baking+biscuit 2023-05 digital

Meet Kwik Lok's

05 23

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Tunnel ovens

In the spotlight

iba ’23 special

Efficient baking assignment

Bundy Baking, American Pan interview

Exhibitor innovations, state of the industry

EDITORIAL

The road to sustainability: the Munich waypoint Vatter Bakery in Germany received a gas bill of EUR 75,000 last year, which was an increase of over 1,200%. The year before, it paid EUR 5,856 per month for the energy going into its ovens and heating. Bakeries in the UK saw a wave of workers departing the industry for career changes during the pandemic, leaving an even bigger gap in the workforce. In France, butter prices doubled in one year, a surge that accelerated from the second half of 2021. By June 2022, butter peaked at EUR 7,900 per ton. By comparison, the same quantity was sold for EUR 2,705 in May 2020 in the country with the biggest dairy industry in Europe, after Germany. In the US, BEMA was painting a picture of a struggling industry throughout the supply chain in 2022, with a lack of raw materials for manufacturing, components for equipment and the workforce needed to meet customer demands.

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

Simultaneous shortages and complex disruptions can be all traced back to an underlying need for the industry to profoundly transform and become truly sustainable – and do so under the ticking clock of an impending closure.

Solutions exist that help baking operations become more sustainable and provide answers to all of these different troubles. Success stories are everywhere, to prove that sustainability works and it’s not just an environment-friendly strategy, but also a profitable endgame. Besides, it is simply the only alternative.

Sustainability is one of the main topics at iba this year, too. Messe Munich will be home to novelties that can help save energy, time and resources, bring better packaging alternatives and cleaning methods, and ingredients with functional benefits. The German Bakers’ Confederation sees a saving potential of 15-30% for baking ovens and 15-40% for cooling equipment, for example. In addition to high-end technology innovation that champions sustainability, iba.START UP AREA will give new concepts a chance to convince of their potential. Here, WECARRY will be showing how to avoid waste by reducing disposable packaging. The WECARRY reusable bags for bread and bakery products in a deposit-based cycle are the first reusable system for bakeries.

Sustainability continues to be at the core of our investigations, too, in our effort to bring you the latest and most promising new concepts, in the pages of our magazines. For the past year, we have also been gathering these perspectives in a brand-new book in our ‘specialty topics’ series, titled ‘Sustainability and innovations supporting it’. We hope you enjoy reading it and adding it to your f2m book collection.

See you in Munich, and have an excellent iba, everyone!

Catalina Mihu

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CONTENTS

HIGHLIGHTS

06 © Bundy Baking Solutions

16

©AMF Bakery Systems

COVER STORIES

IT’S THE PERFECT TRIANGLE! Royal Smilde is known for its rich diversity of sweet and savory baked creations. Either sold under its own labels, through collab-

BUNDY BAKING, AMERICAN PAN INTERVIEW

orations, or as private labels, the products made by the Dutch

William Bundy – Global President, Operations,

bakery are in growing demand worldwide.

Bundy Baking Solutions, and Jason Bowman – President American Pan Europe & MENA talk resilience, acquisitions, technology and, first of

©HEUF T

22

38

© FomaA – stock.adobe.com

all, loyalty, in an interview.

PIZZA: KEEP THEM COMING! At home or at the restaurant, for lunch, office parties, or even

EFFICIENT BAKING ASSIGNMENT: TUNNEL OVENS

for breakfast, ordered in person or online, the interest in pizza

Energy consumption is undisputed at the top of the

choices never fades. On the contrary, new, exciting taste offerings,

industry’s concerns and efforts for improvement.

product claims and ingredient combinations are welcomed

Tunnel ovens offer opportunities to go the extra

opportunities to experiment.

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58

A PIVOTAL MOMENT IN THE BAKING INDUSTRY iba and the German Bakers’ Confederation analyze current dynamics in the industry and the future of baking innovations, exploring possible and necessary directions, as they prepare to welcome

SOLVING UNEXPECTED QUALITY ISSUES IN BAKED GOODS

an industry reunion in Munich.

A systematic approach to fast and economical problem resolution.

www.bakingbiscuit.com 05/2023

© ttz Bremerhaven

mile on the path to resource savings.

© GHM

04

CONTENTS

Media to the global baking industry

BAKERIES 06

Royal Smilde, the Netherlands: It’s the perfect triangle!

IN THE SPOTLIGHT 16

Interview: William Bundy – Global President, Operations, Bundy Baking

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

Solutions, and Jason Bowman – President, American Pan Europe & MENA PRODUCTION 22

Tunnel ovens: Efficient baking assignment

30

Breads, buns: No-stress dough processing

ROBOTICS 34

DIOSNA: Dough on the go with AGVs

36

Syntegon: Automated Intelligent Direct Handling

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

Published six times a year in the English language.

PIZZA LINES 38

AMF Bakery Systems, Rademaker: Keep them coming!

IBA 23 SPECIAL 44

Analysis: A pivotal moment in the baking industry

48

Exhibitor highlights, part II: It’s not a sprint, it’s a marathon!

SCIENCE 58

ttz Bremerhaven: Solving unexpected quality issues in baked goods

64

Grainar: Physical, chemical and rheological changes in bread during dough mixing

68

KPM Analytics: An automated method to hit the ‘sweet spot’ in cookie

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

flour quality MARKETS 72

FMCG Gurus: Healthy snacking trends in the bakery market

SUSTAINABILITY 74

dsm-firmenich: How do we build a better baking future? From communal bakehouses to biotechnology

TRENDS 76

Dawn Foods: The sweet tooth meets the better-for-you mindset

Editorial: The road to sustainability: the Munich waypoint

35

News

78

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

FOLLOW US!

f2m food multimedia GmbH Ehrenbergstrasse 33 22767 Hamburg Germany

f2m food multimedia

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Dictionary of bakery terms

REGULARS Dictionary of bakery terms Dictionary of bakery terms

English

ENG

Wörterbuch der Bäckereitechnik

German

DEU

Dictionnaire des termes techniques pour la boulangerie

French

FRA

Glosario de términos sobre tecnologías de panificación

Spanish

SPA

Термины хлебопекарной индустрии

Russian

RUS

Ordbog over bageriudtryk

Danish

DAN

Japanese

JPN

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

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ram .c o w.in s ta g

m /f o o d 2

multim e

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BAKERIES

Royal Smilde’s AMF pastry line setup – AMF Tromp units:

+ Pastry dough sheeting and make-up line + Tromp depositor for cheese and meat fillings (also suitable for vegan products)

+ Tromp depositor for apple filling + Special robot folding unit for apple turnovers + Sugar decoration station + Spraying water or glaze before freezing products + Tromp waterfall applicator for cheese topping + Egg-wash spinning disc

© AMF

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BAKERIES

It’s the perfect triangle!

Royal Smilde is known for its rich diversity of sweet and savory baked creations. Either sold under its own labels, through collaborations, or as private labels, the products made by the Dutch bakery are in growing demand worldwide. A very flexible production line helped them increase production volumes, built by AMF Bakery Systems (Tromp). Particular care was given to automating apple turnover production, namely – dough folding into a triangle.

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From its production facilities in Edam, Bolsward and Roden, Royal Smilde Bakery supplies bakeries, retailers, food service and end consumers in the Netherlands and its reach goes well beyond its home market, extending from European countries to the US, the Middle East, South Africa and even goes as far as China. Its portfolio includes unique offerings for each industry segment – for example, its popular apple turnovers are sold to retailers, sausage rolls in food service, and ready-to-bake mixes are sold in supermarkets for at-home preparation.

Smilde started as a butcher shop in 1863 and entered the bakery world with the acquisition of Pruvé in 1981, a brand specializing in savory and sweet snacks and semi-processed products for bake-off. Part of a company that has an impressive portfolio of 1,800 food products, which include baking mixes, oils, fats, salads, and sauces, the bakery is a growing business with an expanding distribution range. It is an experienced baker of traditional snacks who also embraces new trends: meat snacks are an

important specialty, but, Smilde has also included vegetarian and vegan creations in its offerings. Better-for-you specialties are also an important segment in the company’s recent R&D focus, to meet the consumers’ evolving interests: clean-label products, smaller portion sizes, low-sugar and low-salt alternatives. The Nutriscore has not officially arrived in the Netherlands yet, but the company is preparing for it: “We are looking into reformulating our snacks to fit into a better Nutriscore category and also at developing new snacks with a Nutriscore of A and B,” shares Nynke Hopmans, NPD & QA Manager, Royal Smilde.

At its Edam plant, Smilde Bakery makes flaky pastries and meringue, as well as various sweet and savory snacks alongside puff pastry tarts, meringue and creamhorns. In Bolsward, shortbread with various filling options is produced.

Pastry snacks are an important segment of the product ranges it produces. Consumers in the UK enjoy Smilde's creamhorns, while in the Netherlands, apple turnovers are

www.bakingbiscuit.com 05/2023

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BAKERIES

© AMF Bakery Systems

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the most popular offering in this category, followed by sausage rolls, frikandelbroodjes, kaasbroodje (cheese rolls) and another popular Dutch specialty – gevulde koeken (cookies with almond paste, crumbly on the outside and soft on the inside).

Wanted: a new and improved pastry line As the company celebrates 160 years in the baking business this year, it has done so with an auspicious investment: a new production line – its biggest running line, tailored to its needs, now automates processes for the manufacture of sweet and savory snacks and pastries. It currently produces mostly apple turnovers. AMF Bakery Systems (Tromp) designed the turnkey pastry line, according to the manufacturing needs in Edam, for the large volume make-up of sweet and savory products. The main products produced on this line are sausage rolls, apple turnovers and cheese rolls. It can also be used for other products, including frikandel rolls, cherry lattice and apricot snacks. In this way, the main product manufactured on the line can easily be switched at any time, to suit changing or new contracts, explains Jeroen Van Dijk, Manager Operations, Royal Smilde Bakery.

In the concept stage of this project for a pastry line, Smilde checked alternatives from several suppliers. Out of them, AMF was the provider who offered the opportunity to build the custom solution for apple turnover folding, as its specialists observed the manual processing stage in Smilde’s factory. This feature was the decision-maker for Smilde. The challenge in this automation concept was delivering artisan-style folding, where the edges are not perfectly aligned, but are slightly overlapping. Manual folding is, in itself, a technique that requires skill to perform.”Not everyone can make apple turnover. The dough needs to be folded, but never stretched,” Hopmans explains.

As the dough slightly shrinks after baking, the piece of dough is not a perfect square until the end of the process,

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Royal Smilde Bakery product portfolio:

+ Savory snack categories: cheese rolls and sticks, sausage rolls, vegetarian snacks

+ Sweet snacks: a wide range of products under the Pruvé brand, private label products such as apple turnovers, apricot turnovers, filled cakes

+ Pies and and tart bases from short crust, puff pastry or meringue

but a rectangle. A certain way of folding is required, so that the two overlapped layers remain together after baking and do not turn their separate ways, which would result in a sub-standard product shape.

The previously used line had no room for automation, and therefore a new line was needed so the bakery could produce more volume. Tromp's line came with a customdesigned robot folding solution, which automated the procedure previously done by hand. The folding unit performs 20 folds simultaneously for standard apple turnovers and artisan-style turnovers, freeing valuable employee hands for other operations in the plant. And robots never get tired, nor do they make mistakes.

Robotics were also deployed for tasks at the end of the line, to place products in boxes. Sustainable processing also played a role in investing in a new line: “We focus on minimizing waste and the new line delivers this, with its improved performance in using raw materials: it rolls the dough more gently and it performs straight, clean cuts of the edges of the dough. Because the dough sheet is rolled better, the edges also have fewer fluctuations that need to be cut off,” Hopmans explains. All the scrap dough is also collected and brought back to the dough reduction station with an automated conveyor. It joins the fresh dough at the start of the line, and reenters the process, further lowering

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BAKERIES

significantly higher capacity and speed that would still preserve the characteristics of the dough through production.

Gentle dough handling to the level of reduction required was the topic of discussion, Hopmans recalls. To achieve this, dough rollers were tested extensively, at AMF’s suggestion for the task. Too much of a good thing should also be considered: some pastries were first visibly puffier than before, thanks to the stress-free dough handling, so the process had to be slightly tweaked to maintain the established product characteristics.

Being able to switch between required processes for product changeovers was also on the priority list. No tooling is needed, and no heavy lifting is required when switching production to a new range.

© AMF Bakery Systems

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waste. Lex van Houten, Regional Marketing Manager, AMF Bakery Systems, explains the process: “The bottom layer is always fresh dough and a layer of scrap dough is placed on top of it, to be rolled out together to form a new sheet.

In this way, the resulting product will consistently have the required properties and retain its quality.”

The old line has not retired, either. For even more production power, it remains active and still proves useful, as it is flexibly running specialty or seasonal products, as well as smaller orders that do not require such laborious manual processing as apple turnovers. The setup of the old line was the ’baseline’ – the original concept that Smilde wanted to work with and enhance with automation features, when it envisioned the new line. “The new line is producing every day in a full three-shift program, 15 shifts per week, while the old line runs 3-4 shifts in a week,” Van Dijk shares the new, optimized production schedule. Footprint was also an issue, and AMF was able to design a more compact machine.

A work in progress starts with a very long wish list The final design of the line is a result of a collaborative project: a group of Royal Smilde people with diverse specializations worked together with AMF’s team, to gain a common understanding of what this line should look like – combining what it needed to accomplish, and what features they would like put into an effective machine design.

From the old line, the bakers knew that they needed a

www.bakingbiscuit.com 05/2023

The line development project was completed over the course of one year. In this time, personnel planning and raw material planning were also carefully perfected. An optimum baking agenda was established: first, the products that use fresh meat; then, it’s the fruit products, and the cheese products are last. Ideally, one type of product is processed per shift, for the best balance of volumes vs. changeovers. In this way, if production needs to stop for any reason, there is less chance that it will occur while working with the more sensitive, expensive materials: the cheese can simply return to cold storage, whereas meat handling is never so simple when it comes to downtimes.

The pastry dough rests for a minimum of two hours before being brought to the production line, by hand. The pastry line automates make-up and sheeting processes. The products are then cooled and packaged. Quality control is performed throughout, and the products are ready for warehouse storage. “The entire process is now about 90% automated,” Van Dijk estimates.

Looking at the bigger manufacturing-improvement picture, the pastry line investment was the final stage that completed the overall revamping of the production process.

First, a new construction was finalized, to house the new line and offices. In it, first arrived a new dough line that is used to feed all production lines in the factory; creating a higher capacity that would match what the new line could process was a necessary upgrade. A new spiral freezer was also installed and an automation solution was put in place for the facility. A mixer for the fillings completed the equipment lineup at the new production site. Altogether, the expansion was developed over the past three years.

A close-up of the pastry line Every technical aspect of the line was weighed against the production wishes that Smilde had on their list. An important priority was the automated folding feature for apple turnovers; but, hygienic design and sustainability were also

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© AMF Bakery Systems

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important and could have several design interpretations, which were all analyzed by Smilde together with AMF’s team of specialists.

“After several personal meetings, where our Executive Product Manager Hans Besems was involved, we designed the line’s architecture, a unique system for Smilde,” van Houten also says. Its features prioritize the safety of the people running it, and ease of cleaning and operating.

Requests regarding the machine’s hygienic design were integrated as early as the first conversation stage, especially stringent since there is meat processing involved in the routine production flows. Also, being able to clean the line daily with water was an important consideration. It may not be among the frequently asked requests in the baking industry, but Smilde wanted to ensure safety in its work with many fresh ingredients, which pose a high risk of contamination. Factory acceptance tests confirmed that the design was what they had been looking for. What’s more, the depositors used for fillings can be wheeled out from the line and thoroughly, washed down in a dedicated room.

To minimize downtimes, the bakery uses two depositors, to simply replace the one that needs washing and continue production with the other. The same method is employed for the egg applicators. Cleaning is carried out after every meat processing cycle, and every time the type of ingredients used changes. When using equipment that decorates products with egg glaze, it is cleaned every eight hours. A more thorough cleaning of the machines and the production hall is scheduled every Saturday.

There is an added benefit to the design when meat is a part of the production cycle: absolute safety. Meat cannot go over 7°C during production, under any circumstance, Hopmans points out. The improved production flow ensures that the meat is immediately processed as it comes out of the cooler, with fewer disruptions. It also goes faster through the production chain and then is safely frozen. Moreover, the environment surrounding the line can be easier controlled to lower the temperature when needed, to maintain the meat

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within the required conditions. All of which add up to passing any inspection visits with flying colors, too, Van Dijk details.

The processing speed also helps preserve the ingredients for food safety: “We can go from making the filling, with better control, to freezing the filling in under 20 minutes. It’s all high-tech,” Hopmans says.

The line can be used for all the pastry products in Smilde’s catalog, as well as Danish pastries. “The make-up section offers generous flexibility in making various shapes, sizes and fillings, as well as many decoration options. In this way, a lot of creative opportunity is open for New Product Development,” AMF’s specialist details. The line can be later upgraded as needed, too: a laminator can be placed in front of it, for example. Smilde has this station in a different hall at the moment, from where it brings laminated dough blocks to the pastry line. “Make-up, decoration, various product shapes and sizes – everything can be done with standard or optional extra equipment,” van Houten explains.

“The Tromp sheeting and make-up line is a standard AMF portfolio solution, used in many pastry factories and bakeries around the world. But, the line Smilde uses was engineered specifically for them, to meet special hygienic design requests. For example, there are no flat areas that would allow the build-up of waste, dust and bacteria,” van Houten adds.

The same goes for the depositors Smilde also chose for their facility, in terms of hygiene standards. They are capable of working with different ingredients, including meat, cheese, apples and even vegan fillings.

The characteristic of the line that is unique to this bakery is the automated folding unit, tailored to its various apple turnover products. AMF had experience with designing an automated process of folding a square piece of dough diagonally, into a triangle shape. Automating the process of folding a square dough piece into a triangle (folded), was a known concept we had designed before. Van Houten: “We built the proof of concept for the dimensions and sizes that Smilde needs, based on the technical

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BAKERIES

© AMF Bakery Systems

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information our team learned from their visits to the factory, where they gained an understanding about the process and products, ingredients and dough characteristics.”

Smilde’s team shared their views on the results of the robot tests, until the process was perfected.

also split some allergens between the two lines – for instance, recipes with peanuts can be produced on the old line only. In the same way, Smilde can also guarantee that vegetarian and vegan specialties never come into contact with equipment where meat was processed.

Things that change and things that must stay the same

Since the new line started running, new products have already been tested and perfected: products with a fixed, smaller width, which are served as in-flight snacks, and new fillings with scrambled egg. These and other more challenging fillings such as those with fruits can be developed thanks to the higher dosing accuracy, compared with the previous line.

The finished line was first installed at AMF’s Gorinchem headquarters, where Smilde traveled for the factory acceptance test. A site acceptance test followed, conducted by a joint AMF/Smilde team. Testing began with one-shift production runs daily, for around six weeks. Various ingredients also went through testing gradually: sausage rolls for the first week, fillings, then the cheese, followed by apple turnovers. “We learned a lot from this process, when the only variable was the type of ingredient, rather than changing several parameters at the same time. The goal here was to perfect the process without altering the recipe.

We cannot have recipe changes,” Hopmans underlines.

This requirement included the number of products in each package and packaging codes, for delivery and logistics reasons.

The old line and the new line produce exactly the same apple turnovers or sausage rolls in this way. The changes stayed in the production facility and the consumers enjoy the products they know, unaltered – just easier produced, and in higher volumes. Certain processes required some adjusting for automation on the new line, such as quiche manufacturing. Since the start of 2023, the bakery has been working with the line at its full capacity, in three shifts.

In with the new!

Another welcomed benefit of the new pastry line is that it allows the NPD team to try out things they were not able to before: “We can add more volume to the products, so new products can be made with fewer grams of dough,” Hopmans shares an example. With the new setup, they can www.bakingbiscuit.com 05/2023

The new line is also open to more improvements over time.

The AMF Tromp sheeting and laminating line has low energy needs, because of the gentle and stress-free reduction of the dough, for which extreme force, respectively energy, is needed. “Using efficient and smart motors optimizes the performance of this line, doubled with preventive maintenance to avoid breakdowns,” AMF’s specialist explains.

Smart software helps with monitoring motors, to compile performance trends and identify possible problems on time.

“This is not a solution that Smilde has already included in its current setup, but it is a possible goal for the future, to make the process more reliable and sustainable,” van Houten underlines.

After-sales support continues the relationship between the supplier and the bakery, long after the installation was completed. AMF can make line inspections, change parts, including belts or rollers, train new operators, and offer remote support and software upgrades, as needed.

The popular demand of the moment is for more sweet snacks over savory; it is the apple turnover’s time to shine and, with this setup, Smilde is ready to provide it. Should tastes change, the bakery remains ready to boost the production of savory creations. +++

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IN THE SPOTLIGHT

“Relationships matter immensely” Bundy Baking has enjoyed successful business worldwide over the past years, with American Pan strengthening its foothold in Europe. Staying close to its customers and listening to their changing needs has not only helped the group weather the storm of recent disruptions, but it has always been the key to thriving. William Bundy – Global President, Operations, Bundy Baking Solutions, and Jason Bowman – President American Pan Europe & MENA talk resilience, acquisitions, technology and, first of all, loyalty, in an interview.

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Catalina Mihu: Since the last iba, in 2018, Bundy Baking has seen growth everywhere in the world.

What was the strategy behind the milestones reached since then, including the new acquisitions in Europe?

William Bundy: Since the last iba in 2018, our global customer base experienced substantial growth worldwide, and our strategy behind these milestones has primarily revolved around meeting our customers’ needs and getting closer to them. The global marketplace during this period was particularly challenging, and our foremost concern was to support our customers effectively, focusing on being where our customers are, getting closer to them, and providing the best possible service.

At American Pan, relationships matter immensely to us. We believe in building strong, lasting connections with our customers. Acquiring or partnering with companies in Europe was a strategic step towards achieving these goals and reinforcing our commitment to our customers. This move allowed us to not only meet the unique demands of European customers but also to provide a level of service and support that aligns with our core values.

The inclusion of Runex in Sweden and Turbel in Turkey enhanced our reach into the Scandinavian and MENA

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© Bundy Baking Solutions

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regions. Even before this, we had a significant international presence; we were already serving customers in approximately 94 countries around the world. We recognized that our European customers, in particular, had specific requirements, including shorter lead times and a desire for closer, more personalized service.

Our proprietary coatings, including Durashield and OptiShield, played a pivotal role in our strategy. Our goal has been to provide European customers with the essential care and support required to extend the lifespan of their baking pans, including offering recoating services. This commitment was crucial in a highly competitive market where product quality and longevity were key factors.

Mihu: What makes a business resilient in the baking industry?

William Bundy: Resilience in the baking industry is a multifaceted endeavor, and American Pan and all of Bundy Baking Solutions’ approach encompasses several critical elements. Efficiencies and innovation have been pivotal in addressing the industry's challenge of high energy costs, for example. Our commitment to innovation not only reduces operational expenses but also extends the life of

baking pans, reducing the need for frequent replacements.

Maintaining close proximity to customers is of the highest importance to us. American Pan has strategically positioned service centers across the globe, ensuring prompt and efficient support. This approach not only strengthens customer relationships but also bolsters resilience, enabling us to balance operations and ensure uninterrupted product and service delivery, even in the face of unexpected challenges. Additionally, strategic acquisitions and scalability have played a key role in diversifying our portfolio, granting access to diverse markets and reducing dependence on any single market while equipping us with the resources to navigate disruptions effectively. It came with a cost for us to have enough raw materials at different locations to ensure our customers didn’t have any supply chain interruptions, but we were willing to do that.

On top of that, our industry-leading coatings play a vital role in resilience. These coatings are renowned for their exceptional performance and durability, ensuring that our products enhance the longevity and performance of the bakeries that use them.

Investing in talent is also at the core of our resilience. Our organization boasts experts across various fields, from engineers to inside sales teams, spanning different functions and countries. This ongoing commitment to developing a skilled and knowledgeable team empowers us to overcome challenges and drive our business forward. Having a robust team also allows us to be closer to our customers, which is our priority as previously stated.

Mihu: What made Runex and Turbel interesting acquisitions?

William Bundy: The acquisitions of Runex and Turbel held significant interest for us at American Pan for several compelling reasons. We recognized that there are notable regional differences in the types of baking pans preferred by different markets. For instance, in Sweden, Finland, and Denmark, there was a prevalence of semi-industrial bakeries using rubberized coatings, while silicon and fluoropolymer coatings were more common in Turkey and the MENA region.

The expertise of Runex and Turbel in these areas allowed us to better understand and cater to these regional nuances.

Both Runex and Turbel were experts in their respective fields, which was immensely valuable to us. Having partners who excelled in their specific markets enabled us to share best practices and leverage their deep knowledge to enhance our offerings.

Jason Bowman: The acquisitions not only introduced us to new types of customers but also opened up opportunities in different types of businesses, bakeries and products.

This diversification expanded our horizons and allowed us to explore new market segments.

Preserving the legacy of these family businesses was essential to us. Both Runex and Turbel were multigenerational businesses with a strong tradition of taking care of their people and a deep passion for the baking industry. This

© Bundy Baking Solutions

IN THE SPOTLIGHT

“Our resilience strategy is a comprehensive blend of efficiency, innovation, customer proximity, industry-leading coatings, operational redundancy, strategic acquisitions, and continuous investment in our team.”

William Bundy, Global President, Operations, Bundy Baking Solutions

common commitment fostered a sense of unity and purpose within the organization. We were dedicated to integrating these acquisitions while respecting their history and maintaining the essence of their family-run operations. We discovered a shared culture and ethos between American Pan, and these acquired companies. This cultural alignment facilitated a smooth integration process and ensured that our values and principles were consistent across the organization.

Mihu: How do they support each other with new product development? And what are the priorities for innovation at Bundy Baking?

William Bundy: In terms of supporting each other with new product development within the American Pan group, we have a wide range of experts, some in materials, some in manufacturing methods, some in coatings and others in baking knowledge. We use all of these to create a pan with our priorities, the best overall value and life for our pans, and, at the same time, meeting our customers’ specific wants and needs. For example, sustainability and energy

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IN THE SPOTLIGHT

efficiency have become a very important topic for our customers and they are a priority for us as well.

One of our key innovations that we take great pride in is the development of the ePAN, which we introduced 15 years ago, even before energy efficiency became a significant concern.

This innovation has been a game-changer in the industry.

Over the years, we’ve made remarkable progress with our products. For example, throughout the evolution of our AMERICOAT glaze coatings, we have increased the release life by nearly 300%. We have achieved similar results with DuraShield, seeing bake cycles of up to over 6,000 at some bun bakeries.

The development of these proprietary coatings and pans was extremely technically challenging and required a serious commitment, strong partnerships and significant investments.

However, it turned out to be an important win for not only our organization but also the entire baking industry. This same commitment, partnership and investment strategy was employed when we developed ePANs and we have made significant enhancements over the years to be able to create pans, both molds for bun trays and now even deep-drawn bread pans.

Mihu: How does the American Pan SMART Pan Tracking® system help bakeries with continuous improvement?

William Bundy: The American Pan SMART Pan Tracking® system plays a vital role in supporting bakeries with continuous improvement in several ways. Firstly, this tracking system is an invaluable tool for bakers as it provides data that allows them to monitor line efficiency, understand overall capacity and product yield and understand the entire pan life cycle. It also allows us to closely monitor each individual pan, and the performance of that pan, so we can draw conclusions about why certain pans may not be performing at their best. This level of detailed analysis leads to more informed decision-making and ultimately fosters stronger partnerships with our customers.

Additionally, the SMART Pan Tracking ® system aids in managing inventory for our customers. It allows us to be proactive rather than reactive in determining when a new set of pans needs to be sent to a bakery. This means we can facilitate a seamless transition from worn to new pans, minimizing any disruption in their pan supply. Importantly, this process ensures that our customers have precisely what they need, without the investment into an extra set of pans.

By anticipating our customers’ needs through this tracking system, we contribute to optimizing their production processes and overall efficiency. It’s a predictive and forwardleaning approach that we are tremendously excited about for the future. We are committed to continuously improving

www.bakingbiscuit.com 05/2023

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it, harnessing the latest technology to provide even greater value in the next generation to our customers.

Mihu: What additional, similar smart features are available?

And what could new developments in this regard target?

William Bundy: In our most advanced applications and partnerships with customers, optimizing the use of smart equipment goes beyond simply selling a product. It involves establishing a true partnership with the customer. This means having joint visibility into their needs and operations. Technology, together with an advanced level of collaboration, will allow us to provide them with an extremely personal level of service that will help them with not only pan performance but also the workload of their bakery managers.

Looking ahead, future developments in this area could focus on tailored solutions, and advanced technologies involving even more sophisticated monitoring and predictive insights to further enhance our support to bakery managers, allowing us to proactively address issues before they impact our customers’ operations. We aim to further enhance our smart features by incorporating innovative technologies that provide real-time data and predictive insights. Ultimately, our aim is to continue evolving and tailoring our services to meet the unique needs of our customers, providing them with peace of mind and freeing them from the burden of worrying about the entire lifecycle of pans and coatings, knowing that they will never have to worry about running out of essential supplies. It’s all about helping bakery managers focus on their core operations without the added concern of managing their pan inventory. This way, we can continue to support bakery managers in streamlining their operations and maximizing efficiency.

In addition to these smart features, having a robust sales team is essential. Our sales professionals work closely with our customers to understand their specific needs and provide personalized solutions. This human element complements our smart features and ensures that our customers receive the highest level of support and service.

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IN THE SPOTLIGHT

Mihu: What changes in industry trends are you observing and how do they reflect in your day-to-day work with customers? How are you preparing to answer them in the long run?

Jason Bowman: We have been closely observing significant changes in industry trends that have a direct impact on our day-to-day work with customers. One notable trend is the price sensitivity and labor issues within the baking industry. To address this, we are committed to providing our customers with the utmost value, focusing on coating longevity and delivering the best possible return on investment with our baking pans. The industry emphasizes the importance of value, longevity, and innovative designs, which are qualities that our ePAN product line excels in, making it a strong fit for the evolving market demands, especially in line with the high energy

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Mihu: How was the waste prevention and reduction program set up? What waste management strategies does Bundy Baking follow?

Jason Bowman: To support our customers with waste prevention and reduction, we prioritize the longevity of pans and coatings. Delivering high-quality products and coatings ensures optimal performance, reducing the likelihood of waste due to product failures. When products last longer, there’s a reduced need for replacements, resulting in decreased material consumption over time.

The SMART Pan Tracking ® system is a crucial tool in waste management strategy. It enables us to pinpoint areas where waste is occurring, providing valuable insights for process optimization.

We actively pursue lightweight pan designs that continue to be strong while requiring fewer materials, which significantly contributes to waste reduction. Additionally, lightweight pans offer ease of handling for our customers at the bakeries.

We maintain multiple refurbishment facilities worldwide to ensure timely service for bakeries. This proactive approach aids our customers in avoiding waste caused by pans or coatings that have exceeded their lifecycle, preventing pans from sticking, or excessive use of oil and greases, for example.

William Bundy: At our own companies, it has always been part of the manufacturing process to reduce waste and energy use from production – whether it is with the recycling of metals, ensuring that valuable resources don’t go to waste, or our commitment to energy efficiency initiatives.

One of our core strategies is reinvesting in our equipment and workforce to enhance the sustainability of our operations.

We meet or exceed all local sustainability requirements for air emissions, water management and are dedicated to responsible handling of scrap materials. Our goal is to minimize waste while delivering top-notch products and services to our customers.

IN THE SPOTLIGHT

costs the European market is facing. Furthermore, there is a heightened focus on energy efficiency and sustainability in the industry, aligning well with our product offerings. We are committed to designing and producing baking pans that contribute to energy savings and sustainable practices. This approach not only meets customer expectations but also aligns with our commitment to environmentally responsible manufacturing.

William Bundy: We have also noticed a shift towards larger-scale production, resulting in greater complexity and larger-sized pans. While this presents both opportunities and risks for our customers, it aligns perfectly with our expertise and capabilities. We are well-prepared to navigate the challenges associated with producing larger pans and can effectively mitigate potential risks.

Another noteworthy trend in the industry is the growing emphasis on bigger, faster, and more efficient production lines. We are actively preparing to meet this trend head-on by developing baking pans that are not only compatible with high-capacity production processes but also enhance efficiency and quality. Our goal is to support our customers in achieving greater production output while maintaining product consistency.

Mihu: What are your views on the global baking community in its competitive/collaborative landscape?

William Bundy: The global baking community thrives on a competitive yet collaborative landscape, with a strong emphasis on cooperation between companies and OEMs. This collaborative spirit leads to enhanced innovation, improved quality, and seamless project execution, benefiting customers and advancing the industry.

Jason Bowman: Customers in the baking industry greatly benefit from this collaboration. They not only want but also expect us to work seamlessly with OEMs to ensure efficient production and smooth start-ups. The openness that we maintain with OEMs paves the way for opportunities in innovation, quality improvement, and design enhancement, especially for start-up ventures.

The early collaboration with OEMs is a key factor. The sooner we engage in this collaborative process, the smoother the project becomes, often resulting in a turnkey solution for our customers and bakeries. This collaborative approach ultimately serves the best interests of both the customer and the industry as a whole.

Mihu: What are the values that determine the way Bundy Baking does business and what would you consider to be the most important KPIs for the company?

Jason Bowman: At Bundy Baking Solutions, the values that support the way we do business are encapsulated in our CREED. This CREED represents our culture and the core principles within our company with Commitment to making a difference, Respect for individuals and opportunities, a Family Environment where we do business, Excellence in

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“Our ePAN® products are a strong fit for the evolving market demands, especially in line with the high energy costs the European market is facing.”

Jason Bowman, President, American Pan Europe & MENA

every decision, every day, and Personal Development for successful individuals and strong teams. These values are integral to how we operate, with eagerness to contribute, and guide our interactions with both customers and partners.

When it comes to key performance indicators (KPIs), the most critical metric for us is customer satisfaction. This metric is at the heart of everything we do. Our success, our partnerships, and our relationships all revolve around the satisfaction of our customers. If our customers are content and fulfilled, everything else naturally falls into place.

William Bundy: In addition, our KPIs align closely with the elements of our CREED. For instance, striving for Excellence, as highlighted by my brother Gil Bundy, is about “exceeding our customers’ expectations every day” with a focus on quality, delivery and service. This is a fundamental aspect of our performance measurement. Furthermore, the longevity of our team members is an indicator of a healthy culture within our organization. We aim to foster a work environment where our team members are proud, excited, and fulfilled in their roles. +++ Read the full interview online, at www.bakingbiscuit.com.

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TUNNEL OVENS

Efficient baking assignment: tunnel ovens Energy consumption is undisputed at the top of the industry’s concerns and efforts for improvement. Tunnel ovens offer opportunities to go the extra mile on the path to resource savings.

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highlighting blisters and colors on the top of the product,” RBS explains.

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The newest technology developments make tunnel ovens more energy-efficient. As more advanced systems enable energy savings, the equipment itself is easier to use, which contributes to minimizing waste of any kind.

User-friendly efficiency by RBS: the Emithermic XE Oven Zone Reading Bakery Systems (RBS) recently launched the new Thomas L. Green Emithermic XE Oven, which was designed as an upgraded technology to replace traditional Direct Gas Fired (DGF) ovens for biscuit and cracker baking. The new Oven Zone replicates the baking process of a DGF cracker or biscuit oven zone, but uses less energy, has lower emissions and simplifies cleaning and maintenance operations.

At the same time, it also improves baking performance.

Typically, DGF oven zones contain a very large number of direct-fired gas burners above and below the baking band.

They supply low- and high-level radiation to heat the product and the traveling baking band in an environment with little to no convection currents.

The Emithermic XE Oven zone is designed to bake via electric radiant heat elements, high radiant Thermatec Panels, and convective heat, eliminating all ribbon burners. The oven delivers a more balanced heat to the product, and imparts the high radiant heat required to develop the flavor and texture of the crackers.

“The Emithermic XE zone matches the same DGF oven heat trace by using a centralized penthouse (gas or electric) to circulate and impinge heated air on thermal plates above the product and on to the baking band below the product.

High-intensity electric radiant burners then provide the

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A unique feature of the new oven zone is the ability to emulate either the still air environment of a DGF or Cyclothermic oven zone or the convection air zone of a dryer, to optimize the baking process. “The baker can configure and store zone settings of product formulas that require either more humidity for product development or less humidity for product shape setting and drying,” RBS says. This unique atmosphere allows baked goods to develop and expand while retaining the necessary moisture to create the product’s flavor and texture profile.

“Using convection air to heat a small humidity-controlled product zone around the product, the Emithermic XE oven zone imparts high- and low-level radiant heat on the product from above and conductive heat from below. To drive humidity out of this small bake zone, the operator can selectively impinge the product with convective air to remove excess water vapor,” RBS explains. The operator easily controls the air temperature, the low-level radiant temperature, high-level radiant energy and the convection air currents all from a single oven control center.

By comparison, traditional DGF oven ovens are more difficult to maintain and its baking results are not as consistent.

DGF ovens need to balance more variables to deliver consistent heat to the product, due to the large number of ribbon burners throughout the oven’s length (all of which need maintenance and adjustments).

The new oven zone also minimizes waste heat: “In most tunnel oven baking processes, only 25-50% of the oven’s heat goes into baking the product. The remaining 50-75% of the heat is considered waste. The computer-controlled Emithermic XE zone minimizes waste heat by providing product downtime software slowing the circulating air and adjusting burners to maintain zone temperatures without product,” RBS specialists explain. Optionally, an exhaust heat exchanger can be incorporated to preheat make-up air

TUNNEL OVENS Siegling – total belting solutions

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entering the oven to replace the high moisture air circulating in the oven to bake the product, saving energy.

The flexibility of the Emithermic XE zone makes it best positioned as the first third of a tunnel oven of three or more zones. “Emithermic XE zones, coupled with convection zones, optimize the baking and drying process by providing a single hybrid baking system delivering efficiency and flexibility for many different types of product profiles,” RBS summarizes.

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Adding to its efficiency, the new Emithermic XE zone is easier to operate and maintain; electric burner components are easily replaced, which eliminates downtime that would be required for cleaning, tuning, or replacing gas burners. Since the heating system of an Emithermic XE zone resides in a penthouse above the oven, operators have access to both sides of the oven for cleaning. Large access doors for cleaning and maintenance are spaced every three meters to allow for thorough sanitation between product runs.

The oven belt returns within the oven zone to minimize heat losses while providing a flat surface below the return path for sanitation.

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“The flexibility of the Emithermic XE zone makes it best positioned as the first third of a tunnel oven of three or more zones. Coupled with convection zones, they become a single hybrid baking system for many different types of product profiles. ” Reading Bakery Systems specialists

Long-term sustainability is covered

RBS thinks of snack baking sustainability in terms of how it affects three pillars – People, Process and Prosperity: + People – The Emithermic XE oven zone is as simple to operate as a convection oven zone. As the labor force moves around more freely in the LinkedIn job marketplace, the controls of ovens need to be more intuitive so new operators can understand how to bake their products more consistently, without steep learning curves. The Emithermic Oven has only 6 control points, compared to the DGF oven, which has more than 30. + Process – The Convection and Emithermic ovens zones designed by RBS already offer sustainable energy solutions today. In addition, “Our standard Emithermic XE oven zone uses a hybrid of electric radiant energy coupled with gas-heated convection air to bake products,” according to the company. This oven can either be fully electrically heated or it can be delivered as a gas oven that can easily be converted to electric in the future. + Prosperity – The Emithermic XE oven zone operates more efficiently reducing energy, waste and labor while simplifying the baking process.

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An electrically heated Emithermic XE oven zone emits no greenhouse gases, RBS highlights. Cameron Johnston, Director of Engineering, RBS, explains what makes the Emithermic XE technology viable: “Commercial cracker bakers are under pressure to reduce energy consumption and harmful emissions and increase operational efficiency. To do so, bakers are looking to replace DGF ovens for newer, more user-friendly technology. RBS ovens and dryers will be operating for the next 24-40 years. Therefore, our oven systems must help bakers achieve their sustainability goals, while optimizing the cracker platform for product quality and production throughput.”

TUNNEL OVENS

For efficiency, the excess heat in the chimney of the burner is used to heat water, which can then be used in the facility.

Possible destinations are the crate washing machines, central heating, or sanitary use. Of the new features, several can be retrofitted onto existing ovens, starting with heat recovery systems. “If the oven is a thermal oil oven, we can also install different or hybrid heating solutions,” HEUFT highlights.

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Thermal oil oven efficiency by HEUFT The eight-generation oven builders at HEUFT have also been observing a surge in the interest in economical and flexible machines, now a universal top priority in the industry. Sharp energy supply disruptions have shown the financial value of having a flexible system that can adapt all types of pre-existing heating methods to the cheapest and/ or immediately available energy source. Low consumption is a given among requests as well. Hybrid thermal oil heaters can be used in small as well as larger artisanal and industrial bakeries.

“With several baking system options, such as radiant heat, forced convection, or a mix of both, we are able to bake all types of pastry and bakery products with maximum efficiency.”

HEUFT specialists

At the same time, the big sustainability picture is not lost on today’s energy worries: “More and more bakeries are trying to reduce their carbon footprint and are looking to heating systems with low or without CO2 emissions,” HEUFT notes. The thermal oil technology powering its ovens was already able to run with at least 25% savings compared to traditional technologies, the company says. But, in addition to this, HEUFT offers hybrid solutions that can heat the ovens with green electricity generated through solar panels in the daytime and change to gas or oil at night. “Besides this, we have our Energy Management System (EMM) that allows us to maximize energy savings,” the German oven maker highlights. Using a thermal oil oven in an industrial bakery working with two or three shifts can save big (energy and money), which also makes its payback time extremely short, the specialist observes.

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With a very precise temperature control system in every zone, tunnel ovens with independent top and bottom heat in combination with thermal oil heating can avoid temperature drops during the baking process. The result is an efficient, consistent baking process with repeatable product quality.

Thermal oil technology makes it easy to automatically control different temperature zones throughout the oven, with independent top and bottom heat. Special valves with direct reaction help avoid temperature fluctuations in the different zones of the oven. “This process is fully and automatically controlled by the newest Siemens control system,” HEUFT adds.

When building custom ovens, the best way to test possible feature combinations is in the bakery’s own facility, with their own ingredients and with their own equipment, HEUFT believes. This is why its teams can deploy a smaller test oven with all the features of a full-scale industrial oven, equipped with different baking surfaces. The process is entirely replicated and the results are evaluated against the previous/desired results.

The company develops tunnel ovens with one, two and three decks with a continuously running belt. “With several baking system options, such as radiant heat, forced convection, or a mix of both, we are able to bake all types of pastry and bakery products with maximum efficiency,” HEUFT’s specialists explain. Having multiple decks helps save space considerably in the bakery and allows for more flexibility in baking planning.

Saving energy: Kaak OvenScan Royal Kaak recently launched a new service that closely investigates the energy-saving potential of an industrial oven, which can help lower energy consumption by up to 15%: the OvenScan, launched last year and introduced in the Benelux countries in 2023. The concept itself was an organic conclusion of its teams’ conversations with their customers.

However, an exact definition of what energy saving entails is unique to each production environment, with numerous factors that can exert an influence on the savings potential.

In this way, the exact solutions that are applicable to the respective environment can be identified. The OvenScan was Kaak’s answer to this equation, as it allows its specialists to quickly run a check and gain an informed understanding of where saving potential may be, in each circumstance.

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TUNNEL OVENS

last three to four years to combine physics and calculations with real-life data. Six years’ worth of extensive measurements were taken for the actual oven run data, which were used to validate their calculations and simulations. The result is the tool that compares the optimum performance data of the latest technology oven with the input from the facility, using the current performance data. “If there is a big difference between the two, that is the potential for savings,” Heijnen points out.

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“What is the savings potential for each particular customer, with their particular product portfolio? This is very important to acknowledge before we even begin to discuss sustainability, hybrid technology, net-zero emissions, or energy savings,” underlines Paul Heijnen, Sales Director, Kaak.

The starting point is a clear understanding of the current production baseline and of the products themselves. These will determine the potential of the solutions that are available on the market, to help achieve energy savings and reach sustainability goals. And this is what the OvenScan does.

The OvenScan has already been finding big potential saving opportunities, of up to 40-50%. There are, of course, ovens that are already very close to the optimum operating performance, where potential gains only range around 5-10%. The next step can be fine-tuning the settings, a service Kaak also provides. Depending on the bakery’s efficiency and sustainability goal, changes can be made. Kaak can improve its existing oven by retrofitting several new technology solutions, including exhaust systems. “Extracting air from the baking chamber is the first process leading to energy loss if the process is not controlled,” Heijnen remarks. Steam use can also be massively improved, a very expensive medium to begin with. Ovens can easily use too much of it without strict control of the steam zone.

Its goal is to ultimately create a condensation zone on the product, protecting it as it develops. “While, in the past, ovens were adjusted just by looking at the end product results, heating power consumed and steam usage were overlooked, when gas was a cheap resource. That is not so anymore; on the contrary, it is now the first place to

“What is the savings potential for each particular customer, with their particular product portfolio? It is very important to acknowledge this before we even begin to discuss sustainability, hybrid technology, net-zero emissions, or energy savings.”

This tool is applicable to all types of oven technologies, including tunnel ovens, either DGF, hybrid, or electricitypowered. The OvenScan provides insight into the current performance of the existing oven, an investigation performed by the bakers, with assistance from Kaak, if needed. It entails gathering a series of process measurements such as gas and steam usage, the type of gas and oven used, or temperatures, for example. In addition, it maps energy flows, linking each consumer inside the oven with its corresponding energy usage.

Product data is also included (production capacity, product weight, recipe, type of dough, etc.), as it also directly influences resource usage. At this stage, they fill in a checklist with the relevant values, which make up the basis of the OvenScan check. This input is delivered to Kaak’s energy balance oven simulation tool, which was developed over the

www.bakingbiscuit.com 05/2023

Paul Heijnen, Sales Director, Kaak

look for energy savings,” Heijnen explains. Product quality and consumption are now equally important aspects. “Do I really need 200 kg of steam per hour for this product? This is exactly the kind of aspect where we can help. We did extensive research in the field so we know with certainty which products are baked with excellent results using only 50 kg/h – on the condition that the right temperature is reached in the steam zone, or that there are no flow disruptions,” he adds.

Insulation can also help save energy; in the next step after running an OvenScan diagnostic, Kaak can also make infrared scans of the ovens to determine the exact spots where heat is lost and target them. The company also takes detailed measurements of the entire process and can determine the potential for improvements along each step, starting from deep inspection data findings.

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TUNNEL OVENS

Electrical baking A logical step towards baking efficiency and net-zero emissions is baking with (green) electricity, in Kaak’s perspective, with the advantage that it is already a widely available resource everywhere in the world, with its own fully-developed technical solutions and infrastructure, as well as several ways of getting it from a renewable source. From the point of view of the baking process itself, it is also the best choice: “You can control with a very high degree of precision, you can achieve very balanced oven designs, it is easy to maintain, it doesn’t take up a lot of space – it is the perfect heat source for baking,” the specialist underlines.

The only possible downside is the cost, which can deter its widespread adoption, and it often does. However, hybrid concepts are key here, combined with a gradual price decrease, which can be observed.

A hybrid solution in this direction can be implementing electrical heating elements in the oven, besides the gas burners, so both electricity and gas can be used depending on their availability and costs. To optimize consumption when using two different heat sources, one is fixed (for example, electricity is kept at a certain value) while the other is adjusted to follow the required baking curve (gas burner regulation). This setup is not only beneficial in cutting costs, but it also helps lower emissions and is available to retrofit into existing ovens, so the investment it requires is small. It does require more complex balancing, but this type of technology is already looking promising, especially a thermo-oil – heated with electricity – and gas combination running in parallel.

“The Artista Deli oven rationalizes the flow in the bakery by minimizing processing and increasing production volumes compared with a traditional deck oven. This process completely replaces baking in traditional pizza and bakery ovens and the baking process thus requires less labor.”

Sveba Dahlen specialists

The Artista Deli is a small electric stone tunnel oven with a baking temperature of up to 450°C / 842°F. This makes it extremely flexible for everything from bread to pizza, and provides precision and consistent baking results: “Artista Deli is ideal for genuine stone-baked pizza, pizza crusts and many other products such as loaves of bread baked either with or without a tin, focaccia, flatbread, pitta bread, Arabic bread, Persian bread, naan bread, and more,” the Swedish specialist explains. Running on electricity, the Artista Deli is completely fossil-free and has a low carbon footprint. The Artista Deli is also energy-efficient since it only uses the energy that is actually needed during the active baking time. “This means that Artista Deli rationalizes the flow in the bakery by minimizing processing and increasing production

The art of tunnel baking: Artista Deli by Sveba Dahlen The Artista Deli is Sveba Dahlen’s recently launched modular oven, for bakery products and pizza. It was designed to deliver three ovens in one, all focusing on craftsmanship, process automation efficiency, at production high capacity.

Sustainability was a main consideration in its design: the energy-efficient modular system minimizes resource waste during manufacturing. “During the actual baking time, the oven uses approximately 30 – 45% of the installed power.

To avoid peaks when starting up the oven, the baker can sequentially start up each heating zone in the oven,” says its manufacturer. It also features a ‘turbo’ function, for greater baking flexibility, in terms of both time and color. This heating mode also provides shorter heating and baking times and lower energy consumption.

Since the included stone hearth belt can be replaced with a perforated or solid steel belt, it can become three different types of ovens: stone hearth belt can be used for pizza, flatbread, pitta bread, naan bread, and similar products, while the steel belt is used for sweeter doughs and low-rise products such as cookies. Thirdly, the perforated steel belt is used for free-form, high-rise loaves.

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TUNNEL OVENS

volumes compared with a traditional deck oven. This process completely replaces baking in traditional pizza and bakery ovens and the baking process thus requires less labor,” says Sveba Dahlen.

The new Sveba Dahlen oven features two heating zones, with independent settings for the top and the bottom. It can come with a baking area ranging from 1.35 to 5.40 sqm.

One of its unique characteristics is that it incorporates three dampers for moisture extraction, in an oven of just 4.5 m in length, which greatly contribute to crust development, for bread and pizza.

Optionally, conveyors can also be added at the infeed and outfeed to further automate the process flow on the line.

This oven can be combined with other machines such as a tin set (strap) conveyors or packaging stations. It can be used by semi-industrial and industrial bakeries, as well as test baking and showrooms. Its modular construction also means that it can be expanded over time.

Meincke DirectBake E by Bühler – ‘e‘ stands for ‘electric’ Bühler also sees an increase in requests for flexibility regarding energy sources, energy-saving solutions and alternative heating technologies. To these, sustainability commitments are added, which also translates into an increasing interest in carbon-neutral solutions. The company’s tunnel ovens can come with several features that help reduce the energy used in the baking process, such as: + Heat recovering system to preheat the fresh air with the heat from the combustion/exhaust air and wet baking air + Gap control to save energy during any production break + Humidity control system to control the residual humidity and decrease the overall energy consumption.

In addition, Bühler offers services to improve energy efficiency, such as: + Energy Consumption Monitoring (ECM): real-time production performance and energy consumption monitoring, enabling energy consumption optimization

+ Oven Performance Optimization (OPO): end-to-end oven assessment giving full transparency on oven & baking profile, visualization of cost, energy, and waste potential + Performance Assessment Workshop

“Full moisture control by zone transfers the air and moisture to the front of the baking zone to reach the convection and moisture levels necessary for ideal baking parameters in each zone, giving the same baking result as a gas oven.”

Celine Vachet, Director Product Management BU Biscuit, Bühler

This year, the Swiss manufacturer launched a new Meincke DirectBake E, the electrical version of the Meincke Direct DGF oven, as the sustainable alternative for the industrial production of biscuits, cookies, crackers, cakes and more.

“It is designed for the highest product quality with zero emissions during the baking process. Full moisture control by zone transfers the air and moisture to the front of the baking zone to reach the convection and moisture levels necessary for ideal baking parameters in each zone, giving the same baking result as a gas oven,” explains Celine Vachet, Director Product Management BU Biscuit. The traditionally heated Meincke DGF can be retrofitted to use electrical power. The heating system would then be changed from gas to electric resulting in no combustion and exhaust gases.

Moreover, by combining the new DirectBake E with Bühler’s existing electrical convection oven TurbuE, a complete hybrid electrical oven can be provided, for sustainably baking all types of biscuits and crackers.

To balance the end product characteristics with process optimization, the baking profile of the products needs to be defined to have an optimized and efficient use of the energy.

“The data from the devices and sensors can be made available in our Bühler Insights, a portal for connected products and services. Users can create custom dashboards, set up data-driven workflows, and visualize process key performance indicators for greater efficiency and informed decision-making,” Vachet explains. This balance can be tested at Bühler’s Biscuit Innovation Center in Denmark.

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www.bakingbiscuit.com 05/2023

Changing times call for flexible methods – and technology concepts can provide several approaches for tunnel ovens that support the goal of baking sustainably, mindful of the resources going into the process.

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BREADS, ROLLS, BAGUETTES

No stress, no stress Stress-free dough processing guarantees artisan-like product results for all kinds of breads and rolls and for any production volumes. Gentle dough reduction is key. © AM

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Consumers’ changing perceptions of the nutritional value of foodstuffs, combined with a renewed interest in bread, have made the segment of artisan breads become particularly interesting. Clean labels are valued, and so are traditional types of products, not only for bringing up nostalgic taste experiences, but also because of the connection with simplicity and healthy eating. For breads and buns, this means baking doughs with a high water percentage, which requires gentle handling and especially stress-free reduction. Sheeting is the best process that ensures their high-volume production.

NEW: AMF Tromp artisan sheeted bread line Gently reducing the dough band ensures the air bubbles stay put and the resulting bread products will look, taste and feel handmade. Working with living organisms as ingredients requires mastering the technique and the art of the craft, and technology can reliably replicate the master baker’s care. AMF Bakery Systems has been perfecting sheeting technology for decades to deliver complete process control as the dough is transformed from a bulk mass into a continuous sheet of dough. Relaxed dough throughout the process is key.

The company now offers new technology to support the production of artisan-style creations: the AMF Tromp artisan sheeted bread line, which will make its official debut in the world of baking at iba 2023. The new line features major upgrades designed to simplify its operation and maintenance, and enable greater process control. “We measure the process, dough quality, speed, dough width, volume, flour application, centering of the dough sheet, amount of waste/trim, and more,” AMF lists some of the features that help control production. At the same time, the line brings energy-use optimizations and also requires less water, both in-demand features for must-have sustainability technology improvements.

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The new equipment has even taken out any falling heights to protect the dough’s integrity. In this way, the dough will not stretch and alter its structure, so the fermentation results will stay within the intended parameters. The dough is also kept in control by applying flour on the top, bottom and sides. AMF Tromp’s patented flour applicator carries out this task – its unique characteristic is the ability to bring flour onto the sides of the dough sheet, improving a stress-free flow. “More process control is what every industrial bakery wishes to achieve, delivering constant quality and throughput every minute of the day, every day of the week,” AMF underlines. With this system, there is no longer any need for oil on the production line, even when working with ‘sticky’ dough, which means easier cleaning, minimizing waste and saving the oil for other uses.

“More process control is what every industrial bakery wishes to achieve, delivering constant quality and throughput every minute of the day, every day of the week.”

Hans Besems, Executive Product Manager, AMF Tromp

Working smarter and faster The new system covers all processes, from mixing to de-panning – at high speed and for high volumes. It has a capacity of up to 4,000 kg of dough per hour and can be used to produce a wide range of specialty products. The make-up stage plays a role in the production capacity of course, with proofing and baking times taken into account.

Since it specializes in artisan-style goods, it is designed to handle high-moisture doughs with efficiency. A notable design improvement of the line is that it uses Artificial Intelligence (AI) to enhance product accuracy and minimize dough waste.

The upgraded line contributes to improved labor distribution, too. Its simplified modules have a ‘toolless sanitation’ design that do not require additional tooling for changeovers, cleaning, or maintenance operations. Changeovers can be

BREADS, ROLLS, BAGUETTES

done very fast, with minimum downtimes, so several types of products can be planned and brought into production in the course of one one day or shift. It also means there is easy access to all the parts that require maintenance, and cleaning can be easily carried out. The AMF Tromp system complies with the EHEDG hygienic design guidelines.

Extensive research went into the development of this line, to address current production requirements. Its modular build means it is flexible to adapt to changing requirements, too.

It comes with a range of precision equipment, including an inline rounder that can produce boules of up to 1 kg and a top and bottom brush system that removes excess flour. There are several make-up and decoration features available: for example, top and bottom seeding, automated inline water splitting and precision molding for products of different shapes and sizes.

More sustainable production was another key design consideration. The system not only runs with less water (to run and for cleaning) and energy, but also helps reduce waste – for example, its dough-centering unit ensures minimal dough trimming, resulting in less waste.

New equipment To shape products, AMF designed and engineered a new rounding solution, which will also be showcased at iba. Using feedback from bakers, the specialist built the rounder to make the process as artisanal as possible, as if the baker was rounding by hand. “From small dough balls to the large and 1 kg breads/boules, the rounding process makes them look unique, and still the same every time,” the specialists describe.

A newly designed guillotine also supports bread production.

Aside from cutting, its traditional task, performed without misshaping the products, the traveling guillotine also seals products. Toolless changeovers are possible for this unit as well and it incorporates improved hygiene features. iba visitors will be the first to see it on display.

Technology lines for all types of bread AMF Tromp breadlines deliver sheeting technology that is renowned in the baking industry. They support an unlimited product diversity and can accommodate growing trends, including gluten-free and vegan recipes. “The dough sheeting process is determined by the type of dough, but, after that,

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BREADS, ROLLS, BAGUETTES

NEW: Glimek Bread Line

© AMF

the variation is endless – all shapes, sizes and weights can be made, either rolled, cut, or molded, with any kind of fillings and decorations,” the company notes.

Supporting variety and automation in breadmaking is a core focus at AMF, with an extensive portfolio of solutions that help improve the process and the results ranging from belt or step proofers, to tray and peelboard handling equipment, and its Den Boer tunnel ovens. Sheeting lines for bread are custom-configured; they handle the dough gently, but with high speeds. To customize solutions addressing each particular baking facility, “Footprint in the building, capacity, production hours, level of automation, proofing times, baking times, and switches per day – these are all factors we take into account when designing new lines,” AMF explains.

Process efficiency is ensured by comprehensive control, establishing recipe-driven settings throughout the production lines, as well as increased automation with reduced need for operator intervention. Smart features go a long way to improving production efficiency, too. “Our systems get smarter using Machine Learning,” AMF highlights.

Sveba Dahlen released a new solution for the industrial production of bread, its largest to date, it says: the Glimek BL600. The line includes a dough divider, a conical rounder, an IPP intermediate pocket proofer, and either one or two molders, depending on the production rate. For possible product variations, the new line can handle dough pieces ranging from 100 to 1,500 g, and can run up to 6,000 pieces per hour, depending on the type and weight of the dough.

It can achieve even and continuous baking and ensure that the results are always the same, the company highlights.

“With a bread line of this type, we can fulfill the demands of customers who have a high volume of products to bake off every day and for whom production costs are front of mind. With a bread line, you can slash your manpower needs while increasing your bakery’s efficiency and uniformity,” says Niklas Alricsson, Sales Manager at Sveba Dahlen.

“With a bread line, you can slash your manpower needs while increasing your bakery’s efficiency and uniformity.”

Niklas Alricsson, Sales Manager, Sveba Dahlen

The Glimek Bread Line BL600 consists of several independent dough-handling machines that together make up a whole line. This design increases safety on the line, as emergency stops can be easily reached from one location and used to stop the entire production flow.

Glimek products are manufactured in Fristad, Sweden and are owned and developed by Sveba Dahlen. The machine will be showcased at Sveba Dahlen’s iba stand, where it will run live demonstrations. +++ Read more about new developments for the production of bread, in the next part of this article, which will be published in the sixth issue of baking+biscuit International.

© Sveba Dahle n

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ROBOTICS

Dough on the go!

Automated dough systems make production flow more efficient and are a safe robotics solution to bring into the factory. © DIOSNA

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By DIOSNA

The past few years have plainly shown how fragile the industry can be. Both the effects and aftermath of a global pandemic as well as worldwide conflicts resulted in challenges that initiated a steep learning process. Automation could answer a lot of these rising issues. The demand for even more automated, safe processes continues today.

DIOSNA developed intelligent solutions that automate the area of pre-dough and kneading technology, while preserving product quality. Recently, the company focused its efforts on the automation of kneading processes through Automated Guided Vehicles (AGVs).

Automated solutions are based on a self-regulating process and designed for maximum flexibility, with possible variations considered for factors such as different recipes, individual dough resting times and cleaning options. Production facilities can include multiple dosing, mixing and/or discharge systems using DIOSNA's solutions, depending on their size.

AGVs coming through!

Inside the plant, an automated transport system, i. e. an AGV solution, handles the dough. There are several ways to program and almost seamlessly monitor dosing and kneading. From the monitoring of kneading energy to the sequence of dosing and mixing processes, up to remote monitoring and remote maintenance, there are almost no limits to the possibilities of automation.

AGVs are highly flexible in automating dough production.

They are already successfully used in various industries and have been continuously optimized in several aspects – regarding battery life, charging, speed and durability, for example. Room concepts can easily be adapted to current requirements. AGVs help process steps in dough production such as dosing, kneading, resting and tilting, to become location-independent. Capacity expansions can also be implemented quickly, as well as process sequences and timing.

Custom room layouts can be mapped out for AGVs to travel efficiently while handling dough production. While classic room concepts only allow maintenance and cleaning to be

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carried out during downtimes, the bowls can now also be cleaned in a separate room during production thanks to AGVs. They can approach dosing points flexibly. In addition to automating handling, they also contribute to a more efficient configuration of the space in the production area: AGVs with high-lift functions allow flexible, multi-level dough resting setups, both horizontally and vertically. In this way, considerably less space is required for dough resting sections.

Safe operations AGVs navigate independently in spaces and transport raw materials, trays and dough resting boxes to the desired location within defined production sequences. For this purpose, they are equipped with state-of-the-art navigation systems and sensor technology. In addition, they are batterypowered and do not need rails or induction loops.

Safety and navigation features are implemented via wellprotected laser scanners. They continuously monitor the movement area and navigate in the respective environment.

In addition, there is a digital map of the operational environment in which the route is stored. In the event of an obstacle, the AGV stops or adapts its speed to the obstacle ahead.

AGVs can interact with several systems via a communication interface, as well as with their stations and a fleet management system. The latter is based on the DIOSNA production software, the Bowl Manager, which has been tried and tested for many years. The routes and the production sequences can be manually changed, at any time. This is also where the digital twin comes into play: DIOSNA simulates all processes and routes in advance so that there are no unpleasant surprises at the start of production.

In the future, further automated dough processing can also bring an automated interlocking of all production areas, in principle, connecting AGVs to the central fleet management system. Integrating other parts of the plant, such as packaging or loading, is also conceivable and would be a logical step. +++

NEWS

BAKON introduces RedControl operating system

ARYZTA reports strong sales growth

© BAKON

BAKON Food Equipment announced a new operating system for their machinery. It allows operators to control complex production systems through an intuitive dashboard.

Bakon has developed the RedControl operating system to help operators manage increasingly technologically complex machines. The software is web-based and developed to be intuitive and logical to use, so that does not require specialty training to learn and to operate the machine. RedControl uses real-time data so that adjustments can be made during the production process, optimizing production performance.

The new operating system will be presented at BAKON’s stand at iba. +++

© Rademaker

Rademaker signs exclusive partnership with Form & Frys Rademaker announced an exclusive partnership with Form & Frys Maskinteknik, a Danish company specializing in folding, forming, and filling machinery for a range of pastry and baked goods. Through the partnership, Rademaker becomes the exclusive representative of Form & Frys solutions in select European countries, including Austria, France, Germany, Ireland, Switzerland, and the UK, as well as across the North American continent in the United States and Canada, where both companies see significant market potential.

The two companies have already collaborated on projects successfully. Both companies will be exhibiting their latest developments at iba in Munich. +++

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With EUR 2.1 b in revenue and EUR 112 m worth of profit, up from EUR 0.9 m, for the third quarter of its 2022/2023 financial year, ARYZTA announces considerably improved performance. Its revenue increased by 20.9% in this interval, to reach EUR 2,123.2 m. ARYZTA AG Chairman and interim CEO Urs Jordi commented on the results: “Our strong organic growth performance of 21.6% underpinned the delivery of a much-improved profit of EUR 112m.

This was achieved in a period of challenging trading, with persistent inflation, cost of living increases, and supply chain and energy costs concerns. Volume growth was supported by a doubling of the share of innovation to 11% of revenue. This ensures our products remain aligned with customers’ needs and consumer trends.

Our strategy remains focused on organic growth, operating efficiencies and strict cost discipline. This will generate free cash flow to deleverage total net debt below 3x by 2025. We remain on track to deliver further improvements across all key metrics in line with our guidance for the remainder of 2023 and reiterate our mid-term 2025 targets. Achievement of total net debt leverage of less than 3x will open up attractive refinancing options.”

+++

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ROBOTICS

FAST, SMOOTH, ACCURATE

Pick-and-place robotics Automated Intelligent Direct Handling (IDH) increases efficiency in cookie and cracker packaging.

©S

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Today’s food industry landscape is increasingly characterized by the integral role of automation, which enables food manufacturers to improve production at nearly every step of the process. In the packaging sector, pick-and-place solutions have become the de facto standard for efficient and safe handling at high output rates. Syntegon’s new IDH (Intelligent Direct Handling) pick-and-place system uses advanced robotics to do just that for the most delicate products: from cookies to crackers of all shapes and sizes, the IDH ensures that crackers won’t crack before they are meant to – when they are consumed.

For bakery products such as cookies and crackers, conventional packaging techniques often prove inadequate for their delicate nature. As a result, robotic solutions have become a key focus for many manufacturers, providing an efficient way to carefully place fragile items into feeder chains and trays. Syntegon’s new IDH packaging solution therefore picks up where many other technologies leave off. The compact, high-performance design of the pick-andplace machine allows for flat and on-edge loading of a wide variety of products.

Versatility for different products and packaging formats The range of cookies and crackers offered by many brands is diverse – and so is their packaging. Typically, manufacturers must switch between products of different sizes and formats during the packaging process – often resulting in extended machine downtime. That’s where robotic solutions offer maximum flexibility: the IDH, for example, groups and loads cookies in four different formats, from slug and pile packs to on-edge or piled cookies in trays, into the downstream infeed. And all this at top speed: up to 1,250 products

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per minute, which, along with low reject rates and short downtimes, results in high Overall Equipment Effectiveness (OEE) – leaving no crumbs on the floor.

Gentle handling with linear motor technology While a strong vacuum may initially provide a firm grip, it can also damage the light texture of cookies and crackers.

Thanks to a new linear motor-driven picker technology, the new IDH ensures gentle handling of delicate products through slow and gentle movements and minimal vacuum application – preventing mechanical stress and damage.

In addition to preserving sensitive products, it also ensures high output: equipped with up to 40 vacuum pickers, the IDH gently picks and places products at high speed into a flow wrapper infeed or trays, making it the ideal choice for higher volumes and wide process belts. On the infeed chain, a built-in camera system detects the position of the cookies and crackers and guides the pickers to precisely place the trays. Meanwhile, a mini-buffer fills in incomplete rows – making the IDH an efficient addition to Syntegon’s comprehensive portfolio for the cookie and cracker industry that offers customers tailored system solutions with a low Total Cost of Ownership (TCO) from a single source. +++

© Syntegon

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PIZZA LINES

© AM

Keep them coming!

F Ba

At home or at the restaurant, for lunch, office parties, or even for breakfast, ordered in person or online, the interest in pizza choices never fades. On the contrary, new, exciting taste offerings, product claims and ingredient combinations are welcomed opportunities to experiment.

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The global pizza market size reached USD 141.1 billion in 2022 and Research And Markets expects it will reach USD 192.4 billion by 2028. Healthier product options such as vegan, low-calorie and gluten-free pizzas are drawing consumers in. The Western European market has grown by 8.6% between 2022 and 20231, the largest growth rate worldwide. Next, APAC was also forecast to grow by 8.3% last year, while the pizza industry in Eastern Europe showed similar growth during this period, ranking third (7.6%).

Preparing pizza implies making and forming dough bases, onto which sauce and toppings are added. With each stage, there are opportunities to diversify the final product.

For industrial production, pizza lines are made to welcome any variations required. Accurate processes are a must for these flexible lines.

AMF Bakery Systems turnkey lines AMF designs an extensive range of equipment for pizza dough preparation. The best equipment lineup is determined to fit specific manufacturing requirements and various types of pizza, in terms of recipe, taste, bite, shelf life and type – either fresh or frozen. “This determines what

kind of dough you produce and use for pizza; ‘it’s all in the dough’ is a well-known slogan” in this regard, AMF explains. Starting from the types of dough that will be used, AMF specialists are testing the recipes to match them to the best technology, starting with horizontal and continuous mixers for dough preparation. “Dough handling is the base of our design philosophy, based on what our customers want,” AMF highlights. Then, the process is key to lining up the most suitable equipment for a wide variety of products – in terms of production capacity, product sizes and varieties, as well as processing sequences, for either dough balls of sheeted pizza for retail, QSRs, baking fresh, or bake-off.

Flexibility can be understood in several ways: lines can be built to be dedicated to a certain type of product, with variations in size only – meaning cutting blade changes – or to accommodate entirely different products. In this case, production can be set up to skip a certain step, change some parts, or wheel in another AMF Tromp unit entirely, for changeovers that only take a few minutes so that production can quickly resume. “There are even examples of lines using two ovens on one sheeting line, to make two

© AMF Bakery Systems

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1

Source: Pizza industry projected growth rate worldwide 2022-2023, by region, Statista Research Department, June 5, 2023

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PIZZA LINES

completely different end products and pizza bases. The possibilities are endless,” AMF illustrates.

AMF pizza and pinsa lines process different kinds of dough, from frozen and cut to molded, or pressed – all on the same line. For the dough mixing (AMF Fusion ensures gentle mixing) and forming stage, there are two options to choose from: making dough balls (which can also be pressed in a pan) or dough sheets, which can either be made via a low-stress process or extrusion, depending on the type of dough.

The right setup for the product The specialist in sheeting lines can offer many options for this process, to achieve a flexible setup for the desired types of pizza. “Any variations, from American style, Italian style, pressed pizza base (for a certain bite), or just long fermented and stone floor baked pizza bases with a lot of ‘bubbles’, they can all be made on the AMF Tromp pizza systems and sheeting lines,” AMF explains. From semiautomated to high-end, high-speed lines that are completely automated, AMF sheeting systems can make over 100,000 pizzas, flatbreads and pinsas per hour.

For proofing, the environment and the climate are crucial, in line with the recipe and the ingredients – if these have

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the same characteristics, then the sheeting and proofing equipment will produce consistent results. For dough proofing, fermentation rooms can be provided, where dough rests before dividing. Belt proofers can handle the entire dough band and work great for pre-proofing and can be used for final proofing, too (cascade proofing), while multideck belt proofers can be used to proof cut pieces and products.

Once the base is perfected, depositing and topping are analyzed, for the most suitable line make-up. AMF Tromp has a wide range of topping lines to choose from. Depositors can be used for gluten-free doughs as well as to deposit toppings of various textures/consistencies – sauces or meat, for instance. “The sauce depositor enables accurate,

Latest technology upgrades on an AMF pizza line + Smart applicator topping + Sustainable Oven Service (SOS) + Mixing, Dough Guardian (patented process control technology)

+ Hybrid systems with hydrogen or electric energy sources

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Sustainability in action: Recycling bread waste saves waste in production.

Bread that cannot be sold due to visual defects does not have to be thrown away.

Waste bread recycling, where the bread waste is crushed, liquefied and added back to the dough, allowing them to be put to good use – and even improves the quality and taste of the dough.

We have the solutions to make your plant suitable for bread waste recycling: With our specifically designed components, bread waste rises to the occasion.

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ENGINEERING SUSTAINABILITY

PIZZA LINES

high-speed sauce depositing,” a fast process that is also done without wasting material or making the belt dirty. A sauce enrober can be used to cover the pizza base completely, with tomato sauce or white sauces. Applicators can use either waterfall or target technology, for ingredients such as cheese or vegetables. A recycling system ensures that ingredients, often expensive, are not lost. AMF’s new Smart Applicator uses a data-driven, intelligent vision system and is the recommended solution to minimize cheese waste.

Roll strewers can also be incorporated to add herbs and spices to the pizzas.

For handling, AMF Workhorse offers multiple solutions, including palletizing, crate/box handling and packaging using robots. In this way, AMF can “Create fully automated lines, with automated mixing and fermentation at the beginning of the line, automated pan handling, cleaning and storage systems at the end of the line, and handling boxes and pallets ready for shipment.”

Rademaker pizza solutions Pizza covers a very wide spectrum of process choices, especially for crust production. Are they produced on baking trays or not? At what stage in the process is fermentation/ proofing required (if at all)? All these aspects can impact the general design of a processing line. Rademaker determines these key decisions with the baker at the beginning of a project. “For example, crusts that must have a ‘fried’ bottom appearance are typically produced in baking trays,” Rademaker illustrates. This type of setup can start with mixing, then direct to sheeting and makeup, with products then transferred onto trays for proofing (step or spiral) and baking, then depanning, cooling, and so on.

The baking process with its corresponding AMF Den Boer technology is determined by the style of the end product – either with a softer crust, such as the varieties preferred in Asia, or a crispy crust in Italy. American-style crust, by comparison, is thicker. Everything else also contributes to selecting the correct baking parameters, from the pizza style to the toppings, or whether it is par-baked or fully baked, for example. Carriers are also taken into consideration, whether the pizza will be baked on a stone floor, a steel belt, mesh belt, or in pans. To perfect the process when working with so many variables in automated production, AMF’s Sustainable Oven Service supports anything from oven settings to feedback based on oven data (analyzed by AI).

On the other side of the spectrum are the more aerated products, with processes that are more similar to artisan bread lines. Here, mixing and pre-fermentation can require extended time intervals, with sheeting and forming optimized for higher hydration/fermented doughs. Continuous sheet proofing and sauce application can be incorporated in this case, prior to transferring the products to a higher temperature oven with a shorter bake time when compared to a tray process, Rademaker explains. Key considerations include the required production rate, which defines various widths and speeds.

After baking, spiral coolers and freezers, or ambient coolers bring the product to the temperature needed for packaging.

“Here, time is important, as is productivity, and gradually lowering the product’s temperature, to preserve its quality,” AMF points out. For this stage, it uses direct drive technology for improved product handling, less ‘shaking’ that could damage the product, less energy needed, less maintenance and better results.

New trends have also entered the market in recent years.

“Just think of the shift from pizza to pinsa. Pinsa is a very airy and crispy ‘pizza’ type made of dough with a very high water percentage (>80%), a Biga or Sourdough with a very long proofing process,” Rademaker points out.

All these different types of pizza require a specific sheeting process with a specific pre-sheeter for each group of doughs.

A very soft, airy and strongly pre-fermented dough cannot be rolled out with an overly aggressive dough sheeter, as it would remove all the air from within the dough, for example. Alternatively, thin and crispy pizzas are made with very low-hydration, stiff doughs – these require a ‘heavy-duty’ extruder.

© Rademaker

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Rademaker lines are designed for the specific type of dough for which it is needed. Rademaker has extensive experience in sheeting anything from “Very low hydration doughs, for more cracker types of crusts, to highly hydrated pre-fermented doughs, thick or thin bottom, soft and hard crumb structure, crispy or just soft, with and without pressed

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PIZZA LINES

© Rademaker

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edges and pizza with a cheese filling in the edge,” the specialist lists. Even more niche applications can be supported, including incorporating ingredients such as corn meal, bread crumb to the bottom of the product, herbs/ spices to the top, or oil application before baking.

As for topping, the most common configuration designed by Rademaker starts with target sauce application, followed by waterfall cheese, meat, or vegetable application, with target slicing in the middle for pepperoni/sausage. “The sequence depends on the product; cheese is delivered on demand from a shredding system. Other ingredients (meats and vegetables) are usually IQF in larger totes,” the specialist details. At the discharge of the topping line, depending on the market and materials, the pizzas will either be lightly sprayed with water or pass through a high temperature/short dwell cheese melter to ensure all the valuable toppings stay on the pizza through freezing.

Changeovers on a crust line can be as simple as changing a cutter for a different size/shape, which on a sheeting system can be done in a matter of seconds with a carousel.

“For products on trays, these may need to be exchanged as well if there is a cavity involved,” Rademaker points out.

As for topping, sauce and slicing heads will have to be changed for a new size/shape. “If different raw materials are introduced, these need to be emptied and started again, although larger producers will do this kind of changeover at a sanitation cycle, or switch to a redundant applicator for fast changeovers. Recipe control and management are standard to minimize the operator’s efforts to the physical changes needed,” Rademaker observes.

Accuracy is profitable In recent years, Rademaker has been focusing its R&D on the development of in-line weighing systems of a continuous dough sheet. “This hybrid weighing system weighs the sheet continuously during the sheeting process and adjusts it into an exact volume; only then, it is formed into the desired pizza shape,” Rademaker explains. Improved weighing accuracy saves dough giveaways and spells big annual savings, especially for large-volume operations.

www.bakingbiscuit.com 05/2023

New systems have also been developed for Rademaker’s topping lines, with improved accuracy when spreading one of the most expensive products of a pizza – cheese. With algorithms monitoring ingredient recirculation to optimize feeding the applicator, topping accuracy brings significant savings. “By refeeding what is consumed and controlling what is on the line, material is added via a buffer system.

A constant flow of material is thereby created so that the applicator is never overfed. In this way, a minimum amount of strewing material in the recirculation system is ensured.

The algorithm further follows the ingredient flow through the system and adjusts the amounts that are re-introduced to the applicator,” Rademaker explains.

“The algorithm further follows the ingredient flow through the system and adjusts the amounts that are re-introduced to the applicator.”

Rademaker specialists

Compared to traditional pizza production from dough balls, sheeting technology allows long pre-fermenting processes to be done before the dough is sheeted, which significantly reduces processing time on the line and improves equipment output. Rademaker can easily scale up the capacity of its sheeting line, if needed, by increasing its line width to 1,600 mm wide. By using rotating guillotine blades that cut the desired shapes in the continuous dough sheet, high processing speeds are ensured. Moreover, “The large in-line belt proofer behind the sheeting line allows the continuous dough sheet to proof before cutting, which helps minimize production costs per item,” Rademaker observes. Pre-fermenting can also be done in bulk, before the dough enters the line, making variations possible in terms of flavor, crumb structure and crust properties.

With its newest developments for pizza production, Rademaker has been focusing on improving the reliability and accuracy of its sauce dosing systems and material flow stability on the topping applicators. +++

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‘23 SPECIAL

A pivotal moment in the baking industry

+

During a five-year time-out imposed by external circumstances, iba organizers evaluated the fundamental transformations changing the whole world and the baking industry, in an effort to adapt and position itself to be able to provide a relevant platform for the 2023 comeback of the show. New features that are introduced this year are meant to accurately mirror current industry needs. iba organization carried out extensive surveys to map the needs of the exhibitors and those of the visitors to the fair. Current and ongoing challenges such as resources, energy costs, health and shortage of skilled workers, present worldwide, were the basis of the focus topics iba chose in response: food trends, artisan bakery, health, sustainability as well as digitalization, turnkey solutions and quality management.

Germany’s bread tradition and industry German bread culture is an inherent part of the trade show held in Bavaria’s capital, Munich. “Germany is the land of bread culture – the more than 3,000 registered bread specialties speak for themselves and show that the bakery trade plays a major role in this country. Of course, there are some challenges such as the competition with industrial production, excessive bureaucracy and the lack of young talent and skilled workers complicate current developments for the artisan bakery, but we see ourselves as a crisis-proof industry that values high-quality production

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© GHM

iba and the German Bakers’ Confederation analyze current dynamics in the industry and the future of baking innovations, exploring possible and necessary directions, as they prepare to welcome an industry reunion in Munich.

processes, regional value chains and innovations for which we are known worldwide,” says Michael Wippler, President of the German Bakers‘ Confederation.

The association’s work has been tackling all these challenges: “COVID-19 and the energy crisis have shown that we, as an interest group, have to have staying power, but that an intensive exchange with politicians can be worthwhile. Currently, we are lobbying for set industrial or SME electricity prices, so that the prices of baked goods do not have to be raised further, for example, and we are actively placing proposals for sensible bureaucracy reduction with politicians. After all, a baker belongs in the bakery and not at a desk! We are tackling the acute shortage of young people and skilled workers by changing working time models in some companies and streamlining application processes. At the start of training, the training allowance was also massively increased so that a career in the bakery trade becomes even more attractive for many,” Wippler shares some priorities in the agenda of the German Bakers’ Confederation.

Among the actions that supported the bakery trade through the recent difficulties has been the fact that it has been considered an essential industry since the COVID crisis.

Politicians sent an important signal extending the needed support at this time. “However, the energy crisis has shown

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that we need to rethink and include support for the bakery trade as well. Because after all, the food trade creates equally important jobs and is a relevant contact point for local supply and social exchange, especially in rural areas,” Wippler highlights.

The craft, the culture, the industry German bread culture has a long tradition and takes pride in recipes that have sometimes been passed down through generations. Sourdough and a long dough process are essential for many artisan bakers, and many skillfully combine traditional production methods with a modern twist. “Germans cultivate their bread culture, for example, by getting together for supper or having a communal snack - these meals are less cultivated in other countries. Bread sommeliers not only help to draw attention to the valuable craftsmanship, they also create awareness for high-quality ingredients and careful production methods, and they bring the senses into focus. In addition, they have extensive knowledge of bread history and can give tips on food pairing. Customers appreciate that,” Wippler underlines.

Bringing together different traditions from all over the world is part of iba’s unique characteristics. Between them, “The German bread culture and its roots are a very interesting topic at an international level. Therefore, we have the bakery tours during iba where participants can visit local bakeries, the iba.ACADEMY where visitors learn more about the secrets of the original and traditional recipes and techniques, and the halls and topics with a focus on artisan bakery. At the same time, we are interested in learning how other bread cultures work and what are their latest innovations at iba in October,” Seidemann anticipates.

The training and work as a bread sommelier is unique for Germany. However, since it garners great interest worldwide, the leading training institution Akademie Deutsches Bäckerhandwerk Weinheim will introduce international bread sommelier training. “Bernd Kütscher, Director of the Akademie Deutsches Bäckerhandwerk Weinheim, told me that they are happy to announce the first classes in English.

The training includes two modules in Germany (September 2023 and September 2024), plus live online sessions and

Michael Wippler supports German bread culture Michael Wippler has been President of the German Bakers‘ Confederation since 2015. In 2019, he was reelected, and his second term ends in November of this year. During his tenure, he was able to record numerous successes, which benefited Germany’s artisan bakers. The framework conditions for the artisan bakers in Germany were improved in many areas during his presidency.

For example, the German Bakers´ Confederation managed to get bakeries to receive financial support from the state during the COVID pandemic. In addition, the organization of the association was modernized and the political representation of interests was strengthened. The image of German bakeries has also been further improved over the past nine years, so that German bakers and German bread culture have a good reputation all over the world.

Milestones of his 10-year tenure: ing, improvements in the legal framework in Germany, e.g. was

established to further promote important messages in

able to prevent some regulation enforcement in the area of

relevant online communities.

food law to support artisan bakers (some exceptions for small

The association also launched a campaign (‘Back dir deine

businesses in labeling and controlling).

Zukunft’ – ‘Bake your future’) to get young people interested

Michael Wippler managed to bring the bakery family closer together and to crystalize a common identity, thanks to his efforts in balancing and integrating member activities.

+ Modernization of the organization

in starting a career in artisan bakeries.

+ Bread culture

Targeting communication to improve the image and exposure of German bread culture and its vast tradition.

Wippler contributed to improving information channels

Various prizes and awards were created, including bread

within the organization. He introduced regular newsletters to

tests and the seal of quality.

share useful information with all artisan bakery members.

The Academy of Bakery in Weinheim modernized its range

The Communication department of the Zentralverband was

of seminars and has a clear focus on conveying artisan

strengthened and its social media presence was

skills, quality of bakery products and excellence.

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Source: Zentralverband des Deutschen Bäckerhandwerks e.V.

Under his leadership, the organization achieved, through lobby-

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we combine all areas of the bakery trade in one place and at the same time, on an international level - with a focus on the roots of the German bakery. Via lectures, products, and competitions we bring the German bread culture closer and, at the same time, exchange knowledge and experiences with other countries about their baking trends and cultures,” Susann Seidemann, Exhibition Director iba, also comments.

© GHM

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Photo: Sustann Seidemann, iba Director

self-study phases in between. The class has only been online for a few days and they already have registrations from Israel, Norway, Brazil, Gambia and Bulgaria. There are still slots to register for the classes in order to become a Certified Bread Sommelier,” Seidemann details (More information: www.akademie-weinheim.de/certified-bread-sommelier).

All types of industry players are represented Recent developments were carefully mapped to learn about the needs of all types of businesses, from industrial to artisan bakeries, ingredient suppliers, and including manufacturers of equipment for processing and packaging.

“That’s what makes the fair special, from my point of view:

Original cereals are still very much on the rise, the German Bakers’ Confederation observes, and many businesses are also expanding their snack offerings. Overall, the demand for high-quality, regional ingredients is particularly high. iba’s organizer has been monitoring developments such as a demand for regional and local food, industrial processes, automation as well as digitalization, all of which will be displayed at iba. For example, a case study where an AI-controlled-in-store-baking concept will be presented.

Hybrid ovens will also be among the highlighted novelties.

Moreover, to bring sustainability into the spotlight, all lectures held on Monday, October 23, will revolve around this theme.

These are the resources that support iba in contouring an outlook to the future of the baking industry. Possible directions can be analyzed together with the experts in the iba.

iba.START UP AREA: Give good ideas a chance!

The iba.START UP AREA supported by Puratos will debut this year at iba, to bring new and emerging concepts into the spotlight and boost their potential to revolutionize the bakery landscape. In addition to start-ups, next-generation entrepreneurs and innovations, renowned experts will also join this area with keynote presentations, in the dedicated space in hall A4. The new iba.START UP AREA is designed together with Puratos – both visually and in terms of organizing the content that will be presented here.

This innovative newcomer zone should provide inspiration to industry professionals who want to find out about short- and long-term solutions.

The concept is not that of a traditional exhibition stand, but a modern, open space that will be shared by all attendees.

Exhibiting startups, all companies launched in the past 10 years and working with fewer than 50 people, will pitch their ideas and experts will bring new perspectives to current issues. Topics here will range from ground-breaking technologies to food trends, in line with the core iba.TOPICS set for this year’s exhibition: food trends, artisan bakery, health and sustainability as well as digitalization, turnkey solutions and quality management.

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“National and international startups from the entire baking trade get their own stage with the iba.START UP AREA. We are very keen to promote young talent and offer them the appropriate space for presentation, exchange and new ideas,” stresses Michael Wippler, President of the German Bakers' Confederation.

Sophie Blum, CMO at Puratos, also says: “Our partnership with iba reflects Puratos’ commitment to fostering a culture of innovation and creating a platform for promising startups to showcase their solutions. By supporting these startups we are not only interested in their success, but also in the longterm success and sustainability of our industry.”

She anticipates this will be a crowd-gathering new feature: "We want to offer a memorable experience for everyone who wants to shape the future of our industry. In the iba.

START UP AREA, you will find groundbreaking ideas and technologies that will drive the way we make and consume bakery, confectionery and chocolate products.” iba aims “to bring visitors and exhibitors, ideas and solutions, visions and passion from all over the world together in one place,” here, in a space meant as a base for innovations and new cooperations, Susann Seidemann, iba Director, points out.

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SPEAKERS AREA, where lectures will share insights into topics such as ‘Energy transition and climate protection in the bakery: The e-Tool web portal for craft enterprises’, or ‘From Carbon footprint to carbon fingerprint’, as well as ‘How to successfully recruit, retain and train your employees’, Seidemann highlights.

Wanted: energy efficiency innovations Sky-rocketing energy prices brought business-shattering bills to German and European bakeries. Drastic changes were called for, and fast, lasting solutions are needed.

There are numerous innovations to help plants and baking facilities of any type produce more efficiently. Iba’s director highlights some of the innovations visitors can look forward to: “The Multibake® VITA tunnel oven from AMF Den Boer is a direct-fired oven with patent-pending hydrogen-powered burners to improve sustainability in baking, WIESHEU, Wanzl and FANUC present an AI-controlled, automated baking process in the bake-off area, Spin dryer from Reich GmbH with a new technology for less energy consumption or new tools and machines that contribute to lowering investments needed and reduce at the same time the manual labor requirements.” In this way, people have more time for other, core activities in planning and production. Visitors can already browse before the fair and compile their own agenda, she recommends, by using the iba.UNIVERSE tool. +++

AW A K E N Y O U R S E N S E S

© GHM

Explore the world of baking with all five senses From the moment we are born, our five senses are the gateway to experiencing and interacting with the world around us.

Visit us at iba 2023 and explore the world of baking with all five senses. Discover the endless opportunities of high-performance baking equipment.

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She invites the trade industry to not only participate but also to actively contribute with individual perspectives, in this idea space.

The annual balance sheet total or annual turnover of what iba and Puratos define as startups for this area does not exceed EUR 10 million. In addition, the companies must have newly developed or significantly improved products, processes and services. Companies with their headquarters and business operations in Germany can also receive financial assistance for participation in the iba.START UP AREA: the Federal Ministry for Economic Affairs and Climate Action (BMWK) supports young companies to join international trade fairs such as iba.

#koenigfivesenses Booth No. B2.370 / B2.570

Koenig Maschinen GmbH info@koenig-rex.com www.koenig-rex.com

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© GHM

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EXHIBITOR HIGHLIGHTS, PART II

It’s not a sprint, it’s a marathon!

As the finishing line to this year’s iba preparations is quickly approaching, here are exhibitor stands worth marking in visiting agendas, with the new developments they are highlighting in Munich. Exhibitors are listed by hall and stand number, for smooth guided navigation.

RONDO

This year, RONDO returns to iba with a focus on solutions for breads and croissants, complete with live demonstrations of its latest solutions and features. Live demos will be staged daily at the stand, to showcase the company’s newest developments.

Fabian Bossard, head of the Marketing & Communications Department, shared the company’s trends in focus: “There is a wide variety of trends where RONDO can be of help to its customers. Automation is one of them. In addition, we see a trend towards healthier products in the market. We can support our clients in creating vegan, gluten-free and free-from baked goods. Our machines have the advantage of being able to handle even difficult types of dough.” RONDO machines also aim to provide flexibility in production, fast changeovers and quality products. © RONDO

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Hall A1

Ashworth

At iba, Ashworth is launching its newest plastic offerings. Ashworth will highlight the best of both worlds – in conveying solutions: the best metal or plastic belt offerings for customized product needs.

“Attendees will have the opportunity to view our PosiDrive Spiral ® System – the industry’s original direct drive spiral.

We will also offer demonstrations of our newest addition to our smart technology, Ashworth’s SmartOven® along with our SmartSpiral® Monitoring System,” Ashworth reveals.

The specialist focuses on customized needs with its

solutions. “Understanding and addressing the belting challenges being faced by the industry is the base for R&D. Our development efforts are led by those challenges. Belts to handle heavier loads, wider processes and that are easier to clean and sanitize have always been a focus. Longer lasting, easy to install and maintain belting are always at the top of the list. Currently, we’ve added the challenge of maintaining product orientation and expansion of our Smart Technology Systems are all being investigated,” the company highlights. © Ashworth

Hall A1

Hall A2

Unifiller Systems

At iba, Unifiller will unveil a sheetcake icing system designed for efficient top and side icing. This compact station reduces icing waste and speeds up production. The company also introduces a depositor with hybrid functionalities – the Compact+. “Unifiller’s newly 251

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© Unifiller Systems

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Hall A2

MIWE

MIWE will organize live baking demonstrations in 510 cooperation with RICHEMONT craft school at its stand, showcasing its holistic solutions for the baking industry, including its latest innovations. “Whether you run a small café or a large bakery, we have something for you to make a baker’s life easier. This goes from automation to digitalization. Some of our product highlights include the MIWE smart baking suite, MIWE ideal, MIWE condo, MIWE roll-in,” MIWE anticipates. The company will also share its take on the future of automated baking as well as its energy solutions.

In 2023 and beyond, MIWE continues to focus on core specialization areas, including bakery refrigeration for

© MIWE

created +Series Depositors blend the power of pneumatic machines with digital precision. With a smart device, operators can control speed, volume, splash reduction, precharge, and deposit pressure profiling for the most accurate deposits,” explains Sonia Bal, Unifiller’s Director of Global Marketing.

Live equipment demonstrations will be staged, featuring servo-driven depositors.

long-term dough management, for extended dough fermentation. Ease of use is a permanent focus. In terms of sustainability, MIWE prioritizes energy efficiency, incorporating features such as heat recovery and optimal heat distribution. The specialist also offers a wide range of digital solutions, from online management software to touch control, which seamlessly integrate every aspect of bakery operations, from production to point of sale.

Hall A3 270

Martin Braun-Gruppe The Bakery Ingredients Division of the Martin Braun-Gruppe is presenting new product and marketing concepts from the brands Agrano,

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Braun, Capfruit and Cresco Italia. Agrano has a focus on regional and international bread and bread roll concepts that reflect consumer preferences in the current markets.

They range from Artisano mashes, in a pasty and ready-tobake form with an additional pre-ferment component, to rustic Swiss ‘Büezer Brot’ as well as pumpkin seed concepts.

The Spicy Crust bread decoration can complete the taste and appearance of breads.

Braun also brings a new finishing concept that it describes as ‘Fusion Croissants – baked gently, topped off divinely’.

Schokobella creams (including new flavors: mango and blueberry) are used to fill and decorate the croissants.

Another trend to watch out for in the new concept folder is New York Rolls.

Vegan creations based on the Your Green Bakery range will also be presented at the fair stand. ‘Rührmasse vegan’ (‘vegan cake mix’) is a cake baking ingredient for vegan cake mixes as well as shortcrust and crumble toppings.

‘Schlagcreme vegan’ (‘vegan whipping cream’) is suitable for vegan cream fillings; it can be flavored and finished in a variety of ways. ‘Kaltcreme vegan’ (‘vegan cold cream’) can be used for vegan pudding fillings, sheet cakes and sweet pretzels.

system. PREMAX AUP top-load dishwashers pump out all the leftover food immediately from the machine, which eliminates the need for time-consuming pre-washing of plates. This saves operating costs, protects the flushing device and protects the environment, the company highlights.

Hall A3

DEBAG

DEBAG highlights its new deck baking oven, DEDEC, and the new control generation D-Control including networking software D-Connect.

Live demonstrations will be held, hosted by industry personalities such as Kullanan Wilaiwan from Thailand, owner of the Grainbaker baking school, world champion baker Johnny Chen from Taiwan, winner of the Mondial du Pain 2015, and Bread Sommelier Paul Müller from Germany.

The new PreciTaste assistance system will also be demonstrated live at the stand. The Oven Station Assistant, developed in cooperation with PreciTaste, uses market-proven AI and camera technology to recognize the type and quantity of baked goods - as soon as they are to be baked.

The new deck baking oven DEDEC has more baking capacity thanks to its double baking chamber. It still bakes on stone slabs, but on a smaller footprint and with a significantly higher baking capacity. In addition, the DEDEC can be connected with the new networking software D-Connect.

© Martin Braun Gruppe

370

HOBART

HOBART will display a wide range of dishwashing technology for the baking industry as well as products for rinsing reusable containers. For baking businesses, HOBART primarily highlights the UX/UP universal dishwashers, which can clean large-format dishes and utensils.

The PREMAX line of universal dishwashers are energy efficient and feature a side washing system in which large-format items and utensils can be washed. In addition, the patented VAPO ACTIVE steam is particularly effective at removing stubborn dirt such as dried or baked dough residues.

For bakeries with lunch menus, the company recommends the PERMANENT-CLEAN dirt removal

© DEBAG

Hall A3

© HOBART

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Hall B1

ECD

ECD will bring its thermal profiling technology to the trade fair. The handheld M.O.L.E.™ EV6 now comes with a full-color touchscreen display, delivering instantaneous data access and intuitive control. In addition to the six-channel M.O.L.E. EV6, the company’s BreadOMETER ™, CakeOMETER™, and OvenBALANCER™sensors will be demonstrated at the stand.

Ray Pearce, ECD Baking Product Manager, has worked with bakers for over 30 years, helping them integrate thermal profiling methodologies into their operations. He comments on how the company’s latest innovation can streamline baking results: “With conventional thermal profilers, data is not viewable on the tool itself,” says Pearce. “Only after download to a PC are you able to make adjustments, 124

© ECD

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which delays corrective measures. Now, M.O.L.E. EV6 enables access to information like S-Curve milestones and various profiling analysis tools in the palm of your hand, on the bakery floor, so immediate remedies can be implemented.”

Hall B1

Sveba Dahlen

Equipment showcased will include deck ovens, rack ovens, combination ovens, a tunnel oven, a proofing cabinet, dough handling machines, and complete bread production lines.

The new stone tunnel oven Artista Deli from Sveba Dahlen will be on display, as well as the F500 proofer/retarder/ freezer, and two deck ovens – the smaller D22 and the bigger D42E. “We will also bring two S-Series The King of Combination Ovens; the SRDP120 (rack + deck + proofer) and the SRP120 (rack + proofer). We will showcase the rotating double-rack oven in gas execution, V42, and the electric rotating rack oven C250,” says Ion Folea, R&D Manager Sveba Dahlen.

The new Glimek Bread Line BL600 will also be at the stand, which can process up to 6,000 pcs/hour. Twice a day, it will be turned on for live baking demonstrations.

The Suction Dough Divders SD180 and SD300 and the CR400 Conical Rounder will also be showcased.

© Sveba Dahlen

150

Hall B1

Rotzinger Group

Rotzinger unveils a hygienic conveyor for dry cleaning and a robot with an integrated buffer, as well as innovations addressing efficiency and food safety concerns in Europe. Designed for confectionery and bakery products, the hygienic conveyor is

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© Rotzinger Group

The company also presents bake- and freeze-stable vegan fillings.

In addition, backaldrin also proposes unusual materials for innovative bread ideas: the ChickpeaMix, a combination of chickpea and sesame flour, and RapsMaxMix, which combines nutrient-rich rapeseeds with durum flour, wheat sourdough, linseed and camelina seeds, as well as barley malt extract.

Hall B2

ABI LTD

ABI is exhibiting its KATANA multi-purpose robot scoring solution, which now includes a waterjet scoring tool. The company will also present Eye-Q, its new AI-enabled complete quality control system that helps analyze product quality across different stages of production.

The KATANA robot scoring system was equipped with a powerful waterjet scoring end-of-arm tool, for increased flexibility added to its ultrasonic plunge and drag blade options. It can be used for a wide range of soft products and crusty breads.

ABI’s EYE- Q solution gathers data with a high-precision degree to perfectly sort the products. It can be installed at several points on the production line (e.g., after make-up and baking, or at the packaging stage). It is adaptable for a wide range of products and classifies each product into several categories based on unique quality criteria and failure modes.

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optimized for dry cleaning, ensuring compliance with stringent European food safety regulations.

The company also showcases a hygienic conveyor for dry cleaning, specifically designed to address food safety concerns and adhere to the highest hygienic standards. It incorporates an intelligent cleaning design, featuring a foldable belt and beveled or rounded horizontal surfaces that prevent the accumulation of dirt particles and crumbs, reducing the risk of mold infestation.

Rotzinger’s Robot with an Integrated Buffer can pick and place both unpacked and packed products into various packaging formats, including cartons, cases, thermoforms and flow-wrappers. With its modular design and flexibility, this integrated solution combines delta robots, buffers and conveyors in one cell with a reduced footprint.

Hall B2

backaldrin

backaldrin presents innovative solutions including Fast Dough that can be used for baking without proofing, Quick’n Easy and stable fillings. The ingredient manufacturer will also highlight plant-based solutions and unusual ingredient offerings at its iba stand.

The latest innovation from backaldrin, which allows bakers to skip proofing, can be used to optimize the production of laminated pastries: the dough pieces are frozen after shaping, saving time, energy and space. backaldrin’s Quick’n Easy for fluid yeast dough is another iba highlight, developed to simplify processing. This dough can be pumped, making Quick’n Easy suitable for producing large quantities.

For fillings, backaldrin presents its Filling Stabiliser, which makes fillings not only bake and freeze stable, but also gives them better structure.

© ABI LTD

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Hall B2

In October, MECATHERM will launch several new solutions, including its new M-VT vertical oven for bakery, pastry and patisserie products, the M-RT – the new, easy to use molder designed for crusty breads, as well as solutions that help optimize energy consumption for production lines.

The M-VT vertical oven is suitable for baking a wide range of products, combining ease of operation and energy efficiency, according to its manufacturer: “The new M-VT vertical oven guarantees a high level of industrial performance and product quality, while reducing energy consumption. The M-VT oven’s connectivity will also enable data collection and processing.”

MECATHERM will also highlight its solutions for production line energy efficiency, aimed at lowering greenhouse gas 150

© backaldrin

www.bakingbiscuit.com 05/2023

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© MECATHERM

Hall B4

emissions and energy consumption, such as an energy recovery solution incorporated into the oven that helps reuse energy on the production line, a new system of automated management for the oven hygrometry, and a smart cooling system to reduce energy consumption during the cooling stage.

MECATHERM will also launch its new M-RT molder, enabling the molding of pointed doughs with various water ratios, an operation that closely resembles the artisanal method.

Grands Moulins de Paris

Exhibiting in the “Raw materials and ingredients” hall, Grands Moulins de Paris highlights its ID Ingredients range, solutions for industrial bakery featuring five categories of functional ingredients and flavor enhancers. They are constantly being updated with new solutions ranging from sourdough to grainbased ingredients, baking mixes, improvers and functional flour.

"Serenity Gluten Replacer is an enzyme-based solution that enables you to use up to 50% less gluten in your products, depending on the recipe and the application. It also meets consumers’ expectations in terms of reducing the number of ingredients in products,” explains Grands Moulins de Paris’s Industrial bakery commercial director, Kevin Melouli.

“ID ingredients is a creative, efficient and responsible way to meet current food and climate challenges,” he adds.

waffles, mochi donuts, mochi bread, and mochi puffs.

Chewco mixes also offer freeze-stability and are designed to meet mass-production requirements.

Hall B4

EUROGERM

EUROGERM will present its ingredient Collection #10, ‘The Art of the Signature!’. The 2023-2024 collection provides a variety of solutions to meet the needs of today’s consumers, focusing on concerns about protecting the planet or maintaining good health.

“EUROGERM has curated a portfolio of ingredients and solutions to inspire ‘artists’ and ensure every miller, baker and pastry chef has what they need to create a whole range of signature products,” the company comments (hence the name ’The Art of the Signature!’).

The ADDIGERM SOFT BRIOCHE EGGS & BUTTER FREE/ REDUC range is free from synthetic additives and has reduced sugar content. It contributes to the finished product’s carbon footprint by excluding eggs and butter.

In addition, the BIOMIX special bread with ancient grains was developed for nutrition.

310E

© EUROGERM

© GMP

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© Texture Maker

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Hall C1

KPM is showcasing a wide range of solutions, including Chopin Technologies’ rheology analyzers, Alveolab, Mixolab 2, SDmatic 2 and Rheo F4, EyePro Systems’ inline and offline vision inspection systems, its NIR Analyzers, online moisture sensors and Artificial Intelligence solutions with its new brand product SmartVisionWorks. Product demonstrations will be staged for visitors throughout the show.

“We recently introduced whole wheat Alveograph test protocol for Alveolab, the industry first. We just launched our nextgeneration starch damage analyzer, SDmatic 2, in July. We will showcase many new applications on our Mixolab 2 analyzer for vital gluten, pulse, keto flowers and other specialty foods. The latest vision technology from EyePro for bakery customers will be showcased,” says Yuegang 320

Hall B4

Texture Maker

Tapioca starch-based ingredient specialist Texture Maker brings Asian dessert trends to Europe with Chewco baking solutions. The company will showcase these baking mixes alongside new KaaS services. The company observes the growing appeal of Asian-inspired delicacies like bubble waffles, mochi ice cream, and taiyaki throughout Europe.

Its answer to this trend is Chewco, a brand, offering a range of baking mixes that harness a stretchy and squishy texture. Chewco achieves this unique texture by incorporating different types of tapioca starches into its baking mixes. It can be used to create a variety of products including mochi 215

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© KPM

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Focusing on new trends, KPM observes initiatives to leverage factory automation, IOT and big data to reduce costs and gain more insights into production processes to improve quality and food safety.

wood pellets, or hydrogen,” explains Master Baker Bernd Ludwig, a member of sales management and food technology teams at HEUFT. With its solutions, HEUFT is focusing on effectively saving energy: “How to monitor, control and plan energy consumption better and how to reuse generated heat reasonably”.

Hall C2

Verhoeven Bakery Equipment Family

Verhoeven Bakery Equipment Family will focus on sending the message of being solution-oriented: “Most of the solutions are custom made, creative and innovative. We demonstrate this by displaying the most advanced machines in the modern bakery: VACTORR A & B, part of our vacuum cooling and baking portfolio,” René van Ass, Business Development Coach, anticipates.

The company highlights working together with its clients to develop the most suitable solution to their challenges. “We are focusing on these and we are able to provide answers and clear solutions to save energy, labor, ingredients, time and space, and to reduce waste,” he adds.

The Dutch company will organize live demonstrations every day, throughout the show, to showcase the benefits of vacuum cooling and baking.

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ICECOOL

ICECOOL will exhibit its YUKON blast freezer as well as one of its slow- and cool proofers. “We will inform you on how to save and manage energy in a day-to-day business efficiently with ISAVE, our energy management concept, and we are baking live with HEUFT to demonstrate our innovative cooling and proofing technology,” explains Peter De Naeghel, – Managing Director ICECOOL INTERNATIONAL. The company will also highlight its heat recovery system as well as its environmentally friendly refrigerants R744 [CO2] and R455A. ICECOOL is investing in R&D, especially in the industrial field. Its BLASTFREEZER LINEAR TRANSPORT as well as BLASTFREEZER SPIRAL TRANSPORT and BLASTFREEZER ELEVATOR are the newest developments.

© BVT

© ICECOOL

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Hall C2 Hall C2

Schubert

At this year’s iba, packaging machine manufacturer Schubert will have its own stand for the first time, where it will highlight flexible, efficient and environmentally friendly packaging solutions for the bakery sector. Schubert-Consulting offers independent advice on the entire supply chain, while the turnkey experts design, configure and deliver complete production lines. The experts from Schubert-Consulting and the Turnkey division can support customers in developing and carrying out their customized packaging solutions for bakery products – from concept through to implementation. +++ 160

HEUFT

HEUFT is bringing its newest hybrid heat exchanger to Munich this October, as well as a deck and a trolley oven. Its thermal oil system will be used to bake live at the show.

One of HEUFT’s New Efficiency – ’NE’ heat exchangers will be highlighted at the stand, as well as a VATO deck oven and a VTR trolley oven. “In addition, our newest development is a hybrid heat exchanger, which gives the possibility to choose between electricity or gas/fuel. For example, electricity can be used during the daytime, when solar panels are producing electricity, and gas during the night. Other alternatives can also include burning liquid gas, biogas,

© HEUF T

© Schubert

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For our complete guide to this year’s exhibitor stands, read the iba ’23 special in baking+biscuit International, issue 4.

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Source: ttz Bremerhaven

Solving unexpected quality issues in baked goods A systematic approach to fast and economical problem resolution.

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By Dr. Julien Huen, Imke Matullat, Dennis Fehner, ttz Bremerhaven

It is a recurrent issue well-known in food processing companies: sometimes, a product that has been successfully manufactured over a long period of time suddenly exhibits a quality problem, although nothing has been intentionally changed (Figure 1). The problem may be discovered by routine quality control, routine sensory analysis, or by customer complaints. Examples include variations of volume, shape, pore structure, color, flavor and mouthfeel, in particular.

In such cases, it is vital for the company to be able to react quickly, as the persistence of the issue may cause critical losses of revenues and reputation. ttz Bremerhaven is often consulted in these issues and has developed over time a systematic approach that can serve as a guideline when such situations are encountered. In this article, we first describe this overall approach and then illustrate its application with a practical case study from a German artisan bakery.

We are not saying that a single approach is appropriate for solving any kind of quality issues, nor that all measures described below need to be applied in all cases. On the contrary, given the need to solve the problem quickly and the always limited amount of resources, it is important to focus on a few selected measures that promise the best result. Therefore, the approach described below should be understood as a toolbox from which single components can be chosen and combined on a case-by-case basis.

Set up a problem-resolution task force Coping with the provisory quality concern, identifying its cause and implementing a durable solution will require concerted action from all concerned functions of the company. Typically, production, quality management, technical services, sourcing, marketing and sales as well as public relations may need to be involved. It is advisable to set up a task force and to define one person responsible for coordinating the actions. Information needs to be communicated transparently and without delay within the task force.

Describe the problem well The first step towards a solution is to make an accurate assessment of the issue. This implies addressing the following points in particular: + Which quality properties are of concern? Are these properties measurable and has reliable data been collected in the company on these properties (Figure 2)? + In the case of a specification being agreed with the customer, is the product clearly out of specification? Or is the product of slightly inferior quality but, depending on subjective appreciation, still suitable for the market? + Which products are concerned? In the case that the problem occurs with several products, identifying the common points between these products will give indications of the possible cause. + When did the problem occur? Was everything fine up until a certain date, and has it occurred all the time ever since? If so, was the deviation slow before that date,

Source: ttz Bremerhaven

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Figure 1: Same recipe, same process, different results – Standardizing the quality of baked goods is difficult. When the reason for a quality deviation is not obvious, a systematic analysis of the root causes needs to be performed

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Source: ttz Bremerhaven

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Figure 2. An instrumental measurement of relevant product properties (here: dimensions, shape and specific volume via VolScan Profiler and pore structure via C-Cell) is helpful to clearly define the quality targets, identify deviations at an early stage and describe quality concerns precisely

even though the values were still in the safe range? Or is the problem occurring only from time to time, in a non-systematic way?

To describe the problem accurately, it is important to gather both relevant data and reports from production and quality control staff. Personnel in daily contact with the product will have developed a high level of personal expertise over time and may be able to contribute very valuable information.

Decide how to deal with the quality problem as long as it remains unsolved It must predominantly be decided whether the product(s) can still be put on the market or not. This may imply negotiation with customers, for instance, to agree on a modified specification for a limited amount of time. If the decision is made to stop deliveries, customers need to be informed appropriately and, if necessary, the product recalled.

Find out what has changed upfront Even though nothing has been changed intentionally, the fact that a quality concern occurs implies that something has changed. There are basically two possibilities: either one of the raw materials has modified properties, or something has changed in the process.

On the raw materials side, analytical values need to be checked, showing possible deviations. Even if the values are still within the specified range, an unusual change of values may cause unexpected effects. Hence, in most cases, specifications are agreed upon without testing the full range of variations. It must also be kept in mind that specifications and the corresponding analytical certificates only imperfectly describe the quality of the raw materials.

Some relevant properties may just not be covered by the specification and not measured. It can be meaningful to talk with suppliers about whether any changes have taken place in their facilities.

On the process side, possible deviations of process parameters need to be checked, as well as a change in personnel behavior (new staff or taking on incorrect practices). Modified environmental conditions, especially the temperature of production and storage areas, may also cause modified product properties.

The assessment of changes having occurred in raw materials and in processing can be performed from two points of view: on the one hand, based on an existing representation of the factors that may have an influence on the concerned product property. On the other hand, all directions should be evaluated, with the idea that any change of any kind may have an impact on the product. The first approach has the advantage of being more focused, while the second is often helpful in determining causal relationships that have not been explored thus far.

If the proposed investigations have allowed identifying a change that clearly appears to be responsible for the problem, the next step will be to try to remedy this change, which will solve the issue. Nevertheless, it may happen that it is not possible to remedy the change. For example, raw material properties may have changed as a consequence of climatic events, and it might not be possible to source the raw material at its original quality anymore.

In addition, it may happen that the analysis of changes has revealed only several possibilities but no single clear cause (keeping in mind that the cause may be multifactorial). In

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Source: ttz Bremerhaven

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Figure 3. For understanding complex causal relationships, it is valuable to characterize the product matrix with a variety of analytical techniques. Confocal microscopy can be one of them

the worst-case scenario, the analysis of changes may have revealed no possible cause at all.

Reproduce the problem on a pilot plant scale and test potential mitigation approaches In all of these cases, it may be worth going to the lab to develop a better understanding of the effect of different factors on product quality and test mitigation strategies.

Testing different scenarios on a pilot plant basis is much faster and cheaper than testing on the industrial production scale.

Different hypotheses may be tested alone and in combination, both recipe and process-wise.

The solution may be either to change one single cause back to its original state, or to redevelop the product. The latter applies especially if it is not possible to restore the original conditions.

Develop a deeper understanding of causal relationships Pilot plant trials may be performed on a trial-and-error basis, which in some cases can be the fastest way to solve the issue.

However, with a view to preventing the reoccurrence of similar quality problems, it is of fundamental importance to develop a deep understanding of the factors affecting product quality. This involves in particular the following actions: + Be aware of the current state of relevant research, and follow new scientific publications

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+ Use diverse analytical techniques to make a comprehensive description of relationships between raw material quality, process conditions and product properties (Figure 3). This may involve physical, chemical, microbiological and microscopic characterization as well as sensory assessment. + Implement data management systems for systematic documentation of analytical values and process conditions. Make correlation analysis on broad data sets to understand the effect. + Make written documentation of the representations of causal relationships that are present within the company.

This allows knowledge to be captured, especially in the case of staff fluctuations. In addition, these representations need to be challenged and improved over time in the light of new observations made.

Case study: Off-flavors in pretzel buns To illustrate the approach described above, we are presenting a project on which we worked a few months ago.

A German artisan bakery faced a quality concern with its pretzel buns (Figure 4). The production process involved kneading, weighing and forming dough pieces, freezing the dough pieces, and frozen storage for a duration of 1 to 4 weeks, followed by dipping them in an alkaline bath, thawing, proofing and baking.

The company observed that if the dough pieces were stored for more than two weeks in the frozen chamber, an off-flavor occurred in the final products, which led to complaints. The reason for the quality problem was unclear, which motivated the company to ask ttz Bremerhaven for support.

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At first glance, the problem seemed to be quite unusual and surprising, as the frozen products were perfectly fine after one week of frozen storage, and quality changes are not expected to take place within a few weeks in a frozen product.

Given the relatively small size and the limited resources of the company, it was of utmost importance to choose a pragmatic approach and to limit the investigations to a reasonable amount. Our first step towards identifying the cause of the problem was a sensory assessment of the concerned products (raw dough and baked pretzel buns).

The bakery had not been able to make a clear description of the nature of the off-flavor, and it was therefore first hypothesized whether the problem may have been caused by molds or by the migration of volatile substances from the frozen storage area to the product.

In ttz’s sensory assessment, both the dough and the products were described as metallic, pungent, and rancid.

With this in mind, fat degradation was considered to be the most probable cause of the quality concern. In order to verify this hypothesis, fat was extracted from the final product (both samples with and without off-flavor) and two parameters of fat degradation were analyzed: the amount of free fatty acids and the peroxide value. It appeared that, while the amount of free fatty acids was identical, the peroxide value was dramatically higher in the samples with off-flavor (the values were over 5 times higher). This confirmed the hypothesis of fat degradation as a possible cause of the off-flavor.

Supporting the Craftspeople at the Heart of your Brand

Nevertheless, it was still unclear why fat degradation occurred, especially under frozen storage conditions. The fact that the off-flavor was already present in the frozen dough indicated that the degradation happened during storage and not in the subsequent phases of proofing and baking. Looking at the recipe and the process, one possible mechanism was hypothesized, although it has, as far as we know, not been described so far in scientific literature. The recipe of the product contains a bakery improver. After asking the manufacturer, we were informed of the enzymes it contains, one of them being a glucose oxidase. Glucose oxidases catalyze the oxidation of glucose to hydrogen peroxide and D-glucono-δ-lactone.

Hydrogen peroxide, in turn, is supposed to react with thiol groups of gluten, favoring the formation of disulfide bridges, hence increasing gluten polymerization and strengthening the rheological properties of the dough.

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However, it seems conceivable that hydrogen peroxide may also reduce with fat, causing its degradation. ttz asked an enzyme manufacturer about this scenario, who confirmed that this side effect of glucose oxidases has already been observed previously. What is more, as

KPM supplies quality and process control solutions to protect brand value and reduce operational costs

kpmanalytics.com

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at all. These findings supported the validity of the formulated hypothesis.

To get more confidence in the results, the peroxide value was measured in the final products. It appeared all the products had an increased peroxide value with the exception of products number 5 and 6, which were the only ones with only glucose oxidase. Interestingly, the highest peroxide value was found in product 2, without margarine, which had only a light off-flavor. It was hypothesized that in the absence of margarine, hydrogen peroxide will react only with the fat coming from wheat flour. As the total amount of fat in the product is lower, the degree of degradation may be higher, leading to higher hydrogen peroxide values.

Alternatively, even if the degree of degradation is higher, a lower fat concentration in the product can explain a lower sensory perception of the off-flavor.

Based on the results obtained at ttz Bremerhaven, the bakery switched its recipe to an improver without glucose oxidase, which solved the quality problem. From a scientific point of view, further investigations would have been possible to further understand the exact mechanism of off-flavor formation but from an economical perspective, it was sufficient that the problem was solved.

Source: ttz Bremerhaven

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Figure 4: Off-flavor check of pretzel buns at ttz Bremerhaven

hydrogen peroxide is known to be highly reactive, it appeared plausible that it could react with fat even at -18°C. As the next steps, ttz Bremerhaven designed and conducted some baking experiments that would help solve the issue.

As it was important to solve the problem quickly, it was decided not to focus only on the main hypothesis but also to test other possibilities. The test involved baking different variations of the original recipe at ttz according to the original process of the bakery, storing the dough pieces in the frozen state and baking the products every week. The variations chosen included: (1) original recipe, (2) no margarine, (3 and 4) margarines from other manufacturers, (5) no bakery improver, (6) alternative bakery improver without glucose oxidase, (7) alternative wheat flour.

The sensory tests of the final products showed that a strong off-flavor was observed after 4 weeks of storage in the products 1, 3, 4, and 7. This showed that the problem could be reproduced under pilot plant conditions, and that using another margarine or another wheat flour does not solve the issue. Product number 2, without margarine, showed a light off-flavor, whereas products 5 and 6, without bakery improver or without a glucose oxidase, showed no off-flavor

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It must be pointed out that in this particular case, the quality concern had a clear single cause, which could be clearly established and remedied with one single change in recipe.

This is not always the case, as sometimes reaching the desired product quality is more a question of reaching a balance point between raw material properties, recipe proportions and process conditions. Small deviations from different sides may over time bring the overall system out of balance, without one single cause being responsible.

Those cases may be more difficult and more frustrating to deal with: in most cases, it is possible to restore the targeted product quality by adapting the recipe and/or the process, however, there is no guarantee on how long the solution will last, as it is not possible to predict future variations of raw material properties (which may be due to natural fluctuations).

Maintaining quality – a Sisyphean task?

In conclusion, it can be said that food products are complex systems and that it lies in the nature of things that impromptu quality issues may occur. When this happens, a clear issue management strategy needs to be adopted and executed.

In the longer term, such events should be used as a chance to increase the company’s expertise. Documenting product knowledge, systematically collecting product and process data, identifying deviations before they get critical, being aware of the state of scientific research and getting all relevant staff involved are keys to getting product quality under control. +++

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Physical, chemical and rheological changes in bread during dough mixing Bread-making is a scientific symphony of physical, chemical, and rheological processes. Beyond the apparent simplicity of mixing flour, water, and yeast lies an intricate web of molecular and mechanical changes that transform these raw materials into bread.

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By Dimitrios Argyriou, Food Scientist and Managing Director, Grainar

Dough mixing is regarded as the most crucial step in the bread making process. The primary goals of mixing are : + Ingredient homogenization + Flour hydration + Gluten network formation + Air bubble incorporation

This series of interconnected physical and chemical phenomena make mixing an indispensable step, impacting everything from dough texture to bread volume and flavor.

The initial stage: hydration and protein activation The cornerstone of dough formation is the hydration process.

Water activates the flour’s primary proteins – gliadins and glutenins – enabling them to uncoil from their compact, globular shape. During this stage, water molecules break through the flour particles, facilitating the swelling and dissolution of proteins and starch granules. The water absorption thus initiates the gluten network's formation, albeit in a rudimentary state.

Non-covalent interactions and gluten matrix formation Once the proteins are activated, the dough undergoes a series of transformations facilitated by non-covalent interactions, such as hydrogen and hydrophobic bonds. The proteins begin to elongate and stretch, weaving an organized matrix that effectively traps water and other molecules, thereby gaining structural integrity. The Farinogram (Figure 1), a tool used for quantifying dough consistency, shows a progression from an inchoate, lumpy mass to a cohesive, elastic structure, hitting a ‘peak development‘ stage where the dough exhibits optimal rheological properties for baking.

Molecular cross-linking: the role of sulfhydryl groups In the world of proteins, the formation of disulfide bonds (SS) between sulfhydryl groups (SH) of amino acids is a pivotal molecular event. These SH groups exist as individual chains in their reduced form. When oxidized, the SH groups link to form SS bonds. This bonding is particularly significant for glutenin molecules, as it enables them to cross-link and create a larger, stronger network (Figure 2). This

Figure 1: Farinograph and Farinogram

Source: Brabender

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Source: Dimler, R. J. 1963

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Figure 3: Photographs demonstrating the extensibility of gluten (left) and its components gliadin (center) and glutenin (right)

Figure 2: The development of the gluten network according to Shewry et al. (1987), Belton (1999), and Veraverbeke and Delcour (2002)

molecular cross-linking contributes to the dough's elasticity, stability, and viscosity, which are crucial properties for bread-making.

Gliadins Vs. Glutenins: complementary roles in gluten formation While both gliadins and glutenins are instrumental in creating the gluten network, they serve distinct roles. Gliadins offer extensibility and viscosity to the dough but lack the ability to form intermolecular SS bonds. Their role is confined to intramolecular bonding due to the structure of their cysteine

amino acids. Glutenins, however, possess an extra cysteine residue at the end of their chain that can form intermolecular SS bonds, thereby serving as the backbone of the gluten network (Figure 3).

Mechanical forces: shear and elongation Mechanically, dough mixing can be broken down into two key forces: shear and elongation. These forces cause extreme strains on the dough, sometimes as high as 500,000%. The high shear rates of 10 to 100 s^-1 are adequate to disrupt the hydrating flour particles‘ outer layers. This shearing action exposes more surface area for hydration, further enhancing the potential for gluten network formation and refinement.

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Rheological shifts: elasticity and viscosity

Grainar

In terms of rheology, the dough transitions from a sticky, highly viscous mass to a more stable and elastic form as mixing proceeds. These changes are marked by shifts in key rheological attributes, such as elasticity, plasticity, and viscosity. The Farinogram captures this evolution, reaching a peak where both elasticity and viscosity are at their optimal balance.

In 1946, Dimitrios Argyriou Sr. founded a local stone mill.

Soon after, he expanded it with the building of a new modern cylinder mill. His son, Christos, took the lead in the 70s and set the foundations of what Grainar is today: a specialist in enzyme-based improver solutions, product development and process optimization.

He also started the passionate work of sharing knowledge

The impact of aeration and starch interactions

and discoveries with other millers. This legacy continues to-

The dough's rheological characteristics are not merely a function of protein interactions. They are also influenced by the air content and starch structure within the dough. Air bubbles entrapped during mixing, and the foam structure from yeast fermentation, play roles in dough rise during baking. Additionally, the interaction between the protein network and starch granules also contributes to the dough‘s stiffness and rheological behavior.

day, as the company still thinks, approaches processes and acts as a miller.

“We are not just good at understanding flour, but we consider ourselves supportive colleagues who are eager to do what is needed to help millers and bakers succeed,” is the company’s belief. Grainar provides its products and services to some of the most admired millers and bakers.

glutenins, initiating the gluten network formation.

+ Proteins stretch and elongate, forming an organized matrix via hydrogen and hydrophobic bonds.

+ Disulfide bonds (SS) form between sulfhydryl groups Figure 4: Dough structure after mixing

Overmixing: a molecular and mechanical downfall The perils of overmixing manifest as a breakdown in both molecular and mechanical properties. Excessive mixing disrupts the delicate balance of SS bonds and non-covalent interactions, leading to a loss of structure. This is signaled by a reduction in the dough's torque and an increase in plasticity, as captured by the Farinogram.

Conclusion Bread-making is a complex interplay of chemistry, physics, and mechanics, each contributing to the dough’s final characteristics. Understanding these intricacies requires an integrated perspective that bridges molecular interactions with mechanical forces and rheological properties. By harmonizing these elements, one gains not only a deeper scientific understanding of what happens during dough mixing but also the key to optimizing the age-old art of bread-making.

Key points summary: + Water absorption activates flour proteins, gliadins and

Source: Courtin 2002

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(SH) of amino acids, significantly contributing to dough's elasticity and stability. + Gliadins add extensibility but can only form intramolecular bonds. Glutenins serve as the backbone of the gluten network due to their ability to form intermolecular bonds. + High shear rates and elongation during mixing disrupt flour particles and enhance the potential for gluten network formation. + Dough transitions from being sticky and highly viscous to more elastic and stable as mixing proceeds. This is tracked using a Farinogram. + Air content and starch structure contribute to dough stiffness and influence its ability to rise during baking. + Excessive mixing breaks down molecular and mechanical properties, leading to loss of structure and increased plasticity.

Note: The terms ‘kneading’ and ‘mixing’ are often used as synonyms in scientific literature, even though they actually explain a temporal sequence of physico-chemical phenomena.

Dough mixing: Refers to the initial phenomena of homogenization and hydration of the ingredients Dough kneading: Refers to the subsequent development of the gluten network In this review, both kneading and mixing terms are used to refer to all the above phenomena. +++

References Reviews in Food Science

1.

Dimler, R. J. 1963. The key to wheat’s utility. Baker’s Dig. 37(1):52-57.

2.

Shewry, P. R., & Tatham, A. S. (1997). Disulphide bonds in wheat gluten pro-

4. and Nutrition, 42(3), 179–208.

teins. Journal of Cereal Science, 25(3), 207–227.

5. Belton, P. S. (1999). Mini review: on the elasticity of wheat gluten.

3. Veraverbeke, W. S., & Delcour, J. A. (2002). Wheat protein composition and properties of wheat glutenin in relation to breadmaking functionality. Critical

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6. Journal of Cereal Science, 29(2), 103–107.

7.

CM. Courtin: Journal of Cereal Science35(2002) 225–243

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Munich : Halle B1, Stand 350

… require individual solutions.

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© FomaA – stock.adobe.com

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An automated method to hit the ‘sweet spot’ in cookie flour quality An internationally recognized method exists to characterize the water absorption capacity with ease and efficiency.

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By: Lena Bosc-Bierne, Food Applications & Products Manager, KPM Analytics

Have you had a walk down the cookie or biscuit aisle of your local supermarket recently? You can probably picture the wide varieties of colorful packaging, cookie styles, shapes, flavor varieties, and many other features cookie companies use to help their product stand out. These attention-grabbing efforts are not just creative marketing techniques; they represent a cookie brand’s promise of a unique snacking experience.

Like many baked products, cookie flavor is an essential aspect of overall quality, as is their texture and appearance.

Consumers open each package of cookies with expectations that the product they have purchased has these important traits with every bite they take.

However, without tight quality control measures at critical moments of the cookie manufacturing process, the experience immediately becomes an empty promise, which reflects poorly on the product brand.

High-quality products begin with superior quality control Flour quality is paramount in manufacturing all baked goods and snack foods. Soft wheat flour is preferred to produce cookies because it binds less water than hard wheat flour.

Water relationship in cookie dough affects a cookie's texture, softness and crunch, and overall appearance, which are at the core of product quality and consumer expectations.

Since most cookie recipes are relatively simple – a mixture of water, flour, sugar, fat, salt, or baking powder – the quality of the finished product depends significantly on the flour. From a production perspective, it is crucial to have good water absorption capacity to formulate the dough

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while also managing dough stickiness. The dough is then divided by volumetric dosers to portion the cookie dough into precise quantities.

At this stage, managing dough consistency and viscosity is critical. During rolling, the dough should show good extensibility. Then for cutting, dough that retreats its shape after cutting (also known as dough elasticity) will negatively impact the finished product size.

There is also a cost-control factor when it comes to cookie flour quality procurement, too. The baking process must remove as much water as possible from the dough to produce a cookie. Flour with a higher water absorption capacity requires a longer baking time and temperature to achieve an ideal final product. Naturally, this process consumes energy, which affects the bakery’s bottom line.

However, there is good news for bakers: Most of these quality variables can be controlled by making extra efforts to understand and manage the water absorption capacity of the flour.

Mastering water absorption control A flour’s water absorption capacity is often top-of-mind for many manufacturers. Water absorption capacity directly affects the handling process of dough, including its firmness, extensibility, elasticity, and other rheological qualities.

However, even if a flour delivery has similar compositions and rheological properties from one batch to the next, it can still exhibit different performances in the process line.

For this reason, analyzing the functional properties of flour

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before production becomes a significant phase in a cookie producer's quality control program.

milling process and affects dough rheology. Finding a balance in damaged starch within flour can help manage sticky dough, cracked products, and similar quality issues. + Pentosans: A polysaccharide that influences a dough’s viscosity. Managing this parameter can also provide benefits to improve final product shelf life.

When a baker understands which of these components binds more water, they are better equipped to anticipate final product properties.

Source: KPM Analytics

Like all baked products, cookies need water to form a dough.

Still, moisture must be removed efficiently during baking to produce the final product. There is a ‘competition’ between three core flour components for this water: + Glutenin: A significant protein component in flour that contributes to the elasticity and strength of a dough, which is vital for the final product's structure.

+ Damaged starch: Ground starch that results from the

Figure 1: The SRC method analyses the swelling behavior of principal flour polymer networks in the selected single diagnostic solvents shown here ADVERTISEMENT

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SRC data explains the functional reasons a flour behaves the way it does during production, allowing bakers to troubleshoot and adjust their process to ensure a consistent final product. Most bakers use SRC data to specify SRC profiles for specific products in their product line to help produce consistent end products from each batch of flour.

Source: KPM Analytics

Many baked goods and snack food manufacturers have adopted the Solvent Retention Capacity (SRC) Method (AACC method 56-11.02) into their flour quality control measures to measure these characteristics. Developed in the 1990s, the SRC Method benefits cookie and cracker producers.

Figure 2: The SRC-CHOPIN 2 from KPM Analytics, shown here, includes all components necessary for cookie producers to conduct SRC testing in a fraction of the time compared to the manual procedure.

The SRC method has been a manual process for years, with several successive steps performed in a quality control lab.

Many bakeries today still conduct the SRC method on non-standardized equipment, which presents the risk of operator-dependent results through the manual process.

This manual method has made the SRC Method challenging to standardize and regulate across multiple production locations.

As shown in Figure 3, the automated SRC testing method can provide more repeatable and reproducible results than the manual method. This tool presents a game-changing analysis application for many cookie producers to anticipate cookie flour quality on their production line without complicating their quality control efforts.

An automated, internationally recognized SRC solution exists

Identifying the key elements affecting cookie quality is essential to implement effective quality control in production.

A common knowledge base can be applied; however, the mechanics of each production line can also influence the results. Cookie manufacturers can take a more modern approach to objectively measure what works on their line and focus their quality control on the most critical elements.

Cookie producers that make the SRC method an integral part of their quality assurance program led the efforts to develop an automated process. Considering the volume of manual steps of the manual method, quality lab technicians were spending much of their time performing this routine test.

These demands led to the development of the automated SRC testing machines. These systems meet standard approvals from the AACC (56-15.01) and, as of 2022, the ICC Standard 186, as a precise alternative to the cookie producer’s usual manual method.

Vital quality assurance data helps cookie producers deliver quality

As demand for new cookie recipe formulations and flavors increases, the texture and quality consumers expect should not suffer. However, thanks to technology, incorporating measures or procedures to ensure flour quality does not need to add extra burden or responsibilities to cookie manufacturers. +++

Source: KPM Analytics

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Figure 3: Comparison of the performance of the automated SRC-CHOPIN 2 method and the manual method using the coefficient of variation (CV).

The lower the CV, the more repeatable/reproducible the process (Cereal Foods World, Vol. 64, No. 3)

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STEP INSIDE

YOUR FUTURE Halle Stand B3 110

MARKETS

© Tayyab – stock.adobe.com

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Healthy snacking trends in the bakery market Consumers snack for a variety of reasons. This can range from being a substitute for a skipped meal, needing an energy boost, or for a moment of escapism and comfort.

+

By Kate Kehoe, Marketing Executive, FMCG Gurus

Bakery products are popular among consumers for snacking, with 63% of global consumers turning to biscuits and cookies as their preferred type of snack. This is due to biscuits and cookies often being associated with more real, authentic and nutritional ingredients, which in some cases can contribute to an overall healthy diet.

As consumer attention is increasingly being drawn to ingredient claims when choosing between snack products, bakery brands should position their products around being free from dietary evils and instead position products as functional and nutritious snacks.

from certain artificial ingredients, chemicals and sugar content in products, and instead want products and specific ingredients associated with naturalness and nutritional value.

“Some of the most popular health claims and functional ingredients include digestive health and fiber-rich foods, with 49% of global consumers turning to these kinds of products.”

Kate Kehoe, Marketing Executive, FMCG Gurus

Healthy indulgence and offering purity When shopping for bakery products and snacks, consumers are paying more attention to the ingredient lists on products.

For example, FMCG Gurus consumer insights highlight that 64% of global consumers check nutritional labeling at least some of the time when choosing a snack. The ingredients of products are significantly influencing consumer perceptions around the value, quality and healthiness of bakery products.

By paying closer attention to the ingredient lists of products, consumers are seeking reassurance that the products they are consuming are packed with natural and authentic ingredients. FMCG Gurus findings reveal that 65% of global consumers who check nutritional labeling some of the time look for sugar content, in particular. Sugar is the ingredient most commonly investigated when consumers check the pack. This highlights that consumers are swaying away

www.bakingbiscuit.com 05/2023

To aid consumer interest in bakery products, companies must have streamlined ingredient lists on their packaging to infer that products are natural and nutritional. In addition, free-from claims have been proven to boost consumer interest. For instance, FMCG Gurus consumer insights illustrate that the most appealing free-from claims are non-GMO (67%) and Natural (66%). Due to this, it is essential that bakery brands make their nutritional labeling clear and simple for consumers so that consumers can easily make decisions on the nutritional profile of bakery products.

Functional ingredients and claims It is evident that consumers have adopted a more proactive approach to their health and wellness in recent years. As a result, consumers are choosing products that have active ingredients, as well as health benefit claims. For example, FMCG Gurus consumer insights highlight that some of the

MARKETS

most popular health claims and functional ingredients include digestive health and fiber-rich foods, with 49% of global consumers turning to these kinds of products. Consumers are recognizing the link between their digestive health and their overall health, so if bakery brands promote products that aid digestive and overall holistic health, these will be of high appeal.

Sustainability and wellness Consumer concern around the environment and sustainability has continued to grow over the years. Some consumer concerns are positioned around the direct impact this is having on health and a concern that brands are not doing enough to protect the planet.

This demonstrates that bakery brands must place sustainability at the core of their business and employ sustainable strategies to restore consumer trust. In doing so, brands must be transparent and proactive in tackling environmental issues in their industry by communicating their sustainable initiatives to consumers. Some examples of these initiatives can include smarter production techniques, as well as addressing the issues of climate change and waste management. FMCG Gurus market research has shown that 61% of global consumers find upcycled ingredients appealing.

This demonstrates that while food waste has become a major concern amongst consumers, bakery brands should aim to be more resourceful in their production and disposal of food waste.

Emotional wellness and affordable indulgence Many consumers have begun to put their emotional wellness at the forefront of their lives. This can range from their sleep hygiene to learning how to deal better with stress and anxiety. Due to this, consumers are also becoming more aware of the link between emotional wellness and their long-term health. FMCG Gurus findings show that 69% of global consumers are interested in food, drink and supplement products that will help to improve their sleeping patterns. As a result, this offers bakery brands the opportunity to present ingredients such as botanicals and CBD which are associated with relaxation. With the introduction of these ingredients, brands should reassure consumers about the safety and efficacy of them.

Amid today's uncertain times during the cost of living crisis, many consumers are looking for ways to make themselves happier. Often, consumers turn to products that will provide them with an affordable indulgence and boost. FMCG Gurus market research offers insight into how 40% of global consumers have sought out products that remind them of past, simpler times. This highlights that the bakery industry has the opportunity to promote their products under this branch of affordable indulgence and promote premium products as offering moments of comfort and escapism for consumers. +++ This article is based on FMCG Gurus: Health & Wellness in the Bakery Market in 2023.

© carl-heyerdahl-unsplash.com

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

FROM COMMUNAL BAKEHOUSES TO BIOTECHNOLOGY

How do we build a better baking future?

Clean-label, functional ingredients go a long way toward the sustainability concerns – of the baker, the material supplier and the consumer.

By Judith van Peij, Innovation Manager dsm-firmenich and Fatima

+

Just before Christmas last year, a London baker called Maisie Collins opened up an industrial-sized oven for her local community to use free of charge.

This generous gesture was not only good for people’s pockets; it was also great for the planet because, of course, it reduced energy consumption. However, this idea was far from original. Communal bakehouses were used in medieval Europe for centuries; and today they remain popular in many parts of the world, including North Africa and the Middle East. dsm-firmenich specializes in sustainable baking ingredients, particularly enzyme technology. However, the company also recognizes its role in the larger food system’s necessary rapid changes. Consequently, we're shifting from our traditional value chain role to impacting how society produces and consumes food, including daily staples such as bread and treats, croissants and cake.

Back to basics – with biotechnology We are now living in an age where the biotechnology that forms the foundation of our business is already able to help solve many of the sustainability challenges faced by the baking industry. But, as the London baker Maisie Collins has shown, history still has something to teach us by tapping into the ‘back to basics’ approach of our ancestors.

Could the real key to building a better baking future therefore be to find creative new ways to marry the two things together? dsm-firmenich thinks so.

www.bakingbiscuit.com 05/2023

© DSM

Zoundri, Head of Sustainability dsm-firmenich

Consider a scenario where communal baking ovens become a reality for consumers. This prompts a thought: could this concept extend to the industrial baking sphere? Picture the advantages in sustainability if manufacturers adopted expansive industrial-communal bakehouses, perpetually operational and manned by adept artisan bakers. Their expertise in optimizing raw materials could yield remarkable results. However, in altering the existing supply chain to accommodate such innovations, the consistency of bread © Anneleven – stock.adobe.com

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

“Thanks to the inherent sturdiness and versatility of enzymes, they can make lower-quality flour sources and/or challenging raw materials like wholewheat flour perform better – thus enabling bakers to use these (locally sourced) ingredients without compromising on the quality of their products, and all the while substantially lowering their carbon footprint.” © DSM

Judith van Peij, Innovation Manager dsm-firmenich and Fatima Zoundri, Head of Sustainability dsm-firmenich

quality faces challenges. This is precisely where biotechnology might step in, offering solutions to maintain the same superior bread quality consistently.

enabling bakers to use these (locally sourced) ingredients without compromising on the quality of their products and all the while substantially lowering their carbon footprint.

Thinking global, acting local on raw materials

Replacing the bad, naturally

Closer to home for dsm-firmenich, there’s another great example of combining biotechnology with a ‘back to basics’ approach: the increasing use of locally sourced raw materials for baked goods.

This of course taps into a major consumer trend for greater transparency and provenance of the foods they buy, with ‘fewer air miles’. After all, bread was not only the original plant-made food; it was also one of the simplest, often containing just three basic ingredients.

For nearly 10,000 years, bread was made using whatever raw materials could be farmed locally. In the industrial age, this naturally changed, with ingredients often being transported many hundreds (indeed thousands) of kilometers, with a huge carbon footprint – and price tag. The reason for this has been amplified by the war in Ukraine, where in many cases manufacturers are left with no choice but to use locally sourced ingredients, which can in certain cases be inferior in quality.

In this scenario, however, there is a solution to this sustainability challenge, and indeed many others. In fact, many manufacturers are already using it today: baking enzymes.

Enhancing baked goods with enzymes

Because they are classed as processing aids, enzymes have a cleaner label. In fact, baking enzymes are able to have the same functionality as traditional, synthetic emulsifiers like DATEM used in baked goods.

Making haste to less waste Perhaps most importantly of all, baking enzymes help solve another major sustainability challenge by taking a huge bite off of food waste – extending the shelf life of baked goods by up to 10 days or more by delaying staling in baked goods. Once again, we see how biotechnology can be combined with the back-to-basics approach of our ancestors – where food waste was simply not an option.

Enzymes are proteins that occur in nature and enable biological reactions to happen faster. dsm-firmenich’s baking enzymes are produced via a long-established microbial fermentation process and then used by customers to make targeted and predictable molecular conversions in the recipe.

Speaking of waste, dsm-firmenich is vocal about the role of baking enzymes in our food system: from how they can influence what ingredients bakers can use, to the recipe and manufacturing and to how people consume baked products.

In turn, these bring a wide variety of properties to baked goods, including improved dough handling, dough stability, volume, crumb structure and softness – to deliver the sensory qualities that consumers love. Crucially, they can achieve this with challenging flour types and other grains.

It’s long been said that safeguarding our planet and food system is everyone’s responsibility – not just commercially but individually. The closer we look at the challenges faced by the baking industry, the truer this statement becomes. Of course, we don’t have all the answers, but the company does have the people and desire to continue creating a better baking future by keeping one eye on the past, and the other very firmly on the continued future of bioscience!

Thanks to the inherent sturdiness and versatility of enzymes, they can make lower-quality flour sources and/or challenging raw materials like wholewheat flour perform better – thus

+++

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TRENDS

The sweet tooth meets the better-for-you mindset

© Dawn Foods

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Today’s consumers are taking a more proactive approach to their diets and being more mindful of how their food choices affect their personal health, their community and their planet. This increasing interest in better-for-you foods continues to fuel product innovation, including in the sweet bakery market.

+

The category has now evolved to include a number of priorities, such as using natural colors and flavors, added protein, or reduced sugar, in addition to removing additives and (artificial) preservatives.

Better-for-you concepts will continue to develop and bring new opportunities for the sweet bakery sector. ‘Guilt-free indulgence’ will still influence consumer shopper behavior as we move into 2024. According to Dawn Foods’ recent Bakery Trends Survey, more than half of European consumers are willing to try more sweet baked goods with better-for-you claims. The industry needs to get the right balance between health, sustainability and indulgence, as consumers look to satisfy cravings with their favorite sweet bake that also has an improved nutritional profile or a positive impact on the environment.

The broad spectrum of what ‘better-for-you’ entails for consumers presents commercially interesting opportunities for bakeries. Dawn Foods’ research shows that 3 in 5 European consumers are willing to pay a slight price premium for better-for-you sweet baked goods.

There are several interesting NPD avenues with promising opportunities for sweet bakery creations.

Key directions

+ V-e-g-a-n – Vegan products are entering mainstream territory: 61% of European consumers said they liked vegan sweet baked goods when they had a taste. Vegan

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alternatives have become better when it comes to taste, with vegan variants tasting as good if not better than the original. They create the possibility to offer vegan as a (new) standard. For vegan developments, the most important challenge is to get the same functionality with alternative ingredients for eggs, milk and butter. For Dawn’s newest – soon to be launched – addition to their vegan range, the Dawn Balance® Sponge Cake Mix Vegan, this was one of the biggest challenges to overcome. A sponge cake is traditionally made with a high number of eggs. Making it vegan means finding a solution to replace the egg with alternative ingredients playing a similar role. Dawn’s R&D teams have managed to keep the same functionality and performance of the mix. It provides a good batter structure and aeration, resulting in a cake or swiss roll with similar eating properties and sensorial experiences as a regular Sponge mix. + Egg-free examples – With the growing vegan and vegetarian demand and the fluctuating prices on eggs, it is great to have egg-free alternatives available. Dawn's range of egg wash substitutes, provides a nice glossy shine on baked goods and includes a wide array of additional dietary benefits on-top of being egg-free. + Gluten-free goodness – Similar to the vegan trend, gluten-free alternatives have become more mainstream. What was a niche product category for people experiencing severe gluten intolerance and coeliac disease has turned into a product category, with better tasting gluten-free products, servicing a broader group of people that are avoiding or reducing gluten in their

f2m book collections Series: specialty topics Title: Sustainability and innovations supporting it Publication: 2023 200 pages, EUR 49*

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TRENDS

© Dawn Foods

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diets. For gluten-free (or other allergens) developments, the challenge lies in avoiding cross-contamination in production. Bakery manufacturers, need either a dedicated area to produce these types of products or meticulous cleaning will need to be done in-between production runs. + Clearly, clean labels – At the moment, there is no clear and uniform European position or regulation on the use of clean-label claims. Therefore, it is important to be aware of different interpretations that exist. Dawn’s criteria when developing cleaner label bakery ingredients are that they are developed with natural flavors and colors,

with no preservatives, minimal e-numbers and allergens, resulting in simpler, easy-to-understand labels on the end product/baked good. + Protein-enriched products – Ingredients that can provide both unique tastes and enhanced nutritional properties include proteins, which are perceived to be good for you and support an active lifestyle as they contribute to the maintenance and growth of muscle mass. Dawn's American mixes with protein offer the possibility to create a range of bakery products such as muffins, cakes, cookies, brownies and pancakes, offering consumers an option to satisfy their sweet tooth while contributing to their daily protein intake to support their active lifestyle.

Sweet bakery will always be strongly connected to indulgence, but, as the interest in better-for-you products continues to rise and broadens so, of course, do market and commercial opportunities for bakers.

With better-for-you solutions, bakers can create healthconscious, yet delicious sweet baked goods without any drastic production changes or the need to develop them from scratch. +++

ADVERTISER DIRECTORY American Pan.. .......................................... 41

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Schwarzwaldmilch. .................................. 55

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Reading Bakery Systems........................ 63

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