baking+biscuit international 2021 issue 05

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In the spotlight

Bakeware

New raw materials

Women in business: interview with Kwik Lok co-owners

Trays, pans and coatings for baking efficiency

Functional ingredients go vegan

05 21

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EDITORIAL

On the road Traveling has resumed. At-home baking and extended lockdowns are, for the most part, a 2020 memory and we are once again arranging meetings abroad and heading to the airport when we need to travel, safety precautions considered. We’ve also seen complete production lines set up and turned on remotely from newly-established and quickly organized specialized control centers, over the past months. Installations with local teams were managed via live streams and new workflows proved to be not only cost-effective, but also just as efficient as having specialized techniCatalina Mihu, Editor-in-chief Your commments or suggestions cians travel to the job. At the same time, safety are always appreciated: measures are still fluctuating, depending on e-mail: mihu@foodmultimedia.de the evolution of COVID-19 infection rates in each country. From another perspective, maps with clear city lights have been making the news rounds, with suddenly less air pollution than we have seen in years. These circumstances prompt the question: when should we travel, how do we evaluate that a trip is necessary?

One of the trips that I had been looking forward to this year was to Munich.

Surely, iba is a destination many of us had planned to attend and naturally it will be in our agendas at this time in 2023. If the Olympic Games that were finally held this summer are any indication, public events are returning – and these firsts provide useful pointers on how to organize the next ones. Anuga is back in force and just a few short weeks away from opening in Cologne, with over 4,000 exhibitors attending. It will be interesting to follow the new special events it introduces, such as ‘Anuga Clean Label’ and ‘Anuga Free From, Health & Functional Foods’. Another international event to be held in a hybrid format that includes an in-person exhibition this year is Food ingredients Europe, taking place in Frankfurt at the end of November.

Meanwhile, in the U.S., the baking industry is also eager to adapt to the new routines of face-to-face meetings. IBIE planned a comeback to ‘regular’ formats in October, with its IBIEducate session in Kansas City, which would debut hands-on workshops and immersive learning experiences. The decision was announced, just as this magazine was prepared for printing, that the organizers are reconsidering this format for a later time (that is yet to be announced) to better serve the industry. In Robb Mackie’s words (ABA president and CEO), strength is in closely connected numbers: “Collaboration within the baking industry is more important than ever.”

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In addition to these meeting opportunities, visiting businesses and partners are (and will be) among the very important reasons to travel, to work and reconnect, which I am very much anticipating and looking forward to. As we are making sure to put our own meaning to the roads we choose to travel, I hope everyone has safe and successful trips.

Catalina Mihu

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New raw materials 42 Palsgaard: Cakes can be better-for-you, too 50 Wacker: Functional ingredients go vegan Interview 46 Armin Juncker: “Quality makes a strong argument again”

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54 Functional ingredients: What’s next?

56 Commercial Baking: Plant-based profits – capitalizing on the new normal

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EDITOR-IN-CHIEF Catalina Mihu mihu@foodmultimedia.de

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Kwik Lok co-owners

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In the spotlight

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IN THE SPOTLIGHT

WOMEN IN BUSINESS

“We’re simply better together” Stephanie Jackson, Kimberly Paxton-Hagner and Melissa Paxton Steiner are the third-generation owners of Kwik Lok. They bring diverse backgrounds to the company they chose to enter into six years ago, and the combined forces of confidence, resourcefulness and authenticity.

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Mihu: Together, you started working in the company when you inherited it; you are also the first women in leadership roles at Kwik Lok. As third-generation owners of Kwik Lok Corporation, how are you building on the family legacy?

Stephanie Jackson: We were not groomed in the family business. While other families may be joining from their late teens or early adulthood, that was not our journey. Six years ago, when our father passed, this opportunity literally landed on our laps. As sisters, it was important to us to consider how we would make an impact and bring value when we were not going to be working in the daily operations. When we started, we had someone working with our family business who presented the opportunity to us and at the same time gave us the confidence that we could do this. The process also involved connecting with other family businesses running their companies into their third, fourth or fifth generations.

We are very engaged owners and are trying to do a great job leading. In this context, the first step was to acknowledge that we could do it. With the three of us having worked in different arenas, we brought together a variety of leadership styles, which combine well as we deeply respect our

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© Kwik Lok

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differences. We genuinely get along well – that is key since it’s not a given for every family. We feel very blessed that we respect each other and our unique styles.

Mihu: What would be the essence of your individual leadership styles?

Kimberly Paxton-Hagner: Because we’ve been sisters longer than we’ve been in business together, it was easy for us to fall back on our regular ways of communicating with each other. We realized that we needed to create space for us to communicate as owners and bring that information to the Board. That’s why we developed the owners’ council that helped us formalize our decisions as owners giving us an avenue with the Board, to promote further discussions with them. For my leadership style, I am more of a thinker, I like to reflect before I act. I’ve always been the bookworm of the family; as an avid reader, there is a lot of information I like to access before I make a decision, and that’s one of the things that we help each other with as sisters: we are always learning and bringing what we are excited about and what we learn back to each other as a way of balancing each other up and gaining new insights.

IN THE SPOTLIGHT

I found going back into school helpful, with courses such as Northwestern University’s Kellogg School of Management which has a family business focus. There, I also learned from the experiences of other business owners. This matches my leadership style closely. I am a great listener, too; this is something that I found helpful to bring to the Boardroom, because you don’t want to be the loudest voice in the room when you are sitting in the Board chair, especially as an owner.

Melissa Paxton Steiner: I would say I am still in the learning process of my leadership style. I joined the Board and became a part of the business in 2018, so it’s been a whirlwind of information. I am more comfortable being behind the scenes – I listen very well and prefer not to add much until I am confident that I have all the information I need and then I feel I can make a meaningful contribution. I count on my sisters a lot to help me through this process and give me the confidence to stand up and voice what I think, even if I disagree – which is OK to do. It’s a work in progress.

Stephanie Jackson: May we all continue with the beginner’s mindset! I would say that I am the loudest of the sisters in my style (laughs). I am not afraid to ask questions, I think that is one of my superpowers - and I’m curious. My style stems from knowing I don’t know all the answers, so I ask a lot of questions and then rely on my support team. It takes a village! I truly believe this, whether it’s in parenting, or in running a business. I certainly rely on my support system, which is why I surround myself with exciting, intelligent, engaging, want-to-make-a-difference kind of people. I look to them and bring all that back to my sisters and the company.

Mihu: From your experience and from interacting with other family business owners, what values do you consider to be at the core of a family business?

Kimberly Paxton-Hagner: The main thing I learned is that what we (and family businesses, in general) bring our deep connection to the family legacy as well as the vision and the values of the family. It’s why family businesses generally do so well. Knowing that we hold a North Star for our business is what keeps us focused on the direction we want to go as we go forward, while also engaging people’s hearts in the process. That is at the core of the impact we can have as owners of a family business. It is something we hear echoed over and over again, from other family business owners. It validates that our work in this family together, as a business, has an innate value that we need to share with those interacting with our business. This is how we will drive our vision forward for generations.

Mihu: How do you view taking on a top management role in the industry as women?

Stephanie Jackson: Going back to our father and grandfather, what they excelled in was making a reliable product, having integrity, treating their people well – with dignity and respect. That was the groundwork of our legacy. With women now leading this legacy, our focus has been on the

impact, and the experience our employees are having.

Women are inclusive; we are very community-based, very world-based and all-around grounded. Those are important values that women leaders bring. This aspect can get lost sometimes; that’s why we need everybody at the table, for a fuller, robust, diverse and inclusive way of doing business.

As women owners, we are adding that as a layer on top of a great foundation.

Mihu: What is your approach to innovation and sustainability, and how do you feel these areas reflect on food safety?

Kimberly Paxton-Hagner: Innovation is the reason why we are even here talking today: it’s because of the innovation that came before us, through our grandfather’s work, on which our father built on for so many years. Innovation thrives in an environment where trust is key; in other words, where people know that they can lean on each other, everybody has the same intent, and we are all trying to accomplish a big goal together. That is why we are focused on building an environment that supports employees to bring up ideas, to make mistakes and learn from them, and to always think of ways to link arms with others and contribute to even bigger work. Sustainability is this kind of ‘big work’, and creates an uncertain path for the future, too. The only way we will get there is together, so building partnerships, and getting people excited about working with Kwik Lok, showing them that we are always going to lead with integrity, follow the science, learn from other people and build on each other’s experiences to come up with the next best solution – and then, keep going for generations.

Mihu: What makes people excited to work with Kwik Lok? Stephanie Jackson: I think when they find out we have a big vision on making this world better, that’s exciting.

Everybody relates to this goal. When people know that they are doing meaningful work and innovating products and processes that make people’s lives better, it engages them.

We have an atmosphere of collaboration as well as respect and dignity. Everyone wants to lean into working with people who truly see you and value you, and I think we bring that.

Mihu: How are responsible labor practices aligned globally at Kwik Lok? Stephanie Jackson: As I said earlier, treating people with dignity and respect is at the core of our business, therefore, we established a code of conduct within Kwik Lok that says we are 100% free of human trafficking. We now want to promote it and ‘walk our talk’ with all the people we work within our supply chain. If we want respect and dignity within our own company, we need to show that out into the world. The people we work with, our partners and our supply chain are where we can make those efforts. I can say proudly that we are 90% free of human trafficking in our supply chain. That is exciting and fills us with pride.

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IN THE SPOTLIGHT

Women are inclusive; we are very community-based, very world-based and all-around grounded.

Stephanie Jackson

© Kwik Lok

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Mihu: Moving on from the inspirational to the challenging, what issues have you encountered professionally as women?

Kimberly Paxton-Hagner: In my past work experience, one recurring challenge was that women in leadership roles or managing departments found themselves skipped over for pay increases or promotions. The reason commonly given by the management was that the men were the providers for their families and needed the pay increase more. Every single one of these women was also a provider to their families, too, but they were held back based on this misconception from the male owner who viewed women as needing the money, instead of earning it, even though they added the most value to the corporation in their position. That is a challenge oftentimes women face.

Mihu: Pandemic measures brought challenges of their own, especially for women who have been working from home full-time while also ‘in charge’ of household work and childcare. What support system have you had in place in the past year to navigate the new day-to-day work challenges?

Kimberly Paxton-Hagner: The first thing we did, which I love, is to check in with our people. We didn’t just tell them what they needed, we asked instead, and learned everyone’s unique situation at home and how to support them. Some people might be the primary caretakers of children in their home, but they are also most likely to be taking care of elderly parents, who are often susceptible at this time. We provided remote work solutions wherever we could, for people who needed that extra layer of safety for their families. We also made sure we were providing benefits including mental health support and reminded people they could lean on the company during this time.

Mihu: How do you see a work routine stabilizing after a year and a half ?

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Stephanie Jackson: During this pandemic we realized that remote work is valued by our employees and we are now establishing a remote-work policy, not just for now but ongoing. We have found that it opens up our ability to access more talent and can often bring higher levels of productivity.

It’s a win-win for everybody. We’ve hired several people during the pandemic and learned we can have a combination of employees working remotely and from the office. It was exciting for the employees to see that they could still do their work without having to come into the office five days a week. This helped out many people who had to stay home and cover homeschooling or keep children motivated in school.

Mihu: How does having the support and solidarity as three sisters help you coordinate the management of the company?

Melissa Paxton Steiner: I wouldn’t even be a part of this family business were it not for my sisters... They give me the strength to step out of my comfort zone and do things that I haven’t been trained for - to take on some of the challenges that I’ve been given.

Stephanie Jackson: I would love to add to this point, that my sisters and I remind each other that our past work experiences have set us up to be able to do what we are doing now, and that’s the solidarity we have. We, as women especially, can forget our other skills and experiences are assets.

I remember recently reminding my sister Kim that her job as a graphic designer and holding the position of chairwoman of a nonprofit has prepared her to fulfill her role as chair of the Board of our company, for example. We all bring our past skills that allow us to be the great leaders that we are now.

Mihu: What are some of the difficult decisions that you feel women have to make professionally in the industry, in your experience?

IN THE SPOTLIGHT

Stephanie Jackson: It’s not necessarily a decision, but more of an situation: the lack of representation is a challenge.

I believe if you can’t see it, how do you aim for it? One of the responsibilities that my sisters and I feel is to provide more opportunities for more women to be represented in all different areas of our company, from engineering to C-suite leadership and being on our Board. That is one of our biggest challenges in the manufacturing industry. We can work to uplift more representation, which will make great inroads.

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Mihu: How can women’s representation in the industry be supported in order to increase?

Kimberly Paxton-Hagner: One of the ways is the work you are doing right here: help make women more visible.

We know that women are out there leading, and we can see what we are able to do. It is not only important to see women in this industry for valuable takeaways, but also how women leaders, in general, are accomplishing their goals. With the Olympics, we saw a viral video of a little girl watching and cheering on a woman in a weightlifting competition. It just reminded me of how powerful it is for us to see somebody who looks like us do that work. We also need to consider that, on top of the challenges we face as women, there is another unique layer of difficulties for black, indigenous and other women of color. We can lift other women up who are dealing with these various levels of difficulties in their professional life, by making sure there is visibility for them, by passing the mic and sitting at the table with women with very different backgrounds and experiences from ours. The narrative needs to be about how we can make room, provide support, get young women into the pipeline so that they can stand up for the next generation as well.

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Mihu: What are some of the decisions you could share that you made not just as a professional, but also which you consider are the type of decision that should come from a woman?

Stephanie Jackson: I feel women can get a bad rap because we lead with our hearts and that can be frowned upon in big business. One of the reasons why we were not groomed for the company is that our father, through no fault of his own but sharing the view of the times, saw women as too emotional for business, and our minds not made for big business. What women bring is heart leadership and we can all now see that the world needs that. We are at a time of crisis in leadership, and I believe that many countries outside of the U.S., have begun to uplift women more and acknowledge the value of this kind of leadership.

We are trailing behind in various things, from sustainability issues to women’s heart-led leadership. This kind of leadership is what we want to focus on.

Kimberly Paxton-Hagner: As a reminder, we started doing CSR right away; it was high up on our list of things

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IN THE SPOTLIGHT

to understand and do, on the same level with understanding continuity of operations and financing. It wasn’t icing on the cake, it was a part of the cake.

©

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Mihu: From this perspective, what other changes did the leadership transition entail including the introduction of CSR? Kimberly Paxton-Hagner: We talked about what women’s leadership brings to the table; before we took over, the focus was more on ways to expand and preserve the business, and how to maintain profitability at a certain level. When we came in, we realized that the key to doing all that work is focusing on people. Our new priorities were to make sure that people feel supported, that they come to work, perform and feel good about it; and then go home and enjoy their life without having to worry about work. We also wanted to make sure that everybody is communicating, that we are sharing best practices. Rather than thinking that every plant can take care of itself, we learned that sometimes different plants can make the same mistakes, and it’s important to share this knowledge, too, so we can learn from each other, as well as sharing the wins. Innovations were developed in Australia, for instance, of which we didn’t take advantage of in gn Kim Ha Yakima until we started talking to each b erly Paxt o nother. Human beings like to collaborate, in general, but women especially love to collaborate because we see an immediate value to it. We put in place the teams that would do this right away. This is the shift we introduced, built on open communication, a trend spearheaded by our current CEO, Don Carrell. We pushed it as leaders of the family and he championed it, opened up his door for people and set the tone for the rest of the organization. er

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Mihu: What would you consider the most meaningful decision you have made and how is it reflected in your work?

Stephanie Jackson: I have two: the first is making the decision to continue our family legacy. It was not a decision that we took lightly, and we chose to take on the opportunity, instead of selling the business. The second meaningful decision is bringing Corporate Social Responsibility to the forefront immediately as we entered as leaders. This needed to be talked about and brought in focus, and not just in the form of a report where you check the box. We needed to integrate these concepts into everything we did. Mind you – we didn’t exactly know how to do it, at first! We asked a lot of questions and brought on a lot of smart, wonderful people to further our vision.

Mihu: What CSR guidelines are you prioritizing?

Kimberly Paxton-Hagner: A progress that I am proud about has to do with sustainability as a part of our CSR work.

Some employees might have thought this was more of a task

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for the engineers or the innovation committees, but we are very happy to see that we have woven it into our business plans and introduced key initiatives that all employees are working on accomplishing, through their managers. In this way, they were able to see sustainability as a companywide goal. We had a challenge brought from a customer: how could we print on a lock without compromising on sustainability? The way we normally would have done it would not have allowed for the lock to be reused, or pieces from it, in order to make it more sustainable. We got the printing done at a later stage of the process instead and kept sustainability a part of the solution provided. I feel very proud knowing that this message has been pushed out and that CSR is how we’ve accomplished that.

Stephanie Jackson: In our listening sessions with our employees, we’ve learned that they were practicing sustainability back home in their own lives, and it’s reflected in how they are now looking at waste in terms of reusing and recycling it. That was exciting to hear, they were thinking about this topic outside the walls of Kwik Lok. Mihu: On this note, a concept you’ve referred to in the past is ‘doing well by doing good’. What is its significance at Kwik Lok? Stephanie Jackson: We believe that providing a great culture for employees is the core of doing well. Data shows that, when employees feel trusted and supported, they literally outperform businesses that are only focused on the bottom line. We know that we have to be profitable and, at the same time, it is important to us to do good by our employees, communities and our planet. We realize doing well is at the center, but we reach it from another angle, working with partners who believe in the same vision as we do. One of our big pillars is opportunity. Advancing the quality of opportunity to all of our employees, upscaling them and showing them they have a stable future. This provides the certainty that human beings need to do good work. On top of that, we also want to have fun! You’re not just coming in and punching a clock at Kwik Lok, we want to make sure that you feel engaged. People who have recently joined our company or who have just passed through the interviewing process have said that they felt very welcomed. People are genuinely smiling and happy to be at work. People feel that Kwik Lok has a nice, inviting atmosphere, which makes them feel excited to be here.

These are unsolicited comments that make us proud of what we are focusing on.

Kimberly Paxton-Hagner: In the recent listening sessions, employees mention feeling good about working for a company that cares about the environment. People are engaged on another level when they are connected to the broader work we do as a group and the bigger impact we have, through things that mean something to them. While doing this, they get to talk about what they do at work, volunteer time off, get paid to do work in their community and can join the

IN THE SPOTLIGHT

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Mihu: Can you share some of the things that the employees had to say, from this session?

Kimberly Paxton-Hagner: We love to see that they are connecting with our core values: they like working for an innovative company, they enjoy collaborating and Me teamwork, they have a great deal of pride in doli s s a ing a job well, they care about the customers they are deeply connected with, sustainability and protecting the environment.

Stephanie Jackson: In other responses, we learned that having a vision and mission provided certainty, excitement and pride, as well as a sense of direction for a path forward.

Mihu: And what inspires each of you?

Stephanie Jackson: I am very connected to the concept of belonging. In my personal life, it is important for me to feel I am part of my family, my community and my friends. I want people I come in contact with to feel like they belong and they matter. That is what inspires me and I like to be a part of activating it. Whether I sit on a Board in my community, help at a fundraiser, support a friend, everything I do comes from a place of belonging and inclusiveness. We’re simply better together; that, right there, inspires me!

Kimberly Paxton-Hagner: My inspiration is somewhat connected to Stephanie’s: it’s about the grassroots work being done in communities all across the world. We often see big organizations that have solutions and the money to back them, but the work on the ground that’s being done by ordinary people in the community is the main work that’s going to change the world.

I am inspired to connect through our philanthropic work here at Kwik Lok to organizations that are moving the needle in important areas, including women in business. Highlighting that work is inspiring to me.

Melissa Paxton Steiner: Being authentic e in e is my biggest inspiration, I would say – both St Paxton professionally and personally. I always want to provide people a safe place to be themselves, to not feel judged. You can see the true beauty in a person when they are their authentic selves, trust them more and also engage with them. I gravitate toward being authentic and letting that be an asset.

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Mihu: How often are these listening sessions held?

Kimberly Paxton-Hagner: We’ve had smaller ones before, but this has been the first time we’ve had a bigger ask, to reach employees across the globe and in all the different departments (in its six factories, Kwik Lok currently employs over 330 people, eds.) and to lift a variety of voices. We are considering how often to repeat them, as we are also doing poll surveys with fewer questions, to hear from the employees regularly so that we make sure we pay attention to the things that matter to them. Many companies do this, but unless you circle back and tell the employees what you’ve learned and what actions are coming in response to it, you are not making full use of this tool and reaching the level of collaboration that you are trying to set.

Mihu: The path forward brings me to the topic of innovation. Having in mind Ms. Paxton-Hagner’s extensive 15-year background as a graphic designer, what similarities are there in the mindset required to work in graphic design to spearheading Kwik Lok and developing innovation in packaging closures?

Kimberly Paxton-Hagner: I love this question! Graphic design is about innovating, so the connection is deep. In both, one of the first things that you need to do is listen: you need to find out not only what the customer thinks they need, but also what they want to accomplish. Also, when you are creating something, you might think pen to paper is the next step; but, creative minds need space and room to be inspired. It’s an undervalued stage in the work because it doesn’t immediately feel productive, but to be really innovative, you need to allow yourself to see things that are inspiring and to give yourself room to breathe, have fun and connect with uplifting people. This is the step that makes great designers and also the place from where great inventions happen. It’s what we want to bring to our work.

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Mihu: These also add to the answers to my earlier question and show what is exciting about working at Kwik Lok. You mentioned listening sessions with your employees, how are they organized?

Stephanie Jackson: We are working with our leadership to share our vision and mission within the company and are talking with the employees to see their perspectives on what we S te thought were great concepts. We ren p h an ie Ja ck so cently did this and the results have just come back. We were pleasantly surprised to learn that people connected to the concepts of what we were saying. Was there room for more context to some of the things we have in mind? Yes. These sessions have been hugely valuable to see where we need to connect the dots, so every employee sees themselves in our vision. That is our intent, to have everybody see their part in the equation of pushing our vision and mission forward, not just engineers or those at management level.

People like the kindness of our culture. The company that helped run the surveys said that they rarely see this as a result.

r

sustainability work that we are doing with our innovations.

Once your heart is involved in what you are doing every day, it’s amazing what magic that brings.

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IN THE SPOTLIGHT

Mihu: World Muse is committed to providing programming that’s accessible and inclusive, always with the intent of promoting and supporting positive social change and amplifying the voices of those who have been historically underrepresented. What values are at its core that can also be found at Kwik Lok? Kimberly Paxton-Hagner: I loved working with World Muse, and I am still supporting them. The project is about 11-12 years old now. Back in 2015, I was board chair.

The reason I connected with it is that it aims to lift voices and give people tools. Its focus is to primarily support young girls and help them see how they could be a force for social change and how they can help their communities through their unique skills. Working with them is very inspiring to me. What we have in common, here at Kwik Lok, is that we also want to help people develop their unique talents and connect these talents for a vision for the future.

Mihu: Speaking of special projects, I would like to look into partnerships that Kwik Lok selects. What does your collaboration with the U.S. Plastics Pact mean for the company?

Stephanie Jackson: Collaborating with U.S. Plastics Pact has been huge for us because it connects us with people who are working on this big current problem. Plastic was, at first, a great solution, but it’s outlived its purpose and its benefits are found to not nearly offset the damages it causes. We need to develop solutions and the U.S. Plastics Pact connects us with a multitude of companies that are also working on the same problem.

Kimberly Paxton-Hagner: We are always looking into working with people who are focusing on the same things we prioritize, around the environment and sustainability or supporting underrepresented groups in their communities and their work environment. I am also thinking about big collaborations in finding solutions for food safety and reducing food waste. We are always working with partners to try to create a closure that meets the needs of our clients while having a minimal negative impact on the environment, and eventually turning that around to a positive one.

Mihu: Ms. Jackson has said to always love a challenge, from health coaching to running a marathon and – together with the Paxton women – a company with a global reach. What were some of the interesting challenges you took on? And what is the mindset of loving a challenge?

Stephanie Jackson: My sisters and I recently came across a great book called ‘The Infinite Game’, by Simon Sinek, where he talks about having an infinite mindset. What we loved about it, enough to share it with our Board, is the

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notion that we are not out to win a big trophy in life, but we should focus on how to stay in the game instead, how do we keep playing, and do the good work that we are doing. That mindset implies looking at the competition as worthy rivals who push us to grow and raise our standards.

Kimberly Paxton-Hagner: I love how you are always saying, Stephanie, “Prepare to be amazed,” which truly encapsulates this. I am thinking of a challenge that is not necessarily huge, but it’s an ongoing one: it’s reminding people that it’s not business as usual to reach a little further, with our new leadership.

While the bottom line is there, we are not going to measure anything against that, as we want to change the way people are looking at success.

Melissa Paxton Steiner: The biggest challenge in my life, one that I’m gradually overcoming, is being a part of the business with my sisters. It required taking a leap of faith, and I took it. I am in it and committed to work and enjoy the journey for as long as we can, together.

Stephanie Jackson: Another running challenge is disruption, to which I say, get comfortable with it! Change is inevitable; we say at Kwik Lok that we are going to push our employees to change, adapt, pivot. Get comfortable with it and even welcome disruption, invite it in and prepare to be amazed.

What’s on the other side is typically better than what we could have ever dreamed! © Kwik Lok

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Mihu: How do you view the industry environment for women for the generations entering the workforce now? What advice would you offer them?

Melissa Paxton-Hagner: This is key to where we are today.

Get yourself a support system! Surround yourself with people who see your value and will gladly remind you of it. Find the people that can help you skill up and push you to try things that might be, at first, difficult to imagine yourself doing.

Make sure you have your core people stand by you during your difficult times, whether it’s your teachers, your friends or your family. You’re always going to have times when you doubt yourself, and somebody may always question your abilities; these people will lift you back up so you can stand strong.

Stephanie Jackson: I would say that you don’t have to know all the answers! There are so many amazing resources, and people who have walked the path before you who can help.

It only takes putting ego aside and asking for help. Doing that is a superpower. We as women are resourceful, we are strong, we are competent – and we do not need to do it alone.

You don’t have to do it alone! What seems like a vulnerability will be your strength.

Mihu: Thank you for a truly inspiring evening! +++

Unit equipment and complete lines, turn-key design

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© IPCO

New cooling tunnel from IPCO IPCO developed a cooling tunnel with improved energy efficiency provided by a newly designed airflow system, for use in the confectionery and bakery industries. The system can be designed with direct, indirect or impingement airflows, with a bottom cooling option also available. Airflow has been designed for maximum efficiency to deliver rapid, controlled cooling and lower energy consumption than comparable lines.

Conceived as an efficient, single-pass process, IPCO’s new line can be equipped with stainless steel or plastic belts in standard widths of 1,500mm or 2,000mm, with other sizes available. The length of the tunnel can be custom-designed. Other features include belt alignment and safety systems; the tunnel is supplied in modular form with all electrical equipment ready for connection, enabling fast installation and commissioning. The cooling system can be used for anything from cooling for forming or molding

processes in confectionery, to cooling bakery goods such as cookies, crackers, brownies, biscuits or cereal bars.

The new cooling tunnel represents a significant extension of the steel belt specialist’s portfolio for the bakery and confectionery industries. +++

Association of German Plant Bakeries: Presidium unanimously reelected

© Verband Deutscher Großbäckereien

UK adds folic acid to flour

The flour used in the UK will have mandatory folic acid fortification to help prevent spinal birth defects in newborns, the government announced. The new rules will only apply to non-wholemeal wheat flour, with gluten-free foods and wholemeal flour exempt.

Prior to the new rule, the government ran a public consultation on the matter in 2019. Women are advised to take 400 micrograms of folic acid a day for at least a month before conception and up to the 12th week of pregnancy. Folic acid is added to flour in more than 80 countries. Since World War II, the UK’s non-wholemeal flour has been fortified with iron, calcium and two other B vitamins – thiamin and niacin. +++ www.bakingbiscuit.com 05/2021

Prof. Dr. Ulrike Detmers (Mestemacher Group) was unanimously reelected by the members of the Association of German Plant Bakeries. She has been President of the Association since 2013. Her two representatives, Hans-Jochen Holthausen (Harry Brot) and Alexander Heberer (Wiener Feinbäckerei), were also reelected Vice-Presidents of the Association. Holthausen is also chairman of the specialist group of delivery bakeries, while Heberer is chairman of the specialist group of branch bakeries. +++ The Presidium during the Annual Conference in Düsseldorf/ Germany: Prof. Dr. Ulrike Detmers, Hans-Jochen Holthausen (right) and Alexander Heberer (left)

Anne Mere appointed MD of Fazer Bakery Baltic

Anne Mere has been appointed Managing Director of Fazer Bakery Baltic and a member of the Bakery Business Area Management Team. She will also become a member of Fazer’s Extended Leadership Team, as of September 20. She has worked in various executive positions in the Nordic food company HKScan and has more than 20 years of experience in managerial positions. Mere has been responsible for business management with profit and loss responsibility, operational excellence, brand strategies’ implementation as well as retail business development in different markets. © Verband Deutscher Großbäckereien

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NEWS

The second edition of iba.Connecting Experts gears up to stream the virtual event from October 25 to 28, structured around four focus points: ‘connect’, ‘discover’, ‘learn’ and ‘entertain’. Virtual attendees will have a comprehensive choice of current topics to delve into, including strategies from industry leaders on how to reduce losses using AI. This lecture will bring together senior manufacturing executives from Nestle, Bimbo, Mondelez, Pepsico and Aryzta to share their experiences, insights and advice on how to use Industrial Artificial Intelligence to master manufacturing processes and reduce production losses in quality, waste and yield.

Batch and continuous dough production is also among the topics in the event’s ‘Learn’ feature, including a lecture on pre-mixing from Dr. Christian Faber, Senior Technology Consulting, Zeppelin.

Hygiene is a discussion topic as well, with a presentation evaluating effective disinfection on hygiene standards given by António Jorge, Marketing Manager at KOMA. He will discuss alternative methods and equipment to measure the output of a washing procedure with respect to hygiene and disinfection. +++

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Koelnmesse to launch Anuga HORIZON in 2022 Koelnmesse is developing a new hybrid event, the Anuga HORIZON, aimed at closing a gap with its interdisciplinary approach, as it identified a rising need for new solutions. As an innovation and business platform, the event examines solutions for the future challenges of the industry every two years. The concept of Anuga HORIZON is based on a combination between an exhibition, conference and experience and unites theory and practice using interactive formats. The first edition will be staged from September 6 to 8, 2022.

“The idea for the event was born two years ago when we placed the focus on future solutions and new technological approaches at Anuga 2019 in the form of the special event, ‘Anuga Horizon 2050’. Changing consumer demands, increased digitalization, the increased implementation of disruptive technologies require a paradigm change within the industry,” explained Gerald Böse, President and Chief Executive Officer of Koelnmesse GmbH. +++

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PRODUCTION

© Rademaker

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The best means to all ends Different types of products made with laminated dough have their own process requirements to achieve the desired characteristics.

Flexible equipment is needed to support variations and to do so efficiently, especially in industrial baking facilities.

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Every type of dough and resulting product requires a specific laminating method. When laminating dough, fat layers can be shaped in different ways. Even distribution in the precise amount is key to perfecting this process, and therefore the best method for the product should be identified that best matches the product and its processing system.

When making this choice, particular attention should be paid to evaluating the dough tensioning in the dough piece, especially on the sides of the slab. “We also look at the fat distribution in the base dough; the goal is that the fat layers are distributed as evenly as possible through the whole dough,” Rademaker’s specialists outline.

Jan Willen Jansen, sales technologist, and Henri in ‘t Veld, head of product management explain how Rademaker lines can support the three laminating methods developed by the company: horizontal, overlapping or by cutting and stacking layers. Laminators are set up according to the production volumes, the type of fat used, the number of layers needed for the products, the desired thickness of the layers and the dough reduction method. Rademaker’s laminators can produce dough sheets up to 512 layers. “Because all these build-up layers need to be reduced to the required dough thickness, the reduction process needs to be done very

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gently. If not, there is a big risk of damaging the layering structure, which leads to a non-acceptable product,” they explain. Going over 512 layers will almost not be visible in the product and would bring no benefits. The number of layers can easily be adjusted from the control screen. The production will automatically change to an adequate production speed.

In the case of large adjustments, the reduction steps must also be closely examined, Rademaker recommends. Once the optimum settings have been found, they can be saved in the system so that they are available again for the next production run.

In addition, proofing systems are added where necessary, as well as a cooling and resting section – if the product requires this step: “To obtain the highest quality layers of dough, it may be necessary to cool and/or rest the dough sheets in a cooling and/or resting cabinet. Within the laminating process, the layers of dough and fat are essential for the baking structure of the final product,” they highlight. The type of fat (butter, margarine, shortening, low-trans or non-trans margarine) is determined by the type of product and the process which is

PRODUCTION

best suited to it. Its influence on the taste is a consideration in this choice, in addition to price differences. The fat pump on the system can handle all options equally well. Choosing the solution that is the closest match to all manufacturing requirements is a collaborative effort. In co-development with its customers, Rademaker translate their wishes and requirements into “tailor-made laminating solutions and thus offers a range of croissant and pastry lines to shape the dough to any product desired,” the specialists add.

Laminators are adjusted to support the desired product in all aspects – from crumb, to shape and texture. For flexibility, they come in different working widths and a modular design, covering a wide range of capacities in its standard configurations. The layout can also be flexibly adjusted, with choices of shapes including L-, U-, and Z-formats. The design of Rademaker’s equipment also allows a good view of the dough flow as it is laminated, for a fast visual assessment of the process.

THE Peelboard Suitable for all industrial baking lines.

Efficiency in every layer Precise control over the entire process is the key to increasing efficiency. The overall setup of the Rademaker Laminator is designed for high production efficiency and user-friendly operations. Its tools are easy to remove, the parts that need to be regularly changed are reduced to a minimumm and its scrapers are exchangeable. All these aspects result in minimal cleaning efforts and increase production uptime.

Furthermore, the system is equipped with automatic settings allowing for a ‘one-button’ press to bring the entire machine to the perfect cleaning or drying status. After cleaning, the operator will be warned if belts are not tensioned properly, Rademaker says.

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Process control by means of intensive data handling and communication is becoming increasingly more important in industrial production processes. “Our control platform enables OMAC based data exchange with neighboring (third party) equipment as well as LMS, MES or ERP systems,” the specialists explain. Furthermore, advanced data processing enables online monitoring and optimization of equipment efficiency. The smart use of the combined information regarding process and recipe allows easy and fast start-up of operations and optimizes flour usage. The existing cascade system and automatic belt speed adaption is an advanced control system. It features fully automatic speed adjustment and enables the different sections to operate independently. While the last section of the production line finishes processing, the first section of the line is ready for cleaning or to begin running another product. The operator will be prompted when the next recipe can be started on the machine. Moreover, the number of sensors the laminator uses is reduced, to guarantee optimal control with minimal risk of downtime due to malfunctions.

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PRODUCTION

impact of changeover times,” the Rademaker specialists underline. + The sturdiness of mechanical and electrical components: the correct choice of materials and using high-end components will make operation predictable and make unexpected breakdowns unlikely.

In addition, external factors can also be responsible for production downtimes, particularly up- and down-stream processes, including mixing, proofing, freezing and baking.

The correct supply of ingredients and product removal is a prerequisite for the optimal functioning of the entire production line. “The Rademaker System Integration department can compose a tailor-made production process for each specific customer demand. Here, a combination of ‘Best of Breed’ partners is selected to ensure uptime (and product quality),” they specify.

© Rademaker

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Downtime management Several aspects related to the equipment itself play a role in how often downtimes occur: + Cleaning: when not carried out correctly, the machine is more likely to come to a standstill because of contamination that can cause malfunctions in the process or the machine.

To mitigate this, Rademaker machines are designed and developed to facilitate easy and thorough cleaning. + Maintenance: the design of the machine also plays an important role in the ease of performing maintenance, to ensure the wear parts are replaced on time and quickly, and that bearings maintain their lubrication levels, for example. + Skill: the experience of the operating staff often plays a major role in minimizing downtimes as well. “On the one hand, we try to make the operation of the machine as easy as possible, both mechanically and in terms of software/ user interface. On the other hand, we have set up Rademaker Academy to educate personnel and bring them up to speed as quickly and efficiently as possible,” Rademaker details. With skilled operators running the line, problems that might occur will be handled and solved much sooner. + Tool changes: when frequent changes need to be made as different types of products run through the line, the ability to quickly change AND correctly set up production tools on the machine is of crucial importance to guarantee downtimes are minimal while also minimizing scrap that can result (incorrectly produced items) during start-up after a tool change. “The sophisticated design of our tool positioning and structural help from the user interface (via the ‘Tool Assistant’ menu) guarantee the lowest possible

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External environmental influences such as temperature and humidity, as well as the choice of ingredients and the composition of the recipes, can also disrupt the production process and can cause downtimes.

Maintenance innovations The optimal balance between production, cleaning, maintenance and any tool changes can bring significant benefits.

The planned downtime for tool changes has been reduced in some cases from one hour to less than 15 minutes. Similar improvements have also been achieved for cleaning and maintenance. Data gathered by the PLC can be used to improve maintenance (e.g. motor loadings, running stops and stop causes).

While service and maintenance requirements are reduced by optimal material selection, on the one hand, Rademaker laminators are designed to be easily accessible for service and maintenance, on the other hand. “This results in minimal wear and increased lifetime of all sensitive items, in combination with minimizing needs for spare parts. Lifetimelubricated bearings in the product zone and clear, comprehensive lubrication locations for bearings outside the product zone consequently result in minimal downtime,” they highlight. Parts that require regular maintenance are located in easily accessible places and, importantly, located outside of the production zone. Furthermore, all conveyor belts are equipped with quick belt release mechanisms to reduce downtimes during cleaning and to keep maintenance to a minimum. All of this results in less time being required for cleaning and maintenance.

Additionally, Rademaker provides 24/7 service assistance for its customers. The Service department can also do preventive maintenance and/or make a list of necessary spare parts, to ensure that they are available in the bakery in case replacements are needed. +++

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© Unifiller

TURNKEY

Fresh off the drawing board Consumers are not just hungry for any cakes, but are seeking diversity and sensory experiences in their choices. The technology behind baking such options needs more flexibility than ever.

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Bakeries are demanding a higher degree of flexibility from their cake production lines. Unifiller took this need to the drawing board and incorporated a comprehensive set of answers in its newly launched Flexline. This line specializes in the production of small batches of many different types of products, with minimum changeover timings. It can produce 500-900 cakes/h for round, two-three layer cakes and 300-400 cakes/h for rectangular, two-three layer cakes of 400x600mm. It processes cakes in one step, from using the freshly baked sponges and cream right up to placing the decorated cakes into packaging before they go into the

cooler or freezer. The 2021 edition of the Flexline needs less space and is more compact, as the heavy syrup spraying unit, which is typically approximately 1.5m long, has been replaced.

Instead, “We are now using a small ELF400 depositor to spray the syrup on the conveyor of the Multi Station. To be able to do this, we added a conveyor extension, only 40cm long, to the Multi Station, and equipped the ELF400 depositor with a syrup shower head,” Unifiller details.

For increased production volumes, cakes with diameters ranging from 10cm to 22cm can be produced on two lanes.

Bigger cakes (up to 30cm in diameter) are processed through the Multi Station on one row. Within the space of under 4m, as many as 700 cakes with a 16cm diameter can be produced per hour, and it only takes a staff of three to process everything from soaking syrup to applying the filling, assembling and icing the cakes. The line comprises the small ELF400 depositor, a Multi Station, a Hopper Topper pump and a Cake-O-Matic.

The conveyor belt of the Multi Station is another novelty brought by the new revision of the equipment. Unifiller added ‘fingers’ to the belt to gently position the sponges correctly and center them for a clean spreading result of the fillings. A catch pan is now also included underneath the Multi Station to prevent the syrup from dripping onto the floor.

© Unifiller

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The first operator puts the sponger through a slicer to obtain the two-three layers, and then handles the placement of the sponges on two rows, onto the conveyor extension of the Multi Station. One or two ELF400 depositors automatically detect the sponges and spray syrup onto them. The filling is applied on the layers with the Multi Station via a Hopper

Topper pump, then the sponges move onto the 4m-long conveyor, where the second team member assembles the layers into a custom-made cake ring. The third staff member is assigned to do the top and side icing on the Cake-O-Matic, with a Hopper Topper Pump. From there, the cakes continue on the conveyor(s) where they are further decorated, finished and packaged. Packaging would require a fourth team member on the line. This process can be modified to add decoration along the conveyor, for example. Possible variations in the equipment line-up can include: + Shorter or longer conveyors (3-5 meters), depending on specific needs - e.g., more steps in between to add decoration, fruits, etc.

+ One or two depositors to spray syrup, depending on the type of cake + If the same type of cream is used for the filling and the icing, the Hopper Topper pump can feed both depositors (Multi Station and the Cake-O-Matic) + 11m-long layout: within a space smaller than 4m in length, the cakes are completely processed, from the addition of syrup to the filling in between the sponge layers, and top and side icing. The rest of the line is used for decorating with frozen fruits, spraying jelly and packaging.

Round layer cakes and rectangular cakes can be produced on the Unifiller Flexline primarily. In addition, a long list of fine bakery products can also be prepared, including muffins and decorated cupcakes, brownies, pies, eclairs, macarons, and single-serve desserts. To add a new range of cakes into production, sets of new nozzles are required and can be easily added. The machine is already prepared to handle everything else, with features included in the line’s hardware and software.

Optionally, drip-free nozzles can be added for liquid fillings and for the addition of chunks in sizes up to 19x19x19mm.

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© Unifiller

TURNKEY

Additional depositors can also be installed along the conveyor to automate the decoration on top of the cakes. The standard machines are flexibly built to allow customizations to be made with little effort. “We just need to add some custom-made nozzles, conveyors or other accessories that are produced locally. Alternatively, our customers can easily modify their products on their own: different cake sizes are easily implemented in the servo control of the Multi Station,” Unifiller explains. Cakes with a different number of layers can be made in this way, with various fruit or inclusions, and diverse decorations.

Moreover, “The newest addition we are working on is to implement Baker-Bots made by Apex Motion Control for further automation of the process,” Unifiller anticipates.

More details will be available soon.

The latest cake line installations were completed this year for customers in Norway, Romania and Switzerland. +++

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INGREDIENTS

Muesli on the go With muesli bread, backaldrin has brought the muesli theme into the bread sector and is responding to the growing number of consumers who want to eat more healthily.

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The basis of muesli bread – a yeast-free wholemeal oat bread – is Muesli Bread Mix. In addition to oats, the mix contains rye, wheat and spelt flakes, puffed corn for the crunch, as well as citrus fibers, apple juice powder, coconut flakes and chokeberry pomace, which all combine to deliver a characteristic, typical muesli taste. The final product has a high fiber content and is low in saturated fat. Based on this premix, bakers can produce muesli bread or muesli bars. The taste and characteristics of the bread or bar can be varied by adding nuts, candied or dried fruits, honey, chocolate, or other ingredients. The finished bread keeps fresh for a long time and can easily be pasteurized as sliced bread.

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The product’s target group is consumers who are mindful of their health, want to eat a wholesome diet, and value a sufficient supply of dietary fiber, vitamins and minerals. The concept behind this idea was for the Austrian baking ingredients manufacturer, backaldrin, to bring the topic of muesli into the bread sector. The result was, as it were, muesli ‘to go’. In this respect, it is not surprising that breakfast is the target meal, as the product keeps you full for a long time and provides the necessary energy for the day. Bread with wholemeal cereals is equally suitable as a snack between meals, even without toppings. A muesli bar is the ideal option as it can be taken everywhere by the consumer, for example to sporting, school or other activities outside the home.

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In backaldrin’s experience, some bakery customers use muesli bread specifically for social or sporting events. It signifies a health-conscious lifestyle.

Muesli Bread is a yeast-free whole grain oat bread with wheat and spelt flakes and puffed corn for crunch

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To make the basic dough, only water or milk needs to be added. For that ‘something extra’, the backaldrin master bakers recommend the use of milk. After all, muesli and milk belong together. If almond milk is added, the product remains vegan.

There are no limits to the number of individual flavors that can be created. backaldrin’s master bakers have developed three recipe variations.

For more information, visit www.backaldrin.com.

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CONVEYING

© IPCO

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Part 2: Upgrade, adapt

All systems go Conveyor systems work under demanding conditions in bakeries. Maintaining them in top condition is the first step to efficiency in production; upgrades will then guarantee optimum performance in handling processes for truly competitive-level manufacturing.

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Conveying systems need to be improved to best ensure product transportation is optimized, according to the type of conveying system, the production steps of the line, and the type of products moved. The design of a reliable conveying system must consider the type of product, whether it’s pastry, bread, or patisserie, and its production process, which differs for raw frozen, pre-parbaked frozen, freshbaked goods, for example, to preserve the product quality.

“To meet this challenge, the conveying system must avoid shocks, vibrations, sudden mechanical movements that could cause the deterioration of the product (e.g., deflating dough) and impact on the quality,” François Retailleau, Line

Product Manager at Mecatherm, underlines. The conveying system must handle the products/bakeware without affecting the products, keeping its alignment throughout processing steps. The conveying system also must be able to adapt itself to the cadence of the line (acceleration and deceleration management) and be flexible and robust.

To answer current market needs for flexibility and product diversity, the conveying system can be part of these trends as a vector of line flexibility, contributing to several processes, from frozen raw products to fresh-baked or frozen products. The challenge is in the industrial performance: if the conveying system is well designed, it is possible to implement solutions in a fairly compact area, for example, or, in any case, to adapt to the customer’s environment.

Mecatherm’s solutions are based on modular conveyors, with switches that allow trays to be routed in different directions and adapted automation management. Retailleau provides an overview: “The MECAFLEX Line is agile architecture served by flexible equipment and enriched by smart software tools, which provides optimized productivity and efficiency to production management.” This flexible line thus allows to run fresh baked products at the same time as raw frozen products, thanks to a smart conveying layout.

© Mecatherm

Systematic cleaning Amounting to 100-200m on a complete line, the conveyors must have few or no retention areas where dough residues can deposit. Sanitation procedures will also be adjusted to manufacturing specifics. A ‘basic’ environment with a dedicated bread line will follow a simple but complete sanitary procedure, for example, while an ‘intermediate’ environment complexity-wise will require additional steps, depending on the rigors of the ingredients used. Eggs and meat are relevant

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CONVEYING

examples in this case. In an industrial bakery environment, cleaning can be based on the following steps: + Cleaning dust + Minimizing/eliminating retention areas in the conveying system, to prevent the formation of dough residues

+ Periodic cleaning with a wet cloth while protecting sensors, motors and other electrical components that cannot be submerged in water Retailleau also points out hygiene among important factors in the conveyor’s design: “To keep food safety all along the line, it is necessary to reduce the dough retention areas, which can lead to bacteria development, and have a conveying system that is easy to clean.”

Cleaning will be much more demanding for lines that frequently produce goods with higher water content, with eggs or perishable and sensitive meat products because of the risk of bacteria development. Food safety and hygiene are therefore key issues to be addressed. In this case, not only the conveyor's design should be adapted, but also cleaning procedures have to be reinforced: + Setting up a dedicated, full-time cleaning team + Thoroughly protecting the motors + Cleaning the conveyors with a combination of acid and basic detergents followed by a rinsing step

The conveyor system must therefore be reliable, adapted according to the types of production, and easy to clean respecting the sanitary measures according to the customer's environment.

A close inspection of the belt Maintaining a conveying system in its fully operational capacity is a prerequisite in increasing efficiency; upgrading it is then the next goal. One of the first elements to be closely inspected as it can provide significant process improvements is the conveyor belt. For baking, a steel belt can act as a window into the performance of the entire oven. For example, if side wandering tends to occur, this can often cause the belt to come into contact with the structure or another rigid object, resulting in burrs. Wavy edges could be another indication of side wandering, or uneven temperature in the oven. “It can also indicate uneven pressure from the belt cleaner or scraper, or a belt scraper that is wider than the belt itself,” Marko Leber, IPCO Global Product Manager, Food, illustrates.

To design solutions and upgrades, IPCO will look for deformations in the belt that could suggest problems with drums, belt supports or other parts coming into contact with the belt. Counter actions include cleaning the drums, cleaning or replacing belt supports, and checking scrapers, rollers and belt tensioning. The underside of the belt is also on this

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CONVEYING

checklist and subject to inspection, as any scratches could indicate worn or damaged belt supports or safety scrapers.

“We understand how a belt interacts with the many other components that make up the system as a whole. For our service teams, an analysis of the condition of a belt gives us an insight into how an entire system is performing,” Leber explains.

A comprehensive conveyor analysis IPCO is a belt specialist first and foremost, but almost 100 years experience of working with the bakery industry has given the company an insight that goes beyond the design and supply of solid and perforated steel belts. The Swedish company can provide support in the form of a full range of conveyor components. Such was the case of a customer experiencing constant problems with a line, for example: while they initially intended to replace the belt, IPCO analyzed the equipment and identified a deeper issue for which it recommended a more elaborate solution, in addition to replacing the belt. It included a new tracking system, replacement tensions and drive drums, scrapers, spring guide rollers and a combination of cast iron and graphite skid bars. “The result was a complete system upgrade, designed, supplied and installed by our teams,” Leber summarizes.

In most cases, the condition of the belt is the symptom of a problem and not the cause. That is why IPCO recommends regular belt inspections. In another recent case, a customer experienced belt tracking problems which, on close inspection, turned out to be caused by several components in the 1970s-built oven, and completely unrelated to the belt itself.

These parts were not able to provide the reliability and performance of modern conveyor equipment. The surfaces of the drums, for example, were no longer suitable for effective belt tracking. IPCO retrofitted a range of new components, including inlet and outlet drums, new tracking devices, a graphite station and a cleaning brush and scrapers. The existing belt did not require replacing. “The customer ended up with a state-of-the-art conveyor system capable of delivering significantly improved productivity, with lower costs than it would have been for a new belt.”

Conveying for the process Several aspects determine what improvements a conveying system needs – starting with the process step it serves. Luis Patricio, Intralox Baking Account Manager, lists: + The work environment and the product conveyed. These will define the type of chassis frame construction and belt material to be used for the right application and surrounding environment. + Health and safety aspects, if people are working on the surroundings to prevent possible hazards.

+ Preventative maintenance plays a key role in the costs of ownership and operation reliability. “As the industry is moving fast into a direction of minimal costs to run operations, conveyor systems (including spirals) with low

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cost of ownership will play a key role moving forward,” Patricio adds.

Intralox developed a new type of belt material (PK) for its modular belt series. “This material is stronger than Acetal and has very good product release characteristics,” Hans Tertoolen, Intralox Bakery Account Manager explains. The PK material for modular belts shows excellent product release characteristics, making it a choice for higher hydration doughs, for example. The company’s ThermoDrive belts also excel at handling wet, sticky doughs; they are “Flat belts made of a homogenous PU material with a patented tensionless drive system based on the same principle as our modular belts,” explains Patricio.

© Intralox

26

For more upgrades, the company’s latest solutions also include a new type of tight transfer modular belt, the S560 series, a strong belt with an upgraded sprocket engagement. Over the past months, Intralox has launched several new belt series, materials and technologies for hygienic applications, spiral technology and P2P (Packer to Palletizer).

When working to optimize new bakery lines with conveying systems, Intralox works closely with the end-users to understand their needs for specific applications. In parallel with OEMs, the company provides support to ensure the right application is in place, corresponding with the manufacturing needs. For manufacturers looking to upgrade existing equipment, Intralox has a specialized engineering department focused on improving existing applications, including complex applications such as spirals.

You can read more about maintaining conveyor systems and process optimization in the previous issue of Baking and Biscuit International. +++

MUESLI BREAD MIX

The new Muesli Bread Mix offers a range of options. Whether as bread or bars, classic or with nuts, berries and other fruit, it’s the perfect offering for consumers looking for an enjoyable power snack. www.backaldrin.com

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PRODUCTION

Thinking outside of the tray Trays come in shapes and sizes as diverse as the products that they will help to make, while also considering the equipment and handling methods in each bakery. A characteristic they all have in common, regardless of endless possibilities in their layouts, is the safety guarantee provided for the products baked, time and again.

h a ll p

+

Trays are provided in the exact design needed to be the best fit for all bakery specialties and can differ in sizes, slide and stack accessories, thickness and coatings, to meet manufacturing requirements. Anneliese has automated the production of standard trays and is channeling its R&D resources towards large-scale customizations. “We are specialized in customizing in big quantities, from flat trays to customized mold trays for croissants or baguettes and different types of special shapes. From 580780mm up to 2,000-800mm, we manufacture industrial trays in any size,” Dennis Wendlinger, Anneliese CEO, highlights. Since no two bakeries are alike, the same is true for their requirements regarding baking trays, pans, coatings and any related accessories. Anneliese makes use of its in-house tooling department and team of product designers to develop a solution for every request. “We cover virtually everything, from robot handles to stacking bolts, to changeable inlets, to special mold designs,” he illustrates. Anneliese also observes a growing trend for the use of plastic peelboards in industrial baking.

Industrial baking: safety is everything Upgrading bakeware will amount to significant improvements in their utilization on industrial lines; in addition, when they are correctly utilized and maintenance is performed, the results become easily visible. For high-volume manufacturing setups, which imply a high degree of automatization, high-quality coatings and timely recoating are a must, to ensure the maximum uptime (and eventually, lifespan) of the trays. The best choice for a coating comes from a good connection with the customer, in Anneliese’s experience.

It requires having detailed information about the product, the line, the bakery environment, the dough, the humidity, among others. “A good coating will ensure products do not

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u b le is d o o n th o to s

page

Anne by ©

stick to the tray or tin, resulting in better product quality, a safe process using non-sticking agents or oils, safe cleaning, and value for money as a result,” Anneliese outlines.

Care for coatings The approach to the product’s safety, as well as hygiene, depends on the tray. The presence and type of coating play a big role in this. Anneliese highly recommends working with coatings in industrial baking, where they contribute to obtaining high-quality products and ensure the utmost hygiene while also being mindful of the environment in the process as no release agents are needed. By and large, it is a combination that amounts to earning ‘safe money’. Coatings come highly specialized to closely match the baking requirements of each type of product, from those designed specifically for buns and craft bakery goods to more ‘extreme’ applications such as those required by automatic tin-set lines or sourdough products. Factors that are frequently behind coating damage start with using the wrong coating for the wrong product: “Not every coating is made for lye products, for example,” Dennis Wendlinger illustrates. Then, inadequate cleaning, baking, depanning, handling and storing are the usual suspects. The optimum coating will depend on material, dough and process. To help maximize the efficiency in repeated production cycles and extend the lifetime of both coating and tray or tin set, Anneliese provides utilization guidelines fitting each production environment. For general

li e s e

PRODUCTION

considerations on how to preserve coatings, empty trays should not be stored in heated ovens, which can heavily compromise the lifetime of anti-stick properties; they should also be thoroughly dried before usage, as water residue will help products adhere to surfaces, which is harmful to the coating. Correct washing and drying is half the battle in maximizing lifespan, to ensure they are ready for reuse as quickly as possible without damaging surfaces. Anneliese bakeware should only be cleaned with water and a commercially available neutral cleaning agent (pH 7), with a soft jet of water and/or soft cleaning brushes. The company advises against plunging or using high pressure to clean trays or tins.

The bottom line is that coated bakeware should not be used until the point when oil or release agents have to be used – because this is not economical in the long term. Anneliese’s advice: “Inform your employees or colleagues about the coating and ask them to report back if it starts losing its non-stick effect. You will receive advice as to whether your bakeware is ready for recoating or you need to invest in new bakeware.”

stainless steel tubes, with no edges – when the products and the production line allow it. Alternatively, smaller options have stainless steel tube frames and are bent on two sides without creating ‘dirt collecting edges’. “This also depends on the line and the bakery. The two-, three-, four-edged or rimmed trays are almost exclusively seen outside of the industrial field, in small and medium-sized bakeries,” Wendlinger observes.

As for the choice of trays for industrial bakeries, the company recommends bakeware with perforated sheets riveted on ADVERTISEMENT

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PRODUCTION

all photos on this page by © LloydPans

30

Made for pizza In most restaurants, pizzerias or foodservice operations, the choice of oven is influenced by financial, space and labor considerations, aside from its technical capabilities. This means that the potential of these ovens can be maximized by innovations that pans can bring, such as mimicking certain baking surfaces. “The first step in this process is thinking of your oven simply as a heat source and your pans as baking systems. With that frame of mind, our pan experts can customize a pan that cooks almost any type of product in any oven. We’ve built pans to bake chocolate lava cakes in high-heat pizza ovens and pans to fry eggs in a conveyor oven,” Traci Rennaker, LloydPans CEO, elaborates.

Avoiding product adherence to the surface of the pan and having it easily released once it is ready are top priorities for pizza manufacturing, too. Dealing with a commonly thin layer of dough topped with various types of ingredients means more challenges are brought to the pan design table.

LloydPans has developed three proprietary coatings to prevent sticking in all pans; all of which are permanent, toxin-free and infused into the pan surface to create a permanent baking platform that will not chip, peel or flake off.

“Unlike traditional seasoning or glazing, our Silver-Kote and Dura-Kote coatings are not damaged by steaming in pans and don’t wear out,” she explains.

1) The PSTK ensures a stick-resistant coating. Rebbaker points out that this coating has proven successful by the top pizza franchises in the world. Pizza experts who are using it have tested its performance and appreciated its durability.

2) The Silver-Kote coating system is designed to eliminate reglazing for bakeware used to prepare pizza. Its baking properties resemble those of bare aluminum but have the added benefit of being a permanent stick-resistant coating.

3) Dura-Kote: this coating for bakeware is similar to PSTK, but fine-tuned for applications in retail and high-volume commercial bakeries.

Specializing in pizza pans for commercial foodservice, LloydPans looks into several aspects when considering new developments. Three criteria stand out in the pursuit to perfect pans suitable for the heat-intense pizza production process: + Durability: LloydPans takes into consideration the everyday rigors of a commercial kitchen, meaning they have to be built to be strong and perform consistently. To increase durability, all PTSK and Dura-Kote coating systems are metal utensil safe. + Coatings: The company has developed a proprietary coating for its pizza pans called Pre-Seasoned Tuff-Kote ® (PSTK).

This permanent coating eliminates pre-seasoning and is heat safe with an empty pan up to 700°F (371°C) – there is no limit when cooking if food is removed when ready.

The coating is stick-resistant and will not chip, peel or flake off.

+ Performance: This is the combined result of constructing a durable pan with a high-quality coating: “Our pans perform exceptionally because they do so regularly over countless cycles,” she highlights.

Pizza under any circumstances The general environment in a bakery or foodservice business can be damaging to pans. LloydPans also sees a lot of pan damage when machine washing detergents are used. To prevent this, it is imperative to clean with a non-corrosive detergent, according to the specialist.

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PRODUCTION

Pans specialized for pizza production need to handle not only different baking equipment, types of manufacturing and handling routines, but also to provide optimum support for various types of products. “We have spent years developing pans for specific pizza types,” Rennaker says. For example, the company’s Detroit Pizza Pan is its bestseller and was developed specifically to cook this trendy pizza. “When we develop any pan, we factor in shape, size, depth and crust/ dough characteristics that we are trying to achieve. From there, we get to work and test multiple iterations until we accomplish our goals,” the CEO explains. In terms of flexibility, LloydPans designs and manufactures custom pans for its clients based on their unique needs. For example, looking into portion control to meet pizzeria and consumer concerns, the company has developed the Equalizer, which is one of its best-selling products. It is a multi-blade rocker knife for accurate pizza slice portion control, used in many commercial foodservice operations, such as schools, to ensure consistently equal slices.

Tray cleaning down to a science Cleaning can quite literally make or break the trays, respectively their life expectancy. This, in turn, comes with a double cost: first in replacing/recoating the pans and, just as importantly, in production time lost. Specializing in cleaning machines for baking trays, Austrian company Precisma develops equipment configured for specific requirements.

As for possible customizations to the cleaning equipment, “No client specification is beyond us,” believes the General Manager, Alois Aichinger.

Precisma’s tray automatic cleaning system for baking lines, ‘BELT Industry’, is designed with easy integration with various technologies in mind. In addition, it can be customized to match the bakery’s needs. It can be configured for any cleaning task thanks to a multitude of options, e.g. washable design, for continuous operation, Precisma details. This machine has a cleaning performance of around 1,200 sheets per hour and removes any leftover flour, seeds and rough efficiently.

Its brushes work in opposite directions to one another to adapt to the bakeware contours and reach all parts of the molds and tray channels.

The ‘BELT Standard’ cleaning machine is designed to clean baking trays with up to four rims in large quantities, as well as baguette and burger trays. The basic version can be fed manually – in which case it is made up of a cleaning and a conveyor unit. It helps save energy compared to wet cleaning and is also particularly suited for bakery production lines, in the form of individually adapted automated systems.

The ‘Easy Belt’ is the newest entry in the company’s portfolio.

This recently-developed tabletop baking tray cleaning machine is meant for universal use by small businesses. For this purpose, its design prioritizes flexibility in terms of

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© Precisma

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types of trays it can thoroughly clean, over quantities. It incorporates the company’s Belt cleaning technology and its use is as simple as setting the machine down on a table and sliding the baking trays through it manually, Precisma recommends.

No matter what types of products are in current (and future) manufacturing rotations, choosing the right bakeware for the job, handling and cleaning it as intended can help achieve significant savings and guarantee product safety, with every bake. +++

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PAC K AG I N G

The Globus bakeries strategy Against the backdrop of climate protection discussions, the Globus retail group relies on recyclable or recycled packaging materials for its own products. Plastic is being saved, but not completely banned. Globus bakeries have also made the switch.

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Around 80% of the fresh bakery and confectionery products produced in Globus bakeries arrive packaged on the shelves of the retail group. The topic of packaging is therefore relevant for scratch bakeries. The packaging for cheesecakes, sand cakes and donuts has been rethought.

Instead of plastic, they are made of two materials: cardboard and a plastic viewing window. The consumer can detach both from each other after use and dispose of them separately (waste paper, plastic waste).

Recyclability is important, but so is customer benefit. Globus, therefore, did not want to do without the plastic viewing window. “Test phases have shown that our customers want to see the goods,” says Alexander Heinrich, who manages the bakeries at Globus. The packaging changeover saves the company around 600,000 plastic packages a year for donuts alone. That corresponds to about 40 tons of plastic.

Paper packaging: natural brown instead of orange The paper packaging is no longer orange, but natural brown.

Without coloring, the paper can be better recycled, Heinrich reports. “For our breads and rolls, we use bags made from 100% recycled paper. For the remaining baked goods, we use packaging material made from recycled plastic. With the

Globus uses blister packaging made from recycled plastic for cakes

innovation of using recycled materials, we want to push the recycling cycle.” This is a goal that the Recyclate Forum, of which the retail group has been a member since 2018 – has set itself (see box on page 36.)

Different foods, different demands Even though plastic is not a renewable resource like paper, it has advantages in terms of hygiene and product protection.

Globus finds that plastics are better than their reputation.

Alexander Heinrich: “Different foods have different requirements. Oily, greasy and moist foods have to be packaged in such a way that they are transportable, food-safe and suitable for storage. For this reason, it is not advisable to completely avoid plastic packaging.” It depends on the type of plastic and the subsequent recycling process, he said. “Instead of black plastic, we now go for ivory plastic. This is more recyclable, can be better recognized by sorting plants at recycling companies and consists of recyclate. So the plastic has gone

Scratch bakeries are part of the hypermarket concept

© Globus

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PAC K AG I N G

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The Globus Group Globus, an independent family-owned company,

© Globus

operates a total of 49 Globus hypermarkets in Germany, 90 Globus DIY stores, six Alpha-Tecc.

Consumer Electronics Centers, as well as 15 Globus hypermarkets in the Czech Republic and 18 hypermarkets in Russia. In total, the trading group generated sales of around EUR 7.95 billion in the past financial year and employs more than 46,000 people, including around 600 bakers and confectioners in © Globus

Germany, 350 in Russia and 300 in the Czech Republic.

They are the backbone of the 41 bakeries in Germany, 15 in the Czech Republic and 18 in Russia.

from Globus’ own central production in Bingen/Germany.

Home bakeries

These include laminated doughs such as Danish pastries

At least 90% of the baked goods offered on the self-service

and croissants, special items such as sand cakes, sponge

shelves of Globus retail stores come from Globus scratch

cakes and seasonal products such as gingerbread.

bakeries. The bakers and confectioners produce around 200 different items every day, ranging from bread and

The in-house bakeries stock the restaurants and/or snack

Baumkuchen to 150 confectionery products. Among them

islands of the hypermarkets with premium items for the

are regional specialties that can be purchased depending

cake counter, with unpackaged breads, sandwiches, snacks

on the location. There are only a few items that are not

to go and with pizza doughs. Above all, however, they

produced in the store itself and are instead taken over

produce for the self-service shelves of the stores.

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through at least one stage of life before being shaped into our ivory packaging through recycling.”

At the same time, Alexander Heinrich points out that the new packaging concept ensures that recyclates are only used if it can be guaranteed that no harm will come to the food.

“Our Clear Cups, for example, are made predominantly of recyclate but have a proportion of 20% virgin plastic mixed in for the benefit of elasticity and the food.” Fresh plastic serves as a barrier between the recyclate and the food, at least in the case of moist, greasy or oily products.

Customers question more Customer attitudes towards packaging have changed, according to the experience of the bakery boss. “Customers are questioning a company’s actions more and more; for this reason, we are interested in optimizing our processes not only for environmental reasons, but also to show our customers that we are doing our bit for the circular economy and sustainability.” He continued, “The pandemic has increased environmental awareness and health awareness not only in the direction of nutrition, but also in other directions, such as packaging alternatives.” Customers are even more interested in the topic than before and are looking for information, he said. Therefore, Globus communicates the advantages and disadvantages of the different materials to the customers.

Heinrich: “Customers should be able to transparently see why we have chosen which type of packaging and understand how it can be fed into the recycling cycle.” Globus communicates the what and the how via the homepage and information on the packaging itself.

As a rule, the production of packaging with recycled raw materials is somewhat more expensive. According to its own

The Recyclate Forum Globus has been a member of the Recyclate Forum since 2018. Retailers, consumer goods manufacturers, packaging suppliers and waste disposal companies have joined forces in the initiative to promote consumer awareness of a circular economy for packaging, to achieve sorting of recyclable materials, to promote the recycling of plastics and to use more recycled plastics. In addition, the forum aims to reduce packaging and to ensure that new packaging is recyclable in the production process so that it remains a resource in the cycle. The initiative now has 47 members.

statements, the retail group has been able to remain at the same purchase price level for many packages through optimizations.

Additional costs would not be passed on to the customers.

Raw material delivery in reusable containers Besides the change in packaging, something else has changed. Some raw materials now reach the bakery in reusable containers. “Both our suppliers and our employees have responded very positively to this,” reports Alexander Heinrich. “Reusable containers not only reduce packaging waste but are also easier to handle.”

At the central production facility in Bingen, Globus uses 400- and 600-liter containers for cooking oil and 500-liter containers for eggs. The company has also switched to reusable containers for fruit fillings. As soon as a container is emptied, it is stored in a separate room. Collection and cleaning are handled by the suppliers. +++ Helga Baumfalk

© Globus

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The bakers and confectioners produce around 200 different items on-site every day

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U N I Q U E FO R YO U R N EEDS

PRODUCTION

Ideas from Mahot The principle of the forked kneader came from the Mahot machine factory and provided mechanization of dough preparation. It has since proved itself in practice – and is still used today. The reason behind this is the technological proximity to French traditional, © VMI

manual dough production.

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The 19th century is quite rightly regarded as the time when mechanization gained momentum in many industries, as it promised to do away with tedious and laborious manual work. Some also hoped that it would protect people from unhygienic and unhealthy working conditions.

In contrast to Northern and Eastern Europe, both France and Italy almost exclusively use wheat for bread baking.

Compared to today, however, the flours available in earlier times were weak in gluten and therefore demanding to process. The manual kneading process was lengthy and had to be divided into different phases. These included the integration of the sourdough starter (levain-chef, madre) and the uneven feeding of the other raw materials. The doughs previously had to be mixed, kneaded, stretched, beaten and aerated, and rested repeatedly in between. Dough making, therefore, required not only time and muscle power but also intellect and sound education.

Enthusiasm from master bakers and dough makers for the first inventions of mechanical dough makers was nevertheless slow in coming, and not only because some feared

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© VMI

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Fork mixers are available with different vat sizes and different speeds, as well as stainless steel kneading forks

for their jobs. The practicality of the mechanization experiments and their savings potential were also seen as limited.

But the loss of manpower due to the countless wars in which European countries on all continents were involved, and not least World War I, in which millions of young men lost their lives, prompted bakery entrepreneurs to look for support from machines.

PRODUCTION

CREATING TOMORROW’S SOLUTIONS

© VMI

Dough heating °C/mn Forks vs Spiral Mixer

One such kneader, the ‘Victorieux’ developed in 1880 had recorded more than 500 sales by the end of the 19th century. The development of this forerunner to all fork kneaders was based on the manual process, until 1964, when Michel Bouton developed the Mahot fork mixer, with the Mahot company at the origin of the Victorieux. Today, the ‘Maison Mahot’ brand belongs to the French machine manufacturer VMI, which still maintains the tradition of fork kneaders and thus the tradition of French dough production. In Italy, too, various manufacturers have fork kneaders in their programs.

FEEL FREE TO REPL ACE EGG IN FINE BAKED GOODS

There are a number of factors that make bakeries turn to this type of technology.

The interplay of fork and vat geometry ensures optimum oxidation of the doughs without them becoming ‘stubborn’ and prevents the temperature from rising too high. Fork kneaders are therefore recommended above all others for doughs that need to absorb a lot of water but do not require the addition of chemical additives. The main areas of application are baguettes, pizzas, brioche, shortcrust doughs and viennese pastries.

Today’s fork kneaders are often supplied with a removable bowl, driven by a belt. In contrast, traditional machines with fixed bowls are driven by wheel and screw or by way of conical gear. Vat sizes vary. VMI, for example, offers fork-type kneaders with a fixed bowl in bowl sizes for up to 160kg of dough and with a removable bowl in bowl sizes for up to 530kg of dough.

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In the meantime, the fork kneader has also made the leap into complex systems for dough preparation with multi-shift operations. Carousels consist of a raw material feed, one or more kneaders, and several dough resting places, as well as linear systems. These also prepare the doughs with one or more kneaders, which then transfer the kettles to automatically controlled rack storage for dough resting, from which the doughs are automatically retrieved according to the process control and transported in kettles to the next processing station.

For many years now, such installations have been found, amongst others, in companies specializing in the production of high-quality frozen baguettes and crusty breads. +++

For more information, please visit www.wacker.com/egg-free-bakery ADVERTISEMENT

Sources: + Chiron, H.: “Les différentes étapes de la mécanisation du pétrissage en France”, erschienen in “Industries des Céréales” July/August/September 1993. + Busas, M.: “Changes in bread production”, student research project, published by Grin Verlag in 2000. + VMI Produktkatalog Removable bowl fork mixer, Fixed Bowl Fork Mixer

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

A simple way to reduce food waste The ‘use by’ recommendation has the potential to significantly decrease at-home food waste, baked goods included, while sell-by dates still result in perfectly good foodstuffs being discarded.

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Twenty-five years ago, my associate and esteemed Garbologist Dr. William Rathje wrote that “There are several specific behavior patterns that are associated with high rates of food waste. Most are obvious. It should come as no surprise, for example, that fresh produce is wasted at 10 times or more than the rate of processed fruits and vegetables, and foods that are used frequently (such as the slices from standard loaves of bread) find themselves in the trash much less often than foods which are used only sporadically (e.g., hot dog buns or muffins).”

Wasting food that we don’t consume on a regular basis is probably a part of human nature. We see something novel in a store. We buy it. We put it in our pantry or in the fridge. We take one bite or eat one slice. And then we forget about it.

In a survey of over 2,000 adults by the Korea Health Industry Development Institute, 56% stated that they believe food should be thrown out after the ‘sell-by’ date.

As Dr. Rathje pointed out, specialty baked goods are particularly prone to waste, thanks to their novelty value. Retailers take advantage of this novelty by merchandising muffins, buns, and pies in ways that maximize consumers’ impulse purchase behavior. These items are thus found throughout the store, stacked on tables and end caps, waiting for recognition, interest, and purchase.

A plan to follow Does packaging have a role to play in improving the use-up rate for perishable foods, especially in the baked goods aisle

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© eldarnurkovic – stock.adobe.com

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and end caps? The South Korean government thinks so.

They just revealed plans to overhaul regulations on food labeling by replacing the current ‘sell-by’ dates with ‘use-by’ dates, which are longer (use-by dates signal to consumers that there will be no safety problem until that date, if the food product was stored properly).

Why is this a big deal? Many consumers misunderstand the label information and dispose of food products too early. In a survey of over 2,000 adults by the Korea Health Industry Development Institute, 56% stated that they believe food should be thrown out after the ‘sell-by’ date. Thus, they are throwing away perfectly safe and edible food.

Using the ‘use-by’ date gives consumers a far more accurate measure of when food will actually spoil, thus enhancing shelf life and potentially reducing at-home food waste. Such a change will have positive implications globally, since most of the Organization for Economic Cooperation and Development (OECD) member countries employ ‘use-by’ dates instead of ‘sell-by’ dates.

There are additional positive ramifications of moving to ‘sell-by’ dates for both producers and retailers. Firstly, in-store shelf life will be longer, reducing food waste at the store level.

Secondly, inventory management should be simpler, both in terms of ordering cycles as well as on shelf merchandising and rotation.

My advice? Follow this trend and if possible, make ‘use-by’ information prominent on the packaging of your baked goods. Doing so will enhance consumer interest in-store, while also increasing product usage and thus decreasing food waste at home. +++

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N E W R AW M AT E R I A L S

Cakes are better-for-you, too

© Palsgaard

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The preference for healthier alternatives is reshaping all bakery product segments, including those long thought of as the epitome of indulgence above all other qualities. Cakes are among such delicious sensory experiences that can now boast better-for-you claims added to their names, thanks to ingredient innovations.

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Good and better ingredients might mean different things to different consumers. To appeal to most, better-for-you cakes should ideally be low in sugar and fat, to begin with, and have plant-based ingredients to meet this newer but compelling growing trend. Palsgaard divides the healthier cake product category into several targets: sugar reduction, valued by consumers monitoring their carbohydrate consumption; fat reduction, with particular attention to avoiding saturated fats; sodium reduction, and plant-based cake formulations. “All these categories should take into consideration that cakes are still eaten for indulgence so consumers should have their better-for-you cake and eat it, too!”, Haydee Carlos, Global Application Manager, Palsgaard A/S, observes. Working formulations take into account and find a balance between health and indulgence.

The ‘Low Sodium’ SuperFruit Cake is an example, prepared

by Palsgaard’s Global Industry Team Bakery: its recipe combines lower saturated fat and sodium contents with an increase in vitamins, antioxidants and amino acids, as well as minerals and fibers coming from the fruits. Salt and sodium bicarbonate were removed from this recipe; the baking powder was replaced with a combination of Potassium Bicarbonate (E501) and Disodium Diphosphate (E450). The cake is based on vegetable oil, meaning it contains less saturated fat and no trans-fatty acids. This recipe combines Palsgaard® SA 6610 – an activated industrial cake emulsifier for crumb structure, Palsgaard® DMG 5611 – a complementary

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emulsifier helping to enhance and preserve product softness, an anti-staling agent in cakes, and Palsgaard® OilBinder® 01 – to stabilize the remaining oil in cakes, creating an appealing texture.

Whipping active emulsifier Many industrial cake manufacturers are using cake gel, which is a mixture of at least two types of emulsifiers, i.e., an alpha-stable blend of emulsifiers in paste/gel form. It usually contains Mono- and diglycerides of fatty acids (E471) and Polyglycerol esters of fatty acids (E475), two types of humectant, and a stabilizer. To replace this, Palsgaard has developed a powder type of whipping active emulsifier with only one or two E-numbers to replace cake gels. The main emulsifier used in Palsgaard extruded whipping emulsifier is Polyglycerol esters of fatty acids (E475), which is extruded on rice starch/ flour, making it an effective emulsifier. Palsgaard® SA 6610 is a whipping active emulsifier in powder form, which means that it can be added into the mix with other dry ingredients such as flour and sugar during pre-mixing. It can easily be dispersed in the cake batter, so the common problem of having lumps and undissolved cake gel during pre-mixing will not be an issue. Palsgaard stresses the reasons making the pre-mixing step a very important one: “Working in a continuous cake system, if the cake emulsifier is not properly dispersed, there will be instability in the specific gravity of the cake batter. Depositing a heavier product means losing yield and hence, profit. Production personnel will also not

N E W R AW M AT E R I A L S

Recipe suggestion for a Vegan Sponge Cake Mix Materials

Grams

The Palsgaard® SA 6610 is developed for use in continuous aerators. It was subjected to repeated aeration to study the stability of the cake batter. This is done by checking the specific gravity of the cake batter during repeated aeration.

“An increase in specific gravity means that air is coming out of the cake batter because of the stress from the mixing head of the aerator and the repeated flow in the pipes during re-circulation to the mixing head. Based on our study, the specific gravity of Palsgaard ® SA 6610 is very stable even when subjected to stress,” explains the specialist. A very stable specific gravity in production means optimum depositing weight, minimal variation and it translates to cost savings.

Sugar

410

Cake flour

370

Native wheat starch

220

Palsgaard® SE 8102

60

Emulpals® 115

50

Glucose syrup 21 DE

20

SAPP28

10

Olive benefits Olive oil is used as a healthier option in another recipe for cake mix developed by the Danish specialist, in which it replaces margarine or butter to lower the cake’s saturated fat contents. “Palsgaard products like Emulpals ® 115 help in creating a soft crumb texture, while Palsgaard® OilBinder 01 was added to bind the liquid oil in the recipe and to give the

Total Batter

Soda Salt Total dry mix Water

8 2 1,150

Source: Palsgaard

experience blow-bys (when air is escaping from the aerated cake batter as it comes out of the pipe),” Carlos elaborates.

650 1,800

same bite or texture to the cake,” Carlos explains. Margarine or butter is usually recommended for home baking using retail cake mixes because these ingredients are usually available in the kitchen. However, healthier options like Olive Oil can also be used.

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N E W R AW M AT E R I A L S

Better industrial cakes Developing healthier cakes for industrial manufacturing is not without challenges. Any changes brought to recipes will affect the sensory attributes of the cake; for example, lowering the amount of fat used will make cakes less soft, while replacing sugar with sweeteners and fillers can have an impact on the overall structure of the cake, the crust color and the baking profile in general.

For products built around plant-based ingredients, Palsgaard® SE 8102 was developed for cake mixes, for manufacturing at an industrial scale, or for use in retail. For example, in a sponge cake recipe recommendation provided by the specialist, the functionality of milk protein and egg whites is replaced with Palsgaard ® SE 8102. The dry and the liquid ingredients are whipped at slow speed for one minute, then at high speed for up to 10 minutes. The density of the batter should be measured. Depending on the size and the weight of the sponge cake, it should be baked for approximately 30-40 minutes, at 175-200°C (347-392°F).

Palsgaard® SE 8102 is a mixture of soy protein, wheat protein, vegetable fiber, xanthan gum (E415), and guar gum (E412).

It is developed to replace eggs for vegan sponge cakes mixes, vegan stirred cake mixes, egg-less sponge cakes mixes, and egg-less stirred cake mixes. Its dosage is typically between 1-3%, based on the total cake recipe.

For egg-less cake mixes that are not plant-based, WPC-80 is used. Whey protein concentrate (WPC) is obtained by removing sufficient non-protein constituents from pasteurized whey so that the finished dry product contains more than 80% protein. This makes it unsuitable for cakes aiming to have a plant-based ingredient claim. This is where Palsgaard ® SE 8102 comes in. “It is developed to replace the eggs in the recipe so the product development of plant-based cake is considerably shorter. The plant-based cake premix that is produced with Palsgaard ® SE 8102 will only need water and oil as additional ingredients in order to bake a good plant-based cake,” Carlos adds. In this way, plant-based cakes can be formulated faster with good volume, structure, and have a moist texture and mouthfeel.

Such compositions can be a start to developing new, innovative cakes that are suitable for production in industrial volumes. Manufacturers can create products with trendy flavors and add a healthy option, depending on which betterfor-you concept is more relevant to their market. Changes in formulations will influence the process parameters, e.g., modifications in the batter viscosity will affect its aeration.

“This can be solved by increasing the amount of cake emulsifier used and/or decreasing the gums in the recipe. The baking profile of the product can be affected as well, so adjustments in baking time and/or temperature should be tested, Carlos recommends.

www.bakingbiscuit.com 05/2021

© Palsgaard

44

Palsgaard’s central application facilities in Denmark include a fully-equipped industrial bakery where realistic industrial pilot tests are carried out on a regular basis. Industrial-sized mixers and aerators feed a dual-zone continuous band oven to accurately reflect industrial conditions. This unique setup facilitates proper upscaling and increases the likelihood of success in the market.

Give and take: reformulation guidelines Margarine or shortenings have traditionally been used in cake production because they give volume and soft crumb structure to the cake. Removing them will improve the production process as there will be no need for several process steps for the creaming of the margarine or shortening with sugar to entrap air and to dissolve the sugar in the fat. By replacing them with oil, all the ingredients except oil can be added in one step. “If we want to go one step further, unsaturated oil can be used as well,” she proposes. Changing to oil can mean that the cake may lose some of the ‘bite’ or elasticity, however. This is where the emulsifiers’ role begins, by stabilizing the foam during aeration. “Cake batter is a foam and an oil-in-water emulsion, with oil as the dispersed phase and water as the continuous phase. This makes the cake softer, with a fine crumb structure and an even cake crumb. Emulsifiers also help reduce the amount of egg in the recipe.

Plant proteins behave differently, in comparison with egg proteins. They produce cake batter with high viscosity, making air incorporation a challenge. Plant proteins are also very efficient at binding water in the recipe, which impacts the baking profile of the cake. As the demand for plant-based products increases, Palsgaard anticipates that more innovation in plant protein will be developed to adapt to processing requirements, with roles in obtaining less viscosity upon hydration, a cleaner taste profile, and improved bake stability.

Opportunities for development are on the rise. +++

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INTERVIEW

Quality makes a strong argument again Armin Juncker, Chief Executive of the Association of German Plant Bakeries, shares his views on the

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impact caused by COVID-19, topics on the table at AIBI and the question of enzyme labeling.

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bbi: Europe seems to have at least put the for example by 3% in Belgium and by 5% in the worst phase of the pandemic behind it.

Netherlands. However, the development of What conclusions have the German plant packaged bread is positive and small artisan bakers drawn thus far? bakeries supplying the local markets Juncker: The spring of 2020, which have also been able to hold their own, saw the first region-wide restaurant and because apparently customers have shop closures, also caused enormous placed a great deal of trust in the disruption in Germany’s bread and products. baked goods industry. Hoarding purchases, as reported in other industries, bbi: What topics are currently on AIBI’s also occurred in bread and baked agenda? goods. As a result, many large bakeries Juncker: AIBI has traditionally been reduced their range of products and only very interested in all food law processes supplied a basic assortment for a period of which, as is well known, have their starting A r m i n n c k er Ju several weeks. By doing this, they ensured that the point or at least have an important promoter at bread shelves in discount stores and grocery stores were not European level. For this purpose, AIBI set up a Technical completely sold out.

Committee some time ago, in which the experts of all AIBI Although customers avoided purchasing unpackaged bakery member associations work on food law issues. The chairman products from the bake-off sections for an extended period of this committee is Alexander Meyer-Kretschmer from the of time, sales of packed bread from the bread shelf and German association. Some of the topics currently being freezer have remained stable. At the time of writing this, the dealt with can be found in the answers below. ‘unpackaged’ sector has yet to return to 2019 levels. The same In addition, AIBI follows the economic and legal developis true for companies located in high-frequency settings ments of the markets, which are located in particular in such as airports and train stations, as well as burger bun Southeastern and Eastern Europe. The changes in food suppliers, for example. The catering sector is also suffering supply that can be observed there and the changes in the from the still restricted business operations in canteens and bakery markets, in particular, are directing interest to these restaurants. markets. Unfortunately, the legal framework conditions for However, the bottom line from the industry’s point of view is market entry or even for investments are often still unclear that bakeries have been able to weather this crisis pretty well at present. overall.

Customers will once again use quality As indirect consequences of the COVID-19 pandemic, there will be longer-term changes in consumer behavior, which will more as an argument for their purchasby no means only affect the bread sector, but also the entire ing decisions, because it has become clear food sector. Digitalization and online ordering options will ‘pick up speed’ and as bakers, we will have to see how we get how important a 'plain loaf' is! our baguettes into the lunch packages of Lieferando & Co. Armin Juncker, Chief Executive Officer of the Association of German Plant Bakeries Another change in consumer behavior will result from the fact that the crisis has sharpened the view of the importance of basic foodstuffs in particular. Empty shelves in the superThe ambitious ‘Green Deal’ agenda set by the von der Leyen market or the bakery were unknown to all of us and literally Commission is triggering a number of important discusunimaginable. Customers will once again use quality as an sions. ‘From farm to fork’ captures the increasing imporargument for their purchasing decisions, because it has tance of environmental, ethical and social aspects. The become clear how important ‘plain bread’ is! sustainability of the food chain is high on the EU agenda and, therefore, also on AIBI’s agenda. AIBI was one of the bbi: What are colleagues from other national associations selected organizations that actively participated in the reporting to AIBI? multi-stakeholder process, from primary production to the Juncker: The impact on the bread and bakery market was consumer. AIBI has been involved in tackling the food quite comparable in other European countries. Overall, loss issue for many years and is a member of the relevant bread consumption declined in the COVID-19 year 2020, EU platform. ©A ss

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www.bakingbiscuit.com 05/2021

INTERVIEW

bbi: In an RDI project, scientists are researching the ‘residual activity and functionality of exogenous enzymes in baked goods (such as amylases, xylanases, lipases and glucose oxidases). What consequences do you expect for baked goods manufacturers?

Juncker: After many years of the firm scientific assumption and in practice that enzymes do not ‘survive’ the baking process that bread and baked goods regularly undergo, i.e. that they lose their enzymatic activity, there are now confirmed findings that this is not completely true in every case. Small amounts of residual activity may be present. The addition of exogenous enzymes is often necessary to balance and improve the activity of endogenous enzymes, i.e. those that occur naturally in wheat flour and yeast, for example. This technological necessity is one of the initial approval requirements for enzymes. Therefore, our association supports the RDI project which aims to further clarify these factual issues. If it turns out that there are also enzymatic activities after the baking process, the question of labeling has to be addressed. In the case of the required transparency and consumer information, we consider corresponding labeling to be absolutely appropriate in such a case.

bbi: What is the current status of acrylamide research? A new RDI project is supposedly being launched – why and with what aim?

Juncker: In all food sectors where products have elevated acrylamide levels, considerable progress has already been made in recent years towards reducing these levels. As you know, this also includes the bakery sector. However, these efforts must be continued and therefore it is necessary to push for carrying out the corresponding research. The plant bakeries that are members of our association are therefore very open to a corresponding RDI project and other research activities. bbi: There are proposals at the EU level to define limit values for prussic acid, morphine and cadmium (in poppy seeds).

Does this mean that there will be consequences for the bakery industry, especially for the manufacturers of fine bakery and patisserie products?

Juncker: Currently, no problems have been reported with the limit values discussed in the draft by raw material suppliers, especially those of linseed and almonds, so there are no direct effects on processing in a bakery. However, if such limit values were to be enacted, this would obviously mean,

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47

INTERVIEW

© EtiAmmos – stock.adobe.com

48

that the analysis work to be carried out by the raw material suppliers and possibly also by the bakeries would increase significantly. bbi: Additives are once again in the spotlight. Retail groups in France are even planning a ban on various substances in the products they trade. What exactly is at stake here and what is the German industry's position on this?

Juncker: It is a great EU achievement that there is intensive harmonization in the area of food law for the European market.

This not only benefits consumers, but also producers, who are increasingly working not just for a single national market, but for several markets. Against this background, we do not believe that it is the right approach for individual EU member states, such as France, to pursue a separate path for certain additives. This applies, for example, to uno- and diglycerides of fatty acids, which are used as emulsifiers in bakery products. From the point of view of German plant bakeries, there is nothing to prevent the use of these additives. They are technologically highly effective and help in the production of high-quality baked goods demanded by customers. The discussion is therefore not sparked by nutritional reasons, but primarily by political considerations. bbi: The fumigation of sesame, spices, amaranth, guar, psyllium with ethylene oxide and di-chloroethanol has not been permitted in the EU since 1979; the USA and Canada still permit it with a limit value. However, it is partly used for container fumigation. Does this represent a problem indirectly?

Juncker: The fumigation of certain additives with ethylene oxide (ETO) and di-chloroethanol, which is permitted in some non-European countries, is causing not only ‘indirect problems’ but massive direct difficulties throughout the European baking market, i.e. not only in Germany. Since the beginning of 2021, there have been more than 150 rapid warnings on this subject throughout Europe and also numerous recalls. The recalls regularly took place because the presence of ETO was detectable in the raw materials used,

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although ETO could no longer be detected in the end product.

In this context, too, a clear European guideline for action makes a great deal of sense, because current practice leads to recalls and food being destroyed, which results in avoidable food waste. This is reported, for example, by our colleagues from the Belgian Bread Association. Therefore, in Belgium, the food sector (FEVIA) is calling for this very strict interpretation to be reviewed after the Corona crisis at the very latest. bbi: A representative of the Lower Austrian Chamber of Agriculture recently explained in a lecture that the soil quality in Austria is declining due to climate change and that cereals are not coping very well with the temperature rise.

He also said that the EU’s Green Deal and the nitrate inputs it requires would mean that wheat would be less rich in protein in the future. Are there similar expectations for Germany?

Juncker: The grain supply produced in Germany is changing and with it, for example, the protein content of bread wheat.

This development has been monitored by the plant bakeries in their own laboratories or with external laboratory support for some time and countermeasures are being taken including changing the recipe and/or the baking process as far as possible. However, this topic is also being intensively pursued in breeding farms, in agriculture and the milling industry. bbi: Are changes to the labeling law under discussion within the EU? Juncker: The labelling law does not stand still. Countless departments and institutions on a national and European level are constantly working on optimizing labeling issues.

This optimization does not always follow scientific findings, but, more often than not political considerations, such as the idea of transparency. From the manufacturer’s point of view, however, plant bakeries traditionally have no relevant problem with this. bbi: Mr Juncker, thank you very much for the interview.

+++

MIXING SOLUTIONS for bread, pastries, cakes and snacking industries

RESEARCH

Improving the shelf-life of sandwich bread The average packaged bread that is found in a supermarket will probably have a useable shelf-life of two to five days, but this can be extended to ten days and beyond using modern preservation technologies.

© Liudmyla – stock.adobe.com

50

RESEARCH

51

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Bread is intrinsically a safe food that does not normally support the growth of food poisoning microorganisms.

Three factors limit how long bread remains fit to eat: moisture loss, staling of the crumb, microbial spoilage.

Tackling each of these can help improve the shelf-life of bread products; but, how is this done in practice?

Moisture loss Bread packaging mostly takes the form of polyethylene (PE) bags with twist ties or sealing tape to create a partial seal.

Waxed paper is another material that offers similar performance to PE. Products intended to be consumed the same day or the next tend to use cardboard and other plastics for their packaging. PE in bread bags provides a physical barrier to protect the bread but is limited in terms of the shelf-life it offers. Moisture loss takes place slowly by transmission through the thin PE material over a few days resulting in the crust drying out. As it does this, water is drawn from the crumb making the bread firmer. This is often confused with the firming of texture that happens over a similar period but is caused by chemical staling of the starches rather than physical moisture loss.

Longer shelf-life breads such as flatbreads use modified atmosphere packaging (MAP) to extend their useable life.

This requires thicker multilayer plastic packaging with barrier properties to slow the moisture loss and prevent oxygen from getting into the packaging and diluting the carbon dioxide atmosphere. There is also a need to chemically preserve longer life products.

Staling of the crumb All bread will become stale over time as the starches change their configuration after baking. This is a chemical change that involves the starch molecules attempting to convert their amorphous gelatinized form back into the original crystalline form. This makes the crust firmer and is easily confused with the firming that happens as the crumb dries out.

Staling can be slowed down by adding a type of amylase enzyme that changes the structure of the starch so it cannot recrystallize as easily. This group of bread softening amylases has attracted considerable attention from enzyme manufacturers and bakers. As enzyme technology has advanced, each generation of amylases works more effectively than the previous. Breads produced with these amylases have a softer and more elastic crumb and enable bread to retain its desirable textural properties beyond two-three days. Most packaged bread with a shelf-life over five days now contains bread

© Campden BRI

Here, I’ll put my many years' worth of experience in working on bakery products at Campden BRI to outline the techniques that will allow these factors that limit shelf-life to be addressed (much of the focus when establishing useable shelf-life is placed on slowing mold growth).

Figure 1: Strands of ‘rope’ in bread, caused by Bacilli breaking down starches to sugars

softening enzymes. The amylases are active during proofing and early stages of baking and are inactivated by the high temperatures reached in the bread. This prevents them from being active in the packaged bread.

Unfortunately, there is not a natural enzyme solution that retains the crumb softness for longer. Certain ingredients can be used to improve the initial softness. Higher levels of fat or oil, increased water content, and increased sugar will perform functions that retain softness for a bit longer. Fats and sugar, however, are not ideal for health reasons or as effective as softening enzymes.

Microbiological growth Most microbiological issues relate to post-bake contamination and these are very unlikely to be with food poisoning bacteria because of the limited handling of the baked products, particularly with larger-scale plant-produced bread. In addition, the times and temperatures achieved within the bread crumb during baking exceed those required to kill vegetative food poisoning bacteria such as Salmonella, Listeria and E. coli. Mold is the primary factor affecting the shelf-life of packaged bread, particularly in warmer conditions when mold will grow more quickly.

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RESEARCH

Molds can produce ‘spores’ as part of their life-cycle which are resistant to heat, light, dryness, acids and alkalis. They are released into the air in vast numbers and some will likely land on bread prior to wrapping. Conditions within packaged bread are ideal for the spores to germinate and grow. As they grow, they extend root-like threads into the loaf, extracting moisture and nutrients, helping them to grow into a ‘colony’.

Each colony can produce many thousands more mold spores.

Control of mold is essential in bakeries, strategies include: + Attention to bakery hygiene: Regular cleaning, equipment maintenance, hygienic design and positive air pressure within the bakery all help to control mold. Lower spore levels landing on bread surfaces reduce the number of visible colonies that will form, as not all mold spores are able to grow.

+ Product formulation: Chemicals based on propionic acid (or fermented alternatives) successfully retard mold growth.

The effectiveness of these can be increased by reducing the pH of the product (e.g. by the use of vinegar).

Post-bake technologies: Treatment with UV or high-in+ tensity pulsed light can provide a surface clean-up before packaging. MAP in combination with preservatives can extend shelf-life beyond 10 days.

Despite mold growth on crusts being the most common microbiological issue with bread, bacterial and yeast spoilage do occur on occasion. Spores from various Bacillus species are heat stable to the extent they will survive the baking process within the crumb. Bacillus subtilis is one of these and causes the spoilage condition known as ‘rope’. Rope occurs when, because of spore germination and growth, the amylases released by the growing Bacilli convert the structural starches into liquid sugars, breaking the crumb into a stringy mass (see Figure 1). A sweet fruity odor is associated with ‘ropey’ bread.

Control of rope requires vinegar and/or calcium propionate to be used in the recipe if its use is permitted in the type of bread being made which in general is only prepacked sliced bread. Vinegar lowers the pH below the level that Bacilli can grow, and propionate inhibits their growth. It is often thought that propionate is used to increase the mold-free shelf-life of bread but it is actually added to control Bacillus spore germination and growth. Its effect on slowing mold is a secondary benefit.

Bacilli will spoil the bread but not cause food poisoning.

With a typical retail shelf-life of five to seven days, the systems used by the industry are proven to be effective against all bacteria. However, as shelf-life is extended beyond this, there is a need to consider protection against more heat resistant and pathogenic bacteria, including anaerobic Clostridium botulinum. Longer life bread products tend to use MAP in carbon dioxide to control mold growth, however, it does not protect against anaerobic bacteria.

www.bakingbiscuit.com 05/2021

© Campden BRI

52

Figure 2: Chalk mold on a slice of bread

Flatbreads are a popular MAP product with market growth for clean label products and with the addition of herbs sprinkled on top, sometimes fresh. Our team at Campden BRI is currently setting up an industry project to challenge test the growth of C. botulinum in these flatbreads. The preservation system in bread is complex, requiring control of pH and preservatives effective against mold, yeast and bacteria. Natural preservatives must contain sufficient levels of active preservatives to control all the relevant microorganisms. It is important to know which ones can grow in bread with no protection and design the preservation system to prevent the growth of microorganisms.

Yeast spoilage of bread is rare but can occur from cross-contamination during bread cooling or slicing. It is confusing that this type of spoilage is known as chalk mold because of its chalky appearance (Figure 2) since the organism responsible is a yeast. Hyphopichia burtonii, Wickerhamomyces anomalus, and Saccharomycopsis fibuligera are spoilage yeasts that can cause chalk mold. Good attention to hygiene conditions around cooling and slicing is required to prevent this from happening.

Shelf-life determination With bread being technically a safe product to eat (in most cases) after expiry, its shelf-life is determined as a best before date (BBD). The target BBD is set as the last test date at which no mold is observed using the incubation temperature appropriate for the country of sale. In the UK, this is taken as 21°C, although a duplicate test at 25°C can be useful to represent home storage conditions during the summer months. The growth of rope-forming bacteria, should this be a possible issue, is likely to be faster at 25°C. The Federation of Bakers, who represent the UK baking sector, has a protocol for setting the BBD for bread. Before testing starts, a target BBD must be set, which is the anticipated date the bread remains mold-free. Twenty loaves are packed, preferably in clear bags, with loaves examined both visually and by opening according to the scheme in Table 1.

It involves examining four loaves each day to look for visible

RESEARCH

53

mold colonies. The test continues for the BBD +1 day or when one or more loaves are moldy.

© JackF – stock.adobe.com

Ideally, three consecutive shelf-life evaluations should be carried out to confirm the same BBD. In the event of mold being found on or before the BBD, the shelf-life should be reduced or further testing carried out following investigations into product formulation and plant hygiene. Table 2 shows example results where the target BBD was six days after production (P+6 days). +++

By Gary Tucker, research fellow, Campden BRI gary.tucker@campdenbri.co.uk Table 1: Testing scheme to set a BBD for packaged bread BBD -3 days

BBD -2 days

BBD -1 days

Target BBD

BBD +1 days

Accumulated loaves opened

4

8

12

16

20

Loaves to be newly opened

4

4

4

4

4

P+3

P+4

P+5

P+6

P+7

Mold Check 1

No mold

No mold

No mold

No mold

1 loaf has mold growth

Mold Check 2

No mold

No mold

No mold

No mold

No mold

Mold Check 3

No mold

No mold

No mold

No mold

1 loaf has mold growth

Source: Campden BRI

Table 2: Example results of BBD testing at 21oC to confirm a BBD of P+6 days

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Functional ingredients: What’s next?

Consumers increasingly favor better-for-you products and their additional spare time at home has changed the way they handle eating occasions. These changes are reflected in developments in the

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There are two important trends for the bakery industry that have intensified over the last 12 months. Firstly, consumers are becoming more conscious about their health, especially as they recognize dietary plans are not as healthy as they should be. Secondly, consumers have had more free time so they have adjusted their cooking habits spending more time in the kitchen. This has resulted in consumers looking to cook from scratch more and focus on nutrition, something that has led to people baking more/learning to bake. A back-to-basics approach to wholesomeness and nutrition is observed, as consumers turn to everyday food and drink that they know and trust, deem natural and nutritious and crucially, tasty and affordable. This is because people are reevaluating their dietary habits and are looking to maximize their intake of ingredients associated with boosting health.

In the case of bakery products, consumers are recognizing that options such as bread are beneficial as a source of fiber.

An opportunity for the bakery industry is to promote active health claims and ingredients on products, especially as consumers want products that are not just based around avoidance and moderation, but actively boosting health. Claims around ingredients such as fiber will be of high appeal, especially as consumers recognize the link between digestive health and immunity and linked to this, the benefits of fiber.

Ingredients and related ingredient claims are under scrutiny more than ever before. This also spells opportunity, as a variety of ingredients are associated with their role in boosting health.

Consumers are currently paying a high level of attention to ingredients such as vitamin C, omega 3, protein, probiotics and fiber. This creates the opportunity to promote functional and fortified ingredients in bakery products.

Functional ingredients with added benefits Consumers want to know more about the science behind health claims than ever before. This is because they are becoming more skeptical about health and wellness claims in

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The proportion of consumers who have sought out fortified/ functional foods and drinks more frequently in the last month

general and questioning the reality behind such claims made by brands. As such, transparency and authenticity are everything and brands should look to validate claims on the packaging – such as providing scientific evidence and information on packaging to validate them.

Nutritional labeling is included in information listed on the packaging that is causing skepticism as consumers are growing wary that it can be deliberately misleading to disguise certain ingredients. High-profile cases of hidden sugars in products are an example of this. As such, it is crucial that nutritional labeling is made as simplistic as possible. To help facilitate this, brands should look to focus on streamlining ingredients.

Clear label style packaging where information is easy to read on the front of the packaging is also helpful.

Probiotics are among the ingredients that have certainly reached consumers with information about their benefits.

People are becoming increasingly accepting of beneficial bacteria and cultures, especially as they become more aware of the related benefits. Moreover, they also now accept that beneficial bacteria content doesn’t compromise on sensory appeal. The popularity of probiotics has grown significantly in recent years, especially as more focus is placed on addressing digestive health and immune health and claims are popular across different categories, which is beneficial for the bakery industry. Postbiotics are currently something of a niche.

Fiber is a well-known ingredient, associated with aiding digestive health and aiding immune health. This is something that is especially appealing at a time when consumers are becoming more conscious about both and also believe that they directly impact each other. As such, ingredients such as fiber are in demand to address issues such as irritable bowel syndrome. In addition, fiber can also be associated with other benefits such as satiety-enhancing and energy boosting. This means that dietary fiber claims will grow in popularity over the next five years. +++

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bakery industry post COVID-19.

Source: FMCG Gurus

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Plant-based profits Consumers have come to expect plant-based products that are as good or better than the original, oftentimes without the use of ingredients that would break their idea of clean label.

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The term ‘plant-based diet’ has been circulating in the US since the 1980s without any formal definition, but now it is one of the trendiest topics in the food industry.

While it was originally used to describe a niche population following vegan diets, today ‘plant-based’ has evolved to mean anyone who is actively trying to reduce the number of products they eat that come from animals. Plant-based eating is often grouped with buzzwords like ‘flexitarian,’ ‘alternative’ and ‘better for you.’

A quick walk through the grocery aisles reveals ever-expanding product selections of alternative meats, dairy-free alfredo sauces and even egg- and dairy-free baked goods, all trying to capture a piece of the plant-based food market that is expected to reap a 19.4% compound annual growth rate (CAGR) over the next six years, according to Grand View Research. Underlying this rapid growth are trends that will gain momentum, and plant-based products should be considered as part of the new normal for doing business in a crowded bakery marketplace.

In a 2020 survey conducted by Archer-Daniels Midland, 44% of respondents said they were actively pursuing a flexitarian diet – which limits the consumption of animal products – going hand-in-hand with the ‘better for you’ market. Increases in plant-based eating are driven by a mixture of changing diets for three main reasons: health factors, dietary preferences and sustainability.

Consumers are concerned with high levels of saturated fats and cholesterol often found in animal products, and they are drawn to the fiber and disease-fighting polyphenols in plantbased products. People following a plant-based diet are also

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more likely to be concerned with their total protein intake, so product lines that feature plant-based protein are particularly important on the health front.

For bakeries, an important segment of consumers who care about health factors include the 8.7 million Americans with allergies to egg and dairy, two of the hardest ingredients to remove from baked goods. However, taking out eggs and dairy is not enough to gain the halo of being plant-based. Even though many baked goods are already part of a plant-based diet, these products also need to be clean-label and ideally include a unique plant ingredient, such as cauliflower for pizza crust and spinach in wraps, to have the positive associations consumers are looking for.

Dietary preferences as the result of religious beliefs, as well as shifts toward vegetarianism, are also driving the plant-based market, with 61% of females and 60% of males ages 18-34 reporting that that they sometimes or always eat a vegetarian diet, according to a 2019 Harris Poll conducted on behalf of the Vegetarian Resource Group.

The enormous increase in sustainability that comes from eating a plant-based diet is also driving this trend. A 2019 assessment from the University of Wageningen found that eggs and dairy require 4.5 lbs. of protein in feed for every pound of protein produced. The production of animal proteins also requires huge amounts of water and generates significantly more greenhouse gases when compared to currently available plant-based alternatives. These factors are an area of public concern, as topics like climate change and water scarcity become increasingly top of mind, particularly with younger audiences.

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This means that products need to maintain the chewy, creamy and fatty textures that milk and eggs provide without compromising on flavor or a clean label.

It may be challenging, but if replacements are chosen carefully, the substitution of animal products for plant-based options not only allows bakeries to capitalize on a new market, but it also gives them a chance to make new health claims in other trending categories including high fiber and high protein.

This is because many of the best available egg and dairy replacers come from companies that have developed novel ways to process pulses, seaweed and even mushrooms to engineer new ingredients that provide sources of functional fiber and protein.

Pulses are legumes – including peas, lentils, chickpeas and other common beans – which are not primarily used for oil.

These plants conform to all the market drivers for plant-based diets including sustainability, health and wellness, and other dietary preferences. They are naturally sustainable, requiring less water than many other crops, and they also fix nitrogen in the soil, reducing the need for fertilizers.

With as many as 1 million species to choose from, the applications of algaederived ingredients include antioxidants, antibacterial ingredients, mold inhibitors and texturizers.

Additionally, pulses do not have any known allergens.

They have exploded in use in the past five years, spurring companies like Ingredion, Cargill’s PURIS and Roquette to dramatically increase their product lines of pea protein for use in meat and dairy imitation products. Today, pulses now make up one of the biggest shares of the USD1.4 billion egg replacement market, quantified by Market Data Forecast. This has helped reduce the price of pea protein and spawned secondary markets for flavor maskers specific to hiding the earthy and beany flavor that pea and other pulse proteins can have.

Pea protein and other pulses including lentils have shown their potential in bakery applications. Due to their unique amino acid composition, pulses form complete proteins when partnered with wheat, which opens the door for “excellent source of protein” claims when using these functional ingredients in reformulating baked goods. Pulse proteins have also been found to help replace the emulsions and gels that eggs form in cookies and cakes, maintaining the texture that consumers are looking for.

Pound for pound, pulses are the cheapest source of the protein on the planet, and as production continues to ramp up for these products, they can reduce the final cost of baked goods in an environment where the price of animal-based products is often volatile and increasing.

60%

61%

61% of females and 60% of males ages 18-34 said they sometimes or always eat a vegetarian diet

Aside from their protein, pulses also have unique fibers which can be good replacers for eggs and dairy. Aquafaba, the wastewater from producing chickpeas, creates the best alternative currently available for the foaming seen in egg whites in applications such as vegan meringue and meringue powder.

On top of pulse fibers’ ability to make plant-based baked goods, they also add fiber, capitalizing on the trending gut health market.

Companies like PeaTos are using blends of pulse flour and protein isolate to make high-protein and high-fiber chips, while Barilla, the world’s largest pasta maker, has launched pulse-based pasta with various shapes and textures made from red lentil flour and chickpea flour, as well as high-protein pasta featuring pea protein.

Since consumers are already comfortable with seeing things like pea protein, fava bean fiber and other functional ingredients on product labels, the pulse market in baked goods will continue to increase. This high level of consumer acceptance, low cost of ingredients and high levels of sustainability make pulses an important cornerstone in any plant-based product lineup.

There are options other than pulses for replacing eggs and dairy in the bakery aisle though, and seeds including quinoa, flax and chia can all be part of a plant-based strategy.

Ardent Mills launched its Great Plains Quinoa program in 2017 and since then has expanded its quinoa lineup to include ingredients intended for extruded products, bars, biscuits and more.

Like pulses, quinoa benefits from strong consumer acceptability, and it is a complete protein, which can help achieve excellent source of protein claims for new product lines.

Quinoa also contains functional fiber, which can be included to replace certain textures in baked goods, as well as reel in

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Source: Harris Poll

Capturing a piece of the growing plant-based market means reformulating indulgent snack cakes and fillings without the use of eggs or dairy.

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adding vegetables to traditional baked goods is another strategy to gain entry to this thriving market. Sweet potatoes, cauliflower, kale, bell peppers and more are all starting to work their way into the baked goods aisle in the form of a partial replacement for flour or even as part of a gluten-free product.

Going plant-based REMOVEÒ Eggs Dairy

Ë

ADD

Pulses Seaweed Vegetables

If done strategically, you can capitalize on plant-based eating, and trends including foods for neurological and gut health

health-conscious customers. Chia and flax seeds are both growing markets in the US and globally and, due to unique carbohydrates, have shown benefits in increasing shelf life in baked goods while also giving a boost in fiber.

They can also be part of egg and dairy replacement strategies, as they have been shown to improve texture in cakes and cookies made without eggs and dairy. Flax is also high in omega-3 fatty acids, opening up the potential for market claims on what is expected to be one of the top trends in 2021 and 2022: foods that promote neurological health. Chia and flax also enjoy high levels of consumer acceptability, and many people group them in the ‘superfoods’ category, which includes ingredients that are particularly nutrient dense.

Some other superfoods such as seaweed have been used for years in the baking industry. They’re often applied in the form of their extracted components carrageenan and agar, but some food manufacturers are now looking at the many other benefits imparted by seaweed.

With as many as 1 million species to choose from, the applications of algae-derived ingredients include antioxidants, antibacterial ingredients, mold inhibitors and texturizers that can aid in replacing eggs and dairy or adding extra nutrition to products. Their bright green or sometimes red colors can also be used as natural sources of color. Additionally, some species contain up to 47% protein.

Seaweed is also considered even more environmentally friendly than pulses, given its incredibly fast growth, removal of carbon dioxide from ocean water and the air, and the fact that they do not require fresh water and fertilizer inputs to grow. These are factors driving the expected 9.7% CAGR for seaweed over the next six years, based on a report from Mordor Intelligence. Companies like Dupont and Cargill and are the largest producers of seaweed powder and blends, and aside from carrageenan and agar, baking companies primarily add seaweed to crackers and other snack goods for an extra kick of umami flavor and to provide unique colors.

While the egg and dairy replacement markets are the most obvious opportunities to capitalize on plant-based additives,

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Source: Harris Poll

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Consumers are increasingly drawn to low-carb and betterfor-you options, and using a vegetable flour to add flavor and color can help catch the shopper’s eye. These color changes are often sought out by those looking for plantbased options. ‘Going green’ can help signal to consumer that you’re also making commitments to sustainability, and these positive associations with natural colors are becoming more popular.

Veggie products have been particularly present in the frozen aisle, where companies like Conagra and Green Giant now offer pot pies and pizza crusts made with cauliflower. Developing strategies around these sorts of ingredients can be another strong entry point for companies trying to figure out how to get into the plant-based market.

Reformulating for the plant-based consumer can be challenging, but the time and effort involved is well worth the potential gain. Providing a diversified lineup of plant-based offerings can help your bakery move toward sustainable and clean-label products that taste just as good as the original.

Ingredients like pulse protein, functional fiber from seaweed and whole flour from pulses can be part of replacing the eggs and dairy in baked goods, and they are already accepted by consumers. Adding these ingredients can also help capitalize on other trending categories like food for neurological health, gut health and benefits from high protein.

Going plant-based can help your bakery capitalize on the new normal, making healthy and sustainable products that consumers feel good about eating. +++

About the author Harrison Helmick is a PhD candidate in food science at Purdue University. His research includes uncovering new structure-function relationships of plantbased protein. Prior to his Purdue studies, he worked as a production supervisor and continuous improvement supervisor at Bimbo Bakeries USA.

Content provided by Commercial Baking magazine (Avant Food Media)

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N E W R AW M AT E R I A L S

Functional ingredients go vegan Health- and sustainability-conscious consumers determine that bakeries follow suit and reformulate products to be better for you while still preserving their indulgence characteristics.

When baking vegan goods, specialty functional ingredients provide the answers to having the best of both worlds.

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Conventional fine baked goods such as cakes, muffins and brioche are traditionally made with animal-based ingredients like egg, milk or butter. Replacing those ingredients is directly linked to poor product performance: the crumb texture will lack cohesion and elasticity, resulting in unstable, crumbly products with low volume and deficits in taste and appearance. Developing vegan bakery products requires a good understanding of the functionality of animal-based ingredients in fine bakery wares. Several functionalities of egg or milk products, such as emulsifying, foaming, texturizing and stabilizing properties, must be provided by other ingredients in order to achieve excellent vegan products without compromising the texture or sensory profile. Furthermore, the ability to use established production processes is important for bakery manufacturers, because they will not need to make any major changes to produce these vegan solutions. At the same time, the challenge is to offer solutions that will allow manufacturers to produce vegan solutions economically.

Cyclodextrins for vegan cakes A functional ingredient that can also be found in nature provides the solution to replacing eggs in vegan baked goods: Alpha-Cyclodextrin, an oligosaccharide derived from starch. It consists of six glucose molecules linked together to form a ring. The secret of cyclodextrins lies in their unique molecular structure, a donut-like shape. The exterior shell of the molecule is hydrophilic (water-soluble) on the one hand, while the inner cavity, on the other hand, is lipophilic (fat-soluble). This structure enables the cyclodextrin to interact with lipophilic components like residual fatty acids

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from triglycerides. The resulting cyclodextrin-triglyceride complex exhibits excellent ‘in situ’ emulsifying properties and stabilizes the oil in the batter – a job usually performed by the lecithin in egg yolk, which stabilizes the batter in conventional fine baked goods and ensures an even distribution of fat.

CAVAMAX® W6 developed by WACKER can be used for egg-free or vegan baked goods to provide excellent crumb texture, volume and a taste profile similar to that obtained with the animal-based counterparts. It is a water-soluble dietary fiber with no taste or odor of its own. The free-flowing white powder can be easily dosed together with dry bakery compounds and it does not require major adjustments when including it in existing production processes.

Alpha-cyclodextrin consists of six glucose molecules linked together to form a ring

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Beyond its emulsification properties, this Alpha-Cyclodextrin also improves cake crumb texture by interacting with other ingredients of the batter such as proteins and carbohydrates. The usage of cyclodextrin significantly increases cake crumb cohesion and elasticity and ensures adequate crumb firmness, which has a clearly noticeable positive effect on the sensory characteristics of the final baked good. Due to its multifunctionality, CAVAMAX® W6 can be used for partial or total egg replacement in combination with either whey protein concentrates or plant-based protein sources. It is suitable for many applications such as pound cake, sponge cake, muffins and sweet dough products.

Vegan dough conditioners: L-cysteine To standardize the flour and improve the dough’s processability, flours can be treated with enzymes, oxidants or reducing agents like cysteine. The use of L-cysteine is especially common in strong flours, where it reduces the disulfide bonds of the gluten network to weaken it. This results in a softer dough with lower viscoelastic properties, greater extensibility and improved workability. Extensibility and reproducible stretchability are key parameters for tortilla and pizza dough processing, which are becoming more and more industrialized. In addition, proper elasticity is needed to prevent these products from shrinking or curling after they are shaped. Improving dough extensibility with cysteine is also valuable for numerous other yeast and chemically

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Utilization Several formulation guidelines for egg-free and vegan baked goods have been developed in WACKER’s food labs. In muffins, pound cake or brioche, the combination of CAVAMAX ® W6, protein and water can completely ® replace egg or the animal- CAVAMAX W6 is a water-solubased ingredients normally ble dietary fiber with no taste or odor of its own. The found in those products. In free-flowing white powder can a vegan muffin formulation be used in existing production tested by WACKER, the processes with no need for Alpha-Cyclodextrin is com- major adjustments and can bined with almond or pea easily be added to dry bakery compounds protein, for example. Water and oil levels have to be adjusted to achieve the desired batter properties. Adding hydrocolloids to work together with CAVAMAX® W6 will help to further finetune product performance.

© WACKER

WACKER produces the oligosaccharide at its site in Eddyville, Iowa, via an enzymatic process that converts plant starch to cyclodextrins. The site began producing cyclodextrins in 1999, and development has been proceeding steadily ever since.

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N E W R AW M AT E R I A L S

plant-based vegan alternative: the FERMOPURE® L-cysteine, which is based on a fermentation process with an extremely low environmental impact. Inorganic source materials and glucose from plant starch are used as raw materials. It is manufactured at WACKER’s fermentation site in León, Spain. Since FERMOPURE® is manufactured from purely plant-based raw materials, this cysteine is halal, kosher and vegan, making it ideal for all specific dietary requirements.

Under its FERMOPURE® brand, WACKER offers ultrapure cystine and cysteine products made exclusively from plant-based raw materials. Cysteine is commonly used in baked goods, for example

leavened applications, including cookies, saltines and other crackers. L-cysteine as a dough conditioner helps the baking industry optimize the throughput of its baking lines. It improves machinability and may therefore reduce mixing as well as proofing times, while providing uniform and standardized products.

The amino-acid cysteine is traditionally obtained from human or animal sources such as hair, feathers or pig bristles with the help of hydrochloric acid. For decades, there had been no substitute for it. WACKER was the first to introduce a

© WACKER

As an additive in baked goods, cysteine makes it easier to handle and shape the dough, which has several advantages throughout the entire production process. It is particularly important in applications where a specific shape of dough is required, such as croissants, cookies, tortillas or pizza.

Highly automated baking facilities benefit from the addition of the amino acid because machines can process the dough properly, resulting in uniform products. In addition, cysteine is of great importance for deep-frozen dough products, as it can partially counteract the negative effects of the freezing process. Furthermore, cysteine increases the gas holding capacity of the dough in the production of toast, buns and baguettes, allowing baked goods to retain their voluminous shape over a longer time and enabling the control of the oven spring. +++ By: Yvonne Haslauer, Food Ingredients Technical Expert, WACKER

ADVERTISER DIRECTORY

Oreo Zero debuts online in China

Mondelēz partnered with MissFresh, a leading online fresh grocery retailer in China, to release Oreo’s new range of sugar-free sandwich cookies – Oreo Zero on the platform. The retailer is growing its selection of more nutritious and healthier choices to its app and WeChat Mini Program users. Oreo chose MissFresh as its online retail partner for the launch to leverage the popularity of the platform’s speedy grocery delivery service (39 minutes on average) with its established customer base of quality-focused young shoppers in China, according to the announcement made at the end of August by MissFresh.

To mark the Oreo Zero launch, MissFresh held an Oreo Super Brand Day on August 17. The new sugar-free Oreo Zero range offers two flavors: Oreo Zero Cookies, which have the classic OREO Chocolate Sandwich Cookie taste, and rose-flavored Oreo Zero Thin Cookies - 40% thinner pieces.

MissFresh has worked with Mondelēz International, Inc. for several years and stocks its popular brands such as Oreo and Chips Ahoy!. The two companies have collaborated for marketing projects, such as Super Brand Days organized by MissFresh over the last year to promote Mondelēz products.

In addition to Mondelēz offerings, the Super Brand Day events featured more than 20 other brands. While MissFresh’s core revenue has historically come from fresh produce, the company is expanding the diversity of its product range to include fast-moving consumer goods. Figures from March this year showed that fresh products accounted for 58% of gross merchandise value (GMV), while FMCG accounted for 42% of GMV.

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