7 minute read
Coatings: Coatings do make the pan
Coatings do make the pan
Having the right coating for the product, the process and the pan goes a long way to obtaining perfectly baked products for longer, while optimizing costs.
+The durability of pan coatings starts the moment they meet the pan, and the design of the pan plays a major role in the life of the coating.
That is why American Pan considers the type of pan coating that will be applied from the very beginning of the bakeware design process. One of the main goals is to ensure that coated surfaces will not come into contact with other pan metal when travelling through the bakery or when pans are stacked.
The company has developed unique stacking designs for trays, tins, and lids, to avoid metal coming into contact with the coating, even if they are nested. “Having a proper stacking design not only ensures the ability to safely stack pans and save bakery space, it also protects the pan surface and coating, ensuring the maximum release life,” states Jesper Albertsen, Vice President of Sales for American Pan Europe.
One American Pan customer was using automated stacking which was causing damage to the coating and premature failure. Switching to a new stacking pan design allowed the customer to extend the coating life by approximately 30%.
Proper use and care
Having a newly coated pan that matches the required specifications is the beginning of the road for the lifespan of that coating. Coatings come in a wide range – for example, there are OptiShield® coatings are specifically formulated to handle sticky doughs such as pretzels, buns, or muffins, while other coatings, such as DuraShield®, can suit a broader range of standard products. For OptiShield® and DuraShield®, the main coatings that American Pan delivers in Europe, utilization guidelines include handling, the use of release agents and toppings, depanning, and their passage through conveyors, proofers, and ovens. Stacking and cleaning guidelines are also provided. Both OptiShield® and DuraShield® coatings are designed with excellent non-stick properties and are corrosion-resistant. To minimize any damage, scratching and abrasion should be avoided. For example, pan indexers should not be allowed to come into contact with the coated surfaces, which would ultimately damage the coating. To avoid this issue, bakeries can add rubber padding to the pan indexing fingers. If the non-stick coating incurs deep scratches, the pan’s surface is subject to corrosion and problems with product release.
Albertsen emphasizes that, “If a bakery notices damage to their pans or coatings, they should contact our team right away so that we can help determine the cause of coating damage and suggest solutions. Our goal is to ensure the longest pan and release life possible.”
What is applied to the pan or product can also affect the life of the coating. Using release agents such as oil or grease can cause build-up on the pans and reduce the effectiveness of the coating. Toppings such as seeds and
© Bundy Baking Solutions
protein or egg wash can also affect the coating life. Bakers should ensure proper cleaning techniques are used to remove the toppings without damaging the pan surface. Oven temperature can also play a role in the longevity of coatings. Ovens operating at a high temperature can decrease coating life through a process called thermal degradation. One American Pan customer switched from a tin set made with standard aluminized steel using a fluoropolymer coating to a set made with American Pan’s proprietary ePAN® materials and DuraShield® coating and were able to decrease oven temperature by 30° C and achieve over 4,200 releases without the use of oil.
Finding the right coating
Identifying the coating that will work best in each case starts with the product and the company’s prior experience with it. Flouropolymers such as DuraShield® and OptiShield® are the most requested coatings in Europe, while AMERICOAT® silicone glaze is also used, especially in the UK.
The key to providing the best coating, according to Albertsen, is working closely with customers to understand their requirements and their bakery process. The company technology experts will then work with suppliers to offer the best and most appropriate coating technology. For example, the company‘s OptiShield® Crumpet Ring coating was developed through this process and nearly doubled the release life for a customer.
As part of the recoating services, American Pan will provide pan straightening, in addition to stripping away the old coating, cleaning, and applying the new coating. When fluoropolymer coatings like DuraShield® and Optishield® are reaching the end of their life, the wear can advance fairly quickly, which is why it is important for bakeries to time refurbishing or reordering of pans well in advance. American Pan Europe has refurbishment locations in Spain, the UK, and Romania, so shipping times can vary according to the proximity to one of these centers.
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Jesper Albertsen, Vice President of Sales, American Pan Europe
www.heuft1700.com
THIS IS
BAGUETTE.
BAKED IN AN ARTISAN HEUFT THERMAL OIL OVEN.
Rubberized coatings are another popular option for bread and baguette pans, among other products, because this coating contributes to achieving a crusty product. American Pan offers FlexiCoat in this range, in addition to RilonElast via the Runex brand, which was acquired in Sweden last year.
Coating automation
KEMPF has recently started working in its new coating plant, built in Rohrbach, Germany – the result of a EUR 18 m investment in equipment and property. The building occupies 5,000 sqm, out of the 80,000 sqm that, in time, will house additional buildings, including new company offices.
KEMPF developed this plant for high-quality bakeware coatings. Three fully-automated coating lines are operating there now, with room for expansion with two additional lines. KEMPF designed the plant with a high level of automation, to ensure consistent product quality and self-sufficient production. “State-of-the-art technology was brought into the new plant,” shares Guido Kempf, KEMPF CEO. Sustainability plays an important role at the new factory, which is powered by solar panels, with over 2,300 units installed on the roof.
Here, the entire range of KEMPF’s KG-FLON non-stick coatings can be applied, coatings dedicated to the bakery industry: Fluoropolymer coatings, original TEFLON©, Silicone coatings, Plasma coatings and Ceramic coatings.
The company is increasingly focusing on burger buns and croissant trays at the new facility, which is home to three fully-automated lines for baking trays, deep-drawn pans, croissant and burger pans, as well as pizza pans. With a daily capacity for coating and recoating of 4,800 sqm, “This plant is exclusively dedicated to coating bakeware,” Kempf tells us.
Coating development
New coatings are also developed at the facility. KEMPF works together with its coating/chemical suppliers and two universities to perfect new solutions. And work is well underway: “We are planning to launch a new type of coating in Q1 2023. We are now in the final testing stages of development and the results we see are outstanding,” Kempf reveals. This coating is said to have an excellent non-stick effect and can extend the life cycle of the trays and pans by up to 40%, in comparison to existing coatings on the market. It can be used for manufacturing standard baguettes, rolls, buns and similar products. In addition, this new coating also shows, “Very, very good results on pans for glazed buns, because of its very smooth surface,” Kempf explains. In this manufacturing scenario, the company determined that the new coating will ensure up to 80% more baking cycles, compared with other coatings.
This coating is undergoing thorough testing, together with bakeries. The first step in perfecting it with feedback from production, was running application trials in the company’s laboratory. Durability over baking cycles was then tested in-house. In the third step, KEMPF trialed small batches of 10-20 pieces, which were put through existing baking lines of selected customers. For the fourth and final testing step, complete lines are equipped and run production cycles in full-scale manufacturing conditions.
Guido Kempf, CEO, KEMPF
Harsh-condition baking
From the product’s standpoint, lye products are among the most challenging ones, regarding the type of coatings needed. KEMPF’s KG-Flon 750 was developed exactly for this use. “This is a coating that has extraordinary diffusion resistance, which is critical for it to withstand the very aggressive lye for a long time.” In addition to pretzels and other lye-dough products, this coating is also a good solution for breads with a high ratio of sourdough.
Custom solutions are perfected to meet specific production environments, current and new product ranges and manufacturing lines. +++
