baking+biscuit 2023-06 digital by landmagd

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RISE TOGETHER into a sustainable future

06 23

AMF Bakery Systems – Your global partner for bakery automation, intelligence, excellence & sustainability. sales@amfbakery.com

www.bakingbiscuit.com

In the spotlight

f2m study

Science

Pauline Kariuki, The Women’s Bakery

The main topic is the staff

Microbiology & the sourdough industry

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EDITORIAL

Words that matter

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

Authentic (adjective): 1. not false or imitation: real, actual; 2. True to one’s own personality, spirit, or character. ‘Authentic’ is Merriam-Webster’s Word of the Year. “Genuinely” so, they recently shared. The dictionary saw a substantial increase in searches for the concept in 2023, which is why the research team dubbed it the most significant word encapsulating the year in review. Curiosity was enticed to look up the word following narratives about Artificial Intelligence, identity, social media and celebrity culture. The search for what is authentic has extended into the bakery world, through similar drivers. And the answer is traditional and artisanal breads. Research from Innova Market Insights on the global bread market found that traditional bread types such as baguettes, ciabatta and naan bread have gained global recognition in 2023 and are now widely available in many markets. Artisanal bread products are even seen as some of the items of choice for ‘revenge spending’ in search of a moment of affordable indulgence, in spite of all the cost-of-living worries. All bread outlets have been enjoying the growing desire to spend and consume authentic breads, as products with this claim are offered in artisanal businesses and supermarket bakeries. Globally, 64% of consumers purchase bread at the supermarket, while 48% of consumers buy their products at the bakery, making it the second-largest market, according to Innova data. ‘Authentic’ is in great company in the industry’s 2023 ‘word cloud’ of big trends. It joins ‘sustainability’, ‘energy’, ‘automation’, ‘workforce shortage’ and ‘raw material costs’. Looking at events that mirror the state of the industry, in trends, challenges and solutions, iba must be mentioned, as a timely sounding board for all of these trends. The entire industry in this hemisphere and beyond was thoroughly prepared and excited to join the big trade show comeback, for this reason. Everyone collectively rolled up their sleeves to not only shake hands, but eager to get work done, right then and there on the Messe Munich fairgrounds. A somewhat compacted show space garnered no less interest than what iba had been accustomed to seeing before the pandemic. You can read about the trending concepts at iba in this issue and online, at www.bakingbiscuit.com. And speaking of words that matter, in the search for authentic bakery creations that consumers will love, what is more important, tradition or innovation? Michael Wippler, President of the German Bakers’ Confederation said: “One brings the roots of our trade; the other embraces the new. Together, they make a full tree with branches and leaves. You cannot have one without the other,” as he declared iba 2023 open. The exhibition not only reflected today’s big issues but also helped set the stage for 2024 and beyond. The still-life moment is definitely behind us and the pace is once again dynamic, with the industry adapting on-the-go to a new day’s realities. ‘Adapt’ has claimed a spot in the concepts that define working in bakery. But, before we step into the rush of 2024, we hope that you enjoy precious family time for the holidays. From our team to yours, wishing you a Merry Christmas and a spectacular New Year! Catalina Mihu

CONTENTS

COVER STORIES

HIGHLIGHTS

06 DOWN TO A FINE ART – AUTHENTIC BAGUETTES The search for authentic products is a growing trend among consumers; it is not by chance that ‘authentic’ is the word of

THE WOMEN’S BAKERY

the year in 2023. When it comes to baguettes, it is simply a

Pauline Kariuki, Director of Operations, shares her

must-have attribute.

story of working in the industry in Africa’s growing market and her journey together with The Women’s

Bakery.

EVERY DAY IS CAKE DAY! Sunday gatherings, university admissions, Christmas lunches, first

THE MAIN TOPIC IS THE STAFF

dates, rainy-day lunch breaks, or snacking on the go: virtually any

Pandemic, war, inflation, skilled worker shortage

occasion, part of the day, or milestone can be accompanied by a

– how are such crises affecting the investment be-

unique, memorable cake. This means there are limitless opportuni-

havior of baked goods manufacturers? We asked

ties to create taste experiences.

MICROBIOLOGY & THE SOURDOUGH INDUSTRY

BAKE TOGETHER, STAY TOGETHER

In industrial production, the modulation of ferment-

New developments aim at bridging the gap between artisan and

ing microbiota is the most critical stage. Under-

industrial production, in terms of product quality and production

standing how it responds to processing conditions

volumes, so that the production lines can grow together with the

is essential to guarantee product quality.

operation.

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what key solution providers think.

CONTENTS

IN THE SPOTLIGHT 06

Interview: Pauline Kariuki, The Women’s Bakery “A woman on a mission to help create access to opportunities for other women”

BAGUETTES, BREADS, ROLLS 14

MECATHERM: Down to a fine art – authentic baguettes

SURVEY 18

f2m study: The main topic is the staff

SNACKS 24

Reading Bakery Systems: Extrusion – the big push

CAKES 26

Dawn Foods: Every day is cake day!

BREAD LINES 30

My ERP. Covers what my business needs.

Rademaker: Bake together, stay together

MARKETS 36

FMCG Gurus: Cost versus value

TRADE SHOWS 38

iba 2023 review: It’s good to be back

Gulfood Manufacturing ’23: Middle East’s bustling food industry

SCIENCE 44

FERMICRO: How microbiology can contribute to the sourdough industry

– this is more essential than ever.

IT will be the key to meeting your

RAW MATERIALS 48

Efficiency, transparency, flexibility

BENEO: Going egg-free with faba beans

challenges. ERP, MES, subsidiary

management, or intelligent planning software: the CSB-System is the

REGULARS 03

Editorial: “Words that matter”

News

Advertiser directory

comprehensive solution for bakeries. It enables you to optimize your

production processes immediately,

laying the foundation for the future digitization of your entire plant.

Cover photo: AMF Bakery Systems advertisement

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IN THE SPOTLIGHT: WOMEN IN THE INDUSTRY

“I’ve been working in the baking industry in East Africa for over 18 years. Working for The Women’s Bakery is different. It is meaningful.” Pauline Kariuki, Director of Operations, The Women’s Bakery

IN THE SPOTLIGHT: WOMEN IN THE INDUSTRY

A woman on a mission to help create access to opportunities for other women The Women’s Bakery brings breads to communities in East Africa and supports women to gain specialty training, a stable income and proper nutrition. Pauline Kariuki, Director of Operations, shares her stor y of working in the industry in Africa’s growing market and her journey together with The Women’s Bakery.

Catalina Mihu: The Women’s Bakery (TWB) was started by two entrepreneurial women who, during their time as Peace Corps Volunteers in Rwanda, saw the lack of opportunity for women there. It then grew to become a network of bakeries in East Africa. What makes this project unique? Pauline Kariuki: The genesis of what became The Women’s Bakery started organically during Markey Culver’s time at the Peace Corps in a village in Rwanda, where she was assigned as an English teacher and in a health center in the nutrition and maternity ward. In most rural Rwandan areas, people only eat one meal a day. So, in the name of solidarity, she contributed to providing that, too, for that first year. Until, one day, she thought to herself: “Wait a minute. I’m super hungry!” This is how she started teaching a group of women how to make salads for lunch with the vegetables at hand. And then one day, she baked a simple loaf of bread. Bread is a known commodity in Rwanda, but it is scarce in the villages. The women she trained wanted to learn how to bake bread, so she began teaching them how to prepare it themselves. The women loved the bread. More importantly, she saw what the women did with their bread. Watching them, she had two ‘aha’ moments: the first was when she noticed the women gave their bread to their children. She thought then, “Aha! This could be a way to address malnutrition.” She began creating new recipes, fortifying more breads with local protein and micronutrients, and taught the women how to do the same. Her goal was simple: to prepare food and teach the women a skill that would help them provide a nutritious snack at home for their children. But, after a few weeks of baking, the women informed her that they had just successfully sold their fortified bread in the nearby market. The second ‘aha’ moment occurred they had also sold their bread! These industrious women had created a market for their breads, meeting local demand with local supply. And that’s when she realized that something as simple as a loaf of bread had the power to create jobs for women, improve community access to nutrition, and spark local economic growth. And the seeds for The Women’s Bakery were sewn. Mihu: What convinced you to join a project like this, and what made it the right time and place for you?

The Women’s Bakery www.womensbakery.com

+ Sales points: 3 TWB bakeries, 2 independently operated bakeries + 80 women received training and graduated from the TWB program + Product portfolio: handcrafted products such as square rolls, sandwich rolls, round rolls and braids

+ 2018 - 463 primary school children receive bread daily + 2023 - 15,000+ primary school children are supplied daily Kariuki: I joined TWB in August 2021; I moved from Nairobi, Kenya to Kigali, Rwanda with my young daughter to work for TWB. This has been one of the most fulfilling decisions in my life. I am an empowered woman, a motivated woman; a woman on a mission to help create access to opportunities for other women. TWB’s own mission is to socially and economically empower women because an empowered woman, by herself, is an outcome worth fighting for. This resonates deeply with me, because my personal life is a testimony of such a mission. My life was transformed by access to opportunities – in my case, access to earn an education. In my adult life, I have always had a desire to give back. And then The Women’s Bakery approached me with an opportunity to work for them. This was it! This was the

www.bakingbiscuit.com 06/2023

IN THE SPOTLIGHT: WOMEN IN THE INDUSTRY

perfect scenario where I could give back through my work, and put my skills and experience to practice, while still not sacrificing my professional and personal growth. Being who I am today is a testimony that lives and families can be transformed by people’s generosity. My testimony is that I wouldn’t be who I am today were it not for access to an opportunity. I come from a very humble background, similar, if not identical to that of the women we work with at The Women’s Bakery. I was born and raised in a slum in Nairobi called Kawangware. My dad was from there, as were my paternal grandparents. To date, most of my paternal family still lives there. I am the second born of five children. I grew up in a two-room house – only two rooms in the whole house with seven people. The toilets and bathroom were communal and outside. I didn’t have electricity until I was in high school and indoor plumbing much later. I’ve lived with one meal a day – dinner, because you can’t go to sleep hungry. I mean this lit-e-rally. Try and see! I got access to education through a charity where generous people donated to people they had never met. Without this opportunity, my life would definitely have been stunted. I have witnessed this firsthand through my childhood friends and family, cousins who did not get the opportunity that I did. So this is my testimony; I am an empowered woman. I am at the pinnacle of my career, witnessing not only my growth but that of my family members. Opportunity changed the course of my life and the life of my child. This is the same impact that I see at The Women’s Bakery, and this Impact is not just for an individual, it is generational. I’ve been working in the baking industry in East Africa for over 18 years. Working for The Women’s Bakery is different. It is meaningful. I’m inspired by the women around me. I see my mother, my aunties, I see my childhood neighbors in the women I work with. I can visualize the transformational impact of these women when empowered. I see creating access to

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opportunities as hope; giving the women and their families a fighting chance at life for a better future. Mihu: And what are some of the milestones in your career that steered you on the path you walk today? Kariuki: I worked at the former Ennsvalley Bakery Ltd, in Nairobi, Kenya, for 12 years. Afer that, I worked at BBROOD Kenya – an artisan bakery chain from the Netherlands, where I was involved from the start of operations in Kenya to it having five successful branches by the time I moved on. I also co-founded a bakery ingredients company in Nairobi, Bakeking Solutions, which unfortunately was adversely affected by the COVID pandemic. Mihu: How would you describe TWB when you joined? How were the women trained, how many enrolled and how many ‘graduated’ certifications have been issued since its inception? Kariuki: I joined The Women’s Bakery in August 2021. This was just after the COVID pandemic, which brought on many challenges in various areas, from equipment to

The Women’s Bakery seeks support for the following projects 1. The One Bread Project (the expanding school feeding program) 2. Training and development for its team 3. Small equipment needs 4. Logistics, including transport, distribution, and storage needs 5. Alternative power backup sources to mitigate electricity disruptions 6. Researching alternatives and supplements for wheat as the primary ingredient

IN THE SPOTLIGHT: WOMEN IN THE INDUSTRY

Breads sold over the years Women bakers have become more efficient in producing bread, contributing to a steady increase in bread sales over the years. 2016

50K

2017

100K

2018

313,327

2019 2020

In 2022, we fed 11,166 children each day across Rwanda through our One Bread Project, accounting for half of our total bread sales.

508,429 672,516

2021

1,480,000

2022

In 2022, TWB bakeries sold 2,2 million pieces of bread. 2,210,091 © The Women’ s Bakery

“Our goal is to forge partnerships with key players in the industry encompassing equipment, ingredients, and manufacturers. Collaborations with such industry stakeholders present diverse avenues for supporting The Women’s Bakery.” Pauline Kariuki, Director of Operations, The Women’s Bakery

documentation including low sales caused by the COVID period. We have since made great improvements and strides forward on all these fronts and I am happy and proud of the progress. About 80 women have been trained and have graduated from the TWB program. Since its inception, The Women’s Bakery has launched seven bakeries. We own and operate three bakeries currently. Two out of the other four are independently operating, while the remaining two have since closed down. Mihu: Please detail the project providing nutrition-enriched bread for schools, made with locally sourced ingredients and naturally fortified with milk, eggs and vegetables. Since it serves areas where children usually only have access to one meal per day, how many children benefit from the program now? Kariuki: The One Bread Project (OBP) initiated by TWB is a transformative initiative aimed at addressing nutritional gaps of vulnerable primary school-aged student populations and improving the nutritional health and well-being of schoolgoing children in Rwanda. The goal of the OBP is to provide a daily nutritious bread roll to students in vulnerable communities ensuring they receive essential nutrients while attending school to help improve their overall health, well-being and school performance.

Initially, we were serving the kids with protein-enriched bread naturally fortified with milk and eggs, but we have since developed the product into a fortified bread roll that incorporates essential micronutrients and macronutrients, to ensure optimal nourishment. The fortified bread meets FAO/WHO/WFP nutritional recommendations and includes iron, zinc, folic acid, vitamin B12, niacin, thiamine and riboflavin, with extra CaCO3 and wheat bran and germ for fiber, which is crucial for the proper digestion of food, but more importantly, a proper intake of vitamin D. The project covers rural and urban areas of Rwanda in the vicinity of Kigali, Ruyenzi and Gicumbi districts, where our three bakeries are located. We are currently serving 18,000 kids daily. Mihu: How is this bread developed? What are the next steps of this project? Kariuki: The bread was developed through technical support from one of the partners in the industry, Rademaker. We were introduced to modern-day product fortification and also introduces to a supplier for it. The next step for the project is to expand the impact, one bread at a time, and sustainably grow it, with the vision of having it incorporated into a national school feeding program. We have a vision of serving one million kids daily but are happy to get to 100,000 in the next stage.

A growing project, bread by bread Mihu: TWB’s mission is to empower local women financially and socially by training them. How do you see your role and your personal influence in TWB? Kariuki: In my capacity at TWB, I see my role and personal influence centered around growing and scaling the company operations while infusing sustainability into our model. My goal is to broaden the access for women to

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IN THE SPOTLIGHT: WOMEN IN THE INDUSTRY

empowerment through skill development opportunities, employment opportunities, and entrepreneurship opportunities.

“We believe that all women are inherently powerful, and with access to social and economic opportunity, the world benefits.” Pauline Kariuki, Director of Operations, The Women’s Bakery

Mihu: How has your role evolved over time? And how has the business model of TWB started transitioning from a charity to a self-sustainable business? Kariuki: My role has evolved into the call to develop the team’s capabilities so that they are able to take on the next phase of growth. The business model of TWB has started transitioning from a charity, donation-based organization to a self-sustainable business model by looking to implement several strategies, including micro-franchising for reseller outlets to increase our reach and distribution. We are also partnering with corporate collaborators to co-fund the One Bread Project School feeding program and we are exploring our product diversification to expand our revenue streams. Although we have this pathway to sustainability, we are not there yet and we are still very much a charity that depends on funding to support and grow our operations. Mihu: The Women’s Bakery is still welcoming donations for its work. For what projects are you currently raising funds now, and how can people/companies support them? Kariuki: To quote our CEO, “Yes we still absolutely are welcoming donations”, to support our initiatives! We are currently fundraising for several projects, and individuals or

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companies can contribute either financially or with in-kind support. Our projects encompass the One Bread Project – our school feeding program, training and development for our team, small equipment needs, logistics including transport, distribution and storage needs, and exploring power backup sources so we do not need to stop production during blackouts. Also on our task list is investigating alternatives and supplements for wheat as the primary ingredient in our recipes. All forms of assistance including partnerships, sponsorships, skill exchange programs, collaborations, technical support and financial support are appreciated! Mihu: I had the pleasure of meeting you in person at iba, in Munich, where we were guests at Rademaker’s stand, whose team introduced us. How is TWB working with its industry partners? Kariuki: We are lucky to have corporate partners from the industry, one of them being Rademaker, which is our longest-serving corporate partner. We have also been invited by industry organizations such as BEMA and IBIE where we have benefited from the networking and introductions made to corporate partners in the industry. Our goal is to forge partnerships with key players in the industry encompassing equipment, ingredients, and manufacturers. Collaborations with such industry stakeholders present diverse avenues for supporting The Women’s Bakery. The significant disparities in the bakery industry abroad and here, in East Africa, highlight the need for support and development in this region to address unemployment and other challenges faced by developing countries. Our mission to empower women from minority groups through training and employment opportunities plays a pivotal role in promoting social and economic empowerment in East Africa. The partnerships made with industry players will contribute to the success of our mission. We aspire to

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IN THE SPOTLIGHT: WOMEN IN THE INDUSTRY

establish strategic partnerships with major industry leaders such as Grupo Bimbo and Flower Foods. These collaborations are not just about support but also seek mentorship, drawing from the wealth of experience that these giants possess. Our quest with industry partners is to enrich our journey, leveraging insights and expertise to propel TWB toward even greater success and expand our reach. Mihu: What product ranges are being prepared and taught at the moment and what new developments are you working on? Kariuki: Our primary focus right now is soft bread and bread rolls. However, we are looking to expand and diversify our range to include other nutritious baked products. Mihu: What have been some of the challenges that you have experienced in your work at TWB? Kariuki: Being part of a social start-up in a developing country, I have experienced unique challenges. We had to ensure additional training and development for our team to align with our growing operations, for example. We had to deal with escalating costs of raw materials, especially wheat – our primary ingredient. Wheat is mostly an export product and is adversely affected by global circumstances. In addition, we have had challenges related to equipment, from lacking certain kinds of machinery to having to manage frequent downtimes and breakdowns. Looking at packaging, we are making adjustments to adapt to the ban on plastic bread bags in Rwanda. We have also faced logistical challenges related to transportation and storage. An additional aspect of our work has been seeking alternative sources of fuel to counter frequent electric shortages. All the while, we have been navigating the challenges of low economic purchasing power and rising inflation. Mihu: How would your experiences help women who are now starting their careers in various roles in the baking industry in the region? Kariuki: My experiences have equipped me to overcome barriers and seize opportunities. I have come from humble beginnings and was able to equip myself with knowledge, which I believe is a valuable resource for any woman embarking on her career in various roles in the industry. I applied the knowledge diligently and combined working smart with hard work. I embraced obstacles and challenges as opportunities for growth and learning. I strived not to be deterred and seized opportunities to assert myself and stand out. I also learned and am still learning to cultivate confidence and believe in my abilities. Mihu: What is on TWB’s agenda going forward? How about your personal agenda? Kariuki: At TWB, we aim to increase our impact on women’s empowerment and enhance community nutrition in East

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Africa. We believe that all women are inherently powerful, and with access to social and economic opportunity, the world benefits. An empowered woman, on her own merits, is an outcome worth fighting for. We see this happening through having a network of The Women’s Bakery subsidiaries in Africa. My personal agenda is to contribute to a meaningful impact on the lives of women and children in East Africa. This profound aspiration is deeply rooted in my commitment to meet my self-actualization goal and contribute positively to the well-being of our society. Mihu: You visited iba for the first time this year. What were some of the observations that made the biggest impression on you and what inspiration did you bring home from Munich? Kariuki: The conference provided a unique opportunity to gain insights into the latest trends, technologies, and practices in the baking industry. It was inspiring to witness the remarkable technological advancements showcased at the Munich bakery exhibition, particularly in addressing labor shortages experienced abroad through advanced production technology. On the other hand, it highlighted a contrasting situation in East Africa, emphasizing the need for support and development in this region, to address unemployment and other challenges faced by developing countries. Our mission to empower women from minority groups through training and employment opportunities plays a pivotal role in promoting social and economic empowerment in East Africa. The connections made at the conference, particularly with the Rademaker team and other industry members, will contribute to our mission’s success. My inspiration included opportunities for product diversification, quality enhancement, food waste reduction, cost savings, and small equipment to support our operations. +++

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BAGUETTES, BREADS, ROLLS

Down to a fine art: authentic baguettes The search for authentic products is a growing trend among consumers; it is not by chance that ‘authentic’ is the word of the year in 2023. When it comes to baguettes, it is simply a must-have attribute.

While recipe variations for baguettes and bread rolls are not only to be expected but also make for unique selling points, high hydration rates and long dough resting times are the calling card of more sophisticated, authentic premium products. MECATHERM developed the MecaAuthentik production line specifically to perfect the production of baguettes, especially the Authentik Baguette, which is described as a synthesis of the traditional and the industrial baguette, and characterized by a high hydration rate and a thin and shiny crust, with an open scoring, meeting the requirements of large-scale distribution. The resting time directly influences the final product. “In the case of the Authentik baguette, for example, a resting stage before dividing makes the crumb appear more open, the volume bigger, the scoring wider and the product tastier, it also allows for reduced improvers for a improvers for a healthier product,” MECATHERM details.

Divide, mold and conquer Dough dividing and molding also play a role in the final results. For dough division, the MecaAuthentik line integrates the M-NS divider, which can divide a wide range of doughs from (single mix) straight dough to high-hydration rested dough. Volumetric dividers are also an available option, for perfect consistency between the pieces of dough. To ensure consistent results throughout production cycles, the M-NS divider monitors the dough density in real-time to reduce weight fluctuations that might occur. “Even when the dough density varies, the set weight remains the same. The divider can eject any dough piece that is non-conforming to the set tolerance,” MECATHERM explains. These pieces are then recycled so no product is lost. The latter process is handled by the new M-RT molder, which was recently unveiled at iba. Handling the dough pieces smoothly, avoiding any impact, is key to preserving the product quality. “The dough pieces are brought to the

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molder on an inclined ramp, which is more adapted to hydrated and rested doughs than the vertical elevator that can be used for straight dough types,” Mélanie Salvi, Product Manager, explains. An isothermal intermediate proofer incorporated in the M-RT molder offers a controlled environment in terms of temperature and humidity, preventing the dough pieces from drying and sticking. Dough pieces are gradually molded: “Alternating phases of mechanical action with resting periods makes it possible to strengthen the gluten network without tearing it, and to obtain a controlled volume. The unique cassette stretcher, developed by MECATHERM, gives the final shape, without tearing the dough pieces to the products before depositing.

“The precise management of hygrometry results in accurate control of crust thickness, softness and water loss of the product.” Xavier Gotti, Oven Product Manager, MECATHERM

The M-RT was designed to process a variety of products and dough types, including hydrated, long-resting time formulations. The new-generation M-RT molder was specifically designed to be easy to maintain, easy to clean and easy to operate. It is also equipped with an innovative system for the precise recentering of products by a camera, resulting in pieces with consistent shape and mass distribution. Duplicates are also detected and automatically ejected from the production line. The M-NS divider combined with the new M-RT molder makes a tandem specially adapted to hydrated doughs: “They both keep the dough pieces in constant motion during the process - unlike sheeting technology – to preserve the softness of the surface of the dough pieces. The M-RT molder requires very little additional flour and contributes

Alyson Slapkauskas, ABI LTD CEO, presents the KATANA system at iba

to preserving the dough’s quality, ensuring the thin crust and well-developed aromas of the final baguettes or bread rolls,” Salvi explains. Another piece of equipment from MECATHERM’s partner ABI LTD can be integrated into the MecaAuthentik line: the KATANA robotic scoring solution. With this system, scoring is adapted to the position and orientation of the dough piece. Moreover, it can adjust the length and space between cuts if the product is longer, shorter, or wider than expected to always ensure the desired scoring homogeneity on products. “KATANA's range of tools includes ultrasonic blades that provide great flexibility for scoring both low-water and highly hydrated products. By oscillating up to 35,000 times per second, the blade will smoothly open the bread little by little to ensure perfect scoring of the dough, even for specialties with flour or toppings.” KATANA now comes with a new, waterjet scoring tool, specifically developed for precise scoring, to preserve dough quality. “The waterjet scoring tool offers the possibility for bakers to personalize their products with complex patterns of scoring,” Alexandre Goasmat, Robotics and Automation product manager at ABI underlines more opportunities to perfect authentic custom products.

Oven and out The baking technology and the choice of oven will also impact the product’s crust, look, shape and development. The new M-VT vertical oven, also launched at iba, can be integrated into the MecaAuthentik production line to offer precise baking parameters, thanks to independent modules as well as its conveying system and a new Hygrometry Control System. “The precise management of hygrometry results in accurate control of crust thickness, softness and water loss of the product,” Xavier Gotti, Oven product manager at MECATHERM illustrates. The compact M-VT oven can be used for baking a wide range of products, including crusty bread, soft bread, pastry and patisserie,

BAGUETTES, BREADS, ROLLS

and was designed to maximize baking efficiency for industrial bakeries, with several features that help lower energy consumption. “For more rustic products, baking on stone will give the bakers more appropriate results, with a thick crust and appropriate coloration,” the French specialists recommend.

Consistent results Consistent results are ensured, with thorough monitoring in place: several sensors are positioned at different steps of the molding process. Moreover, the ABI EYE- Q quality control system developed by ABI LTD can be added to several steps of the production line in order to identify outof-standard products early on in the process. For instance, the EYE-Q, powered by AI, can control the product quality at the depositing stage. By analyzing trends and deviations in production, the EYE-Q helps operators adjust the machine when irregularities are detected. “The system sends operators instant alerts that suggest corrective actions. By identifying the issue at the source, EYE- Q improves production consistency. If associated with a rejection system such as a pick and place robot for example, it is possible to reject defective products and even refeed them at the start of the process, if the system is in place before baking,” Alexandre Goasmat adds. Proofing with equipment such as the vertical M-UB or M-VS proofers is another production step where homogenous results can be achieved. In turn, the M-VT oven plays a decisive role in achieving homogeneous products consistently, thanks to several developments such as the new, shockless conveying system, which was completely redesigned, allowing the intrinsic quality of the products to be preserved while they are not yet solidified. In addition, ”A new airflow circuit design optimizes the precision of the baking process, ensuring excellent product homogeneity,” Xavier Gotti highlights.

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BAGUETTES, BREADS, ROLLS

Industrial setups For customization requests of the MecaAuthentik line, the opportunity to maximize profit is the goal. With ever-increasing product diversity, various aspects come into play, from machine changeovers to handling different processing times. “One of the challenges is understanding the product flow throughout the production line and what happens during changeovers,” the specialists observe. Industrial production volumes are the goal: the biggest baguette production lines made by MECATHERM can process up to 3.5 tons of dough per hour, or from 8,000 to 10,000 baguettes. Manufacturing fully baked Authentik Baguettes implies a complete process of 4.5 hours up to 5 hours.

A smart plan for sustainable production The baguette line benefits from the M-Plan software, which helps operators visualize the production flow to identify the optimal production plan. The M-Plan digital tool is dedicated to production scenario simulation. “It enables manufacturers to simulate production changeovers and determine the best changeover scenario. As a result, they can prevent issues from arising during real production changeovers. This reduces consequent product damage and losses,” François Retailleau explains. As a complementary solution, ‘recipe follow-up’ is available on MECATHERM HMIs to bring additional support to operators during production changeovers, to ensure each product is made under optimal process conditions. “This feature follows up on the production batch progress along the line, checking that every piece of equipment is fully set up to match the product recipe it is currently dealing with,” Retailleau explains.

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Equipment solutions such as buffers can go a long way to keeping production uninterrupted during (unexpected) line stops. The M-VD cooler can also be used as a buffer, for example. MECATHERM is developing several new solutions throughout the production line to improve its sustainability. These include an energy recovery system suitable to use with the M-VT oven, to enable additional energy consumption along the entire line. The energy recovery system helps reduce energy losses and generates energy savings by recycling the vapor energy extracted from the oven. Another notable novelty is the new Hygro Control System that accurately manages the fresh, dry air that enters the oven and extracts the humid air. “Manufacturers will not only enjoy energy savings, but will also find their daily work is facilitated. They can now automatically open the dampers and regulate dry air intake and steam management in each baking chamber,” Xavier Gotti explains. The Hygro Control System was developed together with the new M-VT oven, but the feature can be retrofitted on other oven models, too. In order to reduce energy consumption during the cooling step, MECATHERM is also developing a Smart Cooling System. This system enables the recovery of outside fresh air, which is injected inside the cooler, limiting the use of the air-conditioner. With numerous new technology upgrades, all interpretations of what makes a baguette authentic on a specific market or for a certain manufacturer can be translated into a stable production flow for industrial bakeries. Complex solutions contribute to making manufacturing easy. +++

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SURVEY

A study by Food2Multimedia

The main topic is the staff Pandemic, war, inflation, skilled worker shortage – how are such crises affecting the investment behavior of baked goods manufacturers? We asked well-known solution providers in the industry, who have been supplying baked goods manufacturers worldwide for years, for their assessment; specialists as well as full-service suppliers. The answers were anonymized.

More than half of the suppliers surveyed reported falling customer numbers. This is hardly surprising, as it reflects the global trend towards ever greater concentration in the baking industry that has been observed for years. For just under a third of the suppliers – almost all specialists in fields such as packaging, the supply of molds and trays, or automation solutions – the number has remained the same, nevertheless. This reflects an increased customer interest in solutions in the respective areas, on the one hand, and for the increasing depersonalization and automation of production and logistics processes, on the other. If production lines are to run largely without personnel, they need automated raw material supply as well as standardized and automatically stackable trays and molds. If you want to supply supermarkets, catering and food service, you need hygienically packaged products. Almost one in five suppliers (18.2%) of the responding capital goods manufacturers even reported they saw an increase in customer numbers. These are often full-service providers or turnkey suppliers, which is probably also an indication that customers increasingly want to keep the number of their suppliers manageable. The decline in customer numbers is mitigated slightly if the statements on investment volumes are included in the analysis, as the decline is at least less prevalent there. A good 40% of equipment suppliers complain about a decrease in the total volume per customer. Another 30% have just as much on the order list as before. Moreover, more than a quarter can even look forward to higher sales

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Number of customers currently investing

18.2%

30.3%

Increased

Stationary

51.1% Decreased

per customer. However, it is not possible to extract any clear tendencies from the responses as to which type of system is being invested in more, less, or at constant ratios. It tends to be the larger suppliers with a broader portfolio for whom the order volume has grown. This may reflect a tendency to concentrate on fewer suppliers in the face of automation and the increased importance of higher-level control systems in order to avoid problems with networking. Investments raise a number of questions, regardless of whether they can or must be financed from the company’s own funds or through loans. When will the plant in question be needed? How long will the products manufactured on it

SURVEY

Investment volumes of manufacturing companies

42.4%

27.2%

Decreased

Increased

30.3% Stationary

be successful on the market? What economic benefit will it generate during this time and, last but not least, the question of whether or not it can be sold after use – all of this can be summarized in the question of how long will it take for the investment to be amortized. Such information is also used by investors and banks to assess the value of the company. The majority (57.6%) of capital goods suppliers do not see any change in their customers‘ behavior with regard to the amortization period, but more than one in five customers demand faster amortization than in the past. Slightly fewer have even extended the time horizon. There is harmony and unanimity among suppliers to the baking industry when it comes to the question of how well-informed customers are about potential solutions for their business, the options available to them on the market and the price demands of the various suppliers. According to their own statements, four out of five suppliers encounter

Timeframe in which the investments must be amortized

The price war among suppliers of capital goods has become tougher well-informed customers. However, this could also be due to the fact that competition among capital goods manufacturers has become tougher – something that one of our interviewees explicitly noted – price comparisons and tough negotiations are now part of the investment behavior of baked goods manufacturers. Only one in five of the companies we surveyed ticked ‘no’ when asked about their customers’ prior know-how. However, these are mainly providers that offer tailor-made solutions and are therefore only able to make price comparisons to a limited extent.

Customers are thoroughly prepared and know what they want, what is important for their business, and know supplier price levels

21.2% No

78.8% Yes

Political outlook influences willingness to invest

3.0%

21.2%

No answer

Shorter

18.2%

57.6%

Longer

Stationary

Confidence in the future profitability of one’s own company on the market is the decisive basis for the willingness of managers to invest, as well as for the green light of capital owners and banks to finance them. The economists’ sharp pencil is effective regardless of whether the company is to continue or be sold. The times when corporations in particular were prepared to pay massive amounts of money for market entry or market share, regardless of the profitability of the object of purchase, as was the case in the 1970s and 1980s, are over. You have to believe in the future, and the current profitability situation is being calculated month after month. It is therefore no wonder that almost 80% of all capital goods

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SURVEY

manufacturers cite the current profitability situation as the most important reason for companies’ willingness to invest.

Concerns about permanent staff shortages

In second place among the factors that influence the willingness to invest is the question of whether companies have a sufficient supply of qualified staff or employees who can be trained to meet the specific needs of entrepreneurs. This is by no means just a current issue, and it is also identified by baked goods manufacturers as a problem in the medium and long term. More than half (57.6%) of the suppliers to the bakery industry cite the current and future staff availability as an important reason for the bakers’

willingness to invest money. As we will see later, this is not just about reducing staffing requirements in companies through digitalization and automation, but also about making work processes easier for existing employees. Politics and the society worldwide are in a phase of transformation that is putting many certainties to the test. In Europe in particular, and especially in Germany, where decades of relative calm and predictability a thing of the past, this also influences the willingness to invest. The political situation in Germany and Europe therefore ranks third among the factors influencing willingness to invest, with a decisive ratio of 45.5% of all the responses. In an industry in which the number of companies is decreasing while their size is increasing, the professionalization of

What factors influence the willingness to invest? (multiple answers possible)

78.8%

Current profitability situation

57.6%

Status and expected development of staff availability

45.5%

The political situation in Germany and Europe

39.4%

Long-term development planning, in particular production and sales

39.4%

The larger the company, the greater the willingness to invest

36.4%

Systematic investment planning and corresponding information and decision-making structures

33.3%

Detailed knowledge and planning of energy requirements and energy supply

27.3%

Managers’ knowledge of new technical developments

24.2%

Willingness of banks to finance investments

24.2%

Competition from food retailers

24.2%

Age of the owner, succession planning

15.5%

Energy self-sufficiency of the company

6.1%

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The smaller the company, the greater the willingness to invest

SURVEY

management staff is also growing. Impulse investments ‘on instinct’ because something was discovered at a trade fair or by a competitor are becoming less common. Instead, long-term and systematic planning is taking place and care is being taken to ensure that appropriate information and decision-making structures are anchored in the company. Energy requirements and energy supply are becoming increasingly important, although the promotion of self-sufficiency in terms of energy is cited much less frequently as a driver for the willingness to invest. However, the various subsidy programs that are offered in different countries for energy-saving investments are exerting an influence, too.

Arguments for specific investments (multiple answers possible)

72.7% 66.6% 60.6% 60.6% 48.5% 30.3%

Food retail is no longer a fearful opponent

It may look different in each country, but the time of big battles for the baked goods market seems to be over, at least for the time being. The cards have clearly been dealt, in production as well as in distribution. This indicates that the power of the food trade as a competitor in the market plays a rather subordinate role – which, in turn, says nothing about its power as a distribution partner, especially for bakeries that only use this channel. However, there are probably several reasons why the opinion of banks no longer plays a major role in investment decisions. The financial solidity of current bakery manufacturers would be one and the possibility of obtaining the necessary leeway outside the banks, for example with supplier loans or on the capital market, would be another.

When it comes to specific investments, personnel savings are at the top of the list Just how pressing the issue of sufficient qualified personnel is, today and in the future, is once again made abundantly clear when it comes to specific investments. With a rate of 72.2%, the argument for personnel savings is at the top of the list of assessment criteria.

12.1% 1

1 Personnel savings 2 Higher efficiency of the systems 3 Replacement of old systems due to wear and tear 4 Capacity expansion 5 Energy savings 6 Flexibility of the systems 7 Networking in an integrated production control system

The question remains as to what bakeries are currently investing in, and this is likely to depend largely on what has already been invested in the recent past. At the top of the list, as already mentioned, is the companies’ efforts to make work such as lifting and carrying easier for staff and to save unnecessary walking. This is followed, in second place, by equipment for processing dough, instead of portioning and shaping dough pieces by hand. KOENIG Motiv3 91x53.qxd

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Two out of three investors are simultaneously looking to increase the efficiency of their production facilities, which certainly correlates with the poor supply of personnel. At the same time, however, it is also a sign of the pressure on profitability to which companies are exposed due to rising costs for raw materials, wages, energy, logistics, etc. Only a third of all suppliers surveyed cited energy as a fundamental argument for their willingness to invest. When it comes to specific investments, however, the picture is different. In this case, saving energy is an important criterion for almost half of all customers.

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SURVEY

What equipment features are in demand for investments? (multiple answers possible)

46.4%

1. Easier work processes for staff (lifting, carrying, walking)

42.8%

2. Dough make-up

39.3%

3. Oven systems

39.3%

4. Coolers and freezers

39.3%

5. Increased energy efficiency thanks to fewer losses and better use of process heat, for example

35.7%

6. Use of other energy sources

32.1%

7. Integrated production control

28.6%

8. Internal logistics

21.4%

9. Dough preparation

21.4%

10. Fermentation plants

17.9%

11. Energy networking of the entire production

10.7%

12. Storage and provision of raw materials

10.7%

13. Digital control of individual machines

Making work easier is the order of the day

Of course, other classic systems such as silos, kneaders, processing machines, ovens, fermentation and refrigeration systems, etc., are also on the list. The second major topic regarding operational costs, energy and its efficient use, is reflected in the energy-intensive in the types of investments ranked 3 to 6 above, where the aim is not to send energy ‘up the chimney’ or ‘down the drain’. More than one in four companies is currently investing in an integrated production control system. At first glance, the fact that only 12.1% of respondents to the previous question indicated that networking in an integrated production control system was a criterion for bakeries when making investments may seem contradictory to the 32.1% mentioned here (ranked seventh in the chart above) – respondents who prioritize integrated production control for investments.

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This can be resolved by the fact that the networking capability of newly purchased machines and systems is now a matter of course. The fact that one in three people is currently investing in integrated production control is more likely to indicate that such higher-level systems are now being purchased more frequently because more automation is needed. +++

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SNACKS

The big push Consumers are bound to reach for snacks more and more in the following years. Snacks are diverse and enticing additions to any eating occasion, whether they stand in for an entire meal, or are seen as a treat, a catering option for events, or a movie-night companion. Manufacturers stand to gain by keeping up the pace with innovations in this category. Extrusion provides particularly interesting opportunities.

It’s not just an increasing number of occasions that is boosting snacking; even ‘no occasion at all’ can call for a snack. For example, Euromonitor lists boredom among the core reasons why consumers reach for snacks in 2023, a habit boosted by their availability. To meet this growing appetite, manufacturers of extruded snacks and pretzels have the opportunity to increase their product variety and SKUs. Flexible pretzel and snack systems that can process a variety of snacks can best support an expanding portfolio. Reading Bakery Systems (RBS) provides such technology: “For any type of bread or pretzel snack, the RBS Low Pressure Extruder (LPE) can produce a variety of shapes and types of products. From traditional pretzel twists and flat ‘chips’ to sticks, rods, braided ropes and even filled nuggets, it can handle all ranges and unique variations,” the RBS specialists highlight. Recipedriven oven settings can create customized baking profiles for a wide range of products. The LPE has recently been upgraded for improved functionality, ergonomics, and sanitary design of the hopper structure. The latest hoppers are made of single-piece blue plastic with no seams or weld points, eliminating any nooks where dough could get lodged and risk harboring any pathogens. Additionally, the new hoppers are now easily removed from the machine without the need for tools. “A single operator can easily disassemble the hopper structure in minutes and carry each piece away for cleaning without the need for a crane or any heavy-duty equipment,” the specialist explains.

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“From traditional pretzel twists and flat ‘chips’ to sticks, rods, braided ropes and even filled nuggets, the Low Pressure Extruder can handle all ranges and unique variations.” Reading Bakery Systems specialists

The LPE system forms the dough in a two-step process: at first, the dough must be cut into 4-6 kg chunks (10-12 lb) to feed into its hoppers. “The RBS DoughBot system automatically takes dough from the mixer and cuts it into these chunks using our loafmaker,” RBS says. Then, a shuttle system distributes the dough to the LPE hoppers. In the second step, the dough then works its way into the extrusion chamber of the LPE, where two augers force the dough toward the compression head and die. “This force is what develops the pressure in the chamber. For bread snacks and pretzels,

SNACKS

you typically do not want pressures to exceed 100 psi,” the specialist recommends. This pressure is determined by the spinning speed of the augers. These settings can be automatically adjusted using controls that modify the size of the dough chunk and the pressure applied.

The dough is then cut into its final shape as it exits the extruder die. The bandcutter cuts the dough to the user’s desired thickness. The related settings can also be automatically adjusted based on the recipe needed for each product, keeping in mind that thinner pieces require faster cutting. For sticks and nuggets, the dough is extruded and then cut after the proofer by a guillotine cutter or an ultrasonic guillotine cutter, depending on the fragility or stickiness of the product.

One machine, all of the snacks To increase the product variety of shapes on the LPE, interchangeable compression heads and dies are used. The ability to support fast changeovers is key to the flexibility of this extruder. “Switching between a standard pretzel shape and a round flat piece simply requires changing these plates and takes just a few minutes. Recipes can also be saved into the control system to automatically adjust dough pressure, auger and bandcutter speed to create pieces of dough of consistent weights every time there is a changeover”, RBS explains. There are numerous dies available to choose from with shapes ranging from sticks, rods, braided sticks to filled and co-extruded products. But these are only a few of the options, as a whole world of other new shapes can be custom-designed from ideas brought to the RBS team of engineers and extrusion experts. Snack manufacturers can also visit the Science & Innovation Center to develop the new products together with RBS. A test die can be designed to create the shape desired, and then modified if the shape is not working exactly as intended.

Once a new die has been created, new products can be introduced into production with the LPE system by changing over the system to the new die, and then running its recipe from the control settings. “If the dough has any allergens or requires cleaning from a previous allergen, there would be time needed to clean the line prior to running the new product,” the specialist observes. The high-capacity pretzel lines developed by RBS can run volumes ranging from 500 to 1,000 kg per hour. Volumes will vary according to the size of the product and the weight of each piece and are ultimately determined by the size of the oven. The longer and wider the oven, the more volume the line is capable of. +++

Almost any conceivable shape can be created, with only a few limitations, such as shapes with extended ‘arms’, for instance, that would make the resulting piece prone to

breakage in the process or the package. “The more compact the shape, the stronger it is. Our experts can design shapes with appropriate feed plates that help meter the dough through the die at adequate speed and pressure so the dough is able to knit back together in time to form a cohesive shape. A customer can present a concept to our experts and together we can work with them to make the shape into a snack, or adjust it to improve strength and integrity to withstand the entire process,” RBS explains.

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CAKES

Every day is cake day! Sunday gatherings, university admissions, Christmas lunches, first dates, rainy-day lunch breaks, or snacking on the go: virtually any occasion, part of the day, or milestone can be accompanied by a unique, memorable cake. Some may have an ‘assigned’ favorite, but any moment can be marked with a different choice of cake. This means there are limitless opportunities to create taste experiences. To do so reliably, cake mixes can help achieve excellent results, every time.

Cakes are, probably, the most generous product category in terms of new product development opportunities. Expanding a portfolio of cakes can be infinitely creative but still a cost-effective process – when using versatile cake mixes. “With only one cake mix, you can create thousands of different cake applications. Think different shapes and formats such as muffins, loaf cakes, or layered cakes, or different consumption moments and occasions, like minis to go with coffee, big bold celebration cakes for Sunday family events, or yogurt loaf cakes for breakfast!”, illustrates Marie Frigo – Category Marketing Manager Dry, Europe & AMEAP, Dawn Foods. From the same starting point of a cake mix bag, unique, signature cakes can be created by filling, decorating, flavoring, or adjusting them as seasons change. Inventory space is the immediate benefit of working with mixes, but they also ensure quality consistency, no matter how broad the product variations are. They are designed to be easy to use and eliminate the challenges of precision formulating and dosing of raw materials. Layered cakes, for instance, require skills to create the right density: they need to be light and airy, but also able to sustain their height, so the crumb structure must be tight, otherwise, the layers will collapse during baking or shift under their own weight. “The lower the density of the cake, the more air

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that is needed in the batter and the lighter the cake structure and texture will be. A good layer cake has a tender and moist texture and bakes flat, to create nice, even layers without having to cut off waste,” the specialist explains. Dawn Foods has developed cake mixes that are suited for layered cakes. They are made to create tall cakes, yet still allow firm slices to be cut easily. The addition of water and oil are the only preparation steps for this mix, to achieve consistent flat and even layers with excellent volume.

Getting the mix right and the right mix Depending on the type of mix, preparation only implies adding water and/or oil and/or eggs, to bake cakes of the desired volume, taste and texture consistently. Mixing speed and time impact the volume of the batter – the mixes come with instructions in this regard. Cake makers can choose between full mixes or concentrated mixes to best suit their processes. Frigo explains: “For bigger bakery manufacturers with more automated production processes, a concentrate might be the choice. Oil, eggs and flour are added on the production line, giving the bakery manufacturer full control over the type of flour and category of eggs they want to include in their recipes. For smaller bakeries, who struggle with getting qualified and skilled

CAKES

of what application or type of cake will be made, to ensure the right cake mix is selected as the starting base. Dedicated cake mixes cover different types of cakes: sponge, layered and crème cakes. “The biggest difference between these cakes is the texture. A sponge cake is very light and soft, whereas a crème cake is heavier and dense. Sponge cake batters would not hold inclusions, but are best suited as a base to add layers of cream and/or fruit on top or to create Swiss rolls. If inclusions, like pieces of fruits or chocolate are to be baked into a cake, then a crème cake mix would be a better choice,” she highlights. Making this selection correctly is half the journey to a great cake.

Mixes and more staff, a full mix provides the guarantee that the outcome will be the same, no matter how skilled the person working on the application is.” Besides, having the choice between mixes with and without eggs allows more flexibility in terms of being able to directly control what kind of egg should be selected. To get the best cake structure possible, the most important recommendation Dawn highlights is to have a clear picture

Each type of cake comes with different expectations regarding taste, texture and the performance of the mix used. Dawn has been expanding its range of cake mixes to cover broad consumer preferences and demands for any type of product, from sponge, layered and crème cake, to red velvet and carrot cake. For example, for the ever-increasing ranks of health-conscious consumers, better-for-you options are available in the form of vegan, gluten-free and sugar-reduced cake mixes.

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CAKES

seeing pop up in the market. These cakes can be covered in icings, loaded with extra toppings and served on a stick for ease of consumption without the need for cutlery,” says Browner.

In addition, all of these specialty types of cake mixes come with a complementary range of products, ranging from flavoring pastes to flavor and color the batter, to frostings, custard creams and fruit fillings to fill and decorate cake applications in line with their nutrition label.

Trending: new cakes Whether for special events or just as a daily indulgence, the cake category continues to evolve and adapt to the latest consumer demands. “With 1 in 10 European consumers stating that they eat cakes at least once a week and 19% of all fresh patisserie consumption in Europe coming from the cake category, there is no better time to innovate and expand cake offerings,” Sarah Browner – Market Research & Insights Manager, Europe & AMEAP, points out. When looking at cake formats, it is important to include a diverse range of cake sizes to match a variety of consumption occasions, the specialist’s research shows: “While oversized and towering celebration cakes feed the desire for fun indulgence, mini- and bite-sized cakes are the perfect reminder for people to not just celebrate the big occasions, but also the ‘little wins’ in their lives. According to our research, 84% of European consumers agreed that small, indulgent sweet baked goods are a good way to treat themselves.” Smaller-sized cakes do not only allow brands to deliver a permissible indulgence by helping consumers control their calorie intake but can also encourage new consumption occasions. For example, with 36% of European consumers choosing to eat cake as an on-the-go snack, bakers can tap into this occasion with convenient, mini-sized cake options. This is a space that encourages creativity and unusual experiences: “Building on the desire for interactivity and convenience, food on sticks has emerged into a trend in its own right,” Dawn Foods' Browner observes, as a range of foods is skewered in some way. “Cake pop or cheesecake on a stick are just some of the concepts we are

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Flavors are an undeniable decision-maker when it comes to choosing cakes. Dawn’s research shows that florals have been increasing in popularity for a few years now, with cherry blossom, lavender, and rose being among the ones to watch: “Think rose and raspberry madeleines or lavender and white chocolate sponge cake. The distinct sweet, refreshing, and botanical profile that florals offer work well in baked goods,” the specialist points out. Moreover, nostalgia remains a strong selling point for cakes – evoking joy and bringing feelings of comfort and security. This trend will further develop in 2024, Dawn anticipates, with 'newstalgia' becoming a winning strategy. With four out of five Gen Z and Millennial consumers wanting to try new food and food experiences, the blend of newness and nostalgia can address the need for adventure without taking consumers too far out of their comfort zones. “Incorporating flavors from around the world into the next cake offering is one way to tap into this ‘newstalgia’ trend. International flavors take consumers on a culinary journey across the globe, infusing products with the essence of various cultures and regions. We are seeing an increase in unusual blends from different parts of the world coming together such as the Japanese yuzu and Sicilian lemon or matcha and cardamom,” according to the research specialist. As consumers are seeking colors and flavors that challenge traditions and break boundaries, rich, vibrant colors and flavors, unconventional combinations, and tastes from under-represented regions will shine in the cake category in 2024, the specialist anticipates. Dietary needs and preferences should also be reflected in cake offerings, as consumers internalize how diets shape their physical and mental health. Cakes that provide clear information about their nutritional profile and ingredient list meet these concerns for all eating occasions. Claims that cakes are suitable for various types of diets, such as gluten-free or vegetarian, have been relatively stable over the past five years. Vegan and plant-based claims, however, have seen notable growth of 28% in product launch activity in the same timeframe. Cakes that fall into these categories are not without challenges to perfect, though. Mixes take the problems out of the equation. “The broad range of plant-based ingredients and mixes available have elevated vegan cakes to a level of indulgence that can easily rival, and in many cases, outshine their non-vegan counterparts. We predict that vegan will become the standard for many applications as bakers will try to cater to all customer dietary requirements in a single product,” Browner anticipates.

+++

BREAD LINES

Technology is optimized to meet the clear trend for flexible equipment that can support changes in production and a diverse range of breads, respectively. New developments also aim at bridging the gap between artisan and industrial production, in terms of product quality and production volumes, so that the production lines can grow together with the operation.

iba set the stage for numerous new concepts in all specialty fields. Bread remains at the very core of the industry, with several new developments that serve improved manufacturing processes encompassing all possible needs. The Radini bread line was one of the new technologies making its official debut this October, in Munich. It joins the namesake range of equipment that specializes in laminating, pastries, croissants and donuts under the ‘artisanal meets automation’ theme.

as twisting, braiding, or rounding. Decorations can also be made by hand, by adding almond paste filling to make Christmas bread, for instance, or by adding raisins on top of the product. The flexibility of fully automated combined with manual processes contributes to the flexibility of the baker's product range,” explains Arjen Eberwijn, Manager, Business Development, Radini. To determine the right levels of automation that fit the bakers‘ production goals, they can start with manual shaping and rounding, Eberwijn recommends: “When the baker decides that a higher level of automation or increased output is needed, modules can be added. In this case, a molding unit or rounder can be easily added to an existing line.” Another automation opportunity is the step of placing dough products on trays. A tray loader can be added to the line for automated tray loading even at a later stage and can (gradually) be expanded with a rack (un)loader. “Such options are possible because the software is modular, and so are the mechanical units. The Radini platform is prepared to add units over time,” he adds.

Bread with Radini Rademaker designed the Radini bread line as a modular concept that can process from 250 up to 1,200 kg of dough per hour. The modularity allows for changing configurations and growth together with the business. The line can be configured for partially- or fully-automated setups, for products such as seeded baguettes. “Manual labor can be added, for shaping products from the automatically produced dough sheet with operations such

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The minimum configuration of the Radini bread line consists of a Dynamic Pre Sheeter, combined with a traveling guillotine. To this, every unit in Radini's portfolio can be easily added. Everything following the guillotine is plug and play, designed to be interchangeable and customizable to specific process requirements. “Developments in this segment do not stop with the launch: meanwhile we have developed a molding conveyor, and next year we will start the development of a bread rounding module,” Eberwijn shares. Its pre-sheeting system allows the Radini bread line to handle various types of dough, from firm toast bread to pre-proofed ciabatta. All kinds of multigrain doughs and doughs with inclusions of fruits, seeds, nuts, or olives can be made into bread. “A consistent, low-stress, high-quality dough structure

Bake together, stay together!

BREAD LINES

is achieved by gentle dough handling,” the specialist highlights.

This line prioritizes space limitations, with the Dynamic Pre Sheeter at its heart, which has a footprint that only spans 3.5m and produces dough sheets ranging from 15 to 40mm thick. A relatively thin sheet of dough can already be achieved by this unit, which means that fewer sheeting components are needed further along the line, so that its overall layout can be more compact while producing the desired dough characteristics – to answer one of the questions Rademaker frequently received from iba visitors at the launch. “While the dough batch is processed in a continuous dough sheet, gas is retained,” Eberwijn adds. Another frequently asked question is regarding Radini's ability to eliminate rework dough. “For example, by not having to take rework dough into account, it does not have to be recalculated in the recipe of the next production run and returned in the dough batch. When seeds are added for decoration, there is no costly waste,” the specialist illustrates.

To optimize production efficiency, dough sheets of different widths can be processed. For a changeover, in this case, the final sheeting rollers can be easily exchanged. In addition, the cutting knives can be changed, and the spreading conveyor is adjustable to produce the needed number of lanes. For a different product shape or length, the cutting tool in the guillotine can be switched.

Producing without rework is made possible by enclosing the dough sheet, among other things.

And more bread on the line: the Rademaker bread line When higher volumes are the priority, the Rademaker bread line can be the next step, with a capacity of up to 9,000 kg per hour and the option for dedicated, custommade solutions, to also provide a high degree of flexibility. The latest upgrades to this line were also among the novelties at iba this year, where the latest version of the make-up section was presented. Improvements on this

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BREAD LINES

high-volume line include increased efficiency and functionality. The enhanced line is also more user-friendly, has improved hygiene features and its footprint has been reduced. “A highlight is our state-of-the-art weighing conveyor. The system combines a high-quality weighing system with innovative software algorithms, enabling bakeries to precisely control the weights of any dough products,” Olaf Stok, Product Manager, Rademaker, explains. The weighing conveyor is placed after the spreading conveyor and before the cutting unit. The system helps regulate the line’s software, upstream and downstream. This functionality enables bakeries to precisely control the weight of end products.

“Our new bread rounder has improved process control, excellent process visibility and a new conveyor belt design.” Olaf Stok, Product Manager Rademaker

Product shaping modules have been upgraded: “Our new bread rounder has improved process visibility, a new conveyor belt design and lighter weight of changeover parts,” Stok adds. The rounder is an evolution of the successful previous generation and features a programmable excentre working in a 20mm - 50mm range, to optimize the rounding movement for an optimized end product quality. A wide range of possible configurations increases the flexibility of the Rademaker bread line. Starting with the sheeting technology, a household specialty of the Dutch company, a diverse range of doughs can be handled with this bread line, with either long or short pre-proofing requirements. The first step is creating a continuous sheet of dough, for which there is a choice of two pre-sheeters: the Double Chunking Stress Free System (DSS) and the

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Dynamic Pre Sheeter (DPS). “Processing pre proofed doughs up to TA185, meaning a water percentage up to 85%, both pre-sheeters use the same technological principles to work on their own range of dough processing capacity. The pre-proofed doughs are sheeted using Quick Reducers (multi-roller), Cross Rollers and gauging stations. Depending on the required dough sheet thickness, line configurations can vary. Then, there are various options to form products from the dough sheet: “We have multiple units such as guillotines (for cut products), a molding table (for rolled products) and our new version of the bread rounder (for rounded products), which has just been introduced,” Stok says. The guillotine itself can be equipped with different product-related changeover parts to produce cut products in unique designs, while the versatile molding table can be used to optimize the shaping of artisan baguettes, for example. The bread rounder can handle short and long pre-proofed doughs, as well as rye-based doughs ranging from 40 to 950 grams in dough weight. Rademaker's Radilinq product group offers solutions for further automation in dough handling through the baking facility. “Our innovative and flexible production lines allow our customers to stay ahead of their customer (future) needs. Through smart, modular designed units, fast product changeovers are made possible. It will yield maximum results in terms of product quality and return on investment.” Stok underlines. As market requirements are changing in time, existing lines can be modified by either adding new modules or features, so that the line is ready for the next decade. +++ Read more on bread lines, in the previous issues of baking+biscuit international, 4 and 5.

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NEWS

A more international ProSweets takes shape

Taking place from January 28 to 31, 2024, ProSweets Cologne will bring together over 250 exhibitors from over 25 countries, representing the international supplier industry for sweets and snacks. It will be held together with its traditional counterpart, ISM. The organizers prepared several novelties for the visitors, such as an interactive event

program in the exhibition sections ‘Packaging & Packaging Materials’ and ‘Raw Materials and Ingredients’. The ‘Sustainable Packaging Special Show’ will focus on the origin and procurement of products and their raw materials. The special ‘InGREENients’ exhibition zone will present sustainable snack innovations from all over the globe that are made using unusual ingredients. Here, with a view to future cooperation, the exhibitors and visitors can engage in a direct exchange with selected start-ups, who will present their products within the collaboration section. Important industry players are on board for the fair kicking off in 2024, including Aasted, ACMA, Handtmann, Boettger Food Ingredients, Cavanna, Dumoulin, FUJI Packaging, Gerhard Schubert GmbH, GNT Group B.V., Hänsel Processing, NETZSCH-Feinmahltechnik, Norevo, SACMI Packaging & Chocolate S.p.A., Sollich KG, Syntegon Technology GmbH, Trikno AG, ULMA Packaging S.Coop. and Wilhelm Rasch. Visitors can join Guided Tours across all segments of ProSweets, which emphasize sustainable packaging concepts. Furthermore, ISM exhibitors can invite their employees, who are particularly responsible for the visitor groups relevant to ProSweets, i.e. from the production and development areas, to visit the trade fair. +++

SOLLICH will highlight its chocolate solutions, with a coating machine from its Minicoater range (420 mm wide belt) on display. For an increased variety of products, this mini enrober is equipped with the decorating device Mini Decormatic MD 420. SOLLICH has been focusing its R&D on optimizing the production process, by balancing highly hygienic features - efficient and easy cleaning – that allow the machines to minimize downtimes. Further digitalization improvements have been made to optimize the information exchange between the machine operator and SOLLICH. To do so, the company founded SweetConnect GmbH, for a platform that can help users manage integrated production machines. “Documents such as operating instructions, spare parts catalogs and cross-manufacturer maintenance managers are just some of the basic functions made possible with the help of SweetConnect®. In conjunction with the ‘Fast Lane’ remote maintenance system, data from the application process are transmitted to optimize services and increase machine availability,” the company explains. At ProSweets, SOLLICH will also introduce an AI-based approach to self-analysis for their tempering machines. In the future, this solution will be combined with automated temperature adjustment,

SOLLICH brings chocolate solutions to ProSweets

to reduce the need for operators to control it and increase the consistent results in the quality of the tempered chocolate. Further controls are now also available: for example, the dew point display within the cooling tunnel or the automatic measurement of the degree of temper in the enrobing machine with the Tempergraph. SOLLICH KG will exhibit together with its sister company CHOCOTECH GmbH. +++

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MARKETS

Cost versus value With rising prices having become a major concern for consumers, the bakery industry faces the challenge of offering products that not only meet consumers' expectations but also provide good value for money.

By Kate Kehoe, Marketing Executive, FMCG Gurus

While cost is certainly a factor, consumers are increasingly seeking products that offer a balance between price and quality. Bakery brands need to adopt strategic positioning and strategies that emphasize the value of their products. This involves showcasing maximum efficacy, health-boosting benefits, and excellent taste of their bakery products. By doing so, brands can instill confidence in consumers that their purchases will not only be enjoyable but also provide them with specific need states, benefits, and value.

Consumer concerns FMCG Gurus’ consumer insights reveal that 85% of global consumers feel that food and drink prices have risen over the last 12 months. The rising costs of food and beverages have prompted consumers to actively seek out strategies to make their grocery shopping more affordable. In response, many individuals have opted to remove non-essential items from their weekly shopping lists, aiming to prioritize essential products to manage their budgets more effectively. This shift in consumer behavior reflects the increasing financial pressures consumers face and their efforts to adapt their shopping habits to accommodate these rising costs.

Cutting down on non-essentials FMCG Gurus’ market research highlights that 53% of global consumers say their household is actively trying to reduce spending on food and drink. To address consumer concerns about rising prices, bakery brands should consider positioning their products as multifunctional. By highlighting the

This article is based on FMCG Gurus: Top Ten Trends – Bakery – Global Report 2023. Contact: info@fmcggurus.com.

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various positive attributes of bakery items such as nutrition, taste, and convenience, brands can influence consumers to view them as essential rather than non-essential. Additionally, convenience is a key factor that can influence consumers’ perception of essentiality. Bakery brands can emphasize the convenience of their products, such as prepackaged individual servings or grab-and-go options. This can cater to consumers’ busy lifestyles, providing them with a quick and convenient solution for on-the-go snacking or breakfast choices.

Natural, reduced sugar, and sustainable When consumers make food purchases, their perception of value is heavily influenced by factors such as taste, natural ingredients, reduced sugar content, and sustainability. For instance, FMCG Gurus’ consumer insights reveal that 51% of global consumers deem natural claims an influential product attribute when looking for good value-for-money bakery products. Additionally, 40% of global consumers deem reduced sugar claims as good value for money, followed by 37% who like to see sustainability claims. For bakery brands, highlighting the use of premium, genuine ingredients that deliver guilt-free indulgence can help mitigate consumers' sensitivity to price when making decisions. By emphasizing the use of high-quality, authentic ingredients, bakery brands can effectively convey value and create a positive perception among consumers.

Emotional wellness is a priority Emotional well-being continues to be a key priority for many consumers. Following two years of uncertainty due to the pandemic and the resulting worries, people now face a new wave of unpredictability, including the cost-of-living crisis and other global issues. This ongoing uncertainty is likely to

MARKETS

contribute to increased stress and anxiety among many individuals. During periods of uncertainty, consumers often turn to food as a means of coping, seeking moments of escapism to alleviate daily pressures. In response to this, consumers may seek out nostalgic flavors that evoke feelings of happiness and comfort. For example, FMCG Gurus’ market research illustrates that 40% of global consumers said they have sought out products and flavors that remind them of past and simpler times. Also, 80% of global consumers say they find traditional/nostalgic flavors appealing. The bakery industry can address this by promoting traditional flavors associated with familiarity and simplicity. Products that evoke a sense of nostalgia and remind people of the past and simpler times can elicit emotional responses, leading to impulsive purchasing behaviors and reduced sensitivity to price.

Functional ingredients are appealing Bakery brands have an opportunity to cater to tired and fatigued consumers by promoting high protein content in their products, which can provide a natural energy boost. Addressing consumers’ energy levels will be a key priority in

the next 12 months. The disruptions caused by the pandemic have resulted in disrupted daily routines, increased stress, and anxiety, which can negatively impact relaxation and sleep patterns. As a result, many people may experience fatigue and struggle to get through their day. FMCG Gurus’ consumer insights reveal that 41% of global consumers say they have plans to improve their energy levels over the next 12 months. As a result, protein claims will continue to be popular in the bakery sector. If bakery products can be perceived as high in protein, offering an energy boost without an unpleasant aftertaste, consumers will be more willing to pay a premium for such products.

Conclusion As consumers navigate through the challenges of rising prices, the bakery industry must respond by prioritizing the value that their products offer. By positioning bakery items as having maximum efficacy, health-boosting benefits, and delicious taste, brands can attract and retain customers who are willing to purchase products that provide not only enjoyment but also a strong sense of value. Effective communication of these unique selling points is key to establishing a competitive edge and securing consumer loyalty. +++

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TRADE SHOWS

iba 2023

It’s good to be back! After the pandemic and while navigating war disruptions and ensuing instability, the baking industry warmly celebrated the time to meet again at iba, reconnect and get work done.

Trade visitors were eager to welcome iba’s comeback as they joined to see the latest developments and get inspiration for baking businesses of all sizes. Over five days, 57,000 people from 150 countries traveled to attend the fair in Munich, where 1,073 exhibitors from 46 countries had their latest developments on display. The show introduced a new layout spanning 10 halls, arranged around four fields of interest: production technology and equipment, raw materials and ingredients, artisan bakeries and packaging technology. By comparison, over 77,000 visitors from around 170 countries came to iba in 2018, when 1,300 companies occupied 12 halls of Messe Munich in a parallel spread.

“Thank you to everyone who made my first iba

unique. My team and I are pleased that iba 2023 was so successful for all protagonists and we don't want to (have to) wait another five years until the next iba, so we'll all see each other again in Düsseldorf from May 18 to 22, 2025.” Susann Seidemann, Exhibition Director of iba

iba was, undoubtedly, an international affair, with two-thirds of the exhibitors (69%) coming from outside Germany, as Michael Wippler, President of the German Bakers’ Confederation, highlighted at the official opening event of the fair’s 25th edition, which comes after an almost double waiting time of its regular three-year frequency. All current industry issues were discussed, with solutions to support business resilience, at the kick-off event and in all the show’s features. Following the pandemic, soaring energy costs, two wars, inflation, recession fears and supply issues – a growing list of challenges – Wippler underlined that “the industry has been flexible and adaptable throughout” and continues to meet the needs of the consumers who are now “in the health wave”. Exhibitors observed an increase in international visitors, too, in a general atmosphere of productive talks with well-prepared guests at their stands. “iba was amazing in every aspect of it. The AMF vision ‘Better Food, Better Lives’ really made sense here, where most of the supply chain in food production came together in Munich and shared future visions and projects. It was a chance to meet

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old friends, existing partners and many new potential business partners,” said Lex van Houten, Regional marketing manager, EMEA-AP at AMF Bakery Systems. The company presented a wide range of new developments, including its sustainable concept, the hydrogen-powered MB-VITA tunnel oven by AMF Den Boer. Diverse approaches to sustainability were presented, including stand concepts featuring no equipment to reflect this priority. Royal Kaak’s green, nature concept and the outer space encapsulated by the Verhoeven Family of Companies at its stand were two notable examples. A clear indication of a successful show is the ‘equipment sold’ sign next to the machines on display. Marking its 75th anniversary this year, Sveba Dahlen of the Middleby Group, had this sign up. “We showcased our breadline, BL600, demonstrating how smoothly dough can run through it. The line garnered much fascination, resulting in on-the-spot sales and several inquiries taken home,” said Åsa Ericsson, Marketing Manager. There is no baking show without the smell of freshly baked wholesomeness, and they were in no short supply at iba. Rademaker and backaldrin, for example, were among the providers of treats fresh out of the oven. Robotics played a bigger part among the concepts presented this year, a necessary component of automation, with applications showing opportunities throughout the

TRADE SHOWS 39

TRADE SHOWS

baking process, aside from the already established packaging step. RONDO’s RondoBot, Koenig’s AI-controlled bread scoring system, iSCORE, DIOSNA’s AGVs, and ABI’s Katana with a new waterjet end-of-arm tool: these were only a few of the solutions that attracted attention. The entire spectrum of digital solutions was also in focus: “From vision to realization – our goal was to offer ‘digitalization at your fingertips‘. We ensured this not only through the focus theme and product range, but also through our new iba.DIGITALISATION AREA, where the theme was brought to life,” Susann Seidemann, Exhibition Director of iba, emphasized. Oven innovation was right at home, too, with numerous concepts on how to optimize energy efficiency, as were complete lines that prioritize process automation. FRITSCH, for example, showcased its new production line, IMPRESSA bread. In a new bid to reflect industry priorities, the fair not only focused on solutions, but also on people – namely, recruiting a new generation of bakers into the industry. Artisan baking was also in the spotlight. Among the events at the show, competitions were exciting to witness, and the award ceremonies gathered crowds.

Gold-medal baking Live baking competitions are always among show favorites. This year, the iba.UIBC.Cup of Bakers saw the world’s most skilled competitors bake their way to the top, with impressive creations to prove their artistry. Working in pairs, contestants from 12 countries had to create a showpiece, breads of various sizes and Danish pastries, this year with the ‘animal world’ theme. Lin Yeqiang and Feng Yingjie from China won the gold medal for their creations inspired by Disney’s ‘Zootopia’, which incorporated popular Chinese flavors in the recipes. The two were also awarded in the ‘Best Bread’ and ‘Best Danish Pastry’ categories. Second place went to Hwang Seokyong and Han

Seokwang from South Korea. Nicole and Patrick Mittmann from Germany came in third, while also winning the prize for the best showpiece that conveyed the message, ‘Save our World’. South Asia was also represented in the confectioners’s competition, where Yeon Sunheum and Han Doyoung from South Korea secured the iba.UIBC.Cup of Confectioners. The duo won best in show for their showpiece, iced cake, petit fours, pralines, sculpted figures and sweet baked goods, under the same ‘animal world’ theme. Victoria Gravdal and Xiao Juan Peng from Norway came in second and Taiwan’s Min-Yu Teng and Peng-Yi Lin won bronze. The UIBC World Baker and World Confectioner of the Year were also announced: they are Wu Tzu Ching (Taiwan), respectively Nina Métayer (France). A UIBC committee selected the two for best meeting the competition requirements: participants must actively and independently operate a bakery-confectionery-café, have completed training as a baker or pastry chef, and have successfully participated in competitions, marketing activities, and other innovative activities. Summarizing the five iba days of 2023, Wippler commented: “In addition to competitions with excellent talent and a successful introduction of the National Award of Honour, the topic of young talent was particularly close to our hearts this year. We had trainees on-site at the BackStage young talent days, met vocational school classes and talked to bakers about our ‘Back dir Deine Zukunft’ campaign. We want to whet young people's appetites for artisan bakery, and iba was the best place for that,” as he bid farewell to his role as President of the German Bakers’ Confederation. “The fair was a complete success and that makes me all the more happy. A special thanks to all exhibitors and organizers of the trade fair.” +++

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TRADE SHOWS

Middle East’s bustling food industry The ninth and biggest installment of Gulfood Manufacturing took place between November 7 and 9 at the Dubai World Trade Centre, with 3,000 exhibitors from 80 countries and over 36,000 visitors attending the show and the co-located events, The Speciality Food Festival, ISM Middle East and Private Label Middle East.

Exhibitors came to Dubai with solutions for the food industry in which the new reality means greater sustainability, resilience, agility and efficiency, to showcase their innovations over 21 exhibition halls. The products, services, and solutions showcased at the DWTC reflected this year’s themes: Digitalization, Sustainability, Innovation, Excellence, and Efficiency, which encompassed the Summit, the exhibits and the Gulfood Manufacturing Industry Excellence Awards. Over 600 submissions from all over the world were entered across 10 award categories, of which three made their debut to emphasize sustainability at this year’s event: Renewable Energy Initiative, Plant-Based Manufacturing Company of the Year; and Sustainability Champion of the Year. MECATHERM won the Industry Excellence 2023 award in the Best Processing Innovation category for its new M-VT vertical oven, the second recognition for the technology unveiled in October at iba. Raymond Nogael, Vice-President, Global Marketing and Business Development TMG/ MECATHERM, shared on the occasion: “This new M-VT oven is the culmination of three years of development involving many of our employees, all aiming to offer industrial players a baking solution that supports them in their daily challenges of product quality, industrial performance, and sustainable development. To achieve this, we have

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MECATHERM’s new M-VT vertical oven was awarded Best Processing Innovation at the Gulfood Manufacturing Industry Excellence Awards. From left to right: Nicolas dos Santos, Services Sales Manager, MECATHERM; Raymond Nogael, VP Business Development and Marketing TMG; Gulfood Manufacturing representative; Jérémy Hogrel, Global Strategic Sales Support, MECATHERM; Jean-Yves Bruckert, Account Manager, MECATHERM.

rethought all the concepts of the vertical oven, such as airflow circuit, conveying system, heating, and hygrometry management. This award recognizes the work of all those involved in the project, and we are very proud of it.” Ishida received the Best Food Safety Innovation Award for its

IX-PD X-ray inspection system, which addresses critical challenges in quality control with its advanced sensor and image processing technology. The Sustainable Company of the Year Award went to GEA Middle East FZE, who also won the acknowledgment for the Renewable Energy Initiative category, highlighting its solutions for a wide array of applications, ranging from food and dairy to bakery and packaging. Policymakers and industry experts shared their insights at Gulfood Manufacturing’s Food Tech Summit, where sustainability was a key focus. Tariq AlHashmi, Director of Technology Adoption and Development at the UAE Ministry of Industry and Advanced Technology (MoIAT), delivered the opening address, looking at the food industry’s role in achieving global climate and sustainability goals, and how sustainable solutions will be a hot topic of discussion in a new age of F&B manufacturing. In the year when the UAE hosts the 2023 UN Climate Change Conference (UNFCCC COP 28), he analyzed the role of the food industry in achieving global climate and sustainability goals. “Advanced food technology is not just about feeding the present; it's about nourishing the future. FoodTech will play a pivotal role in driving innovation and improving the quality and accessibility of food while also reducing greenhouse emissions, and promoting resource-efficient practices", said AlHashmi. Bobby Krishna, Senior Food Safety Specialist – Dubai Municipality gave insight into how Dubai has leveraged digitalization to improve food safety: “We were lucky to have digital momentum from the early 2000s. That gave us an enormous amount of data in digital format, which we are currently using to make our decisions. We are able to use that data to predict problems.” Sessions throughout the three days of the Summit explored how the manufacturing industry is integrating sustainable practices and processes to reduce food waste, by introducing energy-efficient machinery with a smaller carbon footprint and driving traceable, ethical and transparent food production. Over 100 of the F&B decision makers and experts

from around the world shared insights into topics including F&B manufacturing economics, applications and impacts of food tech, plant-based alternatives, tech-led safety and quality assurance, supply chain excellence, and ingredient innovations and trends. Among the speakers were Adolfo Orive, President and CEO of Tetra Pak; Athar Siddiqui, EVP-Digital Industries at Siemens Middle East; Mostafa Absoliman, Head of Procurement – MEA at Kraft Heinz; Nihal El Mokdad, Director of Supply Chain Excellence – Global Emerging Markets at Mars; Nadine Elshoubary, R&D Director – Middle East, North Africa and Pakistan at Mondelez; and Laurent Simonpietri, Nutrition Ingredients and Head MEA, Turkey & Central Asia at BASF. Highlights at the stands included sustainable packaging from exhibitors such as Tetra Pak and Husky Technologies; renewable and clean energy solutions from GEA Middle East and Uniconfort; sustainable production solutions from Krones and Bunge, innovative technology to improve efficiency from Ishida and digital solutions harnessing the power of Big Data and AI from Siemens, SIG and Multivac. AMF Bakery Systems showcased a wide range of solutions for products ranging from buns and bread to pastries, pizza and flatbreads.

TRADE SHOWS

Four shows, one pass Three DWTC food and beverage events were co-located with Gulfood Manufacturing from November 7-9, 2023: the Speciality Food Festival is the MENA region’s only dedicated gourmet and fine food event. Visitors were offered immersive masterclasses, demonstrations and workshops from Michelinstarred chefs and rising talents. In turn, ISM Middle East showcased the latest products from the world’s leading brands. And last but not least, the Private Label Licensing ME was also held at the DWTC, MENA’s largest private label and contract manufacturing event, which this year focused on ensuring that brands are meeting the needs of increasingly informed and mindful consumers. +++

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SCIENCE

How microbiology can contribute to the sourdough industry In industrial production, the modulation of fermenting microbiota is the most critical stage. Understanding how it responds to processing conditions is essential to guarantee product quality. By José Guilherme Prado Martin and Thamylles Thuany Mayrink Lima

Microbiology of Fermented Products Laboratory (FERMICRO), Department of Microbiology, Federal University of Viçosa, Minas Gerais, Brazil

The advantages associated with sourdough fermentation stem from the microbial metabolism of sourdough, including lactic acid and acetic bacteria, Saccharomyces and non-Saccharomyces yeasts. The bakery industry stands to benefit from microbial diversity as it enhances the safety of sourdough bread, as well as its sensorial and nutritional properties. The standardization of sourdough production is still a challenge, however, which is why modulating the microbiota becomes a crucial strategy for scaling up the production of sourdough. Understanding how parameters such as temperature, pH, dough yield and flour type impact sourdough microbiota and bread quality is essential for improving sourdough bread production for industrial production. Sourdough breads consist of bakery products with peculiar characteristics, whose qualities have been largely recognized over the past few years. This phenomenon has been evidenced by the growing number of producers, both in artisanal and industrial contexts, as well as consumers attentive to new demands for innovative products. Sourdough ferment (’levain’ in French and ’massa madre’ in Spanish) is traditionally produced by mixing flour and water. In recent years, sourdough products have been incorporated into the portfolio of important bakery product manufacturers, highlighting the relevance of this technology for the global bread market. In 2020, it was valued around USD 2.2 billion. Sourdough bread consumption has also been increasing, with a compound annual growth rate (CAGR) of 8% until 2030. Nowadays, the sourdough market is well-established in Europe and North America. In other countries, it is still an emerging technology, as in Brazil, but with great potential for expansion.

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Sourdough microorganisms include bacteria and yeast. While lactic acid bacteria are predominant, acetic bacteria can also be found in their composition. Its complex microbiota is responsible for the characteristics of interest in the product. In addition to its distinct taste, aroma and texture in comparison to conventional breads, sourdough fermentation can contribute to health benefits for consumers, as well as longer shelf life without the use of additives and/or preservatives, serving a market focused on clean-label foods.

“How to deliver sourdough with appropriate characteristics for the bakery industry? The answer may be provided by microbiota.” José Guilherme Prado Martin, Thamylles Thuany Mayrink Lima

The benefits of sourdough technology extend to the development of quality gluten-free products, and help maintain their physical and sensory characteristics similar to those of conventional breads – which currently represents a major challenge for the industry. In this sense, sourdough fermentation has been considered a promising alternative for producing attractive and widely accepted gluten-free products. Besides that, sourdough fermentation allows the use of unconventional flours, such as quinoa, amaranth and lentils. In general, these ingredients may confer undesirable sensory attributes; however, sourdough technology is capable of improving the sensorial aspects of the product, increasing its added value. Enrichment with different legumes, cereals, pseudocereals and sprouted flours also offers new alternatives. In this way, the bakery

SCIENCE

industry is able to deliver products with even higher nutritional value for consumers.

Sourdough types and uses in the baking industry In short, there are three types of sourdough ferments. Sourdough Type I (traditional/artisanal) is characterized by an autochthonous microbiota and slow fermentation, with successive back-slopping steps. In Sourdough Type II (industrial), starter cultures are added to the mixture of flour and water. Finally, Sourdough Type III is obtained by dehydration of Type II. Before use as a starter culture, microorganisms are extensively studied in order to characterize them in terms of fermentative performance, technological properties and safety. Several research studies have increasingly focused on evaluating the biotechnological potential of microbial species of interest, aiming to develop innovative bakery products. For large-scale production, Sourdough Type I is expensive and laborious. To overcome this problem, Types II and III were developed, and are currently the most used in the industrial context. Both have specificities that facilitate their use, especially the possibility of selecting microbial strains of interest, ensuring their reproducibility. As they are known cultures, Types II and III are microbiologically stable, which makes them relatively safer. Furthermore, they are easier to manipulate, not requiring the back-slopping steps that are typical of Type I.

The sourdough microbiota In industrial production, the most critical point is certainly related to the modulation of fermenting microbiota. In this sense, understanding how it responds to processing conditions is essential to guarantee product quality. Due to the intrinsic characteristics of microbial strains, some of them are more commonly applied as starter cultures. The metabolism of lactic acid bacteria generates organic acids, aromatic and antimicrobial compounds. Furthermore, they can contribute to the functionality of sourdough bread. For example, Lactiplantibacillus plantarum is the most common lactic acid bacteria in sourdough fermentation; it presents the ability to solubilize phenolic compounds in the raw material, resulting in greater antioxidant activity, a functional property that protects the human body from oxidation reactions, providing a protective effect.

their metabolism may be realized by the consumers. For example, the metabolism of the yeast most commonly used in baking, Saccharomyces cerevisiae, is often associated with balsamic, malty, honey, rose and buttery notes. Alternatively, the yeast Kazachstania humilis, now widely found in sourdough, has been recognized for its contribution to fruitier flavors. Therefore, it is important to highlight that for the production of a typical sourdough bread, the presence of both microbial groups is crucial, given that each group contributes to the specific synthesis of compounds relevant to the bread structure, not being restricted only to its sensorial profile. In this context, the diversity of microbial culture combinations allows a greater diversification of the bakeries’ portfolio, improving the physicochemical, sensorial and nutritional properties of sourdough products. It allows the industry to reach different types of audiences, each with their own preferences and requirements. Thus, research in the field of microbiology combined with industry demands can bring interesting insights into sourdough fermentation, contributing to the production of innovative and economically viable sourdough products. In general, starter cultures are often isolated from sourdough ferment. However, the use of microorganisms from other fermented foods has been a widely used strategy in recent years. Several studies reinforce the relevance of non-typical sourdough microorganisms being used as starter cultures. For example, bacteria and yeast isolated from kefir and kombucha have been evaluated for their fermentation potential in baked goods. The impacts of this type of initiative reinforce the need for more research in the area, through partnerships between research institutes or universities and industries interested in sourdough technology.

How can the industry deliver interesting sourdough breads to the market? Modulating the microbiota to achieve desired properties is a relatively expensive task, as several parameters must be controlled for microbial metabolism to occur satisfactorily. Since the quality and characteristics of products are intrinsically related to fermentation, it is essential to understand how the fermenting microbiota responds to factors such as formulation, degree of hydration, and the binomial time x temperature. For example, for fermentation processes that

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In turn, yeasts contribute to bread texture, as compounds generated by them effectively improve the integrity and strength of the gluten network, complementing the role of exopolysaccharides produced by bacteria. Furthermore, yeasts are important for dough growth, through the production of CO2, which can also result from the metabolism of some types of lactic acid bacteria. Depending on the species, flavors and aromas resulting from

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SCIENCE

last more than 12 hours at relatively high temperatures (35°C), L. plantarum proves to be a good choice. The proportion of ferment in the dough is an important factor. Generally, at least 15% of ferment is used in relation to flour content. However, this proportion is highly variable, depending on the characteristics of the ferment used. Studies have shown that nutritional attributes can be improved by using about 30% of ferment. The kneading time is another important factor, with the best results obtained after about seven minutes. Again, these values may vary depending on the characteristics of the ferment, as well as the production model used. Hydration directly impacts the final bread acidity. Firmer ferments tend to be less acidic, as they prioritize the development of yeasts over bacteria, and are more commonly used in sweet dough. This relationship is relevant, as products with excess acidity can be less accepted by consumers. In this case, the use of L. plantarum is also recommended, as the strain does not produce acetic acid. The salt concentration is another relevant factor. Formulations with a higher salt content favor the growth of yeasts, resulting in low-acidity breads. However, the consumption of products with high salt content has been increasingly avoided, due to the harmful effects on health. Nowadays, sourdough technology can be used in different ways. The delayed dough method, where fermentation occurs at low temperatures, tends to generate greater concentrations of flavor and aroma precursor compounds, resulting in more complex sensory attributes, in addition to a greater dough-specific volume and a less dense crumb. Freezing the dough is also a possibility, as long as it is used

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in conjunction with cryoprotectant solutions mixed into the dough in order to preserve its texture. Some studies have evaluated the use of natural additives as cryoprotectants, meeting the demand for clean-label products. It has been shown, for example, that basil seed gum mitigates damage to the structure of the gluten network of frozen dough, making it more uniform and providing properties similar to those observed for fresh sourdough breads. Finally, the well-defined combination of process parameters with the characteristics of the starter cultures used is essential for sourdough bread quality. From this, the industry can diversify its bakery portfolio by including products obtained from sourdough technology, whose sensorial, nutritional and functional properties have been increasingly valued by consumers around the world. In the industrial context, this is a relatively complex task, where challenges can be overcome by a better understanding of the role of microbiota in sourdough fermentation.

Scientific studies on sourdough fermentation Our research group in Brazil has developed studies about sourdough fermentation focused on understanding the role of the microbiota in the quality of the products. Recently, we published an extensive review where we highlighted the main parameters that affect the sourdough microbiota and how they impact the technological, sensorial and functional quality of sourdough breads. In this material, we raise questions in order to answer the following question: How to deliver sourdough with appropriate characteristics for the bakery industry? The answer may be provided by microbiota. The article is available to read at the following address: https://doi.org/10.1016/j.fbio.2023.103072. +++

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Going egg-free with faba beans Following consumer plant-based preferences, the bakery industry is turning to egg alternatives. Faba bean proteins mimic many of the required properties and allow for sustainable solutions.

Driven by the consumer shift towards more sustainable, plant-based diets, the bakery industry is looking for ‘egg-less’ solutions. According to recent figures, more than one third of consumers worldwide are trying to reduce their consumption of products containing eggs from industrial farming and 13% do not eat them at all. In addition to the need to serve people who are egg-intolerant or vegan, unstable and rising egg prices are also fuelling the search for alternative ingredients. Replacing eggs, especially in bakery products, remains a challenge for manufacturers. This is because eggs have several functionalities in bakery applications. For example, they have emulsifying and aeration as well as texturizing properties. Moreover, on a sensorial level, eggs provide flavor and color and, if needed, contribute to a glossy surface. Plus, on a nutritional basis, they can enhance the overall protein content. In the search for a plant-based substitute for eggs, other ingredients have risen to the challenge. One of them is the faba or broad bean, a legume crop grown primarily for its edible seeds and thought to be one of the earliest domesticated legumes. The plant, formally known as Vicia faba L., belongs to the Fabaceae family. Faba beans help to make foods ‘futureproof’ as they come with remarkable sustainability credentials. As a multi-use crop with special nitrogenfixing properties, faba beans significantly reduce the need for fertilizers on farms and, being regionally grown, they can contribute to a reduction in transport.

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A plant-based allrounder BENEO has been exploring the use of faba bean ingredients in different bakery concepts and is increasingly researching their potential as an egg replacer. Tests done by the company have focused on faba bean protein concentrate. “The ingredient shows good solubility, strong emulsifying, thickening and binding properties, as well as good foaming characteristics and a pleasant taste. In this sense, it ticks many of the important boxes that eggs do,” says Dr. Isabel Trogh, Customer Technical Support Manager at the BENEOTechnology Center.

“The ingredient shows good solubility, strong emulsifying, thickening and binding properties, as well as good foaming characteristics and a pleasant taste. In this sense, it ticks many of the important boxes that eggs do.” Dr. Isabel Trogh, Customer Technical Support Manager at the BENEO-Technology Center

One of the company’s first egg-replacement trials was carried out with muffins. The traditional version was compared with a plant-based variety that was reformulated with BENEO’s faba bean protein concentrate. The results showed that the faba bean muffins were very similar in volume and appearance to the egg-containing originals.

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Furthermore, the plant-based muffins had a pleasant taste and a comparable fine crumb structure that mirrored the reference product.

by air classification. As a vegetal protein with an excellent essential amino acid profile, the ingredient is also popular for protein fortification. Among other concepts, BENEO used it in bakery applications by formulating a wholemeal, high-protein bread, for example. The protein enrichment opens the door to nutritional claims such as ‘source of protein’ or ‘high in protein’.

The BENEO-Technology Center paid special attention to crumb firmness as an important indicator of texture. During laboratory tests, the crumb firmness of both muffin versions was successively measured at one day, one week and two weeks after baking using a Texture Analyser (figure below). The results showed a similar crumb firmness for the reference and the egg-free muffins, even after two weeks of storage.

Next to protein concentrate, BENEO’s faba bean range also includes starch-rich flour which is naturally high in protein.

Based on the positive results, further trials have been done – including one with meringue, a confectionary that typically consists of high amounts of egg white. The BENEOTechnology Center tested a completely egg-free, plant-based version by using faba bean protein concentrate. The plantbased meringue had a pleasant taste profile and a good aerated texture (which is characteristic of the product). Another egg-less reformulation was done with shortbread biscuits. The plant-based prototype showed a comparable sandy texture as the egg-reference, delivered a pleasant taste and had a similar appearance.

High in protein and clean label Faba bean protein concentrate is distinguished by its protein content of at least 60% on dry matter base. The concentrate is obtained by dry fractionation, a process that allows the functionality of the native protein to be maintained. After cleaning, dehulling and milling the beans into flour, the starch-rich fraction is separated from the protein-rich particles

The reference and egg-free muffins are very similar in terms of volume and crumb firmness

Recipe: Plant-based muffins with faba bean protein concentrate INGREDIENTS (% w/w)

Test recipe

Reference

Wheat flour

Water

Sugar and inverted sugar syrup

Vegetable fat

Faba bean protein concentrate

—

Rice starch

Orafti® Oligofructose

—

Eggs

—

Skimmed milk powder

—

Minor ingredients (glycerol, raisings agents, salt, etc.)

q.s.

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Source: BENEO

Texture analysis: Muffins were stored in plastic bags at room temperature; an average of 10 measurements per recipe were taken 1 day, 1 week and 2 weeks after baking

Source: BENEO

Although faba bean protein concentrate mimics eggs in the recipe, another ingredient was needed to achieve a completely plant-based solution: Orafti® Oligofructose, a water-soluble prebiotic dietary fiber, serves as a substitute for milk powder in the recipe. Derived from chicory root, this fiber can support gut health by feeding beneficial intestinal bacteria. On a nutritional level, Orafti® Oligofructose increased fiber levels.

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quantities of faba bean ingredients in a recipe may lead to a subtle beany taste, there are easy ways to optimize the sensory attributes of the final product. Bakery manufacturers can use masking flavors or combine faba bean ingredients with other components that have a distinctive taste, such as almond flour, lemon flavor or cocoa powder.

Affordable bakery solutions

Both ingredients are clean label (no E-numbers needed), non-GMO and have a creamy or light-yellow color in powder form. Sensory evaluations indicate that the characteristic bean-like taste of faba beans is milder than that of other plant-based protein sources. Although the use of higher

The reformulated recipes of muffins and, in particular, the egg-free meringue, also reveal faba bean’s potential for cost reductions. The test recipes require a much lower dosage of faba bean protein concentrate than the amount of eggs used in the original formulation. “In this regard, plantbased reformulation can also be an important way to reduce costs, as key raw materials such as eggs have seen significant price increases,” says Dr. Isabel Trogh. The company is now working on egg replacement in further bakery applications. In a first trial with pound cake, the BENEO-Technology Center reduced half of the egg content by adding faba bean protein concentrate. The reformulated prototype allows for a pleasant taste and texture and offers cost-saving potential, depending on local raw material prices. +++

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