Bakery Review 2022

2022

www.foodreview.co.za

Journal for bakery and confectionery professionals

REVIEW

The evolution of the bakery industry

Healthier ingredient options | Stepping up food safety | Sustainable packaging solutions

DIOSNA mixers in hygienic design for excellent dough production with reduced downtimes at fast recipe change.

DIOSNA Innovative Mixing in Hygienic Design

For dough at its best The Wendel Mixer of the Hygienic Design series connects high performance mixing with an open construction to allow easy cleaning, and thus a very fast switch between different recipes.

As it is typical for DIOSNA Wendel Mixers the method of gentle processing of the dough by folding allows perfect dough development in shortest possible time, avoiding crushing of seeds and fruits if used in the recipe. The WH240 ”A” model allows fast succession of batches by the easy change of mixing bowls.

DIOSNA enjoys worldwide recognition as specialist for dough processing and pre-dough fermentation on a large scale. Machine equipment and biotechnology represent the ideal interaction for best results in food production.

→ → → → →

Ideal for all types of dough, masses and bars Gentle dough and ingredient processing Optimal integration in existing line production Easy cleaning - reduced downtimes Hygienic design mixers with changeable bowl or direct ground discharge

4 EDITORIAL Editor: Tennille Aron +27 (0)73 995 5599 tennille.aron@newmedia.co.za Layout & Design: David Kyslinger

ADVERTISING Sales Executive: Anita Raath +27 (0)82 976 6541 anita.raath@newmedia.co.za Sales Executive: Carla Melless +27 (0)83 260 6060 carla.melless@newmedia.co.za Sales Executive: Candida Giambo-Kruger +27 (0)71 438 1918 candida.giambo-kruger@newmedia.co.za

CIRCULATION Circulation Manager: Felicity Garbers +27 (0)21 701 1566 felicity.garbers@newmedia.co.za

PUBLISHING TEAM General Manager: Dev Naidoo Group Account Director B2B: Johann Gerber Production Controller: Mandy Ackerman Art Director: David Kyslinger JOHANNESBURG OFFICE Ground floor, 272 Pretoria Avenue Randburg, 2194 POSTAL ADDRESS PO Box 784698, Sandton, Johannesburg 2146 Published by New Media, a division of Media24 (Pty) Ltd.

8

News Two novel flour blends New colouring on the market A naturally white colour solution Reducing food wastage in the bakery industry

AD INDEX

Eggless baking solutions

7

10 Solving bakery supply chain challenges 14 Overcoming the challenges of hygiene management 17 The best steel bake oven belt in the business 22 Popular bakery packaging trends 24 Top ingredients for all your bakery needs 28 Choosing the best partner for your bakery business 30 The sweet alternatives to baking with sugar

CO NTENTS 2022

AECI Food & Beverage OBC

www.aecifoodandbeverage.com / aeciworld.com

Arbonia www.arbonia.co.za

Cama Group 23

www.usspactech.co.za / www.camagroup.com

Cereal & Malt IBC

cerealandmalt.com

Chemgrit SA 31

www.chemgritsa.co.za

DIOSNA IFC

www.diosna.com

Ingreto 29

www.ingreto.co.za

IPCO International 21

ipco.com/bake

M-Bake Bakery Equipment 9

www.mbake.co.za

Prac-Pak 5

www.pracpak.com

Savannah Fine Chemicals 25

www.savannah.co.za

SUPREME Flour 13

www.supremeflour.co.za

Synercore Food Holdings 11

www.synercore.co.za

MANAGEMENT TEAM MANAGING DIRECTOR: Aileen Lamb COMMERCIAL DIRECTOR: Maria Tiganis STRATEGY DIRECTOR: Andrew Nunneley CHIEF FINANCIAL OFFICER: Venette Malone HEAD OF HR: Ruth Shogoe CEO: MEDIA24: Ishmet Davidson HEAD OFFICE 8th floor, Media24 Centre, 40 Heerengracht, Cape Town 8001 PO Box 440, Green Point, Cape Town 8051 Tel: +27 (0)21 406 2002 www.newmedia.co.za

Bakery Review is published by New Media Publishing (Pty) Ltd. Views expressed in this journal, other than where specifically stated, are not necessarily those of the publisher.

The editor welcomes for publishing consideration news items, press releases, articles and photographs relating to developments in the food and beverage industries. No responsibility is accepted should contributions be lost.

Readers are prohibited from using the contact details displayed in any advertisement or editorial within the pages of this publication to generate and/or distribute unsolicited bulk emails or other forms of mass marketing correspondence.

ED ’S N OTE

Fresh baked goodness As consumers search for healthier food and beverage options, the bakery industry have had to adapt their products to these changing needs. This has meant the creation of baked goods that are more nutritious, contain a lower sugar content and that include more functional ingredients.

Fortunately, ingredient companies throughout the world are focusing on finding the right ingredients and tools to help the food and beverage manufacturing industry produce baked items that not only taste good, but that

also have an impact on the overall health of the consumer. We explore the latest and greatest ingredients and equipment in the bakery industry in this issue of Bakery Review. Plus, discover the most sustainable packaging options for your products. Read on to find the perfect sugar alternative solution or uncover the freshest ingredients available for your bakery needs.

Happy Reading!

Tennille Aron

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3

N EWS

New gluten-free and keto-friendly flour blends Ardent Mills, the premier flour-

friendly blends and

milling and ingredient company,

gluten-free blends

announced the launch of its new

provide bakers with

certified gluten-free flour blends

uncompromised

and keto-friendly flour blends. A

formulations

major step for the industry, Ardent

for keto-friendly

Mills’ keto-friendly flour blends

or gluten-free

can be used as a replacement

applications.”

for conventional flour without

The new flour

compromising taste, texture or

blends will only

functionality, while their new gluten-

be available for

free flour blends offer ease of use for

purchase directly

a variety of formats.

through Ardent Mills

“Interest in keto-friendly and

Canada and bakery

gluten-free lifestyles continues to

and foodservice

grow as consumers seek solutions

distributors across

that match their personal health

Canada. “Today,

values and preferences. In fact, Keto

consumers expect

is the fastest growing ‘healthy claim’

food choices

appearing on menus, and 44% of

that align with their individual

thrilled that we can now offer

consumers eat gluten-free at least

diet preferences and these latest

bread and bakery manufacturers,

some of the time, according to Ardent

alternative offerings are a major step

retail and wholesale bakeries,

Mills proprietary research,” said

forward in making that a reality,”

and foodservice and pizza chain

Elaine O’Doherty, Canada marketing

said Buck Vanniejenhuis, Canada

operators a one-stop shop for all their

lead, Ardent Mills. “Our new keto-

general manager, Ardent Mills. “We’re

flour and alternative grain needs.”

New colouring made from organic safflower GNT has expanded its range of EU organic-certified Exberry Coloring Foods with new yellow and green shades made from organic safflower. Exberry Organics Fruit & Veg Yellow is made from organic safflower and organic apple, while Exberry Organics Veg Green is made from organic safflower and organic spirulina. Both are compliant with Organic Regulation (EU) 2018/848. They are also suitable for a wide variety of food and beverage applications including bakery. Based on the principle of colouring food with food, Exberry Organics are created from edible fruit, vegetables, and plants using traditional physical processing methods.

4 B A K ER YR E V IE W 2 0 2 2

1 READ STREET ♦ CNR HARRIS DRIVE ♦ OTTERY ♦ CAPE TOWN ♦ SOUTH AFRICA

Converters of flexible packaging materials and allied products • Polypropylene (BOPP) / Cellophane • Bio-degradable starch based film • 3 side sealed laminated pouches • Stand-up pouches, with or without zipper • Stand-up pouches, with or without spouts

Tel: (021) 704 1135/6/7 | Fax: (021) 704 1210 | Email: pracpak@iafrica.com | www.pracpak.com

N EWS

A naturally white colour solution With the new PearlEdge

rollout meets the evolving

proprietary white colour

needs of customers and

solutions, ADM have created

consumers, as brands look

a fantastic alternative to

for TiO2 replacements that

titanium dioxide (TiO2). The

not only provide a bright white

new line is derived from

shade, but also meet clean-label

natural ingredients, such

targets.”

Buyer’sguide The PearlEdge portfolio is

THE

as native corn starch, and

delivers brilliant, stable and

designed to address different

uniform white colouring for a

applications and performs

variety of food and beverage applications.

“Our team has been diligently working to perfect our

exceptionally well in confection and bakery icings and

fillings as well as sugar-free offerings. 2017/2018 PearlEdge also

new line of white colour solutions, assuring its ground-

delivers elevated sensory appeal as an opacifying base

breaking quality and performance,” said Hélène Moeller,

coat for vibrant colours, and it creates smoother texture in

vice president of global product marketing, ADM. “This

certain applications.

THE

Buyer’sguide

2021/2022 2020/2021

The directory for manufacturers of food, beverages, pharmaceuticals, cosmetics, toiletries, packaging and the printing industry

Available online: www.thebuyersguide.co.za Buyers Guide 2018.indd 1

6

B A K ER YR E V IE W 2 0 2 2

2018/05/07 3:09 PM

N EWS

Reducing food wastage in the bakery industry The need to reduce food waste has never been more

when a producer is looking

important than now especially in the bakery industry that

at the initial investment

accounts for a large amount of food wastage explains Jessica

in reformulation. But by

Cassity in the KerryDigest Blog.

adding just a day or two, you’re

“On average around the world, about a third of the food

significantly increasing the chance

that we produce goes to waste”, says Emma Cahill, managing

that the food will be able to feed people,

director for Food Protection & Preservation. ‘And that hasn’t

and stretching the reach of your supply chain to a new market.

changed over a number of years.

You’re also increasing the likelihood that products will leave the

“Globally, the bakery category has the greatest volume of

supermarket shelf and decreasing the number of costly returns”.

food waste, in terms of finished processed goods,” says Cahill.

But products can also be rejected much earlier in the

“Being able to extend bakery shelf-life could really impact and

supply chain, suggesting a focus on production processes is

reduce waste figures.” Stale bread, bread rolls and cookies

also essential for reducing food waste. For example, bakery

are said to account for a majority of bakery waste. One recent

dough that sticks to a mixing bowl or to a divider would

study from Sweden suggests that 80 000 tonnes of bread are

count as food loss. Also categorised as waste are misshapen

wasted per year in the country or about 8kg per person. Other

products that can’t be packaged for sale. Here, a combination

research suggests that in the U.S., 25% of bread goes to waste

of process changes and recipe updates can help. For example,

in the consumer’s home due to short shelf-life. In addition, in

one manufacturer of baked crackers was recently able to

bakeries and plants where processes aren’t optimised, a large

process updates and reformulate its recipe to include a new

percentage of output may never even make it to consumers.

enzyme solution, effectively cutting its food waste from 30%

One reason bread and bakery products contribute to so much waste is their naturally short shelf-life—the low cost,

of each batch to just 10%.

Being able to make changes at scale for industrial production

too, makes it easy to discard some products after just one day

can help resources go further, something that is important in

due to freshness concerns. The addition of traditional food

places with food scarcity. As the definition of sustainability

protection and preservation options could be a solution, due to

continues to change, improving conditions for people as well as

their ability to extend palatability. “The impact of an increase in

the planet—such as through a greater availability of sustainable

shelf-life of a few days or a percentage may seem hard to quantify

nutrition—is a growing priority.

Distributors of Rondo equipment in South Africa

Polyline The Polyline is Rondo’s starting point for automatic pie production.

In addition to pies you can produce folded, rolled, filled, decorated, cut and even stamped out products with the Polyline.

Tel: +27 11 462 3224/5 Fax: +27 11 462 3226 E-mail: foodequip@arbonia.co.za

Rondostar 4000 The Rondostar 4000 can produce dough bands and blocks easily and gently.

It can also produce very thin dough bands and process the more difficult dough types like shortcrust pastry.

B A K ER YR E V IE W 2 0 2 2

7

AECI FO O D & B E VER AG E

The nobility of milk proteins in food processing If it is overall peace of mind that you are looking for when it comes to your baked goods, then look no further than the Arla Food Ingredients milk proteins. AECI Food & Beverage in partnership with Arla Food Ingredients, brings you the convenience of eggless baking with their range of milk protein egg replacers.

T

he purpose at AECI Food & Beverage is

consumers who still regard eggs as a natural and

to supply to their customers with a range

desirable ingredient.

of technology driven and consumer-led

Just like egg, Arla milk proteins contain all

additives and ingredients that are cost

the essential amino acids that are beneficial for

effective without compromising the nutritional and

human health, and that add to the nutritional

organoleptic values of the final product. With this

value of the end product. Furthermore, they come

range of milk proteins, that is exactly what they

with the benefit of being cholesterol free, low

can give to their clients.

in fat and are easy to handle and store before

Why choose Arla milk proteins for baking?

manufacturing because they do not require

Eggs are such a traditional ingredient in many cake recipes that it can be hard to imagine baking without them. However, a long history of fluctuating prices and, more recently, a series of supply problems is increasingly making eggs a target for replacement. The challenge for bakers is how to control the cost and quality of their cake products, while pleasing the many

controlled temperatures (refrigeration). They are easy to use in applications and there is a costsaving benefit because you only need a small dosage in your recipe to achieve your goal.

As an egg replacement for baked products, the milk proteins stabilise the cake batter and strengthen the cake structure resulting in improved volume of the final cake. The improved structure makes slicing much easier and there is also reduced production waste. The water binding effect of the protein results in an improved moistness and freshness perception of the final cake, without compromising on the cake quality. These milk proteins also work well for gluten-free baking.

The Arla milk proteins will not only provide you with consistent product quality, but they will also make your processing/baking efficient and keep your customers begging for more.

BR

AECI Food & Beverage - www.aeciworld.com 8

B A K ER YR E V IE W 2 0 2 2

SY N ER CO R E

Solutions to your bakery supply chain challenges The Baking Ingredient Division of African Food Industries (AFI) supplies functional food ingredients to the milling and baking industries within Sub-Saharan Africa. With a combined experience of over 135 years within the industry, this AFI team’s skill set stretches from industrial bakery optimisation to artisanal craft demonstrations.

D

uring the Covid-19 pandemic, many

replacement products DR1000 and DR2000 have

imported ingredients were, and still are,

been the most successful at replacing DATEM,

in short supply. The international freight

which has shown to be the ingredient with the

backlog and rise in fuel prices have resulted in

largest supply shortage. AFI further developed a

the inflation of ingredient prices. It is due to this

yeast-lowering functional ingredient called YR1000

challenge that AFI’s research and development

that enhances the activity

team developed cost-effective, functional enzyme-

of yeast through

based replacements for many imported materials.

improved yeast

The team have developed alternatives for a number

food and nutrient

of emulsifiers and dough conditioners that have

availability

proven to be very successful as 1:1 replacement

during

for DATEM, SSL, monoglycerides and various

proving. The

combinations of conditioners. The emulsifier

boost in yeast

10 B A K ER YR E V IE W 2 0 2 2

SY N ER CO R E

activity has resulted in 25% lower yeast usage, while increasing the control of oven spring.

AFI now also designs and supplies productspecific improvers and enzyme blends to match the expectations of individual customers. Enzymes can modify different components of dough, starch,

“AFI’s research and development team developed cost-effective, functional enzyme-based replacements for many imported materials.”

proteins or lipids, and can be used to improve crumb texture, dough stability, loaf volume, tolerance, taste and flavour. These enzyme blends

Additional chemical leavening systems, like

can optimise ingredient activity or create synergies

baking powders, are available to suit product needs

between a multitude of functional ingredients. At

ranging from doughnuts to flapjacks, flatbreads

AFI, enzymes are selected after extensive trials and

and cakes. Each baking powder is activated by

are sourced from many global enzyme specialist

varying reactions to moisture, time, temperature

suppliers. Enzyme formulations are developed

and physical activity. AFI specialists are available to

according to the individual needs of bakeries

assist customers in evaluating the ideal leavening

and mills, and are only finalised once the blend

product for optimal results.

of enzymes performs optimally according to the customer’s expectation in application.

Tortilla improvers are another example of AFI’S

AFI’s flavour team also supplies a range of colour and flavour options to clients and bakery research and development. With both sweet and

product-specific offering. The tortilla improvers

savoury options, and dozens of flavours available,

contain high-performance ingredient selections

their range is often used in the development of

for extensibility, conditioning, leavening and

cake, sponge and muffin mixes. One of their latest

preservation. Combinations of these technologies

offerings is the bun spice, which makes for the

can be made to suit the plant or product required.

perfect Easter bun glaze.

BR

Synercore - www.synercore.co.za 12 B A K ER YR E V IE W 2 0 2 2

Achieve Professional Results with

SUPREME Flour!

We provide a comprehensive range of professional products to suit your bakery’s needs. Some of our offerings include: 1.

SUPREME Cake Wheat Flour is unfortified, highly refined flour which is purified to reduce bran and mineral content, making it ideal for baked products that require exceptionally white flour. SUPREME Cake Wheat Flour is a high-performance product which is finer in texture for better baking. It’s often used in puff pastry applications and other bakery goods which require consistently reliable and delicious results.

2. SUPREME Bread Wheat Flour is available in two variants: SUPREME White Bread Wheat Flour, which is your ideal choice for producing baked products with lighter colours, are strong in proteins and have robust volume; and SUPREME Brown Bread Wheat Flour, which has a higher bran content than our White Bread Flour and is great for baking products with a warmer colour and higher bran content.

3. SUPREME Turbo 5% Bread Concentrate has been uniquely developed from the highest quality raw materials. Bread baked with Turbo 5% Concentrate exhibits superior shelf life, guaranteed consistency and excellent water absorption, resulting in decreased cost-per-loaf. For best results, use in conjunction with SUPREME White and Brown Bread Wheat Flour, specifically, to produce white and brown tin bread.

4. SUPREME Multi-Pro is specifically created for multiple uses in professional and high-end artisanal baking. This high protein flour contains higher levels of gluten, which delivers increased water absorption rates and greater yields, as well as improved dough strength, stability, and baked volume. This makes it best suited for the manufacturing of bread, pizza bases, artisan bread, bagels and frozen products that are not baked in pans.

If you are interested in enquiring about any of our SUPREME Flours or Prepared Mixes, visit or contact us on our SUPREME website.

D I OS NA

Reaching your goal

more safely with hygiene Today more than ever, hygiene measures play an almost overriding role in both private and professional contexts. In the area of food production, large companies and operations must look beyond personnel hygiene to production hygiene to manufacture safe products. Comprehensive hygiene management is essential in this regard. In this context, a shortage of skilled personnel, higher demands on productivity and efficiency, and short time working also present the bakery industry with special challenges.

C

ompanies like Diosna Dierks & Soehne have

In the context of the above-mentioned focal

broadened their scope to be able to provide

points, consulting in the area of hygiene

an extended service portfolio in addition to

management, including HACCP testing also

their well-known machines and systems for pre-

supports Diosna customers in drawing up

dough, kneading and mixes. In addition to food

cleaning plans and using the right cleaning

technology and analysis services, this portfolio

agents. Environmental and swab samples as

also offers advice on hygiene management issues.

well as air sampling can also be carried out and

Diosna roughly divides hygiene management

a hygiene concept drawn up based on this. In

into the three sub-areas of personnel hygiene,

addition, Diosna offers consulting services to

operational hygiene and process hygiene.

ensure that hygiene regulations, such as EU Regulation 852/2004 and the German Food Hygiene Regulation, are implemented safely in the plants. The comprehensive range of services is complemented by the latest developments in the field of hygienic design plant engineering.

Hygiene in production - What does hygienic design mean?

The challenges in the context of hygiene management are not only faced by food-producing companies. Machine and plant manufacturers must Diosna Wendel Mixer of the Hygienic Design Line (WH series)

14 B A K ER YR E V IE W 2 0 2 2

D I OS NA

also upgrade to remain the first point of contact

are many hygiene-critical points that require

in the future. Therefore, they too have to deal with

attention in quality-controlled installations. These

the current hygiene regulations of their customers

include internal angles and edges, welded joints or

by means of specialised personnel and create

a hygienic cable feed-through.

solutions. Various standards and guidelines, such

Diosna designs machines taking into account

as DIN 10516, help to provide orientation and to

the cleaning-friendly design of parts, components

implement them.

and surfaces. In cooperation between Diosna

Ideally, it is already questioned during the design

designers, technologists, hygiene specialists

phase whether the planned surfaces, especially

and customers, proven and new products are

the product-contacting parts, comply with the

constantly optimised.

recommendations and standards. Thus, in addition

Mobile tanks are the standard, solutions for

to the material, the material properties, such as the

complete draining of cleaning liquids, center

roughness of the surfaces, also play a role.

draining, pincer locking on mixers and elevator

Furthermore, it must be checked whether screw

tippers, sufficient floor clearance and the use

connections and pipe joints are hygienically

of easily removable covers are good solutions

designed and easy to clean. It is also important to

for the general range of machines. The use

avoid ‘dead spaces’ in which liquids can accumulate

of suitable materials and raw materials, e.g.,

or to ensure that they drain off unhindered. There

lubricants, air is essential.

Diosna Hygienic Design Line

B A K ER YR E V IE W 2 0 2 2

15

D I OS NA

Hygienic Design line - The Wendel mixer with special hygienic profile The latest development in the field of Hygienic Design is the Diosna Wendel Mixer of the Hygienic Design Line (WH series). The design is based on the guidelines of the European Hygienic Engineering & Design Group. The aim of this special design is to provide even more support to manufacturers in the baking, dough and snack industries to avoid microbial and particulate contamination of the end product, also on a plant basis.

The Wendel Mixer is designed as an open construction and round stainless-steel profile.

These features guarantee a short and optimised

type); with other kneading systems, the kneading time ranges between 12 and 20 minutes.

For smaller dough quantities, the Diosna Wendel

cleaning process and a reduction of deposits.

mixer WH 240 E has a performance in wheat dough of

Surfaces are hygienically optimised to prevent

240 kg and a yield of 156.

microbial and particulate contamination of the baked product.

This mixing system is suitable for all kinds

Reaching your goal more safely with hygiene

of dough due to the gentle mixing process and

Increased requirements and good hygiene

the low dough heating. At the end of the mixing

management pose a number of challenges for

process, the dough is either discharged through the

manufacturers in the food and mechanical

electrically controlled bowl opening of the under-

engineering sectors.

bowl discharge system (WHE-series) or transferable via the moveable bowl (WHA-series).

Benefits from Wendel mixers in hygienic design

Diosna offers companies comprehensive advice as well as conceptual and practical recommendations on this topic. This includes plant assessment and training of selected personnel on the following themes: personnel hygiene, plant hygiene and

Manufacturers get cooler doughs, shorter kneading

production hygiene. Machines suitable for cleaning

times, higher dough yield, higher water absorption

and the systems of the new Hygienic Design Line,

and improved measurable dough structures. The

together with the comprehensive service portfolio,

dough is not only compressed and pulled during the

represent a holistic offer. In this way, Diosna aims to

kneading process, but also folded. In this process,

continue to secure its position as the first point of

90% of the energy is used for dough production and

contact for quality-leading pre-dough and kneading

only about 10% is lost as rising temperature, i.e.,

machines, organic and pre-dough technology, and

0.5 °C – 1.5 °C temperature rise per minute at high

hygiene management in order to meet current and

speed, depending on dough viscosity. In addition, a

future challenges with its customers.

BR

kneading capacity of up to 3 000 kg/hour per mixer can be achieved. The total kneading time varies between 6 and 8 minutes (depending on the dough

16 B A K ER YR E V IE W 2 0 2 2

Diosna Dierks & Soehne GmbH - www.diosna.com

IP CO

Getting the best from your

steel bake oven belt IPCO is the world’s largest supplier of steel bake oven belts and has nearly 100 years’ experience of working with the bakery industry. This gives the company an understanding of production issues that goes beyond belts themselves, as IPCO global product manager Marko Leber explains.

T

IPCO Global Product Manager: Marko Leber

he primary role of an IPCO steel bake oven belt is to convey goods through a continuously operating oven. The high

thermal conductivity of this type of belt, whether solid or perforated, concentrates heat onto the product to achieve the desired crisp base, and the smooth, flat surface ensures a clean discharge at the end of the line with minimal risk of damage to fragile products.

A high-quality bake oven belt will have key mechanical properties – flatness, straightness – ‘engineered in’ at the production stage to ensure that it runs through the oven as it should. Consistency of colour is important too; dark areas absorb heat

the productivity, quality and profitability of the

while light, shiny areas reflect it, so uneven belt

overall bake oven line.

colour could result in an uneven bake. This has to be engineered into the belt too.

In short, the quality of the manufacturing

A steel belt that has been manufactured to the highest standards is an highly efficient tool, one that with the right maintenance will

process – the transformation of a length of

deliver reliable service for longer than any other

cold rolled carbon steel band into a high

conveying medium; a belt life of 20 or more

precision component – determines the long-

years is not unusual, some can last two or even

term reliability of a bake oven belt and, in turn,

three times that long.

B A K ER YR E V IE W 2 0 2 2

17

IP CO

Maintenance procedures Maintenance requirements are relatively low compared with other belt materials. Solid and

life. It also helps to maintain a regular belt colour for an even bake.

The easiest way to apply a lubricant is via

perforated steel belts are by their very nature

graphite skid bars, which deliver a gradual

highly durable and resistant to stretching and this

deposit of graphite to the inside of the belt. IPCO

alone keeps downtime to a minimum. A premium

graphite skid bars are available for all standard

quality belt will also display good tension and

belt widths.

tracking characteristics, which is key to reliable, trouble-free operation.

So, what maintenance does a steel belt need?

If, for any reason, a skid bar cannot be used, graphite should generally be applied to the inside of the belt once a month for the first three months

Aside from regular checks, more of which in a

after installation, then every three to six months.

moment, lubrication and cleaning are the two

If graphite is not permitted, specially selected oils

most important maintenance tasks.

can be used instead.

Lubricant is essential as well as reducing

Cleaning is usually carried out using rotating

friction. It helps eliminate risk of rust caused

brushes, with the application of scrapers as

by condensation, it reduces wear, prevents belt

necessary. The brushes should be adjusted to

distortion and, ultimately, leads to a longer belt

apply gentle cleaning of the belt surface.

Ineffective cleaning will result in a build-up

“The primary role of an IPCO steel bake oven belt is to convey goods through a continuously operating oven.”

18 B A K ER YR E V IE W 2 0 2 2

of carbon deposits on the baking side of the belt, leading to less than perfect products and, ultimately, a risk to health due to the presence of hazardous acrylamide.

A range of factors including belt type, end product, oven type and personal preference

IP CO

will determine the most effective approach to

a whole. For our service teams, analysis of belt

the removal of carbon deposits and will usually

condition can paint a clear picture of how that

involve the application of chemicals, dry ice or

system is performing.

detergents and great deal of manual input. It’s

It’s almost always the case that any issue

a task that cannot be ignored if an oven is to

with belt condition is the symptom of another

produce high quality goods.

problem, not one in its own right. Once the cause

Of course, some issues go beyond what could

has been identified and rectified, we can return

be termed ‘everyday’ maintenance and this is

our attention to the belt itself and take whatever

where our service support operation comes in.

remedial action may be necessary to make sure

IPCO service support One of the unique strengths of IPCO is our

that it’s in a condition to perform reliably for years to come.

For example, if side wandering is occurring, this

ability to offer maintenance support that looks

can often cause the belt to come into contact with

beyond the belt. For some customers, belt

the structure or another rigid object, resulting

supply is all that’s needed, but for others we

in burrs. Wavy belt edges could be another

support the OEM or end user with a full range

indication of side wandering, or of uneven

of conveyor components, from drums, sheaves

temperature in the oven. It can also indicate

and shafts to tracking systems, break points

uneven pressure from the belt cleaner or scraper,

and graphite stations.

or a belt scraper that is wider than the belt itself.

We understand how a belt interacts with the other components that make up the system as

We look for deformations in the belt, which could suggest problems with drums, belt

B A K ER YR E V IE W 2 0 2 2

19

IP CO

supports or other parts

better than cure. By offering

coming into contact with

Preventative Maintenance

the belt. Remedial actions

Agreements (PMAs), we aim

include cleaning the drums,

to identify risks of failure

cleaning or replacing belt

before they have chance to

supports, and checking

disrupt production.

scrapers, rollers and

Inspection work will cover

belt tensioning.

all major system components.

We also inspect the

We check that terminal

underside of the belt, as

drums, rollers and skid bars

any scratches could indicate

are aligned horizontally and

worn or damaged belt

at right angles to the center

supports or safety scrapers.

line of the longitudinal axis of

In one recent case, a

the oven line. We check that

customer asked us to look

terminal drums and rollers are

at belt tracking problems

rotating freely and that tension

they were experiencing.

and tracking devices are

They believed they’d

operating as they should be.

probably need a new belt

As a company we have

but wanted us to identify the root cause of the

fully trained and equipped service teams

problem first.

on the ground in all key markets, including

As it turned out, the condition of the belt

Africa. This means we can provide a quick

itself was not a concern but it was clear to

response to any service or repair needs, and

our engineers that certain components were

that work is carried out by qualified people

incapable of providing the reliability and

with a real understanding of customers’ needs

performance that could be expected of modern

and values.

conveyor equipment. The surfaces of the drums,

Local teams can call on the support of IPCO’s

for example, were no longer suitable for effective

Special Engineering team, experts who can be

belt tracking.

sent anywhere in the world to troubleshoot issues

We were able to retrofit a range of new components including inlet and outlet drums,

and provide specialist support.

We also support customers in the form

tracking devices, a graphite station and a cleaning

of technician training, either on-site or at

brush and scrapers, and retain the existing belt.

our regional headquarters in Johannesburg.

The customer ended up with a state-of-the-art

Subjects can be tailored to requirements, but

conveyor system capable of delivering significantly

will typically focus on best practices in belt

improved productivity, at a cost 25% less than it

maintenance, repair techniques and use of the

would have been for a new belt.

QuickTools range, all specially designed to make

Preventative Maintenance Agreements While trouble-shooting is a great way of supporting customers, prevention is obviously

20 B A K ER YR E V IE W 2 0 2 2

repair work as efficient as possible.

IPCO - www.ipco.com/bake

BR

Bake more, bake better with IPCO steel belt technology Our solid and perforated steel belts have helped bakeries produce premium quality products for almost 100 years. Flat, straight, durable and easy to clean, they provide a baking surface that’s ideal for everything from rich, chewy all butter cookies to traditional biscuits and crackers.

The other reason for choosing IPCO is our global service capability, providing the reassurance of premium productivity too.

• • • • •

High productivity wide belts up to 3500 mm.

Maximum versatility – bake more on an IPCO steel belt.

Energy efficient – lighter belt means lower carbon footprint.

Belt only or full range of conveyor components.

Installations, upgrades (mesh replacement), repair, maintenance and spare parts.

See us at IBIE Las Vegas · 18-21 Sept · Booth 2971

ipco.com/bake

CAMA

Adapting to the changing needs of the bakery industry Paola Fraschini marketing manager at Cama spoke to Tennille Aron about the ever-changing needs of the bakery industry when it comes to packaging.

Q: What bakery categories do you see growing the fastest?

The largest growth in bakery has been the ‘free

Q: What role does packaging equipment have in helping meet the need for longer shelf-life for bakery products?

from’ sector with ‘no-gluten’ being a reason for

Cama’s range of equipment is around paper-based

new market entrants and start-up producers

packaging, which is less about barrier properties

looking to gain share in the bakery sector. In

and more about the structural side for sleeves,

general, the bakery industry is promoting healthy

cartons and cases that are designed to protect the

products with low-sugar and low-fat content.

product in transit so that it arrives at the consumer

Q: What is the most challenging request that you have received from a bakery customer to help them package their bakery products?

in good condition. This is a pre-requisite even before shelf-life concerns are addressed. Cama’s solutions are helping manufacturers to achieve plastic reduction targets and make efficiency gains. In addition, the wide range of shelf-ready

We receive many requests to automate innovative

packaging covered by the Cama machine is able to

packaging designs, which are normally hand-

provide all the solutions for a shelf-ready pack.

packed first. In every project, Cama supported the

Furthermore, the capability of Cama to have

customer with their knowledge and experience.

developed their own robotic system allows them

Targets can be different, and we can summarise

to cover the requirements coming from the bakery

them into different macro categories, namely:

industry, which now requires a flexible production

• Handle a high number of products per minutes

able to supply different packing configurations

• Deliver a custom and innovative packing

or flavours in a short time. With their fast and

solution developed by the customer’s marketing

automatic change over systems, Cama machines

departments

can easily meet these requests.

• Fit the packaging machine in an existing

of the projects

Q5: What has been the contributing factor to the continued success of the Cama Group?

For all these needs, Cama is able to support

Through the years, the Cama Group staff has

building with limited space • Support the customer in the engineering phase

their customers and deliver the best solution.

22 B A K ER YR E V IE W 2 0 2 2

grown up to 350 employees, including highly-

CAMA

To access video, check out the Bakery Review Digimag.

skilled engineers and technicians, sales

division) and robotic loading units (robotic

consultants, sales engineers, and their own

division), allows Cama to propose complete

packaging consulting department. With

lines starting from the handling of primary

more than 40 years’ experience in the design

packages, such as flow-wraps, bags,

and testing of packaging paperboard and

and trays, to the supply of final carton/

cardboard, the Cama packaging department

corrugated packaging ready for palletising.

is available to help customers achieve high efficiency, improve sustainability and

To find out more about Cama’s bakery

reduce material costs. In addition, the group

solutions, request your free bakery brochure by

annually invests 5% of sales to research and

emailing marketing@camagroup.com

development, to be able to offer its’ customers innovative packaging solutions. The company’s outstanding packaging knowledge, combined with a unique machine range (packaging

CAMA – www.cama.com USS Pactech – www.usspactech.co.za

THERE IS PERFECT SYNERGY AMONG OUR MACHINES. AS BETWEEN YOU AND YOUR FAVORITE COOKIES. Cama Group is a leading supplier of advanced secondary packaging systems in the bakery industry, continuously investing in innovative solutions. www. camagroup.com - sales@camagroup.com

smartpackaginghub.com

B A K ER YR E V IE W 2 0 2 2

23

SAVAN NAH

Savannah has the solutions to all your bakery needs.

Explore some of their top ingredients below: BREADS, CAKES AND BISCUITS Carabuta NH The Carabuta NH is a milk fat replacer with flavour precursors

FROSTINGS, FILLINGS, AERATED CREAM AND TOPPING OF BAKERY GOODS Icing Short 400

creating butter notes

The Icing Short 400 has excellent creaming

during baking similar

power with high mechanical tolerance. It is

to dairy butter. It

suitable for large production volume of buns

gives the natural

and cakes. It gives smooth and light texture

buttery flavour

to filling creams and improves meltdown

to baked goods

sensation. It is able to incorporate a higher

providing economy

quantity of air, giving larger volume of fillings,

in replacing milk fat.

therefore, saving you money. The Icing Short

The flavour will be

400 comes with clean label options.

developed once the heat is induced and it is stable. Being low in trans-fats and free from cholesterol, it is also easier to store compared to dairy fat.

SPONGE AND EMULSIFIED CAKES Durkex 140 The high stability oil Durkex 140 is specially designed to substitute liquid shortening widely used in emulsified cake applications. It decreases the crumb hardening over time by retarding the staling rate of the cake. It also finds good texture and taste for chocolate bakery products like brownies and devil’s food cake. It is non-GMO, non-hydrogenated and nonlauric, providing good economy and functionality benefit to the end product.

24 B A K ER YR E V IE W 2 0 2 2

SAVAN NAH

Durkex 103 Durkex 103 is the most premium product, delivering maximum indulgence and heat resilience. It also has a high stability with nuts like peanuts, hazelnuts, almonds and pistachios in warm climates.

Durkex 105 Durkex 105 contains an

FOR SPREADS

emulsifier to further improve

Durkex is a range of spreads designed to avoid de-

the heat resistance without

oiling at higher storage temperatures or at higher nut

affecting the

(oil) content levels. These give maximum indulgence

mouthfeel

thanks to combination of pasty texture and rich

or flavour.

mouthfeel, delivering a very pleasant overall experience. Spreadability is a key feature, even out of the refrigerator.

C

M

Y

CM

MY

CY

CMY

K

+27 21 830 5306

B A K ER YR E V IE W 2 0 2 2

25

SAVAN NAH

Savannah Fine Chemicals are also the local distributers of Barry Callebaut’s Bensdorp range of cocoa powders and ingredients, which are the perfect ingredients to help manufacturers adapt to the ever-changing needs of the chocolate industry. These are just a few of the ingredients that they have on offer: Dark Chocolate Powder

Defatted Cocoa Powder

Bensdorp’s Dark Chocolate powder

The Defatted Cocoa Powder contains

is made with no addition of dairy.

less than 1% of fat and has a reduced

However, it allows you to claim

risk of fat blooming because it has a

chocolate on the pack and show

very low cocoa butter content. This

real pieces of chocolate on the

powder is ideal for aerated bakery

packaging. These powders have

applications. It provides increased

a round chocolate flavour with

volumes of batter (~+20%) and has

caramel and milky notes.

better baking stability. This powder has a classic balanced cocoa and dark chocolate flavour with a brown colour.

Ebony Black Cocoa Powder This cocoa powder is a fat-reduced highly dutched cocoa powder with distinctive intense black colour. It is one of the blackest cocoa powders on the market and has a strong roasted cocoa flavour with a slightly bitter after-taste.

Croquoa Add Croquoa to your mixture for a delicious multitextured chewy stracciatella. These crunchy inclusions have a light, aerated texture and a delicious dark chocolate flavour. They show excellent behaviour at high temperatures (up to 200 °C). The best part is that they are made of cocoa and sugar only.

26 B A K ER YR E V IE W 2 0 2 2

SAVAN NAH

Callebaut 811 Take on any job with Callebaut 811, which has a full-bodied taste, solid cocoa body and fine, fruity notes. This master in balance pairs perfectly with a wide variety of ingredients and works in all applications ranging from confectionery to biscuits, sauces and drinks. For bakery it is best used for icing.

Callebaut Gold

Callebaut w2

Callebaut Gold is caramel

To create a delightful taste with

chocolate that has rich

pronounced milky, creamy, caramel

notes of toffee, butter,

and vanilla notes that are in perfect

cream and an exciting

balance, Callebaut W2 can be used.

dash of salt, which works

It is best used as icing.

well in almost all applications.

For bakery applications it is best used in enrobing/icing.

Sicao hazelnut filling This is a soft filling with a delicious nutty flavour and a velvety sensation that can be added to rolls, croissants and pastries, and it easily resists temperatures up to 200 °C.

Savannah Fine Chemicals – www.savannah.co.za Barry Callebut Bensdorp - https://www.barry-callebaut.com/en-ZA/manufacturers/bensdorp B A K ER YR E V IE W 2 0 2 2

27

IN G R E TO

Evolving and adapting to South Africa’s baking needs

Choosing a reliable partner to help you produce the best baked goods for the South African market is crucial. Ingreto explains what to consider when choosing your supplier of baking ingredients.

T

he food industry has a long history of

innovative emulsifiers and baking enhancing

responding to the changing needs and

products have sprouted up and are abundantly

expectations of consumers. The challenges,

available on the market.

however, are the complex paradoxes surrounding

However, the genesis of all food is in its

product expectations. Consumers demand quality,

ingredients. To produce optimal quality and

but at their perception of a reasonable price; they

freshness at a competitive price, these additives

want to indulge, yet expect simultaneous nutrition;

must be carefully formulated, requiring

they have hope of a conventional product, but

consistency, stability, structure and texture. Which

believe it must be achieved with a longer shelf-life.

is why choosing a reliable supplier is imperative.

As with other food products, baked goods have also become more intricate over the years. With

Quality begins from the ground up.

Ingreto (Pty) Ltd is a leading ingredient solutions

the high demand for common food products, such

supplier in South Africa. The company offers a wide

as breads, cakes, sauces, margarines and sweets,

range of products and raw materials that are required

28 B A K ER YR E V IE W 2 0 2 2

IN G R E TO

for baking, and it also offers specialist custom blending.

With their sole distribution rights with Lasenor, an international specialist in the production, development and application of emulsifiers, Ingreto has brought a whole new dynamic to food emulsifying in South Africa.

“Adding more complex products, such as innovative emulsifiers, will improve the yield, crumb, texture and colour of products, especially in cakes,” explains Sonia Kittle, director at Ingreto.

Based in Gauteng, Ingreto offers the Lasenor BK101 emulsifier as well as other products such as Lecithin, whipping agents and PGPR, to name a few. The general commodities they supply include sugar, flour, starches, thickeners, and baking powder, to mention a few. “Our clients benefit from products that are competitively priced and approved by multi-national companies,” concludes Kittle.

BR

Ingreto - www.ingreto.co.za

“To produce optimal quality and freshness at a competitive price, bakery ingredients must be carefully formulated, requiring consistency, stability, structure and texture.”

Ingreto - https://www.ingreto.co.za/

B A K ER YR E V IE W 2 0 2 2

29

CH EM G R IT FO O D

Sugar alternatives – finding the sweet spot

The drive for healthier food with reduced sugar content continues to gain momentum and while there are now several sugar alternatives – both natural and synthetic – replacing sugar in baked goods and confectionery remains a bit of a challenge thanks to the fact that sugar does much more than just adding sweetness.

F

ood manufacturers continue to face mounting pressure to reduce the sugar content in food in order to curb the increased incidence

of obesity and diabetes. This includes the confectionery and bakery industry, which due to the nature of many of its products such as cakes, biscuits and other indulgent snacks, shoulders much of the criticism for the incidence of weightrelated health issues.

The challenge for this, and other food producers, is that while consumers are conscious

preventing them from going stale as quickly as

of reducing sugar intake, they are not prepared to

baked goods made without sugar. Its moisture-

compromise the taste experience.

grabbing character also helps to delay gluten

When it comes to baked goods, however, sugar does more than just provide a sweet kick – sugar contributes not only to the taste of food items, but also to other factors including texture, bulk, mouthfeel, aroma and colour.

It also helps to brown goods quickly and evenly

development and it helps with leavening of baked goods by providing a structure for gas expansion in the oven, promoting lift and rise in baked goods.

Although there are several different sweetening options available, none taste or, more importantly, behave

because it caramelises

exactly like sugar.

when heated. It is

According to Margaret

hygroscopic and thus,

Carter Chemgrit, food

helps baked goods hold

product sales manager,

onto moisture, keeping

there are other issues to

them moist and tender,

30 B A K ER YR E V IE W 2 0 2 2

consider when looking at

CH EM G R IT FO O D

Chemgrit Food, a division of Chemgrit SA sugar alternatives. With sweeteners you have to consider whether they are nutritive or non-nutritive, their comparative sweetness to sugar, ease of use, heat stability, how the product is metabolised with other ingredients, after taste, compatibility with other sweeteners and laxative effect.

Furthermore, because sugar does more than one

supplies the bakery and confectionary industry with a number of ingredients including a range of sugar and sugar alternatives. Chemgrit represents industry leaders and deals directly with manufacturers & suppliers both locally and internationally.

thing, it is impossible to replace it with just one thing. Multiple ingredients are needed to fulfil all

than sugar and has zero calories, is very easy to

the other roles it performs. This is not only because

use although it performs best in dairy products as

of the chemistry involved, but also due to physical

well as in beverages and candies.

quantities. Many of the sugar alternatives – be they

Saccharine, Sodium Cyclamate, Aspartame

artificial or natural – are significantly sweeter than

and Acesulfame K are also popular alternatives to

sugar, and are required in much lower quantities,

sugar and are used in many food products.

which affects the bulk of products.

Adding bulk

Smart consumers Consumers are also becoming smarter and savvier,

Bulking agents like

and are more specific

maltodextrin can be

about what goes into their

used, however, if

food. While most sugar

reducing calories is what

alternatives are recognised

manufacturers are after,

as being safe, there

then this is not ideal as

remains some resistance to

maltodextrin actually has a

synthetic sugar alternatives

similar number of calories

with a growing demand

to sugar. Conversely, other

for clean and sustainable

bulking agents that are

ingredients. This is driving

low in calories are more expensive than the

the demand for natural sweeteners such as monk

ingredients they are replacing, making them

fruit, stevia, agave nectar, date syrup and coconut

unattractive from a costing point of view.

palm sugar.

A combination of sweetening options and thickeners may need to be used in order to achieve

Taste still trumps

a palatable outcome. This is easier in sweet baked

“While the industry is making great strides in

goods and has been achieved in some instances,

reducing and replacing sugar in food products,

but has not been as successful in breads.

in particular confectionery and baked goods,

The sweet alternative

it seems that for the moment, taste and experience remain the most important issue

Sucralose has become a popular replacement

for consumers,” says Lucinda Cordia, Chemgrit

for sugar and is in greater demand. While price

Food general manager.

and availability has been an issue, it is now more readily available. Sucralose is 600 times sweeter

32 B A K ER YR E V IE W 2 0 2 2

BR

Chemgrit Food - www.chemgritsa.co.za

LET’S BREAK BREAD

TOGETHER

+27 011 474 2424

MANUFACTURERS OF SPECIALITY FLOURS OAT FLOUR OAT MEAL MALT FLOUR RICE FLOUR

+27 011 474 3141 sales@cerealandmalt.com cerealandmalt.com 6 Bunsen Street, Industria, Johannesburg

The newest name in the Bakery industry is 124 years old!!

Say hello to AECI Food & Beverage!

We are a supplier into the Bakery industry and proud distributor of Budenheim phosphates and cocoa powder from JB Cocoa and milk proteins from Arla Food Ingredients.

Included in our portfolio is a wide range of ingredients for bakery applications.

2 Galaxy Park, 17 Galaxy Avenue, Linbro Business Park, JHB 011 409 5000 99 Kasselsvlei Road, Bellville South, CPT 021 958 2180 Preshonthi Naidoo 064 750 2080 preshonthi.naidoo@aeciworld.com