baking+biscuit 2022-04 digital

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Meet Kwik Lok's

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In the spotlight FRITSCH and MULTIVAC interview

Production The energy-efficient light at the end of the tunnel oven

Events IBIE special, südback preview

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EDITORIAL

The key to bread Katz Bakery is a traditional bakery in the Stuttgart region, with around 1,000 people in all its subsidiaries. It specializes in spelt, which it also farms, and it bakes all of its products with fresh dough, every day. Katz uses wood-fired ovens for breads and rolls, and makes about 1,500 breads per hour. This bakery uses a special spelt sourdough, a 20-year-old strain started by the previous generation owner. The spelt sourdough is prepared by hand, true to their artisan baking tradition. “The key to bread is the time you put into it. Theoretically, you could make a bread in two hours; but, our sourdough is cured and rested,” Nickolas Katz, the fifth generation business owner, highlighted. One of the bakery’s specialties are oversized pretzels, which are used as a sandwich base. I visited his bakery in July, as part of the südback press tour. As most of the work is carried out at night, our group of journalists and fair organizers was welcomed in the production area in the afternoon.

Katz also prepares cakes, confectioneries, and berliners in the cold season using thermo-oil ovens for the cakes.

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

Tradition does meet modern technology here, even though handcrafted products prevail: not long ago, the bakery renewed its bread ovens, with new equipment from MIWE. While there is plenty of space for day-to-day work, the ovens were simply too big to be brought in. They had to therefore be lowered in through the roof, after the old ones left via the same route. The roof was dismantled and has now been rebuilt to open when the need arises in the future.

Katz was one of several bakeries to which Messe Stuttgart granted us access, in anticipation of the trade fair to be held in October. It aims to return as a ‘campfire’ for bakers to reunite around, as Marcus Höffer, marketing manager of the BÄKO organization, explained at the conference.

Before then, another highly-anticipated event is taking place: IBIE returns in September, the Baking Expo, to which we are a Gold Media Partner. IBIE will gather in Las Vegas for the industry with all the innovations we have not been able to see in person for the past two years. A preview of the novelties that exhibitors are putting on display is in the pages of this magazine.

One thing is certain: both of these exciting events are back with a complete range of solutions for their target audience, which are bound to provide an entire chain of keys to baking the best version of every kind of bread. The F2M team will travel to these must-attend events, and analyze the new solutions and innovations showcased there. See you in Las Vegas, and then in Stuttgart!

Catalina Mihu

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CONTENTS

COVER STORIES

HIGHLIGHTS

IBIE PREVIEW There’s no place like IBIE.

14 Jorge Zarate

After unprecedented disruptions in the industry, anticipation is high for the industry to return to IBIE, which will showcase new consumer, © IBIE

© FRITSCH

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technology and business trends.

IN THE SPOTLIGHT FRITSCH was acquired by the MULTIVAC group and with that it joined a network of resources helping it thrive. Guido Spix, Group President, MULTIVAC (right) and Frank Gabriel, Managing Director, FRITSCH (left) explain how the companies help each other to grow together.

56 © IBIE

© Messe Stuttgart

18 EVENTS

EVENTS

südback confirms its support for in-person events as prepara-

As the highly-anticipated Baking Expo (IBIE)

tions are in full swing for this year’s edition. The show will be

is approaching, exhibitors are preparing their

held once again from October 22 to 25. The return of one of

stands to once again welcome visitors to the

Europe’s main industry trade fairs is highly anticipated.

trade fair in Las Vegas.

PRODUCTION The energy-efficient light at the end of the tunnel oven

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INTERVIEW Judith van Peij has been with Royal DSM for 10 years, and has been

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the Innovation Manager for Baking & Confectionery for the past three. © Royal DSM

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© tannujannu and Worawut – stock.adobe.com

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She is a food technologist at heart, with a clear vision of managing R&D teams.

CONTENTS

IN THE SPOTLIGHT 06

Interview: Best practice in innovation, operation, and teamwork – FRITSCH and MULTIVAC

IBIE 2022 SPECIAL 14

Event preview: There’s no place like IBIE

18

Exhibitor showcase: A guide to IBIE’s exhibition stands

PRODUCTION 26

Tunnel ovens: The energy-efficient light at the end of the tunnel oven

36

Coatings: Coatings do make the pan

44

Koenig: Smart scoring innovation is here

46

Diosna: Automation – Ready, set, dough!

RESEARCH 48

Science: Activities of exogenous enzymes in baked products

64

NumberOne

Campden BRI: Strategies to improve sustainability credentials in bakery

PIZZA 40

Bakeware & Coating

AMF Bakery Solutions: Thinking all around the pizza box

EVENTS 56

Trade show preview: südback makes a strong comeback

WOMEN IN BUSINESS 58

Interview: Judith van Peij, Innovation Manager for Baking & Confectionery, Royal DSM

MARKET 63

Food waste: Consumer consciousness has more than doubled

REGULARS 03

Editorial: “The key to bread”

54

News

70

Advertiser directory

Cover photo: Kwik Lok

bakeware and coating

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IN THE SPOTLIGHT

GROWING TOGETHER

Best practice in innovation, operation, and teamwork FRITSCH was acquired by the MULTIVAC group and with that it joined a network of resources helping it thrive. These include everything from R&D to day-to-day operations, with the information exchange going both ways. Guido Spix, Group President, MULTIVAC and Frank Gabriel, Managing Director, FRITSCH explain how the companies help each other to grow together.

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Mihu: To show how the two companies are growing together, it would be interesting to learn how they came together in the first place. Why did MULTIVAC acquire FRITSCH, considering the types of technology each specializes in developing?

Guido Spix: FRITSCH was well known at MULTIVAC, from a large number of projects involving both companies in the past. A good example is the packaging of pretzels for baking stations. MULTIVAC'S strategy to grow as a solution provider in processing has been complimented in an excellent way with the acquisition of FRITSCH. The information that FRITSCH was available for acquisition came to us by chance. However, we immediately saw the opportunities in the acquisition, starting with the similarities in engineering between the two companies. While the industries we serve are different, from an engineering standpoint the companies are closely related. We realized from the beginning that the idea of having both companies under one roof was going to work out perfectly.

And last but not least, I am proud to say that MULTIVAC is an outstanding mechanical engineering company. We very quickly recognized that FRITSCH, an extremely innovative company, could benefit from our ‘operational excellence’.

Innovation is a very important part of our overall strategy.

Both companies are leaders in their fields with innovative products. We work systematically on joint solutions, both in automation and technology.

Frank Gabriel: During MULTIVAC’s due diligence process, it became apparent that FRITSCH had wonderful expertise in innovative solutions, in bakery products, and the highquality of the end products – for which they had earned respect in the market.

There was also potential for further improvement, areas where MULTIVAC could provide feasible solutions with an immediate positive impact on FRITSCH’s business, such as access to a global production network, co-developments, or international sales and service, just to name a few. We were able to directly integrate these benefits into our daily work, especially in what Mr. Spix referred to as ‘operational excellence’ and in mechanical engineering. FRITSCH enjoyed some benefits right after the acquisition, such as access to wet-cleaning, wash-down design, which is very well-known

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in the meat and packaging industries and is seeing a rise in demand in bakery. We could immediately adapt this knowledge from the MULTIVAC Group. Weighing technologies are another similar example. Now we can invest the time saved in further high-end products and customerspecific innovations. Conversely, MULTIVAC were able to gain further insights into the design of complete lines, as customers in the food industry prefer more and more complete lines, to reduce complexity and focus on their core business. We could see from the beginning that this is a good fit.

EUR 35 M THE VALUE OF THE ORDERS FRITSCH RECEIVED IN Q1, 2022 Mihu: FRITSCH has already introduced new technology developments to the market since its acquisition by MULTIVAC. How do the R&D teams at the two companies collaborate?

Guido Spix: We have an innovation strategy for our company. MULTIVAC has been a known solution provider for many years, and so has FRITSCH. MULTIVAC implemented an agile development process very successfully many years ago and has repeatedly adapted and improved it to new boundary conditions. We also introduced this innovation strategy at FRITSCH immediately after the takeover. We have a combination of engineering and digitalization that also works perfectly for FRITSCH. Moreover, we focus on sustainability in packaging, which is something that FRITSCH customers are now increasingly looking for as well.

The first resulting products have already been successfully delivered to customers. There is a lively exchange and good cooperation in all technical areas. For me, this must by no means be a one-way street. The parent company has learned a few things from FRITSCH. Both companies are really growing together.

IN THE SPOTLIGHT

Regarding ‘operational excellence’, I can proudly say that MULTIVAC ranks high. We work extensively on having very well-designed processes for operations, starting with the R&D process, right up to customer delivery. In this regard, FRITSCH was not process-oriented as much in their business and they could learn easily from and adopt the ideas we had at MULTIVAC. We found a group of people at FRITSCH who are open to this support, to clearly define the processes. This is working out very, very well.

A well-coordinated fleet Mihu: And how did R&D adjust from FRITSCH’s perspective?

Frank Gabriel: The adaption of the new R&D process offered us a full view of the complete product life cycle and expanded our focus beyond launching products to the market.

The next steps were to have them available worldwide and to provide service. It helps us to collaborate and synchronize information with the teams from MULTIVAC worldwide. In this way, we could significantly improve our time-to-market.

We also gained access to established MULTIVAC technologies, such as weighing solutions, which were quickly adapted to the special needs of the bakery environment.

It’s easy, simple and without boundaries to collaborate and adapt existing solutions within the same family.

Guido Spix: MULTIVAC is a huge company, with EUR 1.5 bn turnover, which is why it may be seen as one huge ship navigating a world of markets in a straight line. That is not correct. We are a group of small companies, ‘speedboats’, as we call them; we have a ‘speedboat’ for TVI meat portioning and a ‘speedboat’ for tray sealing technology, for example; and, among them, a ‘speedboat’ called FRITSCH. These are all smaller companies, which are used to handling smaller businesses. FRITSCH fit right into this 'fleet' of smaller, ‘speedboat’ businesses, and we were prepared to handle it as such. It was not something new to MULTIVAC; it wasn’t a ‘big ship’ taking over a smaller company, but rather FRITSCH joined an agile fleet of several other smaller businesses. Quite the opposite: looking at the growth potential of FRITSCH, it is going to be one of the big ships of the Group very soon. We are very delighted about the journey.

boundaries to collaborate and adapt existing solutions within the same family.”

Frank Gabriel, Managing Director, FRITSCH

© FRITSCH

Mihu: That is a great analogy! In line with this idea, it appears the benefit for each company is in the network of small ‘speedboats’. What does each stand to learn from the others?

Frank Gabriel: In this analogy, we are, indeed, a ‘speedboat’ connecting to a network of ships. MULTIVAC is providing the communication system and the radar and the process optimization. When you spread a network, you gain more eyes throughout the ocean. One key success factor for the takeover was that both companies shared similar values and culture, with a focus on learning, expertise, and innovation. From the beginning, all discussions and collaborations were at eye level, still acknowledging the differences

“It’s easy, simple and without

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IN THE SPOTLIGHT

“Looking at the growth potential of FRITSCH, it is going to be one of the big ships of the Group very soon.”

Guido Spix, Group President, MULTIVAC

© MULTIVAC

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in the different market segments. Our teams quickly identified the strengths of each party and the potential of generating further product and process innovation. This paid off immediately, as our newly co-developed PROGRESSA bread stands to show. Our MULTIVAC colleagues are also learning from our expertise in creating big lines.

The work behind innovations Mihu: The common drive for all of the Group’s ‘speedboats’ is in their views on innovation. What are the priorities for innovation at FRITSCH and MULTIVAC, respectively?

Guido Spix: The biggest strength of the MULTIVAC Group is its worldwide sales network. We are working globally with our own people. With FRITSCH, we just add to the technologies and product portfolios that we offer through this network. In addition, we now have a common R&D process with the same criteria on how to find the right products for our portfolio development and innovative ideas. We also have a significant amount of standardized methods (e.g., for purchasing components), a common framework for our software and our digitalization, and we use the same tools. We do not need to invent anything from scratch and can instead focus on having the right technology and innovating for each specific market.

Frank Gabriel: It is also important to mention our view on innovation and what we gain from collaborating with MULTIVAC. Aside from the benefits related to technical

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features, we were also able to get closer to our customers.

We already had the dough handling expertise, but now we can listen to more customers in more parts of the world, for information about real production needs. This in itself helps us to further our innovations and to assess the needs of multiple customers, compare similarities in demands and support with special requests in different parts of the world.

Having this comprehensive view of our customers helps us tailor new innovations according to aspects we learn.

PROGRESSA by FRITSCH, a MULTIVAC company Mihu: One of the solutions FRITSCH recently launched is the PROGRESSA bread, the first release of the two teams working together. What were the steps in developing and perfecting it? Please share a timeline and the project stages, starting with the contouring of the concept and the work of the teams involved.

Frank Gabriel: FRITSCH had the idea for the PROGRESSA bread. The cornerstone for this project was laid in 2020, when we saw the chance to enter a new market of high demand for end-product quality, soft-dough products, and the highest flexibility in equipment for mid-size production volumes. This was during the pandemic, with the target of developing it in less than two years. Based on our established technologies from the IMPRESSA lines, our FRITSCH experts had great ideas on how to adapt those for mid-size production requirements. We also wanted to integrate

IN THE SPOTLIGHT

Mihu: How did the two teams cooperate on this project?

What priorities were brought to the drawing board and what challenges need dedicated solutions?

Guido Spix: MULTIVAC is a group of companies working very closely together. Taking advantage of synergies is part of our DNA. There are barely any days where there are no visitors from FRITSCH in Wolfertschwenden and vice versa, now that the restrictions have been lifted. We have working groups in many fields: digitalization, software framework, hygienic design, strategic procurement, CAD, and PDM, to name some of them. In Sofia, we have a group of engineers working for FRITSCH and for other MULTIVAC companies.

Besides that, FRITSCH becomes part of the MULTIVAC Production Network. MULTIVAC has always had a high percentage of in-house manufacturing. Today, we have 13 production sites, and one additional site is under construction in India.

The R&D management of the whole group meets every three months. In these meetings, we share best practices and future projects. We have a group-wide developing process, the same innovation strategy, no overlapping portfolios, the same tools, a high percentage of the same components and suppliers, etc.

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newly-acquired expertise from the MULTIVAC family, such as wash-down design for fast cleaning, common line control and the high-accuracy weighing technology. Every department, from customer experience to final assembly, was highly motivated to get involved and to prove that a machine like this can be developed within the set timeframe; I am proud of this achievement. We were even ready to show it to the market in autumn 2021, and we released it for sale in March 2022. This is how the PROGRESSA bread was created, as a result of great teamwork and a very successful collaboration with our MULTIVAC colleagues.

Guido Spix: We worked together on the development of the PROGRESSA bread. The idea, the concept, and the market analysis to assess the need for this type of equipment – all came from FRITSCH. Then, they were able to choose from all the resources available at MULTIVAC. This is how the weighing technology was incorporated. The development team also asked for support in the wash-down capabilities of the machine and in hygienic design. They also received support in manufacturing certain components. This is how the network of all the companies within the MULTIVAC group works. FRITSCH was able to benefit from being a part of this network and its resources. The weighing technology, for example, involved a bit more than a simple adaptation of existing technology. Our company MULTIVAC Marking and Inspection developed a special solution according to the requirements coming from the FRITSCH development department. This is the workflow between all our companies and business units. FRITSCH was particularly receptive to taking over and implementing available technologies, compared to the older Group members.

IN THE SPOTLIGHT

© FRITSCH

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So, collaboration is not something that is focused on a single project; it is part of our daily work.

Mihu: You mentioned several working groups, by specialization. What does FRITSCH bring on board for them, and what type of information does it receive, in turn?

Frank Gabriel: Looking at digitalization, for example, FRITSCH, in 2018 had already showcased some solutions at the last trade shows before the pandemic, which were rewarded for their merits. We were not beginners in this area. After joining MULTIVAC, we learned we could adapt solutions from their corresponding team, including hardware, architecture and frameworks. We benefitted from some tailwind in our sailboat from them, which we had not experienced before as a standalone company.

Guido Spix: During the acquisition phase, there was a very important rule: when FRITSCH is asking for support, they are free to choose from the solutions, ideas, and processes, which are offered and not imposed on them. This culture of supporting the other members is shared in the entire network.

Each working group collaborates within the Group, and, more often than not, each has solutions they can easily offer to the others, so they do not need to recreate them.

This is not to say that all companies must be the same; on the contrary, each solution must fit the specific business.

We need to make sure that, when things are the same, they are this way because it makes us stronger.

Mihu: How did FRITSCH join MULTIVAC’s global production network?

Guido Spix: Sheet metal production and pre-assembly will come closer together in this network. MULTIVAC has always had a high level of in-house production, in packaging in particular. We have three dedicated factories, in Germany, Austria and Bulgaria. We always supported the other Group members with manufacturing capacities, and the same now applies to FRITSCH. As we develop new factories, such as the one currently being built in India, it is also part of the plan that FRITSCH produces certain products. We are using this network for all our business units.

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Mihu: What are the topics of the R&D management group meetings, and how are strategies approached?

Guido Spix: We recently held our R&D management meeting, in person. 50 members of the Group met over two days.

We had in-depth conversations about our development process, and shared best practices. The newest innovations were presented and showcased in a small exhibition. We ensured there are no double developments among the different groups, which is the most important aspect, in my view. It was also a networking occasion for our engineers.

Frank Gabriel: It was the first time we had been able to meet everyone in person since we joined. It was great to also see and get to know each other. It will help with day-to-day work to know who our colleagues are and what they are working on, for personal contacts. I was there, and I was proud to see the good collaboration with FRITSCH was among the best practices presented.

Mihu: What did everyone most want to learn about FRITSCH? Frank Gabriel: Everyone was very interested in how the bakery industry works, what are its defining characteristics and its special challenges. The first consideration we had to explain regarding dough handling is that we deal with a living product, which changes over time. In this respect, digitalization is an important aspect, to prevent inadvertent line stops that could result in tons of dough being removed from the line and scrapped.

Guido Spix: While delivering packaging equipment to bakeries, we learned that the baking process must not be stopped, unlike the meat industry, where there is no problem doing so. Finding ways to deal with this aspect has been an ongoing topic of conversation at MULTIVAC. It is critically important not to stop the process. We now have a better understanding of this requirement.

Working together, every day Mihu: How are specialists at FRITSCH and MULTIVAC working together to develop new projects? How was this workflow set in place?

IN THE SPOTLIGHT

Guido Spix: The people know each other now, and the working groups are settled, between the headquarters and FRITSCH and within the whole network. For example, a new type of HMI is needed in all our technologies, so everybody needs to work together on such a project to ensure it will fit all the demands. And it works very well.

Frank Gabriel: The specialists developing the weighting technology, for example, are now operating in the bakery industry and keep its requirements in mind when they design new products. In the future, the technology will simply be adapted to our needs and not be built from the ground up.

The basis for all current and future developments at FRITSCH is our overarching innovation strategy. It is closely interlinked with the other companies in the MULTIVAC Group. Nevertheless, it offers sufficient flexibility to respond to customer requirements and market changes. Agile development methods and the introduction of MULTIVAC‘s new development process have enabled us to significantly reduce development times and thus time-to-market.

Mihu: How will a bakery benefit from the resources of a multinational group such as MULTIVAC when beginning collaboration with FRITSCH (ordering and installing, then servicing)?

Guido Spix: The developing process always starts with close communication with our customers and our sales and service organization. MULTIVAC has more than 2,500 sales and service people worldwide in 83 own daughter companies. We are globally present in more than 160 countries.

When it comes to commissioning and after-sales service, we are always close to the customer with local people, decentralized spare part stock and regional experts for all our technologies. They are closely connected with all types of digital tools and equipment with the experts at the production sites.

Frank Gabriel: Having access to MULTIVAC’s global network means, first of all, that the sales and service teams will speak the same language and are in the same time zone as our customers, bringing us closer to them. In addition, the solutions we can offer are now more customer-oriented, because we can find custom technologies for our needs in the network. During the pandemic especially, it was a huge advantage to have teams already in the countries where we needed to be, as we could not travel.

Co-developing new solutions Mihu: What is the strategy for developing a custom solution together?

Frank Gabriel: The customer need stems from the end product. The specific needs are defined in our World of Bakery, according to the expectations from the product. Other requirements are factored in, related to aspects such as the output, the product’s shape, or taste. Then, we determine the technical solution needed for the customer. We now

have a broader set of technologies and resources to apply to our lines.

In parallel to additional customer requirements, FRITSCH continues to launch new developments in a targeted manner to serve new market segments and to close existing gaps in our product portfolio. However, an essential criterion for all new developments always remains the connection to our digital solutions as well as offering significant added value in terms of sustainability and resource-saving. Our PROGRESSA bread is a good demonstration of this approach.

Guido Spix: There is also a very important rule coming from MULTIVAC: reliability is a priority. We never leave a customer’s side before all issues are settled. Customers now recognize that this comes from FRITSCH as well, in addition to its innovations.

Mihu: Automation is one of the underlying innovation drivers in all areas of production. What are the latest advances in this regard, at FRITSCH and MULTIVAC? Guido Spix: Back in 2007, we decided to open our new systems business, to develop ourselves solutions that were missing on the market for operations such as wash-down and improved hygiene, both core requirements in the meat/fresh food industry. MULTIVAC has been developing its own robotics solutions ever since, and is now a global leader in the field of hygiene and the wash-down capability of robots. This is valuable know-how that is also sought after in the bakery industry. We now have a wide variety of hygienic robots and the capabilities to build production lines with a high level of automation, whereas FRITSCH can build large, complex production lines that can incorporate a high percentage of third-party products.

Frank Gabriel: At FRITSCH, we already had several automation and robotic solutions in our portfolio, to cater to rising demands. Bread is a unique product in this regard: it should look hand-made; but, there are no hands to make it. As a result, you have to be very creative in the automation process so that the end product still looks hand-made.

Our automatic pretzel twister has been on the market for more than two decades, and with our robots for croissant bending or product decoration, we offer further robotics for process automation. And there is more to come. With MULTIVAC, we do have the chance now to combine our expertise and further expand our field of operations. Additionally, we see high demand in the implementation of the SMART Services, including predictive maintenance functionalities. This will be one of our next steps for further collaboration in respect of line automation.

Mihu: The next step in automation leads to building smart factories. How can FRITSCH and MULTIVAC contribute to smart production factories together?

Guido Spix: In the age of Industry 4.0, machines and lines are becoming increasingly complex, also in food production.

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IN THE SPOTLIGHT

This fuels the request for further smart factory solutions.

With our digital solutions across the entire product portfolio, we are supporting our customers in further improving their productivity by keeping production processes optimized and running as smoothly as possible.

In a time where production processes become even more complex and complicated, our SMART Services are designed to simplify the operation of our machines and lines. We offer, for example, a MULITVAC Pack Pilot that automatically adjusts the machine for different film types via a cloud service.

We are part of the Industry 4.0 Alliance and other groups, to ensure that third-party components can be integrated into our lines. We have developed MULTIVAC Line Control, where third parties can also connect, even our competitors.

A vast number of services are available on the ‘My MULTIVAC’ platform. Hundreds of customers are already connected; the connectivity we offer to our customers is also available – within limitations – for retrofits.

Frank Gabriel: FRITSCH presented its prototype for SMART Services at iba, in 2018. Together with our colleagues from MULTIVAC, we further developed our former dashboard into a full set of digital solutions, which we now call SMART Production Insights. This solution is already in place for several customers with immense success. Many hours of unplanned downtimes can be avoided, and hidden unproductivity can be detected. We further co-developed predictive

maintenance solutions, which are already being tested with some customers, from which we are receiving incredibly positive feedback. The factory becomes smarter with these tools, and can ‘tell’ our customers what is happening and what is likely to happen in production, to avoid downtimes.

Mihu: What innovations (features, equipment, processrelated) can we expect in the near future?

Guido Spix: MULTIVAC’s Group innovation strategy comprises four essential aspects: merging digitalization and engineering, sustainability, and the solution-providing business. We want to be recognized as a solution provider and not just as a machine builder. We have the capabilities and we can be a solution provider for our customers.

Frank Gabriel: In general, we see increasing demand for the possibility of faster (wet) cleaning, also with high pressure, and further development of our functionalities in terms of flexibility and adaptability, as well as an expansion of our product portfolio across all market segments. In addition, we will place great emphasis on internationalization, digitalization, and sustainability in all new developments in the future. We are already working on great solutions today and our reservoir of further ideas and projects is well filled.

I can promise you: you will be surprised. You can look forward to it! +++

Smart Production Insights for INTER EUROPOL

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In Marki, a small town on the outskirts of Poland’s capital Warsaw, the bakery company INTER EUROPOL is writing its own success story, to which production systems from FRITSCH have contributed. Project manager Rüdiger Stollmeier has played a significant role in this. He has increased the equipment’s efficiency with FRITSCH’s Smart Production Insights (SPI), which were installed on the company’s two IMPRESSA bread lines at the second company location in Malopole.

FRITSCH has been offering this digital solution for selected lines since last fall. Smart Production Insights allow – via Internet connection and cloud – a real-time and very detailed overview of the most important performance data of plants such as the IMPRESSA bread.

All important KPIs at a glance Stollmeier is primarily interested in the view of the dashboard, with all the information available. On a graph, for example, he can read the overall plant effectiveness in the form of a bar chart, by shift. This ultimately shows where improvements can be made. Another SPI overview shows

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how the plant has performed over the past 24 hours in a simple tabular display with a traffic light system. And it does so in five-minute increments: a green field indicates smooth production, a yellow field signals minor malfunctions, and a red field indicates the plant has come to a standstill in the five-minute interval. For cleaning and maintenance work, there is blue as an additional color.

SPI not only displays errors but also generates warnings if individual components are running hot or threatening to fail. This allows shift managers and technicians to react in time and avoid potential downtime.

SPI also provides a precise overview of when, where and which of the regularly scheduled tasks are due. FRITSCH has precisely defined the maintenance tasks and intervals, which mostly depend on the runtime of the plant, in a user manual. In this way, maintenance is carried out faster, downtimes are reduced and efficiency is increased.

After running the SPI tool on two lines, INTER EUROPOL is planning to retrofit its other plants soon. +++

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IBIE SPECIAL

There’s no place like IBIE After unprecedented disruptions in the industry, anticipation is high for the industry to return to the Baking Expo, which will showcase new consumer, technology and business trends.

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Expectations are very high for IBIE this year, for organizers and attendees. Given the current challenges, this is probably the most important show in the last decade, with the industry looking to IBIE for new automation solutions, equipment to help bypass supply chain issues, and training opportunities, as the workforce issues are more stringent than ever. Organization-wise, there have been significant changes in how the planning and the execution of the show were managed. Planning sessions were exclusively done remotely, but everyone is eager to meet face to face and see new solutions directly.

Jorge Zarate, Global Senior Vice President of Operations and Engineering at Grupo Bimbo, Mexico City, and Vice Chairman of IBIE 2022, gave us a glimpse into the new priorities shaping the industry at present, from new consumer choices to tackling challenges related to skilled work, production and supply and the impact of the war in Ukraine. To navigate this space, everyone in the industry is eager to talk – face to face, finally – to their peers. “There is a need to share”, Zarate comments, as bakeries are

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managing their product portfolio to be more productive and avoid disruptions, as the labor shortage worsens.

In North America, workers are exiting the industry seeking a better quality of life elsewhere, with a generous range of opportunities to choose from, as new businesses are growing. Similar developments are emerging in Mexico, South America and Central America,

observes the executive of the Mexicobased company. “We are expecting to show at IBIE how you can automate processes,” he anticipates, with solutions including implementing robotics in new areas, for example. This is a familiar plight in Europe, so visitors will find inspiration at the Las Vegas event. Digital solutions are bound to garner interest as well, given their recent spike in popularity, as they

Jorge Zarate Jorge Zarate Lupercio is Grupo Bimbo´s Global Senior VP of Operations. Since he joined Group in 1987, he has been in charge of different roles in Mexico and South America. He holds a Biochemical Engineering degree from ITESM (Mexico), a postgraduate degree in Strategic Marketing at Universidad Católica de Argentina (UCA) and an MBA at Escuela de Dirección de Empresas de la Universidad © IBIE

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Argentina de Empresas (EDDE).

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provide valuable tools for handling staff shortages, sanitation solutions and sustainability. The adoption of digital solutions in bakeries will see a fast increase, dictated by need, on both sides of the Atlantic Ocean, Zarate anticipates. Grupo Bimbo is making efforts to increase its own digitalization level, taking into account new solutions launched in the past two years, he shares.

Skill and technology training is also a priority, to empower bakery staff to solve problems arising in day-to-day operations by themselves. IBIEducate will offer more than 100 sessions, workshops and specialty courses from September 17 to 21, on topics including plant operations and automation, food safety and sanitation, formulations, sustainability, workforce, and more. Visitors can already plan the IBIEducate sessions they would like to attend. All the information is available on the IBIE's website. Zarate recommends planning an agenda, not just for the sessions during the dedicated day of education before the expo opens, but for the ones held throughout the show.

Going through changes Along with the pandemic restrictions and the consequent challenges for the industry, consumers are going through transformations; they have become more sophisticated and more

demanding, Zarate observes. Coming after two years without direct contacts in the industry, IBIE 2022 is bound be a great show, with everyone with everyone looking forward to getting reacquainted, Zarate anticipates: “Consumers have had the time to reflect, and they are now asking for innovation.

As a result, innovations are rolling out faster than ever and are more focused than ever now. The plant-based trend is currently booming and is not only driven by vegetarians but also by consumers’ personal ideals, including

Great expectations The past two years were an intense learning experience about managing businesses, forcing the industry to quickly automate more, to cope with the pandemic restraints. Development opportunities arose; this big step up is followed by continued movement in this direction, allowing people to take on more value-added tasks as the difficult labor is automated. Sanitation practices that were adopted in the past two years also benefit the process and the end product quality.

“The world has changed, and all the stakeholders of our industry are now focused on sustainability and minimizing their impact on the environment.”

Jorge Zarate , Global Senior Vice President of Operations and Engineering at Grupo Bimbo, Mexico City, and Vice Chairman of IBIE 2022

diet, health, and sustainability goals.

We see products such as keto-friendly and low-carb ranges coming back,” Zarate says. Besides, after two years of at-home cooking, consumers appreciate treats in a new light; often, this means artisanal-style bread, or finishing baking at home – but not necessarily committing to the time and effort to bake from scratch, he adds. Even though active life outside of home has now resumed, these changes remain and bakeries have to accommodate them. “Innovation is a hot topic to seek at IBIE,” he concludes.

“I am really looking forward to having all the solutions that I need as a baker under the same roof. I am convinced I will find ingredients and equipment that enhance the product quality, some of which are already available on the market, which will be new to me,” IBIE’s Vice Chair comments from the baker’s perspective. Visitors will also bring their ideas and problems to be solved together with the exhibitors and their peers. Grupo Bimbo’s global team is reuniting at IBIE 2022, to, first of all, connect, and gather its technology specialists under one roof, for in-depth

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discussions that cannot take place over video calls, Zarate explains. The Group’s commercial departments and heads of business units will also join, to get a clear overview of the current status of the industry, as well as manufacturing and distribution solutions, to get inspired and to analyze issues together, in person.

Organizers are introducing new features for the return of the biggest bakery trade event on the continent and beyond. New pavilions will debut in September, including one dedicated to Cannabis in Bakery, and Santitation Solutions, both rising trends.

In addition, the expanded ‘BEST in Baking’ program will highlight sustainability efforts as well as other paramount topics in the industry, recognizing suppliers for sustainability, automation/ robotics, plant efficiency, workforce development, and product innovation.

Good practices will be shared to benefit everyone in the industry. “The world has changed, and all the stakeholders of our industry are now focused on sustainability and minimizing their impact on the environment,” Zarate underlines the goal of carbon-neutral manufacturing.

Innovation is the underlying theme of the exhibition. An important category that we can look forward to is innovation in improving remote work, to enable not just training, but also troubleshooting, automation and digitalization. “The Innovation Showcase is going to pinpoint such new available technologies,” Zarate says.

International participation The recent challenges could have made it difficult for the trade fair to

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attract more attendees, exhibitors and visitors. However, the figures at present are a perfect match with those from the previous edition of IBIE, despite pandemic/supply chain disruptions, or inflation. To support international participation, IBIE has worked with the US Government and embassies to facilitate the visa issuing process. “I think that we're going to have good international attendance. We already have the exhibitors who confirmed their participation, a similar share to previous IBIE expos,” Zarate anticipates.

In addition to visa renewals, the task force behind IBIE’s international delegation program has been working to provide international attendees benefits that include discounted exhibition hall registration and IBIEducate participation. Even lower rates for hotels and assistance at the booth, including WiFi, were part of this package. In addition, through the corporate meeting program, space can be reserved in meeting rooms at the Las Vegas Convention Center, before or after show hours.

The European and the American markets share more similarities in trends than differences, so international visitors will find relevant solutions and inspiration in Las Vegas; “Bakers are looking into health and wellness products, keto and lowcarb products; they are looking for ways to improve on their sustainability,” he adds. Differences come from the product itself – and corresponding equipment, he concludes: “North American products are more the soft, pan-molded types, what we call Pullman. Europeans appreciate

crusty breads more.” Another difference is in fermentation times for artisan-style breads, which tend to be longer in Europe. Product flavors are stronger in Europe, too. These differences lead to different technology requirements.

America is starting to manufacture European-style products, but bakery products remain mainly on the soft side.

IBIE is supporting European participation and facilitating the transfer of ideas through its collaboration with its European counterpart, iba. The partnership has been beneficial for both sides, “Because now we are sharing trends and knowledge. We intend to take part in iba again next year,” Zarate announces. “Our European colleagues have shown great interest in learning and seeing how we do business, and how we manufacture products. This interest goes both ways. Through such partnerships we're able to connect broader audiences of bakeries and equipment manufacturers across the globe. from bakeries and equipment manufacturers. Our coordination will benefit both industries, in Europe and the US,” he adds.

Zarate hopes the main takeaway for IBIE 2022 attendees will be sharing.

What was the impact, what did everyone learn, and how did they plan operations during the pandemic? It will help prepare the industry for future disruptions of this magnitude. “People are learning that being at IBIE is being part of the baking industry, an amazing industry in which we find ourselves as partners, even though we are competitors. We truly are a family in which everybody is eager to help and share.” +++

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A guide to IBIE’s exhibition stands As the highly-anticipated Baking Expo is approaching, exhibitors are preparing their stands to once again welcome visitors to the trade fair in Las Vegas. We asked some of the industry’s big players for a glimpse into the novelties we can expect. Here are some of the stands worth exploring, listed by booth numbers.

Booth 209 – EnSight

line also features our new SDS nano, adapted from the FRITSCH industrial line dough sheeter, which applies flour to the dough sheet from all sides. “Complete flour-dusting means no need for oil, greater precision in dough production, and faster cleaning. Once dusted, the dough sheet transfers from the SDS nano to the FRITSCH Soft Dough Roller (SDR) for gentle rolling, producing a highly uniform dough sheet, free of shearing forces and separating agents,” FRITSCH explains.

EnSight is presenting its heavy capacity Fenceless palletizing in a washdown environment, high-shear mixing equipment – Likwifier (formally Breddo Likwifier) – batch mixers, jacketed, icing systems, and Inline mixers for continuous applications. Among new developments, a Stäubli TX2-160HE hygienic robot is featured, with wash-down properties and area scanners that will make it slow down and come to a stop when an operator enters the work area. “This allows us to fit the palletizer in smaller areas that couldn’t usually fit palletizing,” EnSight explains. The Stäubli robot can lift up to 75 pounds of product at a time. A new, more hygienically designed frame for high-shear mixers will also be highlighted.

Tecnopool is promoting innovative solutions together with those of their sister companies Gostol and Tecnofryer. TP5 is a newly-designed spiral belt for Tecnopool’s spiral systems. An improved design of Gostol’s TP-N cyclothermic oven will also be highlighted, as well as TEC, a family of tailor-made industrial frying systems, and Gostol’s ‘Smart Bakery Line’ portal. Tecnopool, Gostol and Tecnofryer can offer machines and lines to answer the production requirements of virtually any type of baked good, devising highly automated, flexible, and economical industrial solutions for medium and large-sized bakeries.

Booth 301 – FRITSCH FRITSCH will introduce the new ROLLFIX 3.0, the DOUGHLINER, the MULTIVAC R 105 Thermoforming packaging machine with printing and inspection, and the new compact bread line, the PROGRESSA bread – shown virtually by popular demand.

Launched earlier this year, the PROGRESSA bread was designed for easy accessibility with toolless parts removal and no motors, sensors, or other electrical components in the drive compartment of the line for quick and thorough cleaning with a steam jet. Two weighing units, ensures weight accuracy throughout the entire process. The compact bread

VMI will be exhibiting its range of mixing equipment at IBIE: vertical, planetary and continuous mixers. The company is also introducing its Virtual Reality Area, using technology to transport the user into an immersive experience to discover mixing systems that integrate several mixers and automate the progression of batches from one station to another. Attendees will be able to walk through a full-size batch mixing system to understand the process and

© VMI

Booth 1001 – VMI

© FRITSCH

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© Tecnopool

Booth 725 – Tecnopool SPA

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capture how it will perform in reality. “As our product range includes specific configurations to meet manufacturers’ needs, VR enables visitors to experience large automated systems free from physical constraints,” VMI explains.

VMI’s latest planetary mixer will be showcased, the Phebus mixer. It has a bowl capacity of 200 liters and features an ergonomic and easy handling design, with a hygienic, stainless-steel design. “This mixer excels in the most complex preparations, including creams, sticky doughs, batters and specialty breads,” VMI explains.

VMI is also promoting its ability to design custom solutions to each industrial challenge, with various mixing technologies adapted to ingredients, process, and location constraints.

easy cleaning, allowing mixing bowls to be quickly changed for an efficient succession of batches and a fast switch between different recipes. Surfaces are hygienically optimized to prevent microbial and particulate contamination of the baked product. It can be upgraded to a fully automatic system by adding a transport system.

Booth 1201 – Diosna

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Diosna will focus on equipment flexibility, showcasing the DIOSNA Wendel Mixer WH 240 “A” of the Hygienic Design series. The design of the mixer is based on the high standards and guidelines of the European Hygienic Engineering & Design Group (EHEDG), Diosna explains. This mixer combines high-performance mixing with open stainless steel construction for

Booth 1601 – Dawn Foods Dawn Foods will highlight several solutions, including: + Trends & Insights, with the company’s highly anticipated 2023 global trends on customer behaviors and macro industry influencers. To develop these insights, Dawn collected data across dozens of syndicated sources, conducted proprietary research, and observed customers and consumers firsthand across various channels and regions globally. Sarah Hickey, Senior Director of Insights & Market Research at Dawn Foods, will unveil these trends at a speaker session at IBIE on Saturday, Sept. 17. + Digital advancements: Dawn will demonstrate how its eCommerce platform benefits bakeries. + Top Products presented onsite will include sourdough and brioche donuts, vegan and cleaner label bakery mixes, fillings, icings and glazes; varieties of cake donut

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© Dawn Foods

Koenig is introducing its new I-Rex Compact Easy Clean (EC) machine at the trade show. It incorporates the I-Rex Compact EC Divider and Rounder – a machine with a completely redesigned structure. “The head machine only has one load-bearing end shield, the one on the drive side.

The possibility of opening the cover of this head machine on three sides offers the user the best possible accessibility for cleaning and maintenance,” Koenig explains.

All relevant components can also be removed on the operator’s side.

It has a weight range from 1 to 7 oz (30 to 200 g) – addressing small and medium as well as industrial bakeries. The new machine combines very compact dimensions with an industrial performance of 14,400 pcs/h at 40 strokes/min.

© König

Booth 1033 – Koenig Bakery Systems

HEUFT provides premium oven solutions made in Germany for mediumsized artisan and industrial bakeries. At IBIE, the company will highlight its large oven systems, with reduced CO2 emissions, and its thermal oil technology. “Our large oven systems are custom-made, therefore each piece is an innovation itself. Our ovens are not only maximally flexible but also highly cost-efficient when it comes to energy savings,” HEUFT details. All ovens use thermal oil as a heat transfer medium, as it is a champion in heat conduction.

A patent-pending innovation is the hybrid thermal oil heater, which heats thermal oil sustainably and provides the freedom to choose the energy source. It combines two technologies: an electric and a fired heater. The electric heater can use electricity from regenerative sources, the fired heater, in turn, can use natural gas or heating oil as an energy source.

© Heuft

Booth 1267 – HEUFT Thermo Oel GmbH & Co. KG

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© Kwik Lok

Booth 2131 – ABI Ltd. ABI will be showcasing its automation solutions, robotic scoring system, and vision system platform. A robotic scoring system will give live demonstrations at the show. Waterjet technology is the latest addition to the scoring options they offer. Now bakeries can choose from conventional, ultrasonic, or waterjet cutting. ABI will also share the innovative vision platform they recently developed specifically for the bakery industry that addresses many gaps found in the conventional vision systems. This system is the company’s latest innovation, designed to collect, compile, and analyze multiple image sources in real-time. It provides high precision and consistency for many ABI robotic solutions.

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Bundy Baking Solutions will feature its latest innovations including new American Pan ePAN designs for bread tin sets and the AccuTech Pan Greaser from its newest brand, Synova. The new ePAN designs are up to 30% lighter than other pans and have allowed bakeries to save energy by decreasing oven temperatures and gas usage. The new greaser design features many improvements to application accuracy and sanitation and maintenance procedures. The company will also be highlighting its proprietary release agent formulas, new eRack designs, custom sheet pan capabilities and their exclusive pan coatings and comprehensive services.

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Booth 2625 – Bundy Baking Solutions

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Kwik Lok will bring to IBIE its Eco-Lok, Fibre-Lok, and the New Closing Line of the Future.

Eco-Lok and Fibre-Lok can be used with existing Kwik Lok automatic bag closings.

The Eco-Lok is a great solution for bakeries that are looking to reduce carbon and plastics. It is made with up to 20% renewably-sourced starches.

Fibre-Lok is a 0% plastics solution that is made with cellulose fibers. “In some places, it may be home compostable and/or provisionally recyclable depending on the infrastructure available,” Kwik Lok details.

The packaging company has recently updated ‘Closing Line of the Future’ which includes Kwik Lok’s 893 closing machine bundled with its tamper-evident 909 laster stitch machine and the newest fiber laser print technology. Both Eco-Lok and Fibre-Lok are designed to work with this line.

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Booth 2024 – Kwik Lok

MECATHERM will highlight the M-Care, a new digital solution helping industrial bakers to optimize their performance.

Live demonstrations will be organized to showcase its features. Accessible with a smartphone or tablet, M- Care is an innovative intuitive interface enabling to identify drifts, prevent breakdowns and machine failures, and provide comfort and simplicity to operators and maintenance teams for first-level maintenance operations. Most of the new MECATHERM ovens are M- Care ready. From vertical ovens to flexible production lines, MECATHERM will also explain how their solutions enable industrial bakers to face the market challenges in terms of product quality, industrial performance and sustainability.

Launched at IBIE in 2019, the smart and responsive MECAFLEX line will return. It incorporates the flexible M-TA tunnel oven and the M-UB handling system, for a large range of products, produced using different process combinations with trays of varied types and formats. The M-TA oven offers multiple heat transfer modes, such as convection or radiant heat, or a combination of both in each independent heating zone. The M-UB handling system has been designed to be adaptable and flexible, whatever the product type, production volumes and constraints imposed by industrial

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Booth 2131 – MECATHERM

flavors; Dawn Exceptional ® E-Z Open ™ Flat Icings; Bakery Essentials by Dawn ® – a comprehensive portfolio of bakery ingredients and supplies; new product previews.

© ABI Ltd.

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Booth 2645 – Rademaker

and blocks – and decorative products such as shavings, rolls, pencils, blossoms and many more. The company will be demonstrating a fully operational Rotoform chocolate forming system at IBIE. This is a high-capacity rotary drop depositor that can be used to form chips of different sizes – from 30,000 to 300 pcs/kg.

Rademaker intends to reacquaint visitors with its portfolio of solutions. A product showcase will take center place – all products made with Rademaker machines around the world are available for sampling. Equipment will also be highlighted: a three-section Radini Laminator and Make-Up line will be displayed. “They are perfect for the small to mid-sized wholesale baker looking to automate their production. Our latest sheeting solution for artisan bread features the updated DSS for the most gentle process of the highest quality ciabattas, baguettes, and batards,” Rademaker details.

Innovation should be expected at this stand, with robotics, virtual reality, product scanning, Academy Training, and Systems Integration.

Booth 2971 – IPCO

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Ba ke ry Sy

RBS will feature new snack systems and technologies at IBIE: + Multi-Crisp System – this flexible system produces baked crisps from a variety of different doughs. “This flexible system is perfect for making “healthier-for-you” snacks, including the newest product – the pita chip,” RBS says. + Advanced WCX Wirecut Machine – this machine can create the widest variety of cookies including multi-color dough, filled cookies and bars and encapsulated cookies. + Ovens of the Future – Sustainability is a big initiative at RBS, with efforts specifically focused on ovens.

“Learn about our electric oven options and how we are ‘Baking for a Better Tomorrow',”RBS invites. + Automated Continuous Mixing – The RBS Exact Mixing booth (3435) will feature automated continuous mixing systems that cut costs by reducing labor, energy and mixing errors, while improving consistency and simplifying your entire mixing process. Among them is new Hydobond instant hydration technology. “Now more than ever, with the labor, energy and cost-containment issues, automation is the key to future success,” says RBS.

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Booths 3425, 3435 – Reading Bakery Systems

© Re ad ing

IPCO will be using this year’s IBIE to highlight four key areas: + Solid and perforated steel conveyor belts – “The key qualities of an IPCO bake oven belt include outstanding thermal properties for efficient baking; the inherent ease of cleaning of a belt compared with mesh; and the attractive return on investment when considering the overall lifetime cost.” + A comprehensive range of conveyor components: IPCO can also support OEMs in system design and supply a full range of conveyor equipment, from sheaves and shafts to bearings and breakpoints. Other ancillary equipment available includes active and passive belt alignment solutions such as belt edge detectors, guide rollers and compact/automatic tracking devices + Global service support, with sales and service offices in more than 30 countries. IPCO can deliver inspection and maintenance services that go beyond the belt, with investigations encompassing the entire line to understand how the system as a whole is performing. + Chocolate forming systems: systems designed for the production of industrial ingredients – chips, chunks, drops

Ashworth is expanding on the success of its Smart Spiral monitoring system by introducing the Smart Oven monitoring system. It monitors critical oven operating parameters and provides real-time feedback to maintenance, engineering and plant management, alerting of out-of-tolerance conditions. It offers a graphical representation of the collected data, which authorized personnel can access on a mobile phone, tablet, or personal computer. This graphical data will show current and past operating data, compiling a trend analysis that could indicate pending system issues. By anticipating system failures on time, repairs can be planned and performed before system failures occur.

© Ashworth

© Radmaker

Booth 3008 – Ashworth

© IPCO

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Booths 3435, 3601, 3625, 3801, 3825 – AMF Bakery Systems AMF Bakery Systems is bringing a comprehensive suite of solutions to its stands. Among them, the company highlights its digitalization and sustainability roadmap for bakeries. “<Illuminating the lights-out bakery> is part of our booths at IBIE, showing solutions and equipment that work 24/7,” AMF anticipates. Sustainability and digitalization are hot topics that are reflected in products

with several innovative features, especially for industrial and semi-industrial bakers. In addition, MIWE will exhibit the rack oven MIWE orbit, the choice for small and large bakehouses and market bakeries.

The all-rounder MIWE condo deck oven will also be presented: electrically heated, with a gentle baking atmosphere; it can be used for a wide range of products, from pastries to bake-rolls, or artisan bread. The MIWE backcombi combines convection and deck for maximum flexibility on a very small footprint. It is ideal for small(er) shops and bakers. MIWE econo completes the lineup – a convection oven suitable for point-of-sale baking, ideal for parbaked goods.

© AMF Bakery Systems

Booth 4613 – Sugden

© Sugden

and services that will be showcased: sustainable ovens (e.g. hydrogen, electric and hybrid models of the Den Boer Multibake), the Sustainable Oven Service, with managed services by AMF Den Boer to save gas and get optimal oven management support from AMF’s oven consultants, and the Smart Applicator (used for strewing materials, weight and distribution management). AMF Tromp will display the latest sheeted Breadline for artisan bread, ciabatta, baguettes and other breads.

Booth 4471 – MIWE

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MIWE will highlight a wide range of baking oven technology, ranging from all-around deck ovens for artisan baking and in-store usage, to rack ovens and flexible solutions, combining deck and convection ovens on a small footprint. MIWE will also be exhibiting bakery refrigeration solutions such as the fully automatic proofing unit MIWE GVA. Two different rack ovens will be showcased at the MIWE booth at IBIE, focusing on the MIWE roll-in e+ in its newest version. “It is a rack oven for bakers valuing efficiency, consistency, quality and energy efficiency with new functions for wider product variety, better servicing and new connectivity features,” MIWE explains. The MIWE roll-in stands out

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Sugden highlights its new insulation system, developed for the company’s English Muffin production lines. Belgium waffle lines will also be promoted, to meet the interest for this product on the US market.

For the English Muffin Lines, Sugden has developed a three-layer insulation. With the two rigid boards on the outside and a special product in-between, temperatures of 250°C were reached on the inside, while on the outside, it doesn’t go above 35°C. This insulation protects all the components of the burner system and ensures they are operating well within their upper-temperature limits. “It is a huge step forward to lower the running costs of the production line,” Erik Smink explains. This insulation will be available on all Sugden’s product lines, new or refurbished.

The Belgian Waffle production lines are constantly fine-tuned for products in capacities up to 20,000 pcs./hr.

Booth 6571 – Royal KAAK KAAK will present process automation solutions aiming at reducing labor costs and manual labor dependency, improving hygiene, reducing fallout, and improving product consistency at the highest quality. New innovations that will be showcased at the trade show include robotic dough scoring solutions, using different scoring tools: water jet, rotating knives, and perforated metal scalpels with airflow.

A pizza pressing solution, on a belt and in a pan, is also among the novelties to be presented at the stand. Integrated

production lines with uniform software control should also be noted among the highlights.

Royal KAAK is focusing its expertise on the manufacturing of pizza, hearth and artisanal bread, baguettes, buns and rolls, and tin bread.

Booth 7255 – Stäubli Stäubli will be presenting the HE version of its TX2 robotics series for sensitive food applications that require fast kinematics that can withstand wash-down and temperature changes. The TS2 SCARA industrial robot will also be presented, winner of the prestigious Red Dot Product Design Award 2021.

On display will be the hygienic, fully encapsulated TX2-90 HE,

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© Royal K A AK

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which has a reach of 1,000 mm and will feature ultrasonic cutting as well as showcase an automated wash-down process. It features connections through the base of the robot, no retention areas, complete protective coating and internal pressurization of the arm, as well as a H1 lubrication option.

The award-winning TS2-80 will illustrate a vision, tracking and packaging application. The completely redesigned 4-axis machine with proprietary JCS drive technology facilitates ultra-short cycle times and high repeatability. It also has an encapsulated design, for hygiene standards required in the food industry. +++ Read the full booth previews from the exhibitors online, at www.bakingbiscuit.com.

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The energyefficient light at the end of the tunnel oven Under the current circumstances, it has never been more important to look into ways to increase efficiency in bakeries, starting with their centerpiece: the tunnel oven. Mindful technology innovation is here to provide benefits in efficiency and sustainability. Baking a vast range of high-quality products is only the start of what cutting-edge tunnel ovens can do.

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Oven preferences are different on each side of the ocean: while European bakeries favor product flexibility, high-capacity oven systems are preferred in the US. Electrically heated ovens are also more in demand in Europe. However, all markets and technology developers share one common priority for oven improvements: sustainability.

Hydrogen innovation: AMF For AMF Bakery Systems, innovation in tunnel ovens means focusing on sustainability, primarily looking into energy efficiency and minimizing carbon footprint. As bakeries all over Europe are turning to electricity, AMF can turn its gas-fired Den Boer oven into an electric one, with several other solutions for modular electric baking.

The newest development has already made a name for itself and earned awards for innovation in sustainability: the Multibake® VITA Tunnel Oven by AMF Den Boer is a directfired oven, with hydrogen-fueled burners. It comes in various configurations: it can have grids for pans, mesh belts for hearth products, and stone plates for pizza, flatbread and a large variation of bread products. The versatile Vesta oven is suitable for baking trays for almost any product baked in a tray or tin. Lex van Houten, Regional Marketing Manager at AMF explains: “AMF Vesta Vita Hydrogen-heated tunnel ovens can bake any product that is normally baked in a natural gas-heated oven. AMF is able to offer customized solutions for many baking processes, for sustainable futureproof bakeries with net-zero emissions.”

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Configurations are based on the type of products and the (current and anticipated) desired production rates. A stonebaked pizza will require significantly different conditions than a croissant, for example. Requested specifications will influence anything from steam and convection to impingement and moisture control. And the list continues. “That is why AMF teams and engineers all have a background in bakery and/or processing, so they know the right questions they need to ask and the advice they should provide to customers, to determine together the most advantageous configurations,” van Houten underlines.

Given a ‘to-bake’ list of multiple products, this oven is designed for

© tannujannu and Worawut – stock.adobe.com

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flexibility based on the primary, most demanding product, and including elements identified after reviewing the whole product list in detail, to cover all bases. Based on this analysis, additional features can be added, such as extra top heat, bottom convection, infrared burners, or extra exhausts, to name some.

Resulting configurations of the Multibake Vita Tunnel Oven can comprise loading systems, infeed modules with exhaust hoods, steam modules for creating crust and color, multiple convection modules, modules with higher density burners on the top or bottom of the baking chamber, discharge modules, and even cooling modules. Later upgrades, when needed, entail simply adding modules to address higher production volumes or/and additional product ranges.

Heavy-duty baking

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The AMF Vesta Tunnel Oven a is heavy-duty, high-capacity tunnel oven with lengths of up to 63 m, making it ideal for products requiring longer bake time or higher density. This oven has built-in grid hearths specifically for pans and trays. “It has a robust steam zone to condition products, and options for redundant drives, exhaust, and combustion blowers. It features the patented Guardian Chain Management System with predictive lubrication, and maintenance alarms,” van Houten details. The Guarding Chain Management System stores the length of the main grid chains at installation and keeps a log of the chain's length every time the oven starts and stops. It also incorporates independent pneumatic-hydraulic tensioning systems that use minimal pressure to tension the chain and allow the chain to cool without tensions. Low tension on the chains also facilitates the lubricant’s flow into the chain bushings.

The Vesta Tunnel Oven comes with standard bottom burners and optional top burners and a complete Coloraider convection system, which consists of fans and tubes that collect heat from the top of the baking chamber.

This heat circulates through a series of delivery tubes fitted across the baking chamber, above and below the product zone. “The main ducts are adjustable to direct the heat to the top or the bottom of the oven. In addition, the outlets of the tubes can be rotated to direct the airflow towards or away from the pans,” the specialist details. The number of Coloraider zones is relative to the length of the oven, each having its own fan and 25 to 30 tubes.

“Its efficiency has been improved with better monitoring of the exhaust and the addition of AMF Sustainable Oven Service Technology,” van Houten highlights.

Another efficiency feature is the Direct Spark Ignition (DSI).

AMF uses custom build DSI for all its ovens. The Vesta Tunnel Oven, along with its sister the Vesta Tray Oven, are built to operate 24 hours per day for decades.

Baking smart and smart baking

The AMF Sustainable Oven Service technology monitors all of the functions of the oven, tracking temperature, airflow, occupancy, gas consumption and fan vibration, and logging the data for analysis. “With this information, AMF makes solid recommendations that can improve combustion efficiency, even heat distribution, product color, and more,” he details. In the future, the AMF Mixer Guardian System will be able to provide information to the oven for automatic adjustments, based on mixing energy and dough temperature, AMF anticipates.

For future developments, AMF is looking at alternative and sustainable heating sources that are the best match to the specific market: “Countries with plenty of electricity may choose all-electric ovens, or even hydrogen heated ovens, or both. Countries with limited electricity generation and distribution may choose natural gas, propane, hydrogen, or a blend of different fuels,” van Houten explains.

What should be expected from AMF ovens going forward?

He anticipates: “We will continue to develop more of our ovens modular that can reduce installation time and costs up to 80%. We will keep on developing turnkey systems that are scalable for the future.”

Oven innovation at Reading Bakery Systems For Reading Bakery Systems (RBS), innovation in oven design currently revolves around sustainability initiatives and reducing carbon footprint. New ovens need to be more efficient, flexible in baking and easy to operate.

Different goals can be achieved with similar means: “The European market needs efficiency and alternative energy solutions now, given the price of natural gas and the use of carbon credits. In America, large food companies are leading the push for sustainable oven technologies because the government lacks a clear and concise plan,” Joseph Zaleski, President, RBS, tells us.

The company’s latest oven designs address all energyconsuming areas: “With the new, sustainable designs, we feature reclamation of exhaust heat, better insulation materials and lighter weight conveyor belts to help reduce wasted energy. We also offer alternative fuels and electric oven options,“ Zaleski explains. These features are not exclusive to the new ovens, either; existing equipment can also be upgraded to more sustainable options.

A standard build uses a combination of radiation, conduction and convective heat to create the desired texture, taste and moisture profiles for all types of biscuits, crackers, or snacks. The first third of an RBS oven manages the humidity and the type of heat to help develop the flavor profiles of the product. The remaining two-thirds help set the product

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shape and uses more convective heat to remove moisture.

All these parameters are controlled via the user-friendly RBSConnect Controls Platform. Each product or recipe variation can be stored in the oven’s controls history for fast and easy start-up. “This level of automation and simplicity can eliminate a lot of the problems caused by high turnover and shortage of skilled operators,” Zaleski points out.

RBSConnect downtime software can also improve efficiency by automatically reducing the fuel consumption of an oven.

The software works by automatically setting 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. The smart software provides trend information on parameters such as gas usage, temperature and final product moisture to ensure the line is always running optimally.

Together with its ovens, RBS offers the SCORPION 2 Oven Profiling System, which allows bakeries to maximize operating efficiency by measuring the four key baking parameters – temperature, air velocity, heat flux, and humidity. “This allows you to benchmark your process for each product so you can optimize your baking process,” Zaleski highlights.

The future of the RBS baking oven

Ovens are undeniably headed into a sustainable future; but, this requirement is only the beginning of the features they need to incorporate. Zaleski explains: “Ovens need to have 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

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products more consistently.” This is valid for all processes, as consistency starts with mixing and forming the dough.

The SCORPION tools support baking consistency, as they can quickly identify and solve any issues in the process.

Most RBS ovens currently operate with natural gas, propane, or butane. As countries move away from fossil fuels, ovens can too, and offer more sustainable processes in the future.

“Electric heat is where we see oven technology moving into the future,” anticipates the company’s president.

Products can be tested on a fully electric oven at the RBS Innovation Center in Pennsylvania. The company is also working on the development of an electric cracker oven to replace DGF ovens. This involves modifying the Emithermic Oven Zone that will enable this zone to impart the higher heat required by crackers without a lot of air currents which would dry the product before allowing flavor and texture development.

The ovens’ road to carbon neutrality in 2050 starts today, given their lifespan that can be as long as 40 years. Zaleski shared how RBS envisions the future of oven technology: “RBS offers sustainable ovens that reduce energy, eliminate greenhouse gases and are easy to operate. We will continue to focus on improving our oven designs in each of these categories as we move forward.”

HEUFT tunnel ovens: all-rounders Thermal oil oven specialist HEUFT offers the VULKAN oven in this category. Thermal oil is an excellent heat conductor, transporting 2,600 times more energy than air. Hot thermal oil runs inside the VULKAN’s radiators, which are positioned inside baking chambers. “The result is that, with our thermal oil technology, we need 45% less power to heat our ovens in comparison with traditional oven systems heated with hot air. On average, we can save 25% to 40% on energy consumption,” explains Simon Tabruyn, Export Manager, HEUFT.

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Any heating method works just as well for thermal oil; either gas, fuel, or electricity will have the same results on the baking quality. Taking the ongoing energy crisis into account, HEUFT built a hybrid heat exchanger, to allow bakeries to switch between electricity and gas or fuel as an energy source. Other possible alternatives include liquid gas, biogas, wood pellets and hydrogen. “This means you can choose at any moment the type of energy you want to use: electricity during the day, when solar panels are producing electricity, and gas during the night, for example,” Tabruyn illustrates.

The VULKAN can bake up to 12 tons of bread per hour, with a baking surface that can span 540 sqm. And it will require a small footprint to not only bake high volumes, but also diverse products. Tabruyn explains, “An advantage of our system is that we can easily work with different temperature zones. For example, we can build an oven with five or more decks for tray-baked products or tin breads and two additional decks with a stone belt, for artisan products. This makes it two-ovens-in-one which can be set to bake products coming from two different production lines. And all this on the same footprint!” Future expansions in production volumes/ variety are also considered in the design of the VULKAN oven; it can incorporate built-in additional decks, which can be easily enabled when needed. In this way, it is not necessary to stop the line to add decks.

To best control temperature, top and bottom heating always work independently and different temperature zones can be chosen over the oven’s length. There are no temperature fluctuations: “A constant temperature is maintained thanks to the three-way valves that are continuously regulating the amount of hot oil going into the oven to preserve the requested temperature,” the specialist from HEUFT explains.

Optimized and mindful process

The VULKAN tunnel oven is insulated with 700 mm of Rockwool, to preserve heat so that none radiates through. In

addition, it is also equipped with a heat recovery system that uses flue gases for the burner and baking vapors from the oven to heat water up to 95°C. The hot water is then stored in tanks and can be used for various purposes, from feeding the crate washing machine, to heating the offices, or for cleaning. “Our Heat recovery management system controls the different heat recovery units and integrates it into the building requirements, custom-made. It is even possible to use it for air conditioning solutions,” HEUFT’s specialist details.

The Energy Management System (EMM) is this oven’s smart energy-saving tool. It can measure precisely how much energy the oven needs during production. Using this data, the automated control system automatically shuts down one heat exchanger completely to be more efficient and to maximize energy savings.

Moreover, all HEUFT ovens can be equipped with steam and turbulence systems, which help with process efficiency and product quality. To optimize efficiency, steam can also be generated with thermal oil heating, for example. Depending on the product, some convection (turbulence) can be added in certain oven zones. “This can be helpful if you’re looking for good volume and a crispy crust,” Tabruyn explains.

Sustainability is also considered. Thermal oil technology contributes initially to considerable energy savings; if the oil is heated with an electric heat exchanger, there are no carbon emissions at all.

Big and bigger production rates with Koenig ovens Koenig is also prioritizing sustainability, safety and sanitation for oven innovation that caters to product trends, as the company observes the American market is moving to Europe’s favorite, artisan bread. Trends the company is considering for the design of its tunnel ovens include stone conveyor ovens, bigger lines with bigger baking surfaces

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to match, saving energy (heat recovery systems), and the ability to quickly swap between energy sources, from gas to electricity, or hydrogen. The increase in production rates means big lines, and therefore the oven has a bigger baking surface – the MDI STRATOS oven being a good solution to this kind of request,” Antonio Aiello, Technical Supervisor, Koenig, details. Custom solutions are the norm.

Several unique features can be found in Koenig tunnel ovens: the MDI PHAROS is highly customizable, for example, with its independent zones and insertions of convection sections.

It provides three different heat transfer principles: conduction (with wire mesh, stone plate, or metal plate conveyors), radiation, natural and forced convection. A cross-section heat exchange allows even baking throughout the oven and can fine-tune baking of the product rows placed laterally.

The MDI STRATOS also includes the three heating methods and cross-section heat exchange. This oven is the choice for bakeries that can only assign a very small footprint for their oven, with a baking surface of up to 500 sqm. It features up to six decks, each with its own independent oven, which makes them suitable for baking various types of products simultaneously.

be better adjusted to lateral product rows, preventing these rows from baking/drying incorrectly,” Aiello explains.

For process accuracy and energy savings, each zone comes with its own power unit. For the MDI STRATOS, using several decks provides extra freedom in managing production rates, baking times and product distribution on the conveyor’s surface. The STRATOS can be upgraded by adding decks.

Baking times and temperatures are managed the same way for the SDD EOS. Depending on its length and the requested power for specific products and production rates, a series of independent radiant burners are installed along the oven, over and underneath the conveyor.

Depending on the types of products to be baked with Koenig’s tunnel ovens, a number of configurations can be custom-made, with different types of conveyors, different oven lengths and widths. More customizations can be made regarding the number and the length of zones, the burner capacities for each zone, the presence, location and number of turbulence sections, steaming, and the need to preheat conveyors.

Seamless production

All under control

Automation features help control all process parameters.

The MDI STRATOS and the SDI PHAROS models manage baking times by adjusting the conveyor speed with a frequency converter, via the Automatic Control System. This system also manages temperatures, thanks to the proportional integral derivative (PID) burners and the baking chamber and fumes thermocouples. Humidity is provided by the steamer at the oven’s infeed zone, then air extraction along the oven is managed with fans. Turbulences (air convection) can be integrated into specific sections on customized ovens. Every zone has its own burner. The single-deck PHAROS is the recommended choice when the line needs a big proofer room, which can be placed just above the oven.

SDI PHAROS and MDI STRATOS incorporate a system to finetune the flow distribution of fumes across the baking chamber’ heat exchanger: “This allows the heat transfer to

A constant product flow is the result of good line management. At the same time, process optimization translates into energy savings. Koenig ovens go on stand-by when they detect the product flow upstream has stopped, which reduces wasting flash heat at the beginning of the product flow. “This is greatly helped by a product tracking tool that can show product flow and related interruption-beginning instances along the line,” Aiello adds. To adjust and improve production, automatically logged data about line and oven settings/behavior can be analyzed, together with the resulting product.

Going forward, Koenig anticipates an increase in the use of energy sources other than gas, oil, or electricity. Ovens will need to increasingly lower the consumption of whichever energy is used. Smart features will include computer vision at the end of the oven, for live feedback about the oven’s settings and quality measuring.

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exhausted from the baking chamber. In turn, the volume of air going out is related to the speed of the fan, J4 explains.

© J4

Looking at every product

J4: the optimum baking curve Czech Republic specialist J4 looks at the optimum baking curve for a wide variety of products when designing its tunnel ovens. To ensure it is consistently being reached, each step (and its dedicated zone) of the baking process is controlled. “For an example of a possible setup, an oven with a baking area of 4 x 22.5 m has five baking zones and one heating tower. For each zone, the temperature is automatically regulated, according to the recipe, with a pre-set ratio of bottom and upper heat,” J4 specialists explain. In addition, ‘STIR’ is incorporated in J4 ovens – a patented technology that changes radiant heat to infrared heat, helping the product to develop core temperature faster, and the final volume of the product, while contributing to the process efficiency by shortening baking times. STIR was developed by J4 in cooperation with German company IBT; thanks to a special coating applied to a part of the baking chamber, the heat resonance is changed so that it penetrates the product’s surface and reaches its core more easily.

Optional oven accessories that are commonly used are the ‘Duotherm’ (a turbulence zone helping at the beginning of the baking process to heat pan straps and at the end, for fine-tuning the crust and color) and the exhaust fan, used for proper moisture management inside the oven. The system not only controls the current status of the oven, but also adjusts the process according to information received from the line, such as gaps between products, to always maintain the closest possible temperature to the one set in the recipe.

Setting the best baking curve is the first step in production.

The baker’s skill and experience play the main role in perfecting it, based on information about the product and the materials used, and by testing the oven’s parameters.

The company shows how it can contribute with custom setups: “To get a perfect product, we offer solutions that include steam and moisture management, changes in the baking system itself, or combining heating methods (radiant/ convection/infrared – direct/indirect)m and oven control.”

The amount of moisture is related to the volume of air

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These settings vary for each type of product. For example, bread products need a high temperature at the point of contact with the oven belt and in the first zone, J4 specialists illustrate. Buns have a smoother temperature curve mid-way through baking. For their smoothness and shine, steam is released along the baking chamber. The cyclothermic oven with a shifted tower is mainly used for rye-wheat bread, where the high temperature in the first zone gives the best result. Rye products are steamed in the beginning; it is then best to bake them with very low moisture. “All these kinds of products and processes can be handled with just one oven,” J4 concludes.

Looking at production volumes and product variety, J4 recommends considering tunnel ovens when making at least 150-200 kg of dough per hour, for bread-like products. One of the bigger challenges is in setting the optimum product order, especially when making goods with widely different requirements. “The oven needs a certain amount of time to heat up and there is some temperature inertia when cooling down. Skill and practice are needed to perfect this; but, we are here to help with production planning,” J4 says.

How can they help? First of all, with know-how about the timing of temperature changes. J4 also provides this information as a part of the baker’s training during installation.

“This is necessary because there are some oven features that save on the timings of these processes, which cannot be part of the oven preset included in the recipe,” the company explains. Based on discussions with clients, J4 can recommend the optimal sequence of products during a baking period.

When choosing an oven, its size should be estimated to take into consideration future production growth. A bigger oven can be planned in advance, to use it at full capacity over time. Or, J4 can rebuild and extend an oven by prolonging the tunnel and inserting extra radiators.

For the future, J4 is looking into alternatives to traditional fuels as well. “We have successfully developed cyclothermic ovens using wood pellets and developed a solution for switching between gas and electricity in the heating tower by touching the control panel.”

Flexibility for industrial volumes: MECATHERM MECATHERM provides many choices to adapt tunnel ovens to specific needs, including certain cleaning options, different types of conveyors, energy sources, or settings to adjust baking parameters according to the product range.

For the all-important product quality trend, MECATHERM developed the modular M-TA tunnel oven. This award winning oven offers multiple heat transfer modes, such as convection or radiant heat, or a combination of both, in each of its independent heating zones, to the required product

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specifications. “It is a flexible oven choice for a line that excels at baking vastly different products, from crusty, pastry to patisserie products,” explains Marie Laisne, Product Marketing Manager at MECATHERM. “By providing just the right quantity of energy in a minimum baking time to reach the product quality criteria, this oven offers an optimal energy consumption solution,” she recommends. The kind of product influences the type of energy transfer that should be used for the best results. The baking phase is also considered for this choice, from development to stabilization and coloration.

For industrial production, MECATHERM’s main focus is performance optimization. In this regard, the ease of access for the operators is key to enabling easier maintenance and cleaning operations. For instance, for baking products with the highest sanitation standards (e.g., protein-based products), the FDAN tunnel oven is fully accessible and can be easily cleaned with high-pressure water.

MECATHERM is also making advances with innovative digital solutions to help with current market challenges: “The new M-CARE digital solution is an intuitive interface that enables industrial bakers to detect drifts in equipment, anticipate potential breakdowns, and support operators and maintenance teams to ease the first level of maintenance,” Laisne explains. Most of MECATHERM’s new ovens are ‘M-Care ready’.

Through automatic settings, baking parameters can be precisely controlled via the HMI settings including baking times, temperatures, heat transfer modes and their intensity, as well as steam injection and extraction.

Sustainability and consistency

Regarding the increasing concern for sustainable solutions, MECATHERM recommends using as much as possible convection as a heat transfer mode, which both shortens the baking time and reduces the fumes’ temperature (when using gas burners). In addition, “The oven temperature regulation should be monitored with precision to avoid unnecessary overheating,” she recommends. For instance, lowering the temperature of the fumes from 350°C to 150°C lowers energy loss through fumes by 40%.

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A new energy-saving feature of MECATHERM ovens manages the damper opening settings, to minimize the amount of fresh air that enters the oven during regular baking operations. “A digital solution assesses the exact quantity of extracted flow as well as the quantity that is effectively extracted. This data allows the baker to adjust the extraction settings close to the required balance point and optimize the energy consumption,” the French specialist adds. Additionally, MECATHERM is currently working on project development that will measure and precisely adjust the humidity rate inside the baking chamber, she reveals.

To ensure process consistency between batches, recipes are pre-registered in the HMI. To finetune the process, MECATHERM runs numerous airflow simulations in the oven’s design phase. The company’s R&D team has developed its own simulation tool to help analyze the simulations, which is used for more than five years in every development process.

Last but not least, all Mecatherm tunnel ovens are compatible with an electrical power supply without any changes in baking performance, while also reducing the ovens' CO 2 emissions.

The next steps in oven tech

A new solution is currently under development, to help provide adjustments for increased productivity: a data analysis tool for the information collected from a single piece of equipment, or an entire line. “Ultimately, it will provide a dashboard to monitor the equipment/line performance,” anticipates Laisne.

Long-term developments at MECATHERM will aim to support industrial bakeries in their road to sustainability, with ovens with improved energy management and, consequently, lower CO2 emissions. Green baking is completed by baking precision: “A development area we are researching is, for instance, precise humidity management that plays a key role in the final product quality,” she shared.

Sustainability is well on its way to being profitable, for the environment, for the baking process efficiency, and for the business, with plenty of interesting opportunities regarding tunnel ovens. +++

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Coatings do make the pan Having the right coating for the product, the process and the pan goes a long way to obtaining perfectly baked products for longer, while optimizing costs.

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The durability of pan coatings starts the moment they meet the pan, and the design of the pan plays a major role in the life of the coating.

That is why American Pan considers the type of pan coating that will be applied from the very beginning of the bakeware design process. One of the main goals is to ensure that coated surfaces will not come into contact with other pan metal when travelling through the bakery or when pans are stacked.

The company has developed unique stacking designs for trays, tins, and lids, to avoid metal coming into contact with the coating, even if they are nested. “Having a proper stacking design not only ensures the ability to safely stack pans and save bakery space, it also protects the pan surface and coating, ensuring the maximum release life,” states Jesper Albertsen, Vice President of Sales for American Pan Europe.

One American Pan customer was using automated stacking which was causing damage to the coating and premature failure. Switching to a new stacking pan design allowed the customer to extend the coating life by approximately 30%.

Proper use and care Having a newly coated pan that matches the required specifications is the beginning of the road for the lifespan of that coating. Coatings come in a wide range – for example, there are OptiShield® coatings are specifically formulated to handle sticky doughs such as pretzels, buns, or muffins, while other coatings, such as DuraShield®, can suit a broader range of standard products.

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For OptiShield® and DuraShield®, the main coatings that American Pan delivers in Europe, utilization guidelines include handling, the use of release agents and toppings, depanning, and their passage through conveyors, proofers, and ovens. Stacking and cleaning guidelines are also provided. Both OptiShield ® and DuraShield ® coatings are designed with excellent non-stick properties and are corrosion-resistant. To minimize any damage, scratching and abrasion should be avoided. For example, pan indexers should not be allowed to come into contact with the coated surfaces, which would ultimately damage the coating. To avoid this issue, bakeries can add rubber padding to the pan indexing fingers. If the non-stick coating incurs deep scratches, the pan’s surface is subject to corrosion and problems with product release.

Albertsen emphasizes that, “If a bakery notices damage to their pans or coatings, they should contact our team right away so that we can help determine the cause of coating damage and suggest solutions. Our goal is to ensure the longest pan and release life possible.”

What is applied to the pan or product can also affect the life of the coating. Using release agents such as oil or grease can cause build-up on the pans and reduce the effectiveness of the coating. Toppings such as seeds and

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protein or egg wash can also affect the coating life. Bakers should ensure proper cleaning techniques are used to remove the toppings without damaging the pan surface.

Oven temperature can also play a role in the longevity of coatings. Ovens operating at a high temperature can decrease coating life through a process called thermal degradation. One American Pan customer switched from a tin set made with standard aluminized steel using a fluoropolymer coating to a set made with American Pan’s proprietary ePAN® materials and DuraShield® coating and were able to decrease oven temperature by 30° C and achieve over 4,200 releases without the use of oil.

experts will then work with suppliers to offer the best and most appropriate coating technology. For example, the company‘s OptiShield ® Crumpet Ring coating was developed through this process and nearly doubled the release life for a customer.

Finding the right coating

As part of the recoating services, American Pan will provide pan straightening, in addition to stripping away the old coating, cleaning, and applying the new coating. When fluoropolymer coatings like DuraShield® and Optishield® are reaching the end of their life, the wear can advance fairly quickly, which is why it is important for bakeries to time refurbishing or reordering of pans well in advance.

American Pan Europe has refurbishment locations in Spain, the UK, and Romania, so shipping times can vary according to the proximity to one of these centers.

Identifying the coating that will work best in each case starts with the product and the company’s prior experience with it. Flouropolymers such as DuraShield® and OptiShield® are the most requested coatings in Europe, while AMERICOAT ® silicone glaze is also used, especially in the UK. The key to providing the best coating, according to Albertsen, is working closely with customers to understand their requirements and their bakery process. The company technology

“We can help determine the cause of coating damage and suggest solutions. Our goal is to ensure the longest pan and release life possible.”

Jesper Albertsen, Vice President of Sales, American Pan Europe

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Rubberized coatings are another popular option for bread and baguette pans, among other products, because this coating contributes to achieving a crusty product. American Pan offers FlexiCoat in this range, in addition to RilonElast via the Runex brand, which was acquired in Sweden last year.

Coating automation KEMPF has recently started working in its new coating plant, built in Rohrbach, Germany – the result of a EUR 18 m investment in equipment and property. The building occupies 5,000 sqm, out of the 80,000 sqm that, in time, will house additional buildings, including new company offices.

KEMPF developed this plant for high-quality bakeware coatings. Three fully-automated coating lines are operating there now, with room for expansion with two additional lines. KEMPF designed the plant with a high level of automation, to ensure consistent product quality and self-sufficient production. “State-of-the-art technology was brought into the new plant,” shares Guido Kempf, KEMPF CEO. Sustainability plays an important role at the new factory, which is powered by solar panels, with over 2,300 units installed on the roof.

Here, the entire range of KEMPF’s KG-FLON non-stick coatings can be applied, coatings dedicated to the bakery industry: Fluoropolymer coatings, original TEFLON©, Silicone coatings, Plasma coatings and Ceramic coatings.

The company is increasingly focusing on burger buns and croissant trays at the new facility, which is home to three fully-automated lines for baking trays, deep-drawn pans, croissant and burger pans, as well as pizza pans. With a daily capacity for coating and recoating of 4,800 sqm, “This plant is exclusively dedicated to coating bakeware,” Kempf tells us.

coating in Q1 2023. We are now in the final testing stages of development and the results we see are outstanding,” Kempf reveals. This coating is said to have an excellent non-stick effect and can extend the life cycle of the trays and pans by up to 40%, in comparison to existing coatings on the market. It can be used for manufacturing standard baguettes, rolls, buns and similar products. In addition, this new coating also shows, “Very, very good results on pans for glazed buns, because of its very smooth surface,” Kempf explains. In this manufacturing scenario, the company determined that the new coating will ensure up to 80% more baking cycles, compared with other coatings.

“We are planning to launch a new type of coating in Q1 2023. We are now in the final testing stages of development.”

Guido Kempf, CEO, KEMPF

This coating is undergoing thorough testing, together with bakeries. The first step in perfecting it with feedback from production, was running application trials in the company’s laboratory. Durability over baking cycles was then tested in-house. In the third step, KEMPF trialed small batches of 10-20 pieces, which were put through existing baking lines of selected customers. For the fourth and final testing step, complete lines are equipped and run production cycles in full-scale manufacturing conditions.

Harsh-condition baking

Coating development

From the product’s standpoint, lye products are among the most challenging ones, regarding the type of coatings needed. KEMPF’s KG-Flon 750 was developed exactly for this use. “This is a coating that has extraordinary diffusion resistance, which is critical for it to withstand the very aggressive lye for a long time.” In addition to pretzels and other lye-dough products, this coating is also a good solution for breads with a high ratio of sourdough.

New coatings are also developed at the facility. KEMPF works together with its coating/chemical suppliers and two universities to perfect new solutions. And work is well underway: “We are planning to launch a new type of

Custom solutions are perfected to meet specific production environments, current and new product ranges and manufacturing lines. +++

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PIZZA

Thinking all around the pizza box

© AMF

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Pizza and flatbreads. Naan and wraps. Pitas and handheld snacks. This is a generous and exciting product range, with ample space for new innovations. AMF Bakery Systems (AMF) designs complete systems that support all of them, with results matching artisan craft.

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Either sheeted or pressed, dough pieces will go through the line in a closely controlled process. There are several solutions to choose from, starting with complete pizza production systems, which handle pizza balls, pizza bases, and toppings with complete, dedicated lines, and also include baking and freezing equipment. Almost any kind of pizza can be manufactured with these lines, from thin to thick crust, American or Italian style, to vegan, or gluten-free, and higher rim, for example. Both fresh and frozen pizza can be processed, with the latter having the bigger market share worldwide.

AMF’s pizza systems can produce from 2,000 to upwards of 100,000 pizzas per hour, depending on the size of the pizza and the desired working widths of the line. Lex van Houten, Regional Marketing Manager, AMF Bakery Systems, underlines some possible variations: “We are highly flexible with execution to fit the space available in the bakery, which is often an existing factory, but sometimes also a ‘green

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field’, new location. Variations in products, production volumes, floor space, and future growth are all important elements we consider when designing a new pizza or flatbread production line.” AMF’s solutions for the pizza family of products range from semi-automatic equipment to fully-automated lines. The second category features smart solutions that help with quality control and better accuracy of the line, compared to manual operations.

Any style of pizza can be created and styled on AMF’s dedicated lines, the company says. The AMF Tromp SF Sheeting line can handle pizza dough coming straight out of the mixer, including pre-fermented dough or highlyhydrated types of dough. “Eating cultures around the globe determine what kind of pizza or flatbread a consumer likes best. Europeans like Italian pizza, with stone-baked crust, but also American-style pizza, with a thick base, or even pan-pizza which is a real dinner dish. Asian consumers heat pizza in a microwave as well, so the crust needs to be prepared

differently for that. It all depends on the desired end product,” the specialist illustrates.

Always on top: pizza toppings AMF Tromp pizza topping systems are some of the latest technology developments for this product range at AMF. They are designed to be flexible and very hygienic, which is why they can be easily wheeled away from the line for quick changeovers and cleaning, to keep productivity high. Here, too, we find options: depending on the speed and production volumes, waterfall topping with a recycling system is often used to apply the cheese to the pizza dough.

For more targeted applications (e.g., meat, fish, chicken, or vegetables) centered on the pizza, Tromp’s target applicator is the more efficient choice.

A traveling manifold strews the preset amount of topping onto the product, without wasting ingredients, and then moves on to the next pizza base. “It is a sustainable way of decorating pizzas and flatbreads, and the resulting

PIZZA

product is also visually appealing,” van Houten points out. Depending on the types of toppings used, Tromp’s topping lines often have multiple units to support high production rates in bigger factories. Moreover, this application also works well with semi-automated lines; in this case, it will be fed manually by operators.

AMF’s specialty lines can have custombuilt, flexible solutions to prepare all kinds of dough on the bakery’s to-do list.

then used to bake it; optionally, it can come with a stone floor belt, for authentic Italian crust,” he explains.

Changeovers can be incorporated on several parts of the line. A line can be set up to run only one product, but, for flexibility, it can work with different types of toppings and/or doughs.

AMF’s team of specialists travels all over the world for inspiration, to assess different requirements from pizza and flatbread producers. To perfect the process for a product, trials and demonstrations can be organized at AMF’s Innovation Center in the Netherlands.

The sheeting equipment is designed to handle a range of doughs, from green types to pre-fermented, highlyhydrated recipes. “To accomplish this, the sheeting line will create the perfect base. Depending on the end product, we can include a final proofing stage, which is done with our multi-deck belt proofer. Our AMF Den Boer ovens are

To ferment the dough, AMF offers automated or semi-automated solutions. A fully-automated fermentation room will guide the dough trough during the process and gently handle it to prepare the dough for sheeting or extrusion, afterwards. Handling can also be automated: “The bins or troughs can be moved around from

The dough is the base for great pizza

mixer to fermentation or dividers with our AGV robot system,” van Houten details. AMF’s product diverter manages the handling and conveying of pizza and flatbread throughout the line.

Diverting can be done from multiple lanes into one lane for packaging/ flow-wrapping, or the other way around, from a small sheeting line, creating multiple rows for topping or proofing.

“Using the AMF Smart applicator solution, you could even steer ‘bad’ products to a separate line,” he observes.

Proofing solutions for sheeting pizza lines are another option, using a continuous belt proofer or a step proofer for longer fermentation times of the pizza base or dough sheet. The belt proofer is also useful for pita lines.

A Pizzaflex Divider is also incorporated into AMF’s pizza systems. It uses extrusion technology, then rounds the dough pieces to create balls that will become

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PIZZA

© AMF

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pizza bases (but can also become breads and buns).

For baking, a tunnel oven is the most frequent choice. Pizza and flatbread bake for a short time, at high temperatures, something in which Den Boer Multibake HT specializes in (HT stands for high temperature). “You can see the pita, naan, focaccia and pizza rising in the baking tunnel. But, if a pizza needs to be parbaked, prior to topping and freezing it, the oven will create the optimal conditions in this case, too, to deliver perfect products 24/7,” AMF’s specialist explains.

All oven settings and parameter controls are managed by AMF’s Sustainable Oven Service (SOS), a newlydeveloped tool that helps optimize oven production (and resulting products’ quality) in real-time while minimizing energy consumption and the bakery’s environmental impact. Using the latest sensor technology, the SOS continuously monitors oven use and performance. it connects the oven to the AMF Bakery Intelligence cloud for in-depth operation insights. In addition, heat recovery and burner control and also critical features are available to improve baking efficiency and sustainability.

Variety is key The SOS is among the most frequently requested features, currently. While processing needs may vary from country to country and even more so across continents, AMF sees increasing

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variety in toppings in general. “We offer a flexible topping line to be able to make quick switches, clean and still maintain high speed and productivity,” he adds. Better-for-you product varieties are also increasingly in demand, including gluten-free, vegan and vegetable base pizza. For these types of dough, AMF also provides sheeting and extrusion lines. Van Houten: “We see great variation in recipes worldwide, with well over 1,000 different gluten-free pizza recipes, so we test and validate them all in our Innovation Center and show manufacturers the best solution for them.”

The pressed pan pizza system features large pans with individual indents per product, to allow more processing time and prevent the pans from hitting against each other. Different pizza sizes can be produced in this way, with a wide range of pans tailored to the working width of the line, to maximize efficiency. A pressed pizza base is usually solid and has less air inside the dough than a stress-free sheeted artisan pizza. There are multiple solutions available for this method, depending on the desired type of product, including hot pressing, cold pressing, or pressing in a pan. AMF usually recommends big pans to increase processing time, in order to avoid loud noises from pans touching, and because they are easy to change/ refurbish. Smart conveying solutions and diverter lines will streamline the process. “We also offer unique depanning equipment; by using them, a pizza

is depanned, yet stays perfectly in shape,” he adds. The Tromp Pizza Press Unit is servo operated, allowing complete control of all the movements the press performs. Different movement profiles can be set and used, depending on the specific product characteristics.

In addition to the Pressing Unit, AMF Tromp provides several types of equipment for the pressed pan pizza system, including a pizza finger printer and a pizza docker, for example.

“The R&D teams constantly improve our solutions for these units with new and sustainable techniques, as well as features making it easier to switch between units to change the type of products made on the line,” van Houten highlights, so the equipment keeps up with market trends.

In any of these multiple configurations, the workflow is always adapted to the recipe and the product requirements.

Almost no two lines delivered by AMF are identical, we learn: some use a fast proofing time, while others opt for products requiring long resting time; mixing and baking times also differ, as well as the ingredients used. Baking can be done on a mesh belt or a stone floor; and the sauce and toppings can be applied in various sequences. Supported by horizontal mixing units, unique solutions are developed by AMF for several famous pizza QSRs worldwide, which top and bake their pizzas locally in each store.

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PRODUCTION

Smart scoring innovation is here Koenig has recently developed a scoring unit powered by Artificial Intelligence, with the help of 3D scanners and cameras. It is an all-in-one solution for small and medium-sized bakeries.

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The new scoring machine, ISCORE, is an all-in-one solution, featuring three cutting technologies: a rotary blade tool, a water-jet tool, and an ultrasonic blade can be used by simply switching to the desired one. This smart machine is designed to provide optimum efficiency and high-quality cuts, Koenig elaborates.

With this scoring unit, the Austrian technology specialist has added a new innovative machine to its portfolio, which is able to cut dough pieces with accuracy at high speeds, in the desired pattern. Artificial intelligence (AI) processes and the three scoring technologies are decisive for this.

Designed also with small bakeries in mind, the AI’s ability to sort parts allows the machine to automatically change product references. “Coupled with simple construction, this makes our cutting system the ideal helper for the baker,” Koenig believes.

© Koenig

Rotary blade

Koenig explains. By incorporating three different dough scoring technologies, available by simply changing the tool, ISCORE can make strides toward increasing process efficiency in small- and medium-sized bakeries, while providing consistent quality standards.

Thanks to AI, the system continuously adapts to product variability over time while maintaining an optimal rate of speed/accuracy (with the help of Machine Learning and Closed Loop Control). Additionally, the intelligent cutting units are available in different models to adapt to the

Features built into the ISCORE In ISCORE, Koenig offers an advanced and flexible dough scoring system, which incorporates some of the newest and most promising technologies AI has to offer in baking operations. “Our technological base and the strong alliances carried out with consolidated companies in the sector allow us to offer our clients a very advanced scoring system that simulates and even improves the skills of a master baker,”

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Water-jet

© Koenig

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PRODUCTION

production capacity of each bakery. All models include a scanner unit, one or more cutting robots, a conveyor, an electrical cabinet and a CPU. Remote access to the machine, combined with the robots provided by FANUC, one of the largest robotics manufacturers, ensures the fastest service attention.

ISCORE’s main features include: + The cut is adapted to each dough piece: Thanks to the integrated 3D-vision system, the exact position of the loaf on the board is detected and the score is adapted to each loaf individually, regardless of its position on the board or if irregular shapes are detected, different than the presets. + Precision and speed: The Bread Scoring Smart System cuts in the dough with the precision and speed of expert hands. For this, it uses rotating blades, water-jet, or ultrasonic tools handled by the robot, which allow numerous adjustments such as cutting opening, depth and inclination. + Excellent results in all types of dough: The blade of the rotating tool manages to drag a thin layer of dough that covers the open cells of the loaf, thus avoiding degassing. “This is the reason why an optimum score is obtained even on doughs with high water content,” Koenig explains. The waterjet cut is performed without spilling a single drop out of the piece of bread. Up to 25 bars can be made. If cutting is done with ultrasound, sonotrodes of any type and shape can be used – tools that create ultrasonic vibrations and apply this vibrational energy to a gas, liquid, solid, or tissue. The only limit in this regard is given by the total weight of the tool. + A good value for cost ratio.

ISCORE’s working principle The machine aligns the score to the dough. Taking the scanned product as a reference, the system generates a unique trajectory, according to the position of each piece of dough. In this way, it ensures that the misaligned loaves are still cut up to the standard. It improves the regularity of the loaves: taking the recipe created by the baker as a reference, the system adapts the cut to each loaf.

“Each bakery is unique and exclusive; this is why our systems adapt to the needs and particularities of all of them.” Robotics Application Manager Ramón González López mentioned what is essential for the development of this ISCORE unit: “We study each project individually to adapt it to your facilities and your needs. Our aim is to ensure that our clients achieve excellent scoring quality in their dough, day after day.“ +++

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Optionally, it can be set to achieve an artisan look, using a randomization algorithm. When this option is activated, the system slightly alters the cut for a hand-made feel.

AU TO M AT I O N

Ready, set, dough!

The consistency of perfectly formed dough depends entirely on the conditions during fermentation. DIOSNA develops pre-dough and dough fermentation systems that can ensure required parameters, with various degrees of automation.

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© Diosna

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The stakes are high for pre-dough to develop perfectly, as it has a direct impact on the texture, flavor and shelf-life of the final bread. Automation tools have a decisive contribution to this result, and making the equipment flexible enough to work with widely different types of dough is key. The most useful automation features DIOSNA incorporates in the design of its pre-dough systems help to easily control production. They also offer a high level of flexibility, allowing recipe customization based on specific products and requirements, and system capacity adjustments, via DIOSNA’s system control, according to the desired schedule.

planning.” Parameters can be set for each type of dough: + Spelt flour – a ratio of flour/water of 100:100 is possible, along with temperature control, cooling, cold storage + Wheat flour – flour/water ratio of 100:100 is possible, and temperature control, cooling, cold storage + Rye flour – flour/water ratio of 100:110 is possible, and even 100:120, depending on the rye quality; temperature control, 3-stage fermentation option, cooling, cold storage + Wholegrain Barley flour – flour/water ratio of 100:140 + (Whole) Rice flour fermentation – possible flour/water ratio: 100:150 up to 100:180

Certain production stages can be performed by staff, when using a semi-automated system: the bowls can be handled manually. By reading their labels, the system will indicate on a display what route they need to follow between stations, from the dosing station to the kneader and lifting tipper, for example.

Several recent developments can be incorporated into DIOSNA’s dough resting systems. Depending on processing needs, they can range from multi-level solutions with an elevator, and automated tub or vat cleaning to process controls that allow the system to flexibly react to changing volume requirements.

Spelt, wheat, organic pre-dough and more

A recent dough resting automation project shows how such features come together: a Biga dough system was built over two stories, with a capacity of over 100 containers that can rest in a vast dough resting room, each holding over 120 kg of dough. However, smaller batch sizes also needed to be integrated regularly. DIOSNA’s solution: “After the resting time, the containers are automatically moved out

DIOSNA’s pre-dough systems can flexibly work with different fermenters, including organic dough. The company explains how: “Depending on the dough quantities, our control system can switch the number of fermenters used for organic, respectively non-organic pre-doughs. This automated occupancy control will be connected to the customer's production

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Let the dough rest

AU TO M AT I O N

from the resting room and are then transported following the first-in, first-out (FIFO) principle to a transfer station.

Here, the containers are transported upwards and emptied into the stainless steel vats of a kneading system. The empty containers then move automatically to a cleaning station.”

The elevator automatically handles the dough transfer to hoppers and conveyors. Combining a lifting tipper and a vat transport solution bridges distance flexibly. The elevator, like the entire dough resting system, is controlled by the PLC.

Automation stages Partially automated systems are a flexible solution. A number of processes can be performed manually – and can be gradually automated later – if needed for more efficiency, such as dosing, moving the bowls and cleaning.

A fully automated, linear transport system offers the highest level of automation technology through a completely self-regulating process. It is essentially an individual solution for the bakery, designed for maximum flexibility. “A special feature of the linear transport system is the overhead guiderail, which ensures maximum ground clearance and best cleaning options. The DIOSNA linear transport system can include several dosing, mixing and/or emptying systems. This means that several recipes can be made simultaneously, in different mixers, to serve several subsequent lines with different volumes or equal amounts of dough,” DIOSNA elaborates. This system can be programmed with different dough resting periods, according to the recipes. Inside the system, an automated transport system handles the dough.

The process sequence of individual movements is uniquely adapted to each product.

There are several options to program dosing and kneading on these flexible systems. The mixing energy is monitored throughout the process. The sequence of dosing and mixing processes can be programmed. The frequency control of the tools and bowls ensures individualized dough mixing.

Once defined, mixing programs can be transferred between similar types of mixing systems.

DIOSNA highlights. Data is a valuable asset in dough preparation: monitoring can show if production is still within the predefined parameters, it can detect errors, provide trend reports, and more. “Cloud-based solutions are also becoming increasingly interesting for production planning.

Retrofitting is also no problem for existing machines and can usually be done within one day,” DIOSNA observes.

Pre-dough production planning To integrate a pre-dough system into a production planning system, several aspects need to be considered. “It is not just individual devices, such as dosing units, mixers and conveyors that must be included in planning; they must also interact harmoniously. For optimum results, dough resting time must be taken into account,” DIOSNA underlines.

An automated kneading concept supports gentle dough development with low-temperature rise. “At the end of the mixing time, the finished pre-doughs are discharged through the electrically-controlled opening of the central discharge system into tubs, which are provided by a conveyor.

The dough is then transferred to the dough resting system,” DIOSNA explains its operating principles. Once it arrived here, the next step can begin: long, gentle dough fermentation. The doughs resting in the tubs are constantly cooled by a gentle air stream. When resting time is over, the tubs are automatically removed from storage and transported to a transfer station. Further processing often takes place with the aid of elevator tippers, which empty the tubs into the stainless steel vats of other kneading systems.

Several DIOSNA solutions are available for fully-automated production control, always depending on the products and dough types used. For example, the continuous pre-dough production system can process rye sourdoughs and wheat pastes in various capacities per fermenter. A special feature of DIOSNA's pre-dough system is the optimized process control for constant pre-dough quality. Such systems ensure the dough is ready for baking, and the end products will have the intended texture and flavor. +++ KOENIG Motiv4 NTS 91x53.qxd

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In addition, remote monitoring and remote service can be booked for this system, by defining a sequential step program. DIOSNA illustrates that each step can be programmed with a certain recipe functionality, such as kneading by time or energy, or dosing with/without kneading. Next, each function of a recipe can be optimized according to several parameters. The kneading program can contain up to 40 recipe steps.

Automation features can be sequentially added over time.

One of the tools usually retrofitted is an IoT system. “Production monitoring is becoming increasingly important,”

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RESEARCH

Activities of exogenous enzymes in baked products The activities of various exogenous enzymes in baked products were systematically analyzed from dough preparation, through the baking process and into storage. The texture analysis methods that were developed allowed the events occurring during the development of firmness in the wheat crumb to be differentiated into processes taking place before or after baking. The presence of the enzyme preparations examined during the project showed no detectable functional effects during storage in the crumb that was already formed, due to either previous inactivation or a lack of functionality in the end product.

By Thekla Alpers, Sabina Paulik, Thomas Becker, Mario Jekle, Katrin Reichenberger, Sabine Lutz-Wahl, Lutz Fischer, Gerold Rebholz,

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Katharina A. Scherf

Endogenous enzymes occur naturally in wheat flour and yeast, and added exogenous enzymes are responsible for changes in the constituents of wheat during the manufacture of baked goods. The activities of the endogenous enzymes in cereal flours vary depending on the wheat species and variety, environmental influences in the field, and the state of ripeness at harvest time. Exogenous enzymes are used in the manufacture of baked goods to balance out these differences, improve the properties of the dough and end products, and guarantee that the baked goods have a reproducible high quality. The enzymes used for this purpose come mainly from the oxidoreductase class (EC 1), e.g. glucose- or hexoseoxidases, and the hydrolase class (EC 3) such as amylases, xylanases and lipases [1].

The legal basis for using enzymes in foodstuffs In the EU, adding enzymes to foods is permissible only if they conform to the current implementation status of Regulation (EC) No. 1332/2008. The conditions required for approval are their health safety for consumers, the technological necessity for their use, and the exclusion of consumer deception. According to Regulation (EC) No. 1332/2008, enzymes must be declared in the list of ingredients, with their class name and specific designation, if they are added to foodstuffs for technological purposes in their manufacture, processing, preparation, treatment, packing, transport or storage, and display a technological effect in the end-product.

Insofar as enzymes are inactivated during processing and have no technological effect on the end product, they are exempt from the obligation to declare. In the case of baked goods, it is usually assumed that the added enzymes are inactivated as a result of heating during baking, and therefore need not be declared due to the absence of a technological effect in the end product.

Properties and technological effect of amylases α-Amylases (EC 3.2.1.1) belong to the endo-amylases that split α-(1,4)-glycosidic bonds in starch, and release lower molecular weight α-dextrins. In contrast, maltogenic amylases (EC 3.2.1.133) and malto-oligosaccharide-liberating amylases (e.g. EC 3.2.1.60 and EC 3.2.1.98) are exo-amylases that release maltose and other malto-oligosaccharides such as maltotetraoses or maltohexoses from starch. Pullulanases (EC 3.2.1.41) and iso-amylases (EC 3.2.1.68), which cleave α-(1,6)-glycosidic bonds and thus remove the side-chains of the amylopectin, are also relevant. β-Amylase (EC 3.2.1.2), on the other hand, hydrolyses the α-(1,4)-glycosidic bonds of the non-reducing ends of starch polymers, thus forming β-maltose and β-limit dextrins as the main products.

Figure 1: Effect of various additives to the extraction buffer to determine a residual activity of the maltogenic amylase from G. stearothermophilus from yeast-leavened white bread using different additions to the extraction buffer (1: no addition, 2: with 1 M of maltose, 3: with 20% (w/v) of maltodextrin, 4-8: with 10% (w/v) of maltodextrin and various extraction times; 1-4: 1-hour incubation time; 5-8: 2-, 3-, 4- and 5-hour extraction time)

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The effect of amylases during the production of baked goods depends on their thermal stability and specificity, and on the products that are formed. In general, fungal amylases have low thermal stability, and their activity is lost after starch gelatinization during the baking process.

On the other hand, a few bacterial amylases are stable

RESEARCH

even at high temperatures, and can thus still be active after the baking process [2]. Because of the low endogenous α-amylase activity in wheat flours, one aim of the addition is to achieve an α-amylase-catalyzed increase in the content of fermentable and reducing sugars as a substrate for yeast or sourdough fermentation. However, the essential effect of α-amylase is to degrade starch polymers during gelatinization, and thereby influence the volume of the baked product and the crumb properties concerning softness and pore development. As a side-effect, more reducing sugars are available for the Maillard reaction, and thus for reactions yielding flavor and color.

The addition of amylases delays staling during storage (anti-firming effect). The mechanism at a molecular level has not yet been definitively explained. The fact that dextrins retard the retrogradation of amylopectin, or that modified starch itself displays different properties during retrogradation as a result of the α-amylase activity, are being discussed.

The aim of Research Project AiF (German Federation of Industrial Research Associations) 19543 N was to systematically analyze the activities of various endogenous and exogenous enzymes relevant in the manufacture of baked goods from dough preparation and processing to the end product, and during the storage period.

The thermal stability of various enzymes in the dough matrix In the Department of Biotechnology and Enzyme Science at Hohenheim University, various enzyme assays were carried out to detect amylase, xylanase, glucose-oxidase and lipase activities, and to intercompare them in their sensitivity and applicability to detect possible residual activities in baked goods. The most suitable enzyme assays were then optimized, where necessary, with regard to their sensitivity. In this process, for example, it was possible to increase the sensitivity of the Betamyl-3 assay, which is used to detect exo-amylase activities, by more than 60-fold by increasing the assay run time and adjusting relevant parameters.

After sufficiently sensitive activity assays for all the relevant enzyme classes had been found, a targeted search for possible residual activities became possible.

Among other things, the residual activity of the maltogenic amylase from Geobacillus (G.) stearothermophilus was studied in yeast-leavened white bread. First of all, using an enzyme dosage of 100 mg/kg (relative to the amount of flour), a new sample preparation method was developed to determine the amylase activity in white bread. For this purpose, white bread was freeze-dried, ground and extracted with buffer.

Next, various additives to the extraction buffer were tested, e.g. maltose and maltodextrin. Figure 1 illustrates the specific activities achieved under the various conditions. It was

possible to increase the extraction efficiency by more than 7-fold by adding 10% (w/v) of maltodextrin. Increasing the maltodextrin concentration to 20% (w/v) did not yield any further increase in extraction efficiency. In the last step, the extraction time was examined. In this way, it was possible to increase the extraction efficiency by a further 16% by lengthening the extraction time from one hour to three hours. This provided a suitable sample preparation method to determine the residual activity of maltogenic amylase in yeastleavened white bread. White breads were baked with three different dosages of maltogenic amylase (10, 50 and 100 mg/kg, relative to the amount of flour), and a white bread without added enzyme as a reference. Next, the white breads were examined for residual activity. This determination showed an average residual activity of 17.8% of the added maltogenic amylase activity. The standard deviation on all the measurements carried out was 1.2% [3].

In addition to maltogenic amylase from G. stearothermophilus, other amylases, lipases and glucose-oxidases from the baked products industry were examined with regard to their stability in dough under baking conditions. First of all, a method for extraction from dough was developed for each enzyme. These investigations took place in a speciallydeveloped heating method on a laboratory scale, which enabled the temperature profile inside a white bread loaf during the baking process to be imitated. This was done by heating each dough (5 g) in a glass vessel in an oil-bath at 110°C for 24 minutes, after which it was cooled. This method was used only to estimate the stability of the individual enzymes. This allowed a residual activity of 12.0% to be determined for the maltotetragenic amylase from Pelomonas saccharophila (formerly Pseudomonas saccharophila). Only very small residual activities (0.7% and 1.4%) were determined for the α-amylases from Bacillus subtilis and Aspergillus niger.

Five different lipases were tested, including those from Thermomyces lanuginosus, Fusarium culmorum and Fusarium heterosporum. Of these, only the lipase from Thermomyces lanuginosus showed a small residual activity of 2.5%. In addition, four glucose- or hexose-oxidases from Chondrus crispus, Aspergillus niger and Trichoderma reesei were examined, from which only very small reactivities of less than one percent were detectable.

The influence of various amylases on the sugar content in bread crumb The effects of adding various amylases on the release of mono-, di- and oligosaccharides was examined based on the sugar spectrum in the bread crumb of model toast breads two hours after baking, and after storage for up to 96 hours. Without the addition of amylases, no change in the contents of glucose, fructose, saccharose (sucrose), maltose, maltotriose and maltotetraose was apparent over a storage duration of up to 48 hours (Figure 2 A). When a bacterial α-amylase from Bacillus amyloliquefaciens was

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RESEARCH

added, a distinctly changed spectrum of mono-, di- and oligo-saccharides was evident compared to control bread without any addition (Figure 2 B) [4]. In addition to the sugars already present two hours after baking, maltotetraose was detected in the crumb after 22 hours of storage time, and maltopentaose, maltohexaose, maltoheptaose and maltooctaose after 48 hours. This preparation led to a 3.9-fold increase in maltose content compared to breads without any addition. The maltotriose content rose significantly, from 17.4 mg/g two hours after baking to 46.6 mg/g after a storage time of 96 hours. Maltotetraose also increased significantly from 6.9 mg/g after 22 hours to 43.0 mg/g after a 96-hour storage time. Moreover, the content of the sugars first identified and quantified after 48 hours of storage rose significantly up to 96 hours after storage: maltopentaose rose from 21.4 mg/g to 34.6 mg/g, maltohexaose from 31.4 mg/g to 48.0 mg/g, and maltoheptaose from 31.1 mg/g to 52.0 mg/g. A scarcely measurable amylase activity of 0.07 nkat/g in the crumb was detected by using the enzyme activity assay.

The use of a maltotetragenic amylase from Pelomonas saccharophila also caused a clearly recognizable change in

the contents of mono-, di- and oligosaccharides compared to the control (Figure 3 C) [5]. This preparation also showed only a very small activity of 0.6 nkat/g in the crumb. Nevertheless, after a 48-hour storage time, maltopentaose, maltohexaose, maltoheptaose and maltooctaose were detected in addition to the sugars already detectable after two hours. A characteristic feature of the effect of this preparation was the significant increase in the maltotetraose content from 2.1 mg/g (after two hours) to 29.5 mg/g (after 96 h), with the result that maltotetraose was the main product from this time onwards.

In the case of breads manufactured with maltogenic α-amylase from Geobacillus stearothermophilus, the sugars glucose, fructose, saccharose (sucrose), maltose, maltotriose and maltotetraose were identified two hours after baking (Figure 3 D) [5]. In these cases, scarcely any changes in sugar contents were detected during storage. Only the maltotetraose content rose significantly from 0.6 mg/g (after two hours) to 22.9 mg/g (after 96 hours) during the observed period of time. This could be associated with the measured residual activity of 5.7 nkat/g, corresponding to 14% of the activity originally added. However, due to

Figure 2: Sugar content of the model wheat breads without the addition of an exogenous amylase (A), with the addition of a bacterial α-amylase from Bacillus amyloliquefaciens (B), with the addition of a maltotetragenic amylase from Pelomonas saccharophila (C), and with the addition of a maltogenic α-amylase from Geobacillus stearothermophilus (D). Samples were taken two hours, 22 hours, 48 hours and 96 hours after baking. Values are stated as the mean value ± standard deviation (n = 4). Significant differences between the various time points for each sugar are indicated by asterisks (p < 0.05). Dry matter = relative to dry matter.

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RESEARCH

the altogether comparatively slight changes in the sugar spectrum, no technological activity of the amylases can be assumed here.

Development of texture analysis methods to determine enzymatically-induced bread crumb firming after baking The research project presented in this paper examined primarily the effects of various exogenous amylases on enzyme-induced bread crumb firming after baking. Various novel texture analysis methods were developed to elucidate the causes of the anti-firming effect of exogenous amylases in baked products. The standard crumb texture analysis by means of a Texture Analyser comprises compressing two slices of bread, each 12.5 mm thick, by 40% in two cycles. In this process, among other things, information is obtained about the crumb hardness and crumb elasticity.

What is analyzed here is the response of the crumb structure resulting from the proofing, baking and storage process to the pre-specified deformation. Thus all the influencing parameters that affect the crumb structure and material (e.g. gas volume fraction of the crumb, pore pattern, crumb matrix firmness) contribute to the texture result.

Figure 3: Crumb firmness of reengineered crumb pellets (-✲-) with no additives, (-■-) with the addition of a maltogenic amylase from Bacillus stearothermophilus, (-■-) with the addition of the determined residual activity of a maltogenic amylase (29%) in the crumb after heating to 90°C, (-●-) with the addition of a bacterial α-amylase, and (-●-) with the addition of the determined residual activity of a bacterial α-amylase from Bacillus subtilis (5%) in the crumb after heating to 90°C. The values are stated as the mean value ± standard deviation (n = 3). Significant differences between the various time points are identified by asterisks (p < 0.05).

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RESEARCH

Theoretically, therefore, if amylases are used, a changed crumb firmness could be due, for example, to a changed pore pattern resulting from an increased provision of fermentable sugars. Furthermore, theoretically, a modified crumb formation process based on the amylolytic degradation of starch polymers by amylases during the fermenting and baking process, or even amylolytic activity after baking, also come into question as the cause. In the context of the research project, the current crumb texture analysis method was further developed to achieve the stepwise control and reduction of these material-related dependences and complexities.

In a first step, the dependence of the pore pattern on the yeast was overcome by producing chemically-leavened breads. To standardize the deformation of the material, the sample weight of crumb material was kept constant, and uniaxial compression was carried out until the material was pore-free. However, to study the influences of constituents on crumb firming behavior, it was necessary to introduce hypothetically crumb-modifying materials after the baking process. The challenge in this respect is to distribute the additives homogeneously into the crumb structure that has already formed. For this purpose, a process for the texture analysis of reengineered, pore-free crumb pellets was developed at the Chair of Brewing and Beverage Technology.

This involves initially freeze-drying a chemically leavened crumb, then grinding it in a thermally gentle process, and finally subjecting it to defined rehydration and pelleting. The resulting homogeneous, pore-free, reproducible pellets can be subject to storage tests in a defined environment, and texturally analyzed. The decisive advantage of this methodology lies in the rehydration of the crumb material. Moreover, it allows constituents to be incorporated into the crumb, which are consequently able to develop their effect exclusively during storage. Every influence whatsoever on the crumb during the dough-crumb transition is excluded by using crumb material produced in a standardized way.

The methodology was used to analyze the effects on firming behavior of the possible presence of (residual) maltogenic amylase from Bacillus stearothermophilus and of an α-amylase from Bacillus subtilis in a standard wheat crumb. In this respect, pellet storage experiments (Figure 3) showed that the aging behavior of crumb pellets supplemented with a maltogenic amylase from Bacillus stearothermophilus after baking does not differ from the firming behavior of a standard crumb (firming = crumb solidification during the storage time). Thus the hypothetical presence of this active maltogenic amylase during storage does not appear to have any functionality-modifying influences on the crumb material.

In contrast to this, there would be a tendency for reduced firming behavior to be observed in the event of 100% activity of an α-amylase from Bacillus subtilis in the baked product.

Authors Thekla Alpers1, Sabina Paulik1, Thomas Becker1, Mario Jekle1,2, Katrin Reichenberger3, Sabine Lutz-Wahl3, Lutz Fischer3, Gerold Rebholz 4, Katharina A. Scherf4,5 1

Chair of Brewing and Beverage Technology, TUM School of Life Sciences, Technical University of Munich, Freising, Germany

2

Institute of Food Science and Biotechnology, Department of Plant-based Foods, University of Hohenheim, Stuttgart, Germany

3

Institute of Food Science and Biotechnology, Department of Biotechnology and Enzyme Science, University of Hohenheim, Stuttgart, Germany

4

Leibniz-Institute for Food Systems Biology at the Technical

5

Department of Bioactive and Functional Food Chemistry,

University of Munich, Freising, Germany Institute of Applied Biosciences, Karlsruhe Institute of Technology, Karlsruhe, Germany Contact: katharina.scherf@kit.edu

Literature 1. Goesaert, H., Brijs, K., Veraverbeke, W.S., Courtin, C.M., Gebru-

4. Rebholz, G.F., Sebald, K., Dirndorfer, S., Dawid, C., Hofmann, T.,

ers, K., Delcour, J.A. (2005): Wheat flour constituents. How they

Scherf, K.A. (2021): Impact of exogenous α-amylases on sugar

impact bread quality, and how to impact their functionality.

formation in straight dough wheat bread. European Food Re-

Trends in Food Science and Technology, 16, 12-30. doi:

search and Technology 247, p. 695-706. doi: 10.1007/s00217-

10.1016/j.tifs.2004.02.011

020-03657-y

2. Bowles, L.K. (1996) Amylolytic enzymes. In: R.E. Hebeda, H.F. Zo-

5. Rebholz, G.F., Sebald, K., Dirndorfer, S., Dawid, C., Hofmann, T.,

bel (Eds.), Baked goods freshness: Technology, evaluation, and

Scherf, K.A. (2021): Impact of exogenous maltogenic α-amylase

inhibition of staling. Marcel Dekker, New York, NY, pp. 105-129

and maltotetraogenic amylase on sugar release in wheat

3. Reichenberger, K., Luz, A., Seitl, I., Fischer, L. (2020): Determina-

bread. European Food Research and Technology 247: 1425-

tion of the direct activity of the maltogenic amylase from Geobacillus stearothermophilus in white bread. Food Analytical Methods 13: 496-502. doi: 10.1007/s12161-019-01673-7

1436. doi: 10.1007/s00217-021-03721-1 6. Paulik, S. and Jekle, M. (2019): Novel approach to investigate the mechanical properties of crumb matrix during storage – Re-engineering of gas-free crumb pellets. Food Chemistry, 288, 333-340. doi: 10.1016/j.foodchem.2019.03.014

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RESEARCH

NEWS

Alternatively, simulation of the actually determined residual activity (5% of the initial activity) resulted in no anti-firming effect. Thus, for both enzyme preparations tested at the manufacturer’s recommended dosage, it was possible to exclude a functional influence on the end-product as a result of (i) a lack of functionality in the end-product (the example of maltogenic amylase from Bacillus stearothermophilus ) or (ii) successful activity reduction during the baking process (the example of α-amylase from Bacillus subtilis).

New sales leadership for American Pan Europe

For most of the amylase preparations analyzed in the context of the project, there was only a very slight resulting residual activity in the baked product, or none at all. Moreover, by focussing on amylases, the relationship between residual activity and functionality was illuminated more exactly. In the consideration of various different amylase preparations, significant residual activity occurred only in the case of a maltogenic amylase from Bacillus stearothermophilus. Furthermore, we confirmed in the context of the project that endogenous wheat enzymes are completely inactivated by the baking process. Thus, from today’s point of view, it can be assumed that endogenous and thermosensitive exogenous enzymes are denatured during the baking process. Moreover, the texture analysis methods developed in the framework of the project allowed for the first time a differentiation in changes in the firming behaviors of wheat crumbs caused by the pre- and post-baking process. Consequently, the workgroup ascribed the anti-firming effect of maltogenic amylase to crumb modification before the baking process.

Initial results based on a new, model experimental approach showed that the mere presence of enzyme during storage no longer has any functional influence in the crumb that has already been formed. Thus, from the results achieved in the context of the project, it can be concluded that the preparations examined here do not evoke any active antifirming effect in the end product, either as a result of inactivation in the baking process, or due to the absence of functionality in the end product. +++

Funding notice This IGF (Cooperative Industrial Research) Project Nr. AiF (German Federation of Industrial Research Associations) 19543 N of the Research Group of the German Food Industry e.V. (FEI), Godesberger Allee 125, 53175 Bonn, Germany, was funded via the AiF by the German Federal Ministry for Economic Affairs and Energy, based on a resolution by the German Federal Parliament within the framework of the Program to Promote Cooperative Industrial Research (IGF).

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© Bundy Baking Solutions

Conclusions

Bundy Baking Solutions appointed new leadership for the sales team of American Pan Europe. The company restructured its team “to better serve our customers across Europe and continue to provide full lifecycle solutions that are tailored to customers’ needs,” Bundy Baking’s announcement detailed.

The new sales team leaders of American Pan in Europe are (pictured, left to right): + Jesper Albertsen Vice President Sales, American Pan Europe + Helen Dooley Director of Inside Sales, American Pan Europe + Dario De Prato Director of Sales, American Pan Southern Europe + Steve Eaton Director of Sales, American Pan UK & Ireland +++

Koenig acquires Finnish spiral specialist The Koenig Group expands as it took over Vulganus Oy in July. The traditional company, based in Nastola, Finland, specializes in tailor-made spiral systems for the bakery and food industry, which have been a part of its portfolio for over 40 years. In addition to the core business of process solutions for proofing, cooling and freezing, Vulganus also offers various types of conveyor and proofing cabinet systems. The VULGANUS brand will be continued independently, Koenig announced. © vulganus.com

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“We are pleased that Vulganus is now part of the Koenig Group. The purchase supports the implementation of our growth strategy and we are convinced that together we can further expand our product range in the field of cooling and refrigeration technology and our solutions for the international markets,” said the management of Koenig Maschinen GmbH in a statement. +++

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EVENTS

südback makes strong comeback südback confirms its support for in-person events as preparations are in full swing for this year’s edition, which will be held once again from October 22 to 25. The return of one of Europe’s main industry trade fairs is highly anticipated.

+

While organizers and industry representatives agree on the value of digital tools in an industry burdened by staff shortages, the in-person meetings traditionally held in Stuttgart for südback cannot be replaced. The upcoming event is anticipated to mark the restart of industry events after a two-year pause. For the first time, a gelato area powered by GELATISSIMO will be held, focusing on artisan ice cream. Relevant materials and technology will be presented in October; the Grand Prix GELATISSIMO competition will also debut.

The Trend Award also returns, with 60 submissions this year. The rules for this competition have been slightly adapted, to include innovations launched during the pandemic, to give them exposure. While the rule initially asked for submissions to be for products not older than one year, all products launched after January 2021 can participate.

The jury meeting took place in July 2022, and the official award ceremony will be held at südback. The Carlo Wildt Cup will also be presented at südback – the apprentice competition for trainee confectioners.

Stefan Körber, Managing Director of the Baden-Württemberg, Hessen and Southwest German Regional Associations of Bakers' Guilds, provided an overview of the industry at the press conference held in July: “südback was established in 1978 to create a trade fair for craft bakeries where they could obtain information about new machines, tools, raw materials, services and trends in their industry. Futureoriented technical programs and technical talks have

www.bakingbiscuit.com 04/2022

always been associated with these trade fairs and still are today.

For the last two years, the bakery trade at home and abroad has been unable to meet at a national industry trade fair. It was shown during this period that a great deal is possible both digitally and virtually. However, it was also clearly revealed that many people regard real encounters and personal communication as irreplaceable. We are therefore delighted that the 29th südback will open its doors in October 2022.”

Current challenges were analyzed during the press event, particularly those related to the lack of new skilled workers to join the industry, competition, and supply chain issues.

Klaus Vollmer, Guild Master, State Association of Guild of Baden-Württemberg Confectioners also brought good news from his field – there is an increase of women joining the sector: 40% of the new Masters are women.

Looking into trends, the preference for vegan and regional products is on the rise, Körber stated. He does not anticipate flour supply issues for Germany if there is a good harvest.

Analyzing the current volatile market environment, he sees information as critical – regarding changing developments as well as innovations and trends. “By visiting südback, companies in the bakery trade acquire up-to-date information firsthand that they can use to optimize and increase the quality and efficiency of their daily work,” he said. The exhibits in the five exhibition halls reflect industry

EVENTS

TECHNOLOGY MEETS BAKER‘S CRAFT.

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FOR YOUR PERFECT BUNS.

developments in the areas of working and operating technology, business equipment, shop fittings, raw materials and semi-finished products, merchandise, sales promotion and services.

The Bakers’ Trend Forum A diverse technical program will be held in the Bakers’ Trend Forum in Hall 8. Topics will focus on production sales, marketing and cafés.The technical program will include contributions from the Academies of the German Baking Trade in Southwest Germany and Weinheim, as well as by experts known far beyond the region from Germany, Austria, Switzerland, France and Italy.

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A competition for apprentices will be held, as an incentive for newcomers to the industry and as an opportunity for them to improve their skills.

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On Monday and Tuesday, bakery trainees (production and sales) from different vocational schools in BadenWürttemberg, Hesse and Alsace will compete in baking a sweet, yeast-based dough pastry with filling. The specialist sales staff will have to produce three different filled sandwich snacks in a specified period of time.

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Five trade fair halls were already occupied at the beginning of July, with a total exhibition space of 56,600 sqm. The bakers’ guild will hold its forum platform in Hall 8, and the confectioners are in Hall 7.

Exhibitor registrations are still open. +++

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WOMEN IN BUSINESS

“Women excel at building teams” Judith van Peij has been with Royal DSM for 10 years, and has been the Innovation Manager for Baking & Confectionery for the past three. She is a food technologist at heart, with a clear vision of managing innovation teams including R&D, operations and commercial.

+

Catalina Mihu: You joined DSM 10 years ago. How has the approach for new product development evolved in this time and what are some of your favorite contributions in this regard?

Judith van Peij: I was already working as a food technologist as a food technologist when I joined DSM. Coming from an ingredients company, I was already somewhat familiar with how the industry was working. In the 10 years that have passed since then, we have transitioned from being an ingredients company to being a solutions provider. In the beginning, I was more focused on applications (and not so much on innovation at that time). But, I felt that there was a need for us to do something in the shorter term, by adding not only focused R&D projects to our pipeline, but also making more use of our existing products in other types of applications, throughout the company. I like to work with people, and I think that there is added value that can be gained from working with ingredients that have been already developed to transform them into (a part of) a solution rather than simply offering them as an ingredient.

Mihu: What is your favorite aspect of R&D? Judith van Peij: DSM is a biotechnology and nutrition-driven company in the food industry. When I was starting out in research, particularly enzymes, I remember being amazed at being able to model protein structures, for example. We could look through 3D glasses to understand our enzyme products better, which, in turn, would help to engineer new molecules themselves, but also make second- or third-generation of products. This is the next step to making the kind of improvements that are really needed in the industry. Subsequently, we look into interactions in the matrix.

Food matrices are not always very easy to understand; we mostly start to analyze them from the physical perspective.

Baking is the end goal, of course – but, the process is facilitated by using the right design, then using the resulting data to make an even smarter design, a process that helps to go into the market quicker.

This is an ongoing evolution with iterative cycles. We have had a new research center for a few years now, where we work with automation and robots, for simple tasks. People can, in turn, focus on thinking and analyzing the data, rather than repetitive, day-to-day routine.

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© Royal DSM

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WOMEN IN BUSINESS

Innovation: the science, the art, and the people Mihu: What are some of your favorite projects over the last 10 years?

Judith van Peij: Projects usually start with trends and needs: we are looking at aspects such as cleaner labels, more sustainable solutions, or being more cost-effective, as more raw materials change and the requests from retail are quite strict. All solutions related to these goals are important. For example, we have developed a new maltogenic amylase that contributes to product freshness. Bread using it will have a longer shelf-life and remain soft, while still being resilient so it can be buttered without breaking. In addition, less bread needs to be thrown away – a plus for sustainability efforts.

We have also been researching opportunities to boost nutritional profiles lately, with nutritional lipids, for example.

Bakery products can become healthier by including additional fibers, for example, to support better digestion.

Mihu: What is your view on innovation in bakery and confectionery, and how have its defining characteristics changed over the past 25 years?

Judith van Peij: The baking industry is quite conservative.

There is always a debate about whether baking is an art or a science. It needs science to work efficiently, some argue.

Raw material quality changes every day, depending on

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their source and even on the weather. Looking at product development, modelling helps to solve such challenges.

Going into new ingredient development, improved products are formulated, to be more nutritious, more sustainable, or fresh for longer, for example. While, in the past, baking a good bread was the goal, the product diversity on the market is now great: we used to have a loaf of bread, and now we have a great variety of breads.

Mihu: So, do you consider baking an art or a science?

Judith van Peij: We approach it from a scientific perspective, of course. But, in the end, I think it remains an art that uses science, a well-structured art that we try to explain with science. It still takes the hand of a baker skilled in the art to make it work. The dependency on this skill set is lesser, with the development of industrial lines (the science), but a baker who understands the touch and feel of the product (the art) remains a core need in a bakery, so that such lines run smoothly. This only can be supported by science.

Team and project development Mihu: How are your personal values reflected in your professional work, from the perspective of a woman advancing in her career?

Judith van Peij: I like to have a broader perspective on the whole field. I am a person who tries to look at the bigger

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WOMEN IN BUSINESS

picture to determine whether something is relevant and then help the team. Women excel at building teams, and putting heart into what they do is a defining part of their leadership style. Together, as a confident team, we approach challenges and turn them around into solutions, which then reach our customers. With this mindset, I am not afraid to take any decisions. I do not need to have all the answers to do so, but the decision needs to be well considered. I am not afraid to also ask for help and to ask the team about their advice. A timely decision does not need to be based on full insights, but it should consider as many aspects as possible to provide a direction. In the end, a speedy decision is better than no decision at all.

Having a broader perspective also helps to keep the team on track. Everybody in R&D is interested in exploring the sidetracks, and this enthusiasm should not be curved. In the end, though, we need to deliver results, and the team needs to stay on track to reach them, without putting too much effort into details that are not directly related to our end goal. This is the leadership style I have found helpful. © Royal DSM

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“Together, as a confident team, we approach challenges and turn them around into solutions, which then reach our customers. ” Judith van Peij, Innovation Manager for Baking & Confectionery, DSM

Mihu: What are some difficult decisions that you need to make professionally?

Judith van Peij: Sometimes, they can be difficult: you have to change the team, when all members are going in the same direction, for example. The diversity of the team is important to ensure members keep challenging each other.

All personalities are needed in the team – dreamers, people who can lead, people who can follow, or goaloriented people. As a leader, one must ensure that there is enough diversity and collaboration in the team for good project development. Accept that there are multiple ways of reaching a goal, but also follow the progress – the big lines, not micromanaging.

Mihu: What are your priorities in a product development project?

Judith van Peij: First, we must understand what consumers are looking for. Our inspiration comes from three fields: trends, customers, and internal ideas/technology-push products. It starts with understanding the field and understanding the needs; sometimes, it involves bringing knowledge to our customers, as they might not always have a very clear picture of the solutions they want to reach or the solutions we can provide. We can help to guide them through the unknown.

www.bakingbiscuit.com 04/2022

Mihu: How do specific markets inspire innovation at DSM? Judith van Peij: In the past, tin bread was popular here, in the Netherlands; now, we are leaning more toward tortilla, bagels and laminated products, for example. Overall, the baked goods market is still growing. But, the (white) bread market is not growing at the same speed as other product categories. We see a growing variety of healthier products, meaning sugar-, salt- and fat-reduced, cleaner labels, organic, whole wheat and plant-based products. Breads already are plant-based, but cakes and confectionery have room for the development of new product segments, in this sense.

Mihu: What is your approach to developing a new project, and the steps to managing it?

Judith van Peij: Assuming we already know what we want to develop, we start with brainstorming sessions, which are usually very engaging. We investigate the angles from which we can approach the innovation solution and we scope it well, and only then do we advance with the different phases of a project, going from ideation and proof of principle to feasibility and development. The most important aspect from my perspective and in my role is to keep asking questions and challenge myself and the rest of the team, to reiterate the validity of the process. Within the scope of the project, we try to be open and focus on the tasks, while assessing if we are still on the right track. I encourage the team to always ask questions as well, and to not be afraid to ask for help. This helps the team to grow, and myself along with them.

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WOMEN IN BUSINESS

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Mihu: What will the future bring for enzymes and emulsifiers in the baking industry?

Judith van Peij: Different combinations are used, and sometimes enzymes replace emulsifiers in certain products now.

But, both types of ingredients can play a role in the future, with different utilizations in different markets.

Women in R&D Mihu: What are the challenges women face when building a career in this field?

Judith van Peij: The difference in communication styles was the biggest hurdle, in my experience. They can vary by gender, background and culture. At the beginning of my career, the field was dominated by men. I felt at the time a need to adjust my communication style. The food technology field is more diverse now, but it can still be further improved in this direction. Diversity is very much valued at DSM. I have found consulting with the multidisciplinary team to be an asset in developing a communication style.

The pressure of making key decisions is a challenge, sometimes. It may refer to choosing the right project, or ensuring the resources or the necessary time for it, for example.

Working together with the team and approaching different angles helps in making decisions.

Mihu: What made you decide to follow this career path, and what advice would you offer young women entering the business?

Judith van Peij: I am a curious person, with broad interests.

My father worked in the food industry all his life and he inspired me to become a food technologist. The further development of my career came naturally. Sometimes, people change jobs to be closer to family; in my case, this kind of change helped me advance in my career.

My main advice to women at the start of their career is something I have experienced: follow your heart. Things come

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naturally if you follow your passion; then, you automatically do what you are good at – most of the time. Be creative!

Things may not always be ideal, but a positive mindset and passion will help you go through stormy weather, I’ve learned. Also, you have to be honest with yourself: when you realize that the job doesn’t fit you or that you don’t fit the job, then you have to muster the courage to make a change. Be authentic, and do not try to be somebody else.

Mihu: What do you find the most rewarding in innovating in food ingredients?

Judith van Peij: Being able to make a difference in the quality of the product is motivating, starting from the raw materials and with the help of the whole value chain in the baking industry. Bread is a staple product in many countries, and being able to improve it while keeping the costs down contributes to feeding the world.

There is so much opportunity in raw materials and their different combinations, that it would be a bit short-sighted to only use them for staple foods, when there are two markets that can benefit from them: basic foodstuffs and specialty products. I think we can serve both.

Mihu: What type of leadership should be coming from a woman?

Judith van Peij: The heart leadership is usually associated with the way women lead. Connecting people is what women usually excel in, and what also energizes them. I like to engage with people within and outside of the team, bring them together, and get energy from helping them achieve the best out of the collaboration.

Mihu: How should women’s representation in the industry be supported?

Judith van Peij: We should appreciate people with their differences. The results are what count in the end. +++

MARKET

Consumer consciousness around food waste has more than doubled Today, 72% of consumers are aware of their food wastage; by comparison, this ratio was 33% in 2020, according to a report published by the Capgemini Research Institute.

+

Consumer consciousness regarding food waste grew to 72% in the past two years. It is one of the population’s main concerns, together with rising food prices, supply chain challenges and the pandemic, with an impact on their behavior. For the report, titled “Reflect. Rethink. Reconsider. Why food waste is everybody’s problem”, the institute surveyed 10,000 consumers and executives from 1,000 large organizations in food manufacturing and retail.

Consumers are already looking into ways to reduce their food waste: there is an 80% year-on-year growth in social media searches for methods to increase the life of food items, the research shows. Cost savings (56%), concerns around world hunger (52%) and climate change (51%) are the primary reasons contributing to this.

Looking into the causes of food waste, consumers take responsibility, with 60% feeling guilty about wasting food. However, they also think that retailers and food manufacturers are not doing enough to help them curb this issue. Nearly twothirds (61%) of consumers want brands and retailers to do more to help them tackle food waste and 57% are disappointed as they feel that businesses don’t care enough about the issue. The study reveals that consumers feel they are too often left to their own devices regarding reducing food waste. When it comes to increasing food longevity at home, two-thirds (67%) are going to third-party sources for information (friends, family, influencers, and social media) with only a third (33%) getting information from packaging, commercials or campaigns run by food manufacturers and retailers.

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Although reducing food waste at the retail and consumption phase is an important facet, much more food is lost during production and distribution (1.5bn tons vs 931m tons).[1] More than three in four (77%) organizations say they have committed to the United Nations’ Sustainability Development Goals 12.3 (UN SDG 12.3), a framework that focuses on halving per-capita food waste at retail and consumer levels and reducing food losses along production and supply chains, including post-harvest losses, by 2030. However, only 15% of organizations say they have achieved or are on track to achieve their targets.

According to the report, this is due to a fragmented approach to addressing food waste and loss across the food chain. Although food retailers and manufacturers focus on reducing food waste in upstream logistics (44% of retailers and 50% of manufacturers) and processing and packaging (43% retailers, 46% manufacturers), few players pay the same attention to agricultural production (22% retailers and 23% manufacturers) or downstream storage (18% retailers and 21% manufacturers).

The global survey was conducted in 11 countries across North America, Europe, and Asia Pacific in April and May 2022. +++

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[1] WWF, “Over 15% of food is lost before leaving the farm – WWF report,” July 21, 2021.

[1] United Nations Environment Programme, “Definition of food loss and waste, “UN: 17% of all food available at consumer levels is wasted,” March 4, 2021.

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References

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RESEARCH

Strategies to improve sustainability credentials in bakery

© penofoto.de – stock.adobe.com

To achieve net-zero, it is necessary to manage the complete life cycle of products by considering and calculating all emissions along the chain, both to and from the atmosphere.

+

By Gary Tucker, Fellow, Campden BRI

Net-zero emissions is a sustainability target set by the UK Government to be achieved by 2050. Simply put, net-zero means that all the damaging gases released in the life cycle of a ‘product’ are balanced by those removed from the atmosphere. A product can be a physical object such as a loaf of bread or a service, like Internet banking. They each contribute emissions in their life cycle and ideally also lock away carbon.

Life cycle assessment When assessing environmental impact, it is essential calculations cover the complete life cycle (known as cradle-tograve) of the product, process, or activity; from raw materials acquisition through production, use and disposal. This is

done using Life Cycle Assessment (LCA) software in which the effect of an activity is assessed on resource use, human health and ecological consequences. Many LCA impact factors are used to quantify these effects and commercial software differs in the emphasis it places on each. Some of the relevant categories to food manufacturing are given in Table 1.

Probably the best-known and well-understood LCA impact factor is global warming potential (GWP). This is used to calculate a product’s carbon footprint (CF) or its Greenhouse Gas (GHG) emissions. Input data to calculate CF is based on 100-year figures for gases relative to carbon dioxide (CO 2e), which is given a relative figure of one (1.0).

The GWP figures represent the ability of a gas to insulate the earth from heat loss to space, and in doing so,

Table 1: Examples of LCA impact factors IMPACT CATEGORY

DESCRIPTION

Global warming potential (GWP)

Emissions of gases that warm the atmosphere, calculated as kg CO2 equivalents (CO2e).

Acidification of the environment

Increased acidity through the release of gases such as nitrogen and sulfur oxides.

Eutrophication

Increased concentration of nitrogen and phosphorous compounds in water sources, causing toxic algal blooms.

Depletion of abiotic resources

Decrease in natural resources, both mineral and fossil.

Water and land use

Changes in water availability and soil quality.

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Source: Campden BRI

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increase the earth’s temperature. Tables of relative values can be found in various sources, such as the Intergovernmental Panel on Climate Change (IPCC). The most common gases involved with bakery products made from wheat flour are carbon dioxide (CO 2), methane (CH 4) and nitrous oxide (N2O). + CO2 is given a value of 1 and is the reference gas for CF calculations. CO2 is released in the burning of fossil fuels for transport and heating and released during the proving of yeasted bakery products, but this is small in comparison. + CH4 has a value of 25, meaning it is 25 times more damaging than CO 2. The main sources of methane are from agriculture including ruminants such as cattle and the anaerobic breakdown of plant materials in soil. + N2O has a value of 298 and has a major influence on CF calculations. It is released from nitrogenous fertilizers as they break down in soils. Correct fertilizer application levels and timing are important to minimize excess in soils and its runoff to water courses.

Company GHG accounting GHG emissions for a company are categorized into three groups or 'scopes'. The most widely used international

accounting tool is the GHG Protocol (2004) which classifies a company’s GHG emissions into three ‘scopes’, defined as follows: + Scope 1 – direct emissions from owned or controlled sources. These include combustion gases from fuel used by the company and from company-owned vehicles. + Scope 2 – indirect emissions from the generation of purchased electricity and heating fuels. + Scope 3 – all indirect emissions (not included in scope 2) that occur in the value chain of the company, including both upstream and downstream emissions. This is the largest and most complex of the scopes to calculate. It includes all purchased goods and services, transport and distribution to and from the sites, business travel, employee commuting, waste disposal and emissions from leased and franchised assets.

Product GHG accounting The three scopes methodology above can also be applied to products. When calculating a CF for a product, it is necessary to consider every stage in its production, from raw materials to consumer use (see Figure 1). Calculations for scopes 1 to 3 are required at each stage. Information and

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RESEARCH

Raw Materials Transport

Manufacture

Distribution

Consumer Use

Disposal source: Gary Tucker

Raw Materials Production

Figure 1: Stages required when calculating the CF of a product

Table 2: GHG emissions for white sandwich bread, expressed in kg of CO2e per 800g Functional Unit (FU) STAGE

KG CO2e/FU

% of total

Comments

Raw materials

0.3972

66.7

Packaging

0.0323

5.4

Calculated for a single use polythene bag.

Transport

0.0038

0.6

Road transport of raw materials, packaging and waste.

Processing

0.1601

27.0

Waste

0.0014

0.2

Scrap dough and bread goes to animal feed, some to landfill.

Resources

0.0003

0.1

Emissions from water use are very low for bakery operations.

Total

0.5951

100.0

Dominated by wheat emissions with N2O and CH4. Includes minor raw materials.

Dominated by gas use during baking.

data to help calculate the CF of a product are available in the Publicly Available Specification 2050:2011 – Specification for the assessment of life cycle greenhouse gas emissions of goods and services published by the British Standards Institution (BSI).

An example of a CF calculation for white bread was done as part of the specification project. Table 2 presents the stages in the product life cycle that were calculated. These show that wheat flour production, including growing and milling, contributed two-thirds of the total product CF. Data in Table 2 does not include the consumer use stage.

Raw materials production: Wheat is the major ingredient in most bakery products, accounting for up to 80% of the finished weight in crackers, reduced to 25% in cakes. If water is excluded from the CF calculation, although it should not be because it has a small CF, the contribution from wheat flour is even higher. The crucial contribution to the CF for wheat flour is the release of excess nitrous oxide (N 2O) from soil. Fertilizer additions must take place at appropriate times during the wheatgrowing cycle to avoid unused fertilizer converting to gases such as N 2O or leaching into water courses. This applies to both manures and to artificial fertilizers.

Most of the wheat used in the UK for bread making is grown in the UK, with Canada supplying much of the rest. UK soils are suited to wheat growing and, despite the variable weather, wheat grows well in most areas. It is interesting to note that the Chorleywood Bread Process (CBP) enabled

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more UK wheat to be used for UK bread production through the improved development of gluten during high shear mixing. Prior to the CBP being introduced around 1961, only 30% of UK wheat was suitable for bread making, so there was a greater reliance on imported higher quality wheat from Canada and the USA. This would have increased the GHG emissions for transporting wheat to the UK, resulting in a higher CF for bread. The current situation, with 80% UK wheat being used for UK bread making, is a more sustainable and lower CF solution.

There are various functional ingredients required for bread making at levels of 1-2%, as well as several at ppm level.

Their contribution to the CF will not be significant but it is necessary to estimate values based on the best knowledge of their production. Of equal significance to the CF is the impact some of these have on other LCA factors, like water and land use. Most are sourced from outside the UK, which has presented supply chain issues in recent months. One example of this is glycerol, a key ingredient in cake manufacture.

Case study - glycerol During Spring 2022, glycerol was in short supply and remains an expensive ingredient. Glycerol is a by-product of vegetable oil processes, typically from palm oil, with about 80% coming from biodiesel production, 15% from oleochemical production and the remaining 5% from soap production.

The biodiesel market is struggling because of the drive towards electrification for transport and the desire to use vegetable oils for food uses. The situation was exacerbated

source: Wiltshire et al, 2008; Tucker et al, 2010

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RESEARCH

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68

when Indonesia imposed a ban on palm oil exports between April 22 and May 23, 2022 to protect its domestic market.

Palm oil is a major feedstock for biodiesel. The ban came at a time of immense pressure on the supply of vegetable oils into the global market because of unconnected supply issues with oils such as soy, sunflower and rapeseed. With many food oils likely to be in short supply until the 2022 harvests are available, food companies may need to reduce their requirements or find alternatives to oil-derived ingredients. Glycerol is one example of an ingredient manufactured as a by-product of food oils.

Replacement of fossil fuels for transport and energy is one of the enabling strategies to achieve the UK Government’s net-zero target but this will not happen overnight. Renewable electricity capacity has more than quadrupled in the UK since 2010 and low carbon electricity now provides 50% of total generation (www.gov.uk as of 20/08/21). These are impressive figures but the drive to convert most fossil fuel processes to electrification needs to accelerate as more processes require electricity. This relies on there being sufficient nuclear, solar, wind and wave generation to provide all the UK energy needs as low carbon electricity.

Bakery packaging materials also need to be considered when calculating a product’s CF, as does the intermediate packaging that is discarded or recycled during manufacture.

Much of this is cardboard or plastics, or a combination of the two materials, as with sandwich cartons. Most plastics are made from petrochemicals that originate from crude oil. This is not a sustainable solution. Alternatives based on plant materials or recycled plastics are needed urgently.

Manufacture: Bakery products tend to have a lower CF than many food products. This is because they generally do not include high CF meat and do not require refrigerated or frozen storage.

As detailed above, wheat flour production contributes around two-thirds of the CF for bread, with the processing stages accounting for 27% for white sandwich bread.

Baking is the main GHG generator in processing. Data generated for the Industrial Energy Efficiency Accelerator (IEEA) report (Carbon Trust, 2014), estimated the UK industrial bakery sector consumed some 2,000 GWh, equating to emissions of approximately 570,000 tonnes of CO2 (tCO2) per year. The vast majority of this was from bakery ovens.

The baking industry is one of the food processing industries that remains heavily reliant on natural gas. Most process operations within bakeries already use electricity for power but the ovens are where change is needed. GHG emissions reduction will happen through incremental energy saving improvements in oven technology, and by movement to electrical industrial bakery ovens and greater use of hydrogen within natural gas.

Craft bakery ovens are predominantly electric. However, according to the Federation of Bakers, craft bakeries only

Raw materials transport: With many raw materials and ingredients manufactured outside of the UK, there is a cost and a CF associated with their transport. Most bakery ingredients have a long ambient shelf-life so can be transported by ship. Container shipping has a relatively low CF because of economies of scale.

The distribution of finished bakery products has a separate category for CF calculation. Most transport is by road, using diesel-fueled lorries so CF can be significant. There are examples of battery-powered lorries but their range prohibits their use currently. Few finished bakery products go overseas in shipping containers or air freight because of their short shelf-life.

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RESEARCH

produce around 3% of UK bread. Medium sized bakeries, such as retailer in-store bakeries (ISBs), produce around 17% of UK bread, although some of this is produced within large bakeries for reheating prior to sale. Most ISB ovens are now electric. The area where change is required is the high-speed travelling ovens that are gas-fired. Electrical versions are now available from several suppliers and are certain to become more popular as the move to cut carbon increases in pace. They contain radiant and convective heating components and bake bread to the same quality as their gas-fired counterparts. Apart from the yeast-generated CO2 released from bread dough during baking, the emissions from an electric oven are zero, assuming the electricity generation is from renewables or nuclear.

Another low carbon alternative to electricity is hydrogen, bled initially into the natural gas network at 20% and ultimately at 100%. A 20% hydrogen blend should allow existing bakery ovens to be used and avoid the huge expense of replacing a natural gas oven with electric. Hydrogen is a clean fuel that combusts to produce only water vapour. It can be used for transport, power generation, industrial applications and heating. Electrical generation of hydrogen from water will be the ultimate low carbon fuel that allows combustion processes like engines and burners to be used.

The move from natural gas to a fuel blend containing 20% hydrogen is currently being investigated. There could be implications for the performance of bakery ovens, therefore this change requires thorough testing. Experimental trials are ongoing with Campden BRI to measure the effects on oven performance and product quality from burning 20% hydrogen in natural gas. Products of interest are bread, cake and biscuits. This work is part of a UK-wide project to investigate sectors where natural gas use is high and electrification could be difficult.

69

Consumer use: Most bakery products do not require refrigeration or cooking, reducing the impact on the product CF. Probably the major contribution to the CF is the way the consumer disposes of the waste product, including the packaging. This has attracted a lot of interest recently.

Data presented in Table 2 was generated for the industrial production of food products such as bread. The impact on the CF from consumer use stages is separate. The most significant aspect within consumer use is the management of waste.

Disposal: Reduction in bread waste at all stages in its life cycle is one of the most impactful strategies to improve the sustainability credentials of bread manufacturing. This involves reducing, reusing and recycling bread (and its packaging materials), so less bread is manufactured in the first place, reducing wheat requirements and environmental impact.

Bread waste is well-publicized. Around 900,000 tonnes of bread are thrown away each year, much of which is avoidable. The proportion of wheat in bread is around 50% by weight, so the potential exists to reduce wheat grown in the UK by up to 450,000 tonnes each year by minimizing bread waste. CF savings are made at all production stages but the high agricultural and baking impacts make waste reduction vitally important.

Bakery packaging tends to use both paper and plastic.

Recycling, reusing or disposing of these materials is complex. The food packaging industry is working to find the best solution. Calculations on just one of the LCA impact factors can be misleading and suggest a solution is not required. For example, GHG emission data is based on gases released into the atmosphere over a timescale of

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RESEARCH

100 years. Plastics remain in solid form for at least 100 years and therefore do not contribute to GHG emissions during the disposal stages. The CF from disposal of a plastic food package will be zero. This is where other LCA impact factors must be considered so that a true picture of the environmental impact of plastics can be assessed. It is well documented that plastic packaging needs to be reduced because of the damage it causes to the environment. Factors like ‘depletion of abiotic resources’ and ‘water and land use’ should be used to generate the true LCA assessment.

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Summary

Diosna.................................................................................. 35

The baking industry does not differ from any other in that it faces several sustainability challenges. This article has outlined some of these and highlighted strategies to improve the situation. Global financial constraints are inhibiting the funding required to advance the solutions to the point they are readily available and economic. Consumer pressure and a desire for companies to ‘do the right thing’, are going to help move this on fast. Materials and fossil fuels will have no option but to find alternatives within a timescale of a few decades. Some issues such as plastic waste building up in the environment cannot wait this long.

Solutions are needed within the next 5-10 years. +++

FRITSCH............................................................................... 39 Hansaloy............................................................................. 69 Heuft............................................................................ 37 + 51 IPCO. ..................................................................................... 31 J4. ........................................................................................ 45 Kempf.................................................................................... 5 Koenig, Werl....................................................................... 47 König.................................................................................... 57

References

Kwik Lok............................................................... Cover + 21

Defra (2010). Trialling the PAS 2050. www.scienceresearch.defra.gov.uk Goucher, L., Bruce, R., Cameron, D., Lenny Koh, S.C. and Horton, P. (2017). The environ-

Mecatherm. ......................................................................... 55

mental impact of fertilizer embodied in a wheat-to-bread supply chain. Nature Plants 3,

MIWE................................................................................... 41

article number 17012.

Rademaker.......................................................................... 25

Wiltshire, J., Tucker, G. and Fendler, A. (2008). Carbon footprint of British food production. www.researchgate.net/publication/296165915.

Reading Bakery Systems................................................. 53

Tucker, G., Foster, C., Wiltshire, J. (2010). Life cycle analysis and carbon footprinting with

Reading Bakery Thermal.................................................. 61

respect to sustainability in the agri-food sector. CAB Direct. www.cabdirect.org/cabdirect/

Roayal Kaak........................................................................ 72

abstract/20103223638 Carbon Trust (2014). Improving the efficiency of bakery ovens. https://c2e2.unepdtu.org/

Sollich................................................................................. 33

wp-content/uploads/sites/3/2016/03/cts402-improving-efficiency-of-bakery-ovens-0.pdf

Sugden................................................................................ 43

The Greenhous Gas Protocol (2004). https://ghgprotocol.org/sites/default/files/stand-

VMI. ........................................................................................ 9

ards/ghg-protocol-revised.pdf PAS 2050:2011 - Specification for the assessment of life cycle greenhouse gas emissions

Zeppelin.............................................................................. 59

of goods and services, BSI

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WP Bakery Group.............................................................. 23

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

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