements and compliance reporting requirements. In some cases, the value of a rejected non-conforming product may recommend re-processing the item, rather than directly discarding it. In such cases, the redirection system can be used in place of a rejection system to reroute the flagged product for secondary inspection or other processing. For example, when dealing with small or lightweight baked goods, air jets installed above or to the side of the product are one method to isolate or redistribute products, based on their measurements. Larger items may need a servo-driven paddle, a pusher system, or other product-specific rejection method. Each vision inspection system can also come with its own visual dashboard that can be displayed on a large display above the production floor, or virtually so that it can be accessed anywhere within the plant. The dashboard displays real-time production information such as the number of products inspected, yield, uptime, etc.

The EyePro Q -Bake Vision Inspection Systems from KPM Analytics are specifically tailored for high-volume baking operations to maximize productivity, optimize the inspection process and reduce waste. Each system is installed directly onto the production line to measure products for various visual traits, including 2D/3D height, bake color, shape, length and width. Moreover, other detailed measurements can also be made, such as the inclusion coverage (chocolate chips, seeds, etc.), the product shine, and foreign object detection.

Another frequently used optional feature is having a lane balancing system after the final product inspection. For certain products such as bagels, the lane balancing system helps optimize the flow of the product before entering the packaging machine, to prevent jamming and improve productivity.

The root cause

Rheological instruments can be incorporated in this effort, to quickly analyze incoming flour from millers and suppliers. One such rheological instrument is the Mixolab 2, a universal dough characterizer that measures the constraints flour goes through from the mixing process to baking, providing comprehensive information on protein, starch, improvers, enzymes, and all interactions among them. Mixolab 2 helps to provide ‘acceptance curves’ for flour quality based on these analyzed parameters.

Once vision inspection systems are in place, the next step in production efficiency is to investigate the root causes of the defects and how to minimize them. This requires bakers to go upstream in the production line and inspect dough and flour properties according to their production recipe. Some bakeries are even exploring new uses for vision inspection technology in combination with their flour and dough analysis efforts.

Vision inspection aids in the creation of these quality standards by verifying product appearance at various process stages. By matching the final baked product outcome from a baking test against the analysis curve from Mixolab 2, bakers can more accurately assess whether a new flour delivery will adapt to produce the desired final product. +++

Q-Bake systems feature product-specific software that takes into account all the predefined measurements of interest for the specific product. Users can set the limits of tolerance for each measurement and add new measurements whenever necessary.

F L AT B R E A D S

Around the world with flatbreads Bread, a staple of the daily diet, has a history intricately linked to human civilization. Among its myriad forms, ‘flat’ breads stand out due to their distinctive thinness, ranging from mere millimeters to a few centimeters in thickness.

These ancient breads, originating from varied parts of the world, have found their way from the Fertile Crescent to regions including North Africa, Southern Europe, the Middle East, the Anatolian peninsula, the Indian subcontinent, the Caucasian region, Xinjiang, and the Arabian Peninsula, with connections extending to the Horn of Africa. In the Americas, flatbreads are prevalent too, especially in Central and South America, and also among Native American communities. Flatbreads contribute significantly to the sustainability of food systems. They can be made from various cereals, pseudocereals, or pulses, promoting the use of local produce from marginal lands. Their short baking times, which can even eliminate the need for an oven, reduce energy consumption. Additionally, their ability to wrap around food or serve as utensils lessens the need for tableware and saves water. Their compactness during transportation reduces energy impact, and when baked dry, they have a prolonged shelf life, minimizing waste. Despite their ancient origins, flatbreads remain popular today. They can be produced traditionally or through modern, fully automated industrial processes. They are versatile, often used as a base for street foods like döner kebab, shawarma, gyro, Italian pizza, focaccia, and French fougasse, which are enriched with various ingredients. The demand for ready-to-eat foods has led to a significant increase in the consumption of flatbreads, with the global market expected to grow substantially.

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However, there is still potential for improvement in both technical and nutritional aspects. The fast, high-temperature baking process can cause quality issues, such as uneven cooking and the formation of harmful compounds like benzopyrenes and polycyclic aromatic hydrocarbons (PAHs). New baking systems, such as indirect heating with rotary baking trays, and Bake Off Technology (BOT) for domestic baking, show promise. Moreover, flatbreads offer opportunities for nutritional enhancement through fortification with various animal or plant-based ingredients, boosting protein and micronutrient content.

“Incorporating optional ingredients not only improves the processing quality but often enhances the nutritional value of flatbreads, leading to the creation of specialty and novelty products.” Dimitris Agryriou, Food Scientist, Managing Director, Grainar

Fact: The global flatbread market size was valued at USD 38.8 billion in 2018, then increased to USD 41.17 billion in 2019, and is estimated to reach USD 62.8 billion by 2026, at a compound annual growth rate of 6.2% (Allied Market Research, 2021). Flatbreads are generally made from flattened dough of flour, salt, water, and yeast. The main production steps are kneading of ingredients, leavening (optional), shaping and baking.

F L AT B R E A D S

Owing to their unique composition and preparation techniques (Figure 1), various classifications have been proposed to categorize flatbreads. Broadly, flatbreads can be divided into two main types: single-layered and doublelayered. Single-layered flatbreads are typically categorized into two subgroups: leavened and unleavened. Leavened flatbreads are created from semi-fluid batters or doughs. An example of a flatbread made from a semi-fluid batter is the Ethiopian injera, often made from gluten-free cereals such as rice, sorghum, teff, maize, or black beans. These batters are usually fermented twice before being pan-baked. The fermentation process, involving lactic organisms and yeast, imbues these breads with prebiotic and probiotic benefits. Alternatively, leavened flatbreads from doughs are allowed to rise twice before being baked at high temperatures in an oven. Unleavened single-layered flatbreads, like roti, tortilla, and paratha, typically measure 12–25 cm in diameter and have a thickness of 1.3–3.0 mm. They are traditionally cooked on a clay griddle like naan, iron pan like roti, or fried with oil like paratha or deep-fried like poories. These frying methods impart unique organoleptic properties, identified by specific compounds like δ-decalactone-oily/peach, 2-acetyl-1-pyrroline-roasty/popcorn-like. However, due to their high fat

Semi-fluiddough, leavened; Baked on fire plate Dough consistency and baking method

content, these fried flatbreads are generally less recommended for consumption. Industrially, flatbreads are produced using methods such as hot-press, die-cut, and handstretch. Double-layered flatbreads, like Arabic flatbread pita and baladi, undergo a dual rising process and expand during high-temperature baking (350–600 °C), forming a balloonlike shape with distinct upper and lower surfaces. This expansion is influenced by the viscoelastic properties of the flour, which typically has high gluten content. After baking and cooling, the balloon deflates, resulting in a soft, flexible flatbread ideal for stuffing with meat and/or vegetables.

Main ingredients used The quality of flatbread is significantly influenced by two primary factors: the genetics of the wheat and its growing conditions, and the quality and quantity of raw materials used in conjunction with the breadmaking methods. High-quality flatbread is characterized by its ease of digestion, a delightful and fine aroma, and a texture that neither crumbles too easily nor stales rapidly. Flour For flatbreads like lavas, taftoon, barbari and sangak, the preferred flour is usually soft white wheat flour with higher extraction levels. It is generally observed that for several

Anjero/Canjeero Dosa Kisra Injera Lahoh Marquq/Markouka Pitha Ruqaq/Roqaq/Raqaq Unleavened; Baked on fire plate or in vertical oven

Compact and elastic dough

Figure 1: Types of flatbreads

Chapati Kesra Rakhsis Roti Yufka

Baked in vertical oven; Single-layered bread Leavened

Baked in domed oven

Consistent dough, which can be sheeted The two layers are seperated and submitted to a second baking c Baked on a layer of red-hot pebbles a b

Barbari Bazlama Chorek Khameerie roti Malooga Mtlouh/Matloua/Makla Matnakash Naan Patyr Pide Spianata di Ozieri Tachnift Taftoon/Taftan Baladi Tamees Barbout Carasaub Dingle-layered Pistoccub bread Pita Samoon Single-layered bread

Nan-e Sangakc Tafarnoutc

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Source: A. Pasqualone, Tecnica Molitoria International, Yearly issue 2018

Flatbreads categorization

F L AT B R E A D S

types of flatbread, flour with an extraction rate of 80% or less is ideal. Extensive research has been conducted to identify the most suitable type of soft wheat flour for flatbread production. For instance, soft white wheat has been found to be optimal for making baladi bread. In the context of Arabic bread, which is a double-layered flatbread, the finest quality is achieved using hard wheat flour with a protein content of 10-12% and over 6% of damaged starch. Mixing durum wheat flour with Indian wheat flour has been shown to enhance the quality of Chapati. Durum wheat flour, known for its higher starch damage during the grinding process, results in a softer crumb in flat bread due to increased water absorption and starch gelatinization. The water absorption rates of flours used in flatbread production vary widely. While flour for pan bread typically has an optimum water absorption of 60-65%, the range for flatbread flour can be between 38% and 85%. Water Water plays a crucial role in achieving a homogenous dough mixture, providing the desired visco-elastic structure, and significantly impacting the final product's quality. It acts as a solvent for various organic and inorganic substances, aiding in the dissolution of hydrophilic components like salt and sugar, and facilitates the formation of gluten. Salt The use of salt, one of the four basic components of bread dough, is essential for high-quality bread. It should dissolve well in water and be physically clean, bright, and white. Yeast Regarding leavening agents, flatbreads can be either leavened, using bakers’ yeast or sourdough, or unleavened. Bakers’ yeast contributes to the aroma, matures the dough through the fermentation of fermentable carbohydrates, and aids in dough rise through CO 2 formation. Sourdough, a mixture of flour, salt, water, and a piece of dough from previous baking, involves a complex interaction of lactic acid bacteria and yeasts. Sourdough fermentation can improve the texture and palatability of various bread types, stabilize or increase levels of bioactive compounds, reduce starch bioavailability (resulting in low glycemic index products), and enhance mineral bioavailability.

Key production steps 1. Mixing and kneading: The process begins by combining wheat flour with ingredients like salt and water, and often bakers’ yeast or sourdough, to create a dough. This step is crucial for blending all elements uniformly. 2. Resting: Unlike fermented breads, many flatbreads are made from unleavened dough that doesn’t undergo fermentation. Therefore, the dough is typically allowed to rest for 30 to 60 minutes. This resting period is essential

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Figure 2: Hot plate oven for products such as Yufka and Gozleme

for the dough to absorb water, which aids in the development of starch and proteins. However, too long a rest can negatively impact the quality of the flatbread. 3. Fermentation: For flatbreads requiring fermentation, the dough is leavened with bakers’ yeast or sourdough. This process produces carbon dioxide and ethanol, causing the dough to rise. Fermented doughs often have enhanced flavor, texture, and longer shelf life. 4. Dividing, rounding, sheeting: The dough is divided into portions and rounded to improve gas retention and facilitate shaping. The thickness of the dough sheet, which ranges from 2 to 10 mm, is critical and varies based on the type of bread. This stage also involves removing gas from the dough structure. 5. Baking: Flatbreads are baked at high temperatures (typically between 350-550°C) in specialized ovens or on hot plates (see above). The baking time and method vary depending on the type of flat bread. For example, some are baked quickly on a hot plate, while others are baked in an oven for a longer period. The high temperature and baking duration are key factors in achieving the desired crust characteristics.

Key types of flatbreads around the world 1. Chapati: A staple Indian unleavened flatbread made from whole wheat flour; chapatis are usually consumed fresh. They are round, about 15 cm in diameter, and 2 mm thick, often prepared in homes and commercial kitchens.

F L AT B R E A D S

2. Tandoori Roti: An unleavened Indian bread, baked in a clay tandoor oven for 60-90 seconds, made from a simple dough of flour, water, and salt. 3. Sangak: A leavened Iranian sourdough flatbread, 7080 cm long and 3-5 mm thick, baked on hot pebbles and often topped with sesame or poppy seeds. 4. Tanoor Bread: Popular in southwestern Iran, this leavened, docked bread is made with flour, yeast, salt, and water, and is known for its reddish-brown crust and uniform thickness. 5. Rye Flat Bread: Common in Scandinavia, this bread mixes barley, oat, and rye flours, and is baked on a hot plate. The Finnish version includes a well-developed sourdough starter. 6. Parotta: A South Indian unleavened flatbread, circular and creamish white, known for its soft, chewy texture and distinct layers. 7. Tortilla: A staple in Central and South America, these thin, unleavened flatbreads are made from maize or wheat flour and are versatile in use.

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8. Pita: A Middle Eastern leavened bread with a unique pocket, made from flour, water, yeast, and salt, and baked at high temperatures to create its characteristic two-layered structure. 9. Bazlama: A Turkish single-layered, leavened bread, circular in shape with a creamy yellow color, typically about 3 cm thick and 10-20 cm in diameter.

Shelf life enhancement in flatbreads Flatbreads, valued for their taste, aroma, and texture, tend to stale quickly due to lean formulations. This staling, marked by firmness and altered organoleptic qualities, diminishes consumer acceptance. With lifestyle changes, urbanization, and a shift towards convenience foods, there’s a growing demand for fresh flatbreads. Large-scale production, mechanization, and packaging that preserves the bread’s sensory characteristics are required. New technologies and processing conditions have been developed to combat staling and extend shelf life. This includes altering recipe components and modifying process conditions to provide fresh bread at any time. Emulsifiers like Glycerol Monostearate (GMS) and Sodium Stearoyl Lactate (SSL) have been effective in reducing staling, particularly in Chapatis stored at ambient and refrigerated temperatures. They help by forming complexes with starch, maintaining moisture content and reducing starch

solubilization. Surfactants can form complexes with amylose and amylopectin, contributing to bread softening. This interaction helps in preserving the freshness of the bread. Hydrocolloids such as guar gum enhance the extensibility of both fresh and stored flatbreads, contributing to longer shelf life. Alpha-amylases of the maltogeMIC type A are used to slow down the staling rate of flatbreads. These, along with water, act as plasticizers, preventing the rigidity of starch and gluten chains, thus extending shelf life. Various wrapping materials have also been explored for packaging flatbreads, showing potential in keeping them fresh during storage and distribution.

Nutritional value of flatbread The nutritive value of flatbread is fundamentally linked to the chemical composition of the flour and additional ingredients used in its preparation. Incorporating optional ingredients not only improves the processing quality but often enhances the nutritional value, leading to the creation of specialty and novelty breads. The main ingredient in flat breads, wheat flour, significantly influences their nutritional quality. The use of wheat flour with different extraction rates in flatbread production markedly affects its nutritional profile. Lower extraction rate flours reduce the content of minerals and other phytochemicals in flat breads, whereas higher extraction rates result in increased levels of protein, fiber, sugars, lipids, and minerals, along with a reduction in starch content. Flatbreads made from whole wheat flour

Table 1: Nutritional profiles of the main flatbread types Tortilla

Pita bread

Naan

Parathas

Focaccias

965

635

729

379

773

Energy (kcal/100g)

295.10

262.35

282.98

306.39

286.10

Fat (g/100g)

6.84

2.44

6.36

11.37

8.81

Of which saturated (g/100g)

1.98

0.53

1.45

5.23

2.03

Carbohydrates (g/100g)

49.63

50.67

48.1

44.97

43.68

Of which sugars (g/100g)

2.82

2.59

3.74

3.41

2.70

Fiber (g/100g)

5.06

3.90

3.12

3.96

3.20

Protein (g/100g)

8.48

9.31

8.13

6.92

8.00

Sodium (mg/100g)

573.43

467.41

522.97

371.28

569.22

Number of products tested Average values of nutrients

Source: Table 1 is based on Mintel’s GNPD database, using the following criteria: food category ‘Bread & Bread Product’; launched from January 2015 to December 2021.

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are particularly noted for their higher levels of nutrients and minerals. Consumer perceptions of flatbread quality are largely based on sensory experiences and health attributes. In line with the increasing awareness of healthy lifestyles, breads containing whole grain, multi-grain, or other functional ingredients are becoming more prominent in the market. Enhancing the nutritive value of flatbreads can also be achieved by incorporating grains like rye, barley, and oats into the bread formula. However, it’s important to note that the levels and availability of bioactive compounds in these cereal grains may vary during bread production. Additionally, the nutritional value of flatbread is influenced by its interactions with companion foods, which can affect the overall nutrient availability and health benefits.

tradition and modernity. As symbols of cultural heritage, they remain integral to our diets even amidst evolving culinary trends. Flatbreads have changed to fit modern tastes and health needs. They are a big part of street food culture and are now being made healthier to meet what people want today. This shows how flatbreads have grown from being an ancient basic food to something that brings together old traditions and new ways of eating. +++

About the author Managing Director at Grainar, Dimitris Agryriou is a team leader and scientist in product and service development for the bakery and milling industry. In his work, he explores the latest developments in biotechnology, cereal chemistry and industrial analytics. He is a subject matter expert on bringing

Conclusion In conclusion, flatbreads, encompassing varieties like naan, pita, and focaccia, are today a remarkable blend of

Selected references

improver performance with rheology and baking with the help of analytics. Contact: dargyriou@grainar.com

4. Mintel. (2020). A year of innovation in bread & bread products, 2020 – Mintel

1. AlliedAnalytics. (2021). Flatbread market size 2021 | business status, industry trends and forecast to 2026 | allied market research – EIN Presswire www. einnews.com/pr_news/557304899/flatbread-market-size-2021-business-status-

https://clients. mintel.com/report/a-year-of-innovation-in-bread-bread-products2020?fromSearch = %3Ffreetext%3Dbread%2520types 5. Mintel. (2021). Mintel global new product database www.gnpd.com/sinatra/ search_ results/?search_id = 3tMdwh5e47&page = 0

industry-trends-and -forecast-to-2026-allied-market-research 2. AlliedMarketResearch. (2021). Flatbread market size and demand | industry research report, 2026 www.alliedmarketresearch.com/flatbread-market 3. Boukid, F. Flatbread-a canvas for innovation: A review. Appl. Food Res. 2022, 2,

6. Pasqualone, A. Traditional flat breads spread from the Fertile Crescent: Production process and history of baking systems. J. Ethn. Foods 2018, 5, 10–19 7. Qarooni, J. Flat Bread Technology; Chapman and Hall: New York, NY, USA, 1996; p. 208

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