baking+biscuit international 2021 issue 04

Successful Snacks Start Here BAKED – AND HEALTHIER – SNACK SYSTEMS FROM RBS

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Pizza

Bakeware

In the spotlight

RBS: Exact Continuous Mixing System put to use

Trays, pans and coatings for baking efficiency

Women in business: Carrie Jones-Barber, Dawn Foods CEO

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EDITORIAL

Looking into improvements from grain to bread G20 countries have ‘room for improvement’ regarding food sustainability, the Economist Intelligence Unit and Barilla Foundation found.

The co-authors of the Food Sustainability Index (FSI) also highlighted areas that are lacking, which are our diets, the way we manage food loss and waste, and our agricultural practices. For perspective, although 13 countries had stringent new climate action targets, only Indonesia and Canada factored the agricultural sector into their national plans, the FSI reveals.

Canada and Japan can provide some inspiraCatalina Mihu, Editor-in-chief tion for how to do better, as top performers in Your commments or suggestions are always appreciated: the study, followed by Australia, France, Italy e-mail: mihu@foodmultimedia.de and the UK. The research ranked the US among the worst countries in sustainability practices, because of excessive meat consumption (on average, around 250g more than the daily recommended serving) and because the land is still being converted for agriculture there.

Another new analysis aims to clarify how greenhouse emissions are quantified, as the food systems have only held agriculture responsible in these metrics, while packaging, transportation, disposal, and agriculture-driven deforestation also contribute. Experts from FAO, NASA Goddard Institute for Space Studies, New York University, and Columbia University have developed a new accounting system to evaluate the food system’s impact on the climate: “Our findings highlight that conventional IPCC categories, used by countries to report emissions in the National GHG inventory, systematically underestimate the contribution of the food system to total anthropogenic emissions.” To correct this, the report uses new estimates developed at the country level, which “integrate data from crop and livestock production, on-farm energy use, land use and land-use change, domestic food transport, and food waste disposal. With these new components, and by adding global and regional estimates of energy use in food supply chains, the reports estimates that total GHG emissions from the food system were about 16 billion metric tons (CO2eq yr−1) in 2018, or one-third of the global anthropogenic total.”

How can bakery manufacturing improve in its sustainability efforts? The good news is there are many possible answers and courses of action. Traceability tools are here to help monitor not just all incoming materials in detail, but every step of the supply chain from grain to bread. Waste management can also be perfected along the production line and smart tools can intuitively optimize energy consumption by profiling the bakery’s entire workflow. Moreover, heat recovery systems can also contribute to sustainability and save money at the same time.

The lifespan of all consumables can be extended considerably – innovations are made to help. And the entire bakery environment can be flexibly adjusted, course-corrected, and updated to match production changes, including new additions. Trust the technology.

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CONTENT

IMPRINT

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EDITOR EMERITUS Hildegard M. Keil hildegard_keil@t-online.de

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06 Women in business: Interview with Carrie Jones-Barber, Dawn Foods CEO

10 Pizza production: Continuous mixing, turnkey solutions

SUBSCRIPTIONS Viktoria Usanova usanova@foodmultimedia.de

16 AMF Tromp: New Smart Applicator Solution perfects ingredient topping Production

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20 Conveying: Inspection and maintenance to keep conveying systems up to

ADVERTISING dixon@foodmultimedia.de

speed (part I) 24 Ashworth: A guide to a new baking band

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26 Bakeware: Trays, pans and coatings for baking efficiency 32 FRITSCH: Automated ‘pigs in a blanket’

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36 Deck ovens: Configurations for all new requests Training

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Additives 42 EFSA: Evaluations for food safety (E 171 and beyond)

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Market 52 Pizza innovations: Pizza moves forward, at home and in foodservice

Regulars 03 Editorial 14 News

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

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In the spotlight

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04

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IN THE SPOTLIGHT

WOMEN IN BUSINESS

“Passion gives you the positive perspective” In our new series of interviews, we look into the value of women’s representation in the business world, at a top management level. Carrie Jones-Barber, Dawn Foods CEO, has graciously agreed to be the first to share her experience and beliefs driving one of the biggest companies in the business.

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Mihu: What are your thoughts on the concerned if your career changes over time. glass ceiling in the workforce, parWe all change, but if you are passionate ticularly in the baking industry? And about what you do, it will not seem like what should feminism stand for, in this work. Even on the bad days or in the perspective? difficult times, passion gives you the Carrie Jones-Barber: While considpositive perspective to know that you erable progress has been made since I will get through whatever challenge started my career in the food industry, you are facing and get back to doing there is still more work to be done. For what you love. However, it must be businesses, it is critical that opportunisaid that sometimes you must take on ties are available for women to succeed. other roles that might not be quite so We must not let assumptions about women fun, as long as your long-term career path – or anyone for that matter – dictate how our still brings you to something that you are r Car r ie Jo n es - B a r b e teams and business evolve. More women, more passionate about. people of color and more employees with diverse backgrounds Secondly, set goals. These can range from long-term, threelead to different perspectives that fuel innovation and inspito-five years or even one-year goals. Doing this will give you rational solutions for companies and customers. confidence in the choices you make both personally and Mihu: What personal experiences do you share with other professionally. women in the industry?

Thirdly, women need to ask for what they want. Do not Jones-Barber: The primary observation is simple – we need wait for your manager or another leader to offer the next to have more women in our industry. We must look for opportunity to you, because that might not happen. You opportunities to engage with women earlier in education must be an advocate for yourself and go after what you want systems and share what a great career path the baking industry in your career. can provide. The opportunities in the baking industry are Mihu: Why did you choose the baking industry? What did it endless: from business ownership to manufacturing, logistics, mean growing with the 100-year-old family business that marketing, eCommerce, distribution and food science. We determined you to join it and now lead it? must do a better job of getting the word out and engaging Jones-Barber: I was extremely fortunate as I knew around with talented women.

12-years-old that I wanted to do what my dad did. With Mihu: And what are the takeaways from that experience that Dawn being a family business, I had the opportunity to have guided you to move forward throughout your career? watch my dad, my uncles and my grandfather at the office Jones-Barber: As a CEO, I must be involved in the industry and in the factory. We would attend conferences together, and community as a whole. I must lead and show by example and on family trips, we always visited local bakeries. All through interaction and participation in school and industry these experiences piqued my interest in the baking industry. events, networking opportunities and more. I enjoy speaking Equally important, I saw how much they loved what they with students at culinary or business schools that are looking did – taking great care of team members, partnering with for insight into industries that can provide a fulfilling career. customers, and of course, eating our delicious bakery products!

The baking industry is a great career choice for women and Mihu: What values define Dawn Foods and what are the one I love being involved in. values guiding your leadership?

Mihu: What career advice do you share with your daughter Jones-Barber: At Dawn, our values have never changed; we Samantha (and young women starting their careers), drawing live them everyday. Everyone at Dawn must believe in not from that? only what we do, but how we do it. It sets us apart and is one Jones-Barber: Firstly, ensure that what you pick for your of our competitive advantages. Our values are Relationships, career is something you are passionate about and do not be Optimism, Integrity, Passion and Progress. These values are ©D aw

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IN THE SPOTLIGHT

supported by what we call our Circle of Excellence, which embodies our commitments to our wonderful people, our fantastic products, and taking great care of our customers.

The Dawn Difference, as we call it, is palpable, and we talk about our culture anytime we have gatherings of our team members to reinforce our values, our Circle of Excellence and our mission and vision. I cannot do it alone, a group of leaders cannot do it alone, everyone in the organization must believe and live and embrace this way of working every day.

My dad taught me early on about the value of relationships in this business, with our team members, customers, partners and suppliers. He also taught me that I have a choice in how I want to face the world and how I want to react to challenges. I choose to be optimistic about life and business. Integrity is one of Dawn’s most important values to me – I must trust the people I work with and each of our individual skills to make great decisions for our team members, our customers and for Dawn.

Mihu: What difficult decisions have you had to make at the company since you became CEO in 2006, and what are some of your favorites?

Jones-Barber: Without a doubt, the most difficult decisions all came with the global pandemic. The world changed in an instant, and everything we knew about business had to change with it. There was not just one decision to be made, but many decisions with no experience to build upon, just the knowledge we had of our business, our trust in each other and our agility. Team member safety was our priority.

We came together across all functions, created work teams for every situation we needed to address, and created processes and systems for managing our teams and our business. As we did this, restrictions and regulations around the world were dynamic, so we had to get accustomed to quickly making decisions and changing them as new information became available and new regulations rolled out. We learned how to communicate at faster speeds than ever before. Each role in our organization had to learn new ways of working that have shaped our lives and our business for the future.

When I think about what I love most about my job, it is connecting with our customers and our team members. I am passionate about supporting our team and their ambitions to grow in their careers. When I witness someone on our team overcome a challenge, learn a new skill, or close a sale with a customer they have been prospecting, I feel immensely proud.

When I speak with our customers and hear them talk about the solutions, partnership and support they receive from our team to help them open their first location, get their products into a new store, or introduce a new product, again, I feel an incredible amount of pride. My daughter, Samantha, recently joined me and members of our team as we visited customers in Chicago. It was such a joy to see her engage with our team and customers.

Mihu: Where does Dawn Foods draw inspiration for innovation?

Jones-Barber: At Dawn, our innovation is focused on solutions that truly matter to our customers. Our innovations

come to life in many ways. We partner with our customers and listen to them to understand the challenges and opportunities they have. Our commercial and technical teams work closely with research and development to understand what will make the biggest impact with our customers, and how we can innovate and provide solutions to grow their business.

We have inspiration studios around the globe where customers visit and work side-by-side with our teams to test out new products and ideate on new flavors. Some recent examples of this include an extension of our cake mix flavors and brioche donut mix in the United States and our sourdough donut mix, which is available in North America and Europe.

Innovation can also be market-driven. One of the trends we have seen for the past few years is the demand for vegan products. We have an extensive vegan line in North America and Europe that delivers on this consumer need for our customers. It provides opportunities for our customers to reach new customers and for incremental sales.

Mihu: How is the role of women working in the bakery field evolving?

Jones-Barber: I am excited to see that women are filling more roles within the industry, but there is room for even more growth. At Dawn, we have some incredible women leaders, and I am committed to providing even more opportunities for women to grow at Dawn. We are currently working on a Women’s Leadership Development Program to provide women at Dawn with resources and clear paths to grow into larger leadership roles. We currently have women leading our marketing efforts as vice president and senior vice president in our Europe & AMEAP and North America regions; our national accounts team and supply chain team in North America are both led by women senior vice presidents; and we have additional women in vice president roles in finance, and people (human resources).

I look forward to adding even more women and diverse team members at every level at Dawn and I encourage other leaders to do the same. Embracing different perspectives and cultures makes us stronger, both as an internal team and as a partner to our customers.

Mihu: How did COVID-19 impact working women in particular? What support systems are emerging that have been shown to work?

Jones-Barber: Talking with our own leadership team and leaders from other organizations, the pandemic disproportionately impacted more women than men around the globe.

In fact, a recent McKinsey study found that 23% of working women considered leaving the workforce in 2020.

While progress has been made in business, many women continue to be the primary caregivers in their families, whether it is for their own children, a family member, spouse or friend. Under normal circumstances, it’s challenging to find balance with all the responsibilities people have. One bright spot has been the openness, at every level, to talk about the challenges we all face. I think we have seen

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IN THE SPOTLIGHT

Everyone at Dawn must believe in not only what we do, but how we do it.” Carrie Jones-Barber Jones family photo (from left to right): Ron Jones, Miles Jones, Carrie Jones-Barber, Sam Jones, Sarah Richmond, Aaron Jones

empathy demonstrated more than ever before. It has been eye-opening for many people to recognize we are all just doing our best to take care of ourselves and our families.

For women, progress has been made, but companies need to think about how they can support women through Employee Assistance Programs and wellbeing benefits. We must ensure that we as leaders lead with empathy and flexibility to help our teams and their families. We need to check in with each other and take time to listen and ask what we can do to help.

Mihu: How do you see women’s presence in the industry now, particularly in top management? What career support is available for women compared to 10 years ago, and what additional steps do you think need to be claimed?

Jones-Barber: Significant progress has been made in recent years, however, I would love to see more women in leadership roles. For instance, a 2020 McKinsey study found that about 21% of C-suite roles were held by women and less than 30% of vice president, senior vice president and C-suite roles were held by women. Across industries, these numbers must change. In the baking industry specifically, leadership needs to be more representative of the baking profession. In the United States, 62% of bakers are female. I want to see leadership better reflect these numbers globally.

I am thankful there is a lot more career support available for women now than there was 10 years ago. Networking and mentorship are critical for any person looking to grow in their career. Now, people no longer have to go through a formal program to gain knowledge or to learn – there are so many online courses, seminars and conferences available to support your future career. Companies should provide these opportunities and support their teams through continuous learning to help them gain experience and confidence to elevate to the next level.

Mihu: Can you share some examples you have experienced of solidarity among women in the industry?

Jones-Barber: The Society of Bakery Women in the United States is a great organization for women in our industry. It brings women together for events to network, learn from

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each other and hear from featured speakers about elevating our own leadership skills. Transparent discussions are so valuable. I was lucky to speak at one event and I loved the questions I got during and after my presentation. I continue to invest in this program and build relationships across our industry with the students that attended as well.

Another example is specific to Dawn. This past March for International Women’s Day, we hosted an internal panel of female leaders from Dawn, where they openly spoke about the challenges they have overcome and their advice for the next generation of women leaders. I am proud of our team, I am proud of our progress and I am proud to say that women are not slowing down anytime soon.

Mihu: How do you view dedicated networking organizations? And how does Dawn Foods support the Society of Bakery Women (SBW)?

Jones-Barber: Dedicated networking organizations are crucial to the development and empowerment of people at every stage of their careers. I am a proud member of the Society of Bakery Women, which offers incredible resources to women in the industry. The American Bakers Association is another great organization that provides opportunities for people to learn, network and grow. Just before the pandemic last year, I had the honor of sharing my advice with other women in the industry at a Society of Bakery Women breakfast in Chicago. The more we can network and create opportunities for women to connect, the better off we’ll be.

Mihu: What will the industry narrative focus on over the next years?

Jones-Barber: As a woman and CEO, I am hopeful for what the future holds for diversity, equity and inclusion. I am glad more people are paying attention to DE&I (Diversity, Equity & Inclusion, ed.) and putting it at the forefront of their internal and external decision-making. We need to keep pushing to make things better for everyone in an authentic and transparent way that welcomes all people to the table – and welcomes them to pull up a chair if one isn’t there.

Mihu: Thank you for an insightful conversation! +++

© Hollis Conway

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PIZZA

All elements align To consistently produce high-quality pizza, especially at high speeds in industrial environments, all types of equipment on the production line must contribute at the right time, with the exact process they are programmed to perform.

Jim Warren, Vice President of Exact Mixing at RBS, shares with us an overview of this system: “The MX Mixer is our most versatile mixer and is designed for doughs above 40% hydration. This would include all bakery doughs except the stiffer doughs such as crackers and pretzels. It is also ideal for icings and high-fat mixtures. We also included an HDX mixer, which combines the en d i MX mixer and high-speed developer s Ji m re W a r r e n, V i c e P to make all types of bread and bun doughs.” All types of two-stage cookie doughs can also be mixed, changing the mixer’s shafts.

Putting Hydrobond Technology to use The purpose of Hydrobond Technology is to instantly hydrate dry ingredients with liquid ingredients. Typically, the first 30% of the mixing time and energy in a batch mixer is strictly used to hydrate the dries with the liquids. In a continuous mixer, that is reduced to 10%, but in the case of rapid hydration, that number is reduced to almost zero. “There are numerous advantages to this system,” highlights Warren. The Exact Mixing Hydrobond Technology brings liquids and a dry ingredient stream (typically flour) together quickly and evenly, with little temperature gain. It can be used with a continuous mixer to make the mixing process more efficient or with a pre-hydration system to mix flour, minor ingredients and water directly into a brew holding tank. This system speeds up the continuous process allowing for the use of a shorter mixer, which means a smaller footprint, lower equipment costs, and lower energy costs, he explains. Hydrobond Technology can be added to existing Continuous mixers, as well as some batch mixers.

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Mixing at R BS

require different shaft designs for mixing the dough in the MX Mixer. Anything from pizza balls, frozen/parbaked crusts and finished pizza dough can be made with the same mixer design, but with different types of shafts. Exact Mixing is also using special systems, specifically designed for pizza production, including: + Auto trim return systems for rotary cut crusts + Auto dough temp control out of the mixer + Dough handling systems to keep forming hoppers at a constant level + Auto dough chunking systems integrated into the mixer

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The best way to evaluate and select the equipment that best fits your specific pizza production process is to see it working live. This is why Reading Bakery Systems (RBS) showcases an Exact Continuous Mixing System at the AMF Tromp Innovation Center in the Netherlands. It is used demonstrate continuous mixing for pizza, and a wide range of other bakery products. The two sister companies have designed the dough handling equipment between the Continuous Mixer and the AMF Tromp pizza forming equipment, to offer a smooth transition of dough without operator intervention.

Typically, pizza doughs are characterized by a mid-hydration level and mid-development level, which makes them suitable for the MX Continuous Mixer. Different types of products

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© Verhoeven Bakery Equipment Family

PIZZA

THE Peelboard Suitable for all industrial baking lines.

What aspects should determine the choice between mixing technologies when making pizza? “Economics suggest that continuous mixing makes more sense financially, as the dough throughput increases, changeovers decrease, and the value of the dough increases. Other factors include the labor force available, available plant space, and others,” Warren summarizes. To optimize continuous mixing, particularly when making pizza, the specialist recommends looking into the complexity of the recipe, the desired throughput, the number of daily changeovers required, and the level of automation needed. “Continuous mixing systems are designed to constantly monitor potential variables and to auto-correct when disruption occurs. This advanced technology leaves little chance for error,” he concludes.

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Excellent non-stick effect

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Perfectly hygienic

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Stable & durable

© RBS

MX continuous mixer with Hydrobond Technology

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bakeware & coating Kempf GmbH | Carl-Benz-Straße 3 | 85296 Rohrbach ++49 8442/9669-0 | www.kempfgmbh.de

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PIZZA

© Verhoeven Bakery Equipment Family

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From the drawing board The Verhoeven Bakery Equipment Family (BVT Dough Process Solutions, NewCap Industrial Handling Solutions, Vacuum Cooling & Baking Solutions and Bakepack End of Line Solutions) is known for its custom-made designs as a turnkey solution provider. To design solutions for pizza manufacturing, the specialists begin by understanding precisely what the manufacturer is looking for, starting with the desired capacity, followed by the correct end product(s), shapes, fillings, toppings, etc. The necessary process parameters are then analyzed, including those of the dough itself, dough handling, pre-proofing and proofing, cooling & baking, up to freezing and packaging. “When all details are clear, we will look at the available space in the factory. That’s when we start developing customized turn-key solutions,” Maarten van der Coer, Sales Director at the Verhoeven Bakery Equipment Family explains.

To optimize preparation, “Manufacturing times are determined based on the desired capacity and quality, divided by the output per hour,” he adds. With quality becoming more important, longer proofing times are considered, as well as the use of pre-dough and sourdough. Regarding the line’s capacity, everything can be achieved (at a cost): “Automation has a price and the added value should be in balance with the total investment,” explains van der Coer.

Once the design phase has begun, many aspects influence what its final aspect will be. The company determines the design of the line to the wishes of the customer regarding capacity, process and the final product. These parameters finally lead to a custom-made line configuration. “As a turnkey supplier, there are multiple options we can provide, for pizza dough slices or pizza dough slices rolled on paper, pizzas with just sauce or pizzas with sauce and different toppings, fresh or frozen. There are no limits,” he emphasizes,

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as he shares a recent installation example – the design of a make-up line that allows their customer to produce pizza as well as baguettes.

To the future Future changes in product variety and capacity are also considered when customizing a pizza line, as the company aims to provide as much equipment flexibility as possible.

“We always discuss the expectations/predictions for the future in order to offer/think about solutions to produce higher capacities or different products on the same line, for example,” van der Coer says. Capacities the company provides start from approximately 800kg dough per hour, with its biggest custom-made line for pizzas going up to 12,000 kg of dough per hour.

The company observes a trend for quite a traditional way of making pizza in the market. In response, its latest innovations are mainly based on hygiene optimization and system cleaning.

“Time is key regarding cleaning and machine changeover,” the specialist stresses.

To improve manufacturing efficiency, the company recommends using a sheeting line for the production of pizza. “In addition, it is more efficient to use a dough sheet in the pre-proofing process; it is quite thick at that stage, which takes care of a smaller footprint for the proofing systems,” he explains.

Innovation also targets certain varieties – such is the case for Turkish pizza, for which the company developed a dedicated depositing and flattening system. These pizzas were topped with a combination of tomato sauce, herbs and minced meat. No matter what the (current and potential) production range is, a solution can be found to match it exactly. +++

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NEWS

Papa John’s expands into Germany

Papa John's International, in partnership with its franchise partner PJ Western Group, announced its expansion into Germany, with plans to open 250 restaurants in the German market over the next seven years. PJ Western Group, one of Papa John’s largest global franchisees in Central and Eastern Europe, has opened the first seven Papa John’s in Magdeburg and Leipzig and plans to open six other stores in Halle and Merseburg by the end of the summer.

“We are excited to expand our business farther west into the heart of Europe,” said Christopher Wynne, CEO and founder of the PJ Western Group, which currently operates 200 Papa John’s restaurants, in addition to 10 dough production plants in Europe and Asia. To accelerate this expansion into Germany, PJ Western is looking for new franchisees to join the Papa John's family.

The expansion into Germany follows a record year of sales and growth, which helped propel the chain’s international development, said Jack Swaysland, Chief Operating Officer, International at Papa John’s. +++

LINXIS Group acquires Bakon

LINXIS Group together with its key financial partner IK Investment Partners announced the acquisition of Bakon from managers and current investor Rabo Investments. Bakon’s activity complements the ‘Portion Process’ division of LINXIS, so far represented by Unifiller, and brings expertise in depositing on board, as well as in ultrasonic cutting and spraying processes. “With Bakon’s acquisition, LINXIS Group will further strengthen its expertise and excellence. Representing the third acquisition following investment from IK Investment Partners, we pursue our strategy of adding companies and brands with deep knowledge and complementary technologies to our existing portfolio, in order to continuously develop solutions that closely meet the needs of our markets,” said LINXIS Group CEO, Didier Soumet, in a statement. +++

RBS expands Science & Innovation Center services

© RBS

Reading Bakery Systems (RBS) announced new Virtual Trials as it seeks to hire additional food technologists. “While businesses are still being impacted by pandemic-related restrictions, consumer demand for new and healthier snack foods has accelerated. With this in mind, we needed an efficient and effective way to serve our customer’s everchanging product innovation and development efforts with the expertise they expect from RBS,” said Travis Getz, vice president of Operations for RBS. RBS Virtual Trials provide remote access to the Science & Innovation Center for product development, equipment testing and demonstration, and production of samples. It welcomes experienced food technologists to help guide Virtual Trials for customers and provide onsite expertise.

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New Education Event: IBIEducate 2021

As a part of the IBIE, the American Bakers Association (ABA), Baking Equipment Manufacturers and Allieds (BEMA), and the Retail Bakers of America (RBA) are putting together an in-person educational conference, IBIEducate 2021. The new gathering will be held October 26-28, 2021, in Kansas City, MO. With the COVID-19 pandemic and shifting consumer preferences, IBIEducate comes in response to a need for “an educational event to deliver top-quality education through one-of-a-kind immersive sessions for the industry’s retail bakers, wholesale production, R&D, engineering, management professionals, and suppliers,” according to the organizers’ announcement. The event follows the concept of the established education program at IBIE: each session will teach practical solutions for attendees to bring back to their facility and implement: a skill, a plan, a new way to stay ahead of baking industry advancements, and more. It is organized with a collaborative approach and will comprise diversified sessions delving into best practices and techniques on a variety of topics, including, but not limited to: retail, people, production, sanitary design, hands-on training, certification courses, IncuBAKER™ , technology and ingredients, Insights Discovery® , and facility tours. +++ www.bakingbiscuit.com 04/2021

© IBIE

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NEWS

On June 24, Kaak announced on the occasion of its 175th anniversary that it would bundle all specializations in the organization within the Kaak brand name, answering to both the wishes of its customers and the focus of its own organization. “It fits in seamlessly with the strategy used for vertical integration of the complete production process, from silo to crate,” Kaak explained in the announcement.

During a transitional period, it is only the newcomer Silowacht that still operates under its own name. As non-bakery-related entities within the group, both technical intermediary JAWS (NL) and producer of 3D metal printing K3D (NL) will retain their distinctive name.

The organization has experienced significant growth, especially over the past 30 years. The addition of the specializations for dough making (Benier/NL), thermo-oil ovens (Daub/DE), cyclo-thermal ovens (MCS/IT), (re)coating of material (Lhotellier/FR) and the systems for silo storage/ process optimization (Silowacht/NL) has considerably expanded Kaak’s portfolio and established its international status. Sales offices in the United Kingdom, France, Taiwan, Brazil and more recently North America have been opened.

Eurogerm USA to Launch New European Donut to U.S. Market

Eurogerm is set to introduce Quarkbällchen to the U.S. market, donut balls rolled in granulated sugar featuring quark, a kind of silky cheese similar to yogurt or sour cream.

Rick Gizzi, sales director at Eurogerm USA, described the unique taste and texture, “The donut has a crispy style exterior and a soft, almost spongy interior. The flavor is a perfect blend of egg and vanilla, with the tartness of the cheese.” Eurogerm USA has formulated a mix that only requires the addition of water and cheese. More traditional bakeries may seek out quark, but it can also be made with cream cheese or other similar substitutes. +++

© Eurogerm

Kaak marks 175th anniversary with organizational changes

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© AMF Tromp

PIZZA

The smart way around a pizza AMF Tromp has developed a smart applicator solution for pizza production, cloud-based software that uses artificial intelligence to automate quality control for pizza toppings such as cheese. At the end of the production line, this means minimizing product waste, standardization and efficiency.

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Pizza production still routinely requires manual work for quality checks, even when done with automated lines, with operators regularly weighing and (subjectively) assessing products. Artificial intelligence has the potential to improve this process and effectively take variations out of the pizza topping equation. AMF Tromp’s Smart Applicator Solution, launched in June this year, analyzes in real-time images of all the products on the pizza line, to evaluate the application of the cheese topping, based on a database with preloaded pizza images. The software recognizes the cheese toppings and compares them with the established baseline.

It does this by translating data into values. Based on the findings, the software adjusts the speed and volume settings of the applicator, to ensure consistency within the preset parameters. “Every anomaly will be detected, and our system and algorithms will change settings immediately, to go back to the ‘base’ value, explains Lex van Houten, regional marketing manager, AMF Bakery Systems.

retrofitted or newly configured for the AMF Tromp Waterfall Applicator. This enables weight control management and ensures quality depositing of the toppings, with the right amount of cheese perfectly spread on the surface of the pizza.

AMF Tromp will add this Software-as-a-Service to a production line together with its customers; all that is required is the hardware unit with cameras, lights and Internet connection.

It is placed above the line, and the service is then activated in AMF’s Service Center. All the specifications and settings are determined during installation and commissioning. “The first run will immediately give valuable data for the dataset to start building and training itself,” the specialist points out.

From point on, (remote) support is also available, anytime.

Staying on top of pizza toppings AMF Tromp prioritized the producers’ efforts towards sustainability and digitalization in the development stage. This meant minimizing giveaways, reducing waste, and replacing manual work to automate the process. The AI-based solution answers all challenges in applying toppings consistently. The Smart Applicator has started the quality control check with the cheese deposited on pizza (but not limited to it), so significant savings are evident when dealing with an expensive ingredient.

The waterfall applicator unit is strewing cheese at many pizza production sites, but the goal was to improve it and make it smarter. In conjunction with the company’s pizza production machines, the Smart Applicator Solution can be either

The Smart Applicator Solution Smart processes in pizza manufacturing will generate immediate savings and impact the production process and topping application, by: 1. Reducing giveaways and having accurate weight control for every pizza 2. Minimizing waste of expensive ingredients 3. Reducing operator time, handling, and cost 4. No hands touching the product, thanks to vision-based monitoring applicators in the production area will be trained

www.bakingbiscuit.com 04/2021

with this data, and results will only become better based on data analysis

Source: AMF Tromp

5. Machine-learning: not only AMF machines, but all © AMF Tromp

16

PIZZA

Multiple aspects can contribute to variations in pizza weight and quality. In their R&D process, AMF Tromp observed among recurring factors the humidity and temperature in the production area, fluctuations caused by the operator handling manual operations, as well as the characteristics of the cheese itself. “The thickness of the grated cheese, the length of the pieces, their moisture and stickiness, temperature, and density, will determine whether the waterfall applicator strews an even and smooth bed of cheese,” van Houten explains.

Changes in any of these parameters can impact the amount of cheese that is strewed.

The Software-as-a-Service uses machine learning technology to optimize this process over time, as it detects and indicates anomalies. Process parameters it learns include weight control, even distribution of the topping, and the list is growing. The data is used instantly, but as it continues to gather information and learn, it continuously improves. The result: pizzas with standardized topping distribution, regardless of external influences, human interaction, or the sophistication of AI technology. The specialist shares how the new smart solution learns: “We generate the data by taking images of each pizza, which are added to the dataset, and the algorithm will learn

and improve based on this data, to become value. During a single production run, thousands of quality checks are done, and all this data trains and the machine learns how to act, so the next runs will only be better.” By comparison, an operator usually performs four checks per hour, all of which require time, manual labor and personal skill – and this can vary between persons and shifts. “That is why the value of the data solution is better and trustworthy for reducing giveaways and cost,” he underlines. So when are staff needed, in this case? It depends, according to the size of the operation and the level of automation in the manufacturing facility. Fully automated, industrial-scale lines can apply toppings on pizza at an optimum level with no operator supervision, using this smart applicator software.

To ensure the ingredients are deposited evenly and in the correct amount, the data analyzing each piece determines if the amount of cheese, weight and distribution match the specifications determined with the producer. When the software identifies pizza outside of the parameters, the applicator adjusts the cheese dispersion to correct the process. In addition to having consistent topping perfected, the system also provides the added benefit of identifying every single piece

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PIZZA

© AMF Tromp

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falling over or under the presets, so the manufacturer can choose a course of action for them as well, by either removing the sub-standard product from the line or correcting the issue.

The result will be ingredient distribution exactly as intended, for every single piece.

Waterfall application fares well with high speeds, and it helps prevent waste with recirculation. The targeted application works best when a certain amount of topping is needed, and precision/central placement on a pizza or flatbread, and is best suited for low to medium production speeds.

Any production speeds and volumes can make use of this smart solution: “We work with the largest manufacturers with thousands of pizzas per hour, but also entry volumes can benefit from this new service of AMF Tromp. It requires no investment, only a monthly subscription fee to have all data deliver immediate savings up to 3% per day. Our ROI calculations show most cases become profitable in less than one year. A no-brainer!” van Houten points out.

Waste is controlled and minimized by constantly adjusting the ingredient quantity and dispersion, to stay within specifications. No product is wasted when using the AMF Tromp waterfall applicator, for example, as the recirculation system reuses the cheese during a run. When products are constantly within standards, fewer have to be removed at the end of the line, which further counts towards minimizing waste.

“The OEE of our customers will go up, and we will offer new tools soon, for more smart quality control,” van Houten anticipates.

Flexibility The Smart Applicator is designed to handle any type of grated cheese, places on pizzas of any shape and size, from mini to standard and large, oval or square, even baguettes or flatbreads.

And cheese is only the beginning: “We kick off the new service with cheese application on pizza, but we are developing new services as we speak, to also add other topping devices to the platform, like target applicating (exact positioning of a topping instead of a waterfall) and sauce application. Autonomous pizza production lines are the dot on the horizon for us and our customers,” explains the specialist.

Both application methods come with their own benefits and can be the better choice in certain settings, depending on the process, production volume, speed and the type of topping.

www.bakingbiscuit.com 04/2021

Such smart, autonomous lines will inherently increase the efficiency of the process, as minimizing waste and product loss also means shorter runs and less energy consumption.

The software adds to AMF’s portfolio of tools aimed at improving efficiency, which includes the gas-fueled tunnel ovens, and the latest development – the hydrogen-powered oven. The specialist also recommends these types of ovens for pizza and flatbread production. They can be tested at its Dutch Innovation Center.

Enter the age of Artificial Intelligence The Smart Applicator Solution is AMF’s first such service in a line of many, which finds the company at the beginning of a new chapter. “The world of AMF will become smart, digital, sustainable and focus on what our customers need to be successful. AI, machine learning, data-to-value, robotics, and autonomous bakery production – these are all concepts and technologies you will see more at AMF in the coming years,” van Houten anticipates. The company aims to add process and bakery knowledge to analyzing and imaging solutions, and is working on changing and improving the machine and process itself. AMF Tromp’s Smart Applicator Solution is the first step to smart solutions meant to optimize production processes and enhancing productivity across the plant floor. +++

PERFECT WAFFLES. PERFECT VANDERPOL BAKING EQUIPMENT

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CONVEYING

Part 1: Inspect, maintain

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

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Regular monitoring helps conveyor systems contribute to the performance of the line. A poorly maintained conveyor can experience rapid belt wear and component failure as they operate in either very high or freezing temperatures, or in environments with humidity and dust. This can lead to detrimental downtimes to the productivity of the bakery. If the conveyors of a high-speed production line experience downtimes, the operator must first check whether the first-level maintenance is well performed. This includes cleaning the assemblies and checking the tightening of the assemblies (mechanical sets), lists François Retailleau, Line Product Manager at Mecatherm. The periodic implementation of specific control points on equipment is the second step; according to the specialist, this should include: + The correct tension of the chains and belts to reduce premature wear of the elements of the kinematics. If the chains are relaxed, the operator will have to remove links. + The examination of the chain lubrication, for metal chain conveyors: a lack of oil can lead to untimely conveyor stops. The last points to check are the lubrication of shaft bearings and the condition of engines.

+ In addition to these mechanical adjustments, the user will have to control the flow of the supports (automatism control). These settings affect the management of slowdowns, shocks, transitions from one machine to another.

The operation of detectors and pneumatic elements. A + malfunction can cause recurrent downtimes.

Mecatherm also recommends that the operator consults the history of alarms on the HMIs, as they provide an operational overview of the process in real-time and allow the state of the engines and some other parameters of the production line to be controlled.

www.bakingbiscuit.com 04/2021

Finally, downtimes can be minimized by adding retrofit solutions to maintain high-speed production objectives: “If the line is programmed to operate at 300 trays per hour, and the customer wants to upgrade to 400 trays per hour, Mecatherm services can suggest retrofitting and intervene on site to support them,” Retailleau illustrates.

Optimum working settings A Mecatherm conveying system should operate within several parameters, including the cadence and product capacity of the line. As it links all equipment, it must also be easily integrated within the production line. In addition, “The conveying system contributes to maintaining the cadence of the line, as much as the line equipment does. The feeding speed of the conveyors follows the flow of the line. The higher the cadence, the more important the speed of the conveying system.

That’s why it’s a consideration in industrial performance and contributes to the efficiency of continuous line processes,” explains Retailleau.

The conveyors also play an important role in the process: maintaining products aligned on trays from the depositing until the demolding. Missing this mark during transport can lead to sub-standard products in product shape. “From the industrial performance point of view, if the conveyor is smartly designed, it’s possible to adapt and implement solutions in a fairly compact area,” Mecatherm’s specialist adds, listing among solutions: modular conveyors, adaptable in length, width, height, even overhead or superimposed conveyors.

Mecatherm’s MECAFLEX conveying system is designed for flexibility, to allow handling of different types of goods, from raw frozen, pre-pressed frozen, to fresh-baked or frozen. It

© Intralox

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CONVEYING

also supports variety in ranges conveyed at the same time: “The Mecaflex line can produce brioche, baguettes, tin bread, croissants, buns, etc,” lists the specialist.

For real-time product traceability, Mecatherm also develops digital solutions such as the M-Plan, an application that helps visualize the products going through the line, their progress, and helps to manage changeovers and optimize production planning. Combined with M-Plan to anticipate production scenarios, the entire line is designed to ensure continuous production with a modular conveying system, turnouts to route trays in several directions.

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dry ice or detergents and a great deal of manual input,” Leber explains.

The application of an appropriate belt lubricant is also extremely important, he stresses: “The easiest way to achieve this is by installing graphite skid bars, which deliver a gradual deposit of graphite to the inside of the belt.” This reduces friction and helps to eliminate the risk of rust caused by condensation, reduces wear, prevents belt distortion, and ultimately extends the belt’s life. It also helps to maintain a regular belt color for a more even bake. IPCO graphite skid bars are available for all standard belt widths.

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Steel belt management for efficiency “If this type of skid bar cannot be used, then graphite should Steel belt expert IPCO shares its close analysis of the conveying generally be applied to the inside of the belt once a month system that it performs to ensure the efficiency and the for the first three months after installation, then every three integrity of the belt over time. Two of the most important to six months. If graphite is not permitted for any reason, maintenance tasks, aside from regular checks, are specially selected oils can be used instead,” IPCO’s lubrication and effective cleaning, Marko specialist recommends.

Leber, Global Product Manager, Food, IPCO, highlights. On solid steel belts, cleaning is While it is virtually unheard of for a steel usually carried out using rotating brushes, bake oven belt to reach ‘end of life’ due to with the application of scrapers as necesfatigue stress, a lifespan of 20 years is sary. The brushes should be adjusted to not uncommon and good maintenance gently clean the belt surface and the belt extends it up to 50. During the baking should be rubbed manually with clean process, the belt is placed under considcloths at the same time. Ineffective cleaning erable thermal stress as it heats up and d cools down every time it completes a revoluwill result in a build-up of carbon deposits on ro lP Ma a the baking side of the belt, leading to subtion. “A combination of steel belt grade and r k o L e e r, G l o b b standard products and, potentially, a risk to human special manufacturing phases is used to achieve the health due to the presence of hazardous acrylamide. “A range necessary thermal properties of the material. These propof factors – belt type, end product, oven type, personal erties give steel belts the durability to operate for decades preferences – will determine the most effective approach to under what are severely challenging processing conditions,” cleaning and will usually involve the application of chemicals, Leber says.

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© IPCO

CONVEYING

In terms of maintenance, qualities such as good tension, tracking characteristics and resistance to stretching combine to result in significantly less downtime than other belt materials, important considerations when even an hour’s lost production can be costly. IPCO can help with conveying system maintenance with sales/service offices and trained service teams in over 30 countries. “And, of course, prevention is better than cure,” concludes Leber, adding that IPCO also offers comprehensive Preventative Maintenance Agreements (PMAs), designed to identify risks of failure before they have a chance to disrupt production. Preventative maintenance checks will cover all major system components: + Terminal drums, rollers and skid bars must be aligned horizontally and at right angles to the centerline of the longitudinal axis of the oven line + Terminal drums and rollers should rotate freely + Tension devices + Tracking devices Once the cause of the problem has been identified and rectified, the belt itself is inspected to repair any damage that may have occurred to ensure that it continues to deliver reliable operation for years to come.

Maintenance-free systems The main factor that reduces the belt life is tensioning, often leading to mistracking of the belt, Hans Tertoolen, Intralox Bakery Account Manager, explains: “Mistracking also leads to fraying of the sides of the belt, which increases the risk of foreign material contamination. Tensioning not only means wearing out the belt, but it also leads to excessive wear of shafts and bearings.” Since all Intralox modular and flat top ThermoDrive belts are not tensioned, the belt itself and the components last much longer. Moreover, since there is no risk of mistracking of the belt, contamination risk is reduced to a minimum. He highlights, “Since our belts are not tensioned and do not need to be tracked, maintenance is reduced to an absolute minimum, with shafts and bearings now also lasting much longer.”

Luis Patricio, Intralox Baking Account Manager, also weighs in: “Intralox conveyor design guidelines are critical to ensure the ThermoDrive belting technology works under optimum conditions.” This means avoiding excess dough in critical areas and ensuring that cleaning is performed with minimum effort and time. “The accumulation of dough on the belt surface, return way and outfeed areas can become very

© Mecatherm

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www.bakingbiscuit.com 04/2021

CONVEYING

TECHNOLOGY MEETS BAKER‘S CRAFT. © Intralox

FOR YOUR PERFECT BUNS.

critical on the mechanical aspects, as well as regarding food safety; therefore, the relevance of respecting Intralox design guidelines,” Patricio recommends.

Proofing is the task To ensure pan control while proofing, Intralox has belts with integrated magnets to keep maximum control of pans and baking trays, also in case of inclines and declines. “In case of aluminum pans and trays, we have an alternative with friction top belts (rubber surface on top for maximum friction with the pans/trays),” illustrates Tertoolen.

The company’s spiral technology Direct Drive will ensure a smooth operation of the system, thanks to its positive drive and zero friction between drum and belt. “Its unique feature contributes to a very stable proofing process without damaging the dough due to the excess of micro-vibrations between the drum and the spiral belt,” adds Patricio. The same applies when the proofing is done on Direct Drive spiral with metal trays: the reduced amount of vibrations on the system will ensure the trays complete the cycle without losing their orientation, ensuring a stable proofing cycle without affecting the dough.

GENTLE DOUGH PROCESSING

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Hygienic design The hygienic design represents the first step in effective cleaning, in all processes. To guarantee sanitation upkeep, Intralox recommends the 7-step-of-Dry Sanitation-Guidelines that describe a sequenced approach to effective and efficient cleaning. Another key aspect in cleaning and preparing the conveyor for safe manufacturing is “Using the right tools, color-coded and hygienically designed to prevent cross-contamination during the sanitation process,” explains Roger Scheffler, Food Safety Specialist at Commercial Food Sanitation, an Intralox company.

“Twin Sat” satellite head Two satellite rollers positioned one above the other produce a virtually tension-free dough sheet.

The Twin Sat module reduces high mechanical load to a minimum while gently forming the dough sheet.

“H“

IC H Y G IE N D E S IG N

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Maintenance is the first necessary step towards preserving efficiency; upgrades will be the goal for significant, quantifiable improvements, from single-feature innovations to those revising the operating concept altogether. These will be detailed in the second part of this article. +++

GENTLE DOUGH SHEET FORMING

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© Ashworth

The guide to your new baking band It takes considerable experience to determine which belt works best with specific bakery products.

Ashworth provides recommendations in terms of materials, design, and engineering. The choice will be the result of an extensive checklist and case-by-case analysis.

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Ashworth has been manufacturing baking bands for 75 years, all translating into experience in selecting the right belt for each application. Here are the key points to consider when selecting a metal belt the specialist shared with us, having in mind that its approach is very much solution-based, and Ashworth tailors each belt to specifically meet the requirements of its customers.

“When determining the correct belt, materials and design that best meet our customer needs, we review the current situation, their goals and parameters,” said Dale Jeavons, Factory Representative Manager EMEA. “These are all imperative considerations for successful recommendations.”

According to Jeavons, the following key factors are important when specifying the correct oven belt: + Be aware of the processing temperature – this is productspecific + Consider the number of zones and the temperature of each heating zone

+ Method of heating - direct fire, infrared, forced air, etc. + The weight and size of the product – these parameters determine how strong the belt needs to be, allowing for maximum belt tension + Consider the lateral weave and wire diameter. Remember, the cross-sectional area of the belt is the strongest part of the belt.

+ Belt path + Belt strength required + Product support required + Condition of the product when placed on the belt www.bakingbiscuit.com 04/2021

+ The ingredients used in the product. If you have a product

with high-fat content, you need to choose a solid steel band rather than woven wire. Fat is harder to clean from a mesh belt. Avoid product getting stuck in the mesh – this is particularly true with chocolate chip cookies. Ashworth’s CB5 is perfect for savory crackers, for example. + The belt support structure must be adequate. This is a case-by-case consideration, and it will determine the width of the belt, its load capacity, and how the load is distributed on the belt. Take note that this is an important consideration, especially with breads.

+ Belt speed: belts can operate up to 30 meters per minute (or faster), on a straight run conveyor for an oven. + Terminal transfers also have an impact on the choice of the baking belt. Consider the terminal transfer, as a rule of thumb, the closer the crimps the tighter the transfer.

The longitudinal pitch of the belt has an impact on the terminal and transfer roller diameter.

Ashworth Bros., Inc., headquartered in Winchester, Virginia, is the only conveyor belt company that manufactures and services both metal and plastic belting for straight running, turn-curve, lo-tension, and selfstacking spirals – offering customers the best solution for their specific requirements. With 75 years of innovation in conveyor belts, Ashworth is a market leader, with the most conveyor belt patents in the food processing, can making, and material handling industries.

PRODUCTION

+ The open area of the belt – to allow cooking gases to escape. + The type of drive and diameter of drive rollers or sprockets

– some belts are friction-driven (the bigger the friction drive, the better for more contact). Positive (sprocket) driven belts often use smaller diameters.

+ Tracking and control devices Jeavons explains, “We have our own Ashworth tracking device and control systems. Most ovens builders have an automatic tracking device (sensors) as part of the oven. You need to consider what type of tracking device is on the machine. When considering a control system, use control rollers to track the belt from a company that offers installation and service as part of their offering.”

© Ashworth

The belt is part of the baking process Taking all these into account, Ashworth can advise their client on the best belt for the application. “Of course, we have several belt types that we have supplied over the years and these belts have become industry standards. One such belt would be our CB5 Baking Band ® , a band we have been manufacturing since 1964,” he illustrates. Due to its very solid construction, the CB5 belt itself is part of the cooking process, as the band retains a lot of residual heat when it passes through the oven. The product is baked using a combination of convection heat and conductive heat from the belt itself. This enables the processor to produce a very crisp product, which makes this type of belt particularly favored by biscuit and cracker manufacturers globally. The CB5 is also a very durable belt, its life span often exceeds 20 years, in Ashworth’s experience.

There are many benefits to using the CB5 Baking Band ® for various products. “Since the belt is so dense, it heats up quickly and maintains the heat required for good thermal transfer,” underlines Jeavons. “For example, the heat from the belt combined with ambient air results in a nice crispy cracker.”

According to Jeavons, other belt types that Ashworth has had huge success with are its B66 (balanced) and U66 (unilateral) weaves. “In the EU, you can use those belts for any biscuit product. Ashworth’s balanced and unilateral weave belts were developed specifically for the customer who uses the Z47 belt—apart from those products that consist of high amounts of oil or fat,” he notes. These bands are specifically designed to replace the Z47 type belt, and have several advantages: + Straighter running when using the balanced construction + Lower tension is required to drive the belt + Easier to repair compared to Z47, meaning less downtime + Smaller terminal rollers for better transfers + Shorter lead time in many cases + Inherently stronger construction, meaning longer belt life

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The key is in the installation As with any type of high-temperature band, correct installation is critical to ensure a long and successful operation of the oven and conveyor belt. The optimal installation starts with an assessment on location: “One of the most common installation problems that we’ve come across after visiting a new customer is that the previous installer did not ensure that the terminal rollers were parallel to each other,” said Jeavons.

“This is a critical mistake! It’s important to understand that one side of the belt can stretch during installation, which means it is no longer even. Our customers rely on our factory service experts because it is very easy to ruin the belt during installation. Once the stretch occurs you cannot correct it; a whole new belt is required. That one mistake can be very costly.”

This is particularly true with wire mesh belts, which are made using annealed wire. “If the band has uneven forces imparted during the installation, the belt can be damaged and will never operate correctly, which can lead to the belt requiring premature replacement – along with all the other associated costs,” according to Jeavons.

The company offers a package available to all customers, based on three fundamental points: 1. The belts are tested for lateral band waver during the manufacturing process. Ashworth works within clearly defined tolerances; belts are tested and are guaranteed to run straight when leaving the factory.

2. It also offers a full installation service for all its oven bands with experienced service engineers.

3. Ashworth’s proprietary control systems can be fitted to most ovens, to help ensure that the belt is not damaged, even when things go wrong in the oven.

“Each product and oven are unique, which we recognize when we engineer an individual solution for each,” concludes Jeavons. +++ KOENIG Motiv4 NTS 91x53.qxd

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PRODUCTION

The best support system The benefits of innovative, custom-made bakeware only begin with providing support for baked goods throughout manufacturing. Minute details in their make-up, design, coating and handling amount to a lot in terms of efficiency and bring significant process improvements in industrial baking.

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Trays used for automated, industrial lines must be able to withstand constant mechanical handling, and, in many cases, their own large size and considerable weight, plus the load of products deposited on them. There is also the temperature challenge, going from -40°C to 270°C. Most industrial trays have a robust stainless-steel frame to support weight and excessive handling. “They are made to measurement with absolute accuracy to ensure a smooth production process. Securing accurate bakeware measurements is extremely important for a smooth operation of the lines, avoiding crashes and maintaining packaging requirements,” Guido Kempf, Kempf CEO, details. The company provides special micro-perforations of 1.6 or 2.0mm, various mold designs, styles, perforations, and coatings, respecting the specifications of the manufacturer of the line and the customer requests.

The lifespan of baking pans and trays relies on the quality of the materials they are made of, the coatings protecting them, and the way they are handled. One of the most common causes of bakeware damage is their cleaning process, Kempf illustrates: using the wrong cleaning agent, for example, can dramatically reduce the number of baking cycles or even cause irreversible damage to the nonstick coatings. Innovation seeks to bring upgrades to pans’ properties while looking to enhance the entire baking process they travel through.

The impact of a tray’s micro-perforations on cleaning depends on the products being baked: although, on the one hand, in a standard baguette production, there is almost no need to clean the trays, for instance, passing them through a brushing

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Bread ePAN customized for a Mecatherm line

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system with soft plastic bristles is always a plus, Kempf recommends. On the other hand, for products decorated with seeds, flour or sprayed liquid ingredients, where the perforations tend to get clogged after a while, washing the trays in-line, or outside is required.

There are several good technologies for in-line brushing and/or washing of trays and tins available in Europe.

Wanted: automation and flexibility With higher output and more efficiency in mind, the company has recently invested in new custom-made equipment such as continuous coating lines, stamping presses and a state-ofthe-art station for tray cutting, folding, and laser engraving – in response to needs for automation and more flexibility they observed. Kempf highlights the work of the company’s R&D team: “Our main goals are to constantly increase our high levels of quality, productivity, and sustainability, always bearing in mind the wellbeing of our staff and the focus on competitiveness.” Among the newest advancements, he shares, is that the new coatings KG-Flon 734 and KG-Flon 970 are suitable for doughs high in sugar, with perfect non-stick characteristics.

In general, Kempf ’s production lines are highly automated, to achieve a consistent quality of the products. The metal punching equipment is singled out by the company’s CEO for its very fast, precise, and clean perforations on both sides of the aluminum sheets, which is extremely important for safety and coating purposes.

Coatings make the difference The quality of the trays doubled with that of the coatings will influence their efficiency. Correctly identifying the best non-stick coating for specific needs, and then ensuring their protection throughout their life cycle implies many different approaches. The bad news is that there is no one-size-fits-all solution; however, that is also the good news, as the final choice will be a perfect match for each production environment. “There are many factors to be considered before we can decide which nonstick coating to offer: such as, recipes, ingredients, processes, equipment, room conditions (temperature, humidity, etc.),” according to Kempf.

PRODUCTION

The company goes into detail with specific questions for their customers and, if possible, will also observe every process on-site. Kempf constantly contacts its raw material suppliers for coatings to identify the best and newest technologies.

This is the case of their recent work with a leading Swiss supermarket chain, for example: “They were looking for a better coating solution for their in-house bakeries, where they still produce a wide variety of products with long proofing times and other demanding parameters every day. Then our premium Teflon coating KG-Flon 704 green was the perfect choice thanks to its non-stick properties. After the introduction of KG-Flon 704 green, we were able to solve their problems, saving them time, money, and cleaning efforts, and reducing the amount of waste in their bakeries,” illustrates Kempf.

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From Kempf ’s perspective, the biggest technology advancements in bakeware over the past 10 years are coming from innovation in coatings. “Many companies have switched from silicone rubber to fluoropolymer (e.g. Teflon) coatings.

We are constantly in contact with our suppliers of coating materials, testing new systems and trends, looking for more sustainable solutions and the best baking results,” Kempf shares. In this regard, improved heat resistance is one of the items on the company’s R&D board.

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27

PRODUCTION

Kempf is aiming to bring the best technology and materials to the drawing board of the bakeware it produces. For example, the company has recently upgraded the abrasion resistance of its premium Teflon coating KG-Flon 704 green, which can now successfully withstand 15% more baking cycles. ©

Peelboards Special products require special support: Kempf offers peelboards for handling special doughs (i.e., rye dough, or highly hydrated doughs), for their excellent non-stick properties.

They are a versatile choice for all kinds of products, regardless of size or flour sprinkling, and can be used for manual, semi- or fully automatic loading, on racks or conveyor belts. Specialty products often imply premium ingredients and costly waste; hygiene is a priority in the design of the peelboards, so they can be cleaned quickly and efficiently, either manually or automatically. “The method (brushing, dry/wet) and the need for a cleaning agent will depend on the type of product and operation,” Kempf adds.

Pan customizations are made according to several factors, including: + The size of the conveyors; + How the pans move through the system; + The pan stacking solution used; + Depanning systems on the line; + Oven system used.

Industrial & custom-made: thinner and better Even for industrial baking, all bakeware and coatings American Pan delivers are custom-made to perfectly fit the manufacturing needs of the bakery. The majority of baking pans are made of aluminized steel can be used anda blend optimized to be resistant and conduct heat well. Stainless steel can be used and is a very strong material with the advantage of being very corrosion-resistant, but it lacks in heat conductivity, by comparison. Aluminum is also used, but while it has exceptional heat conductivity, it may not be strong enough for many automated bakeries.

The company uses different types of aluminized steel. Aside from the standard blend, American Pan developed the ePAN steel in collaboration with its providers, which is used to make lighter, thinner, and stronger baking pans. The pans made with it not only come with benefits regarding usability but contribute to the efficiency of the process overall: lighter pans also mean energy and time savings, as they will heat up and cool down quicker; they are easier on the production line and need less energy to be moved around. “One of our customers was able to reduce their oven temperature, and others could decrease their baking time with ePAN bun pans,”

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Ke

American Pan’s specialist adds. The ePAN steel is currently used for bun pans, bread pans, and specialty system pans (dedicated to a certain type of manufacturing line). Its quality was also a challenge in molding it into shape, because it is strong and pans for bread have certain depth requirements.

American Pan has developed new manufacturing processes to solve this issue and bring the deep-drawn pans to the needed specifications.

Features that are commonly requested will target pan strengthening to match various ways of strapping them together or larger sizes; another growing trend is for bigger pans to support higher production volumes without other changes to existing equipment. “When looking into larger pans to increase capacity, you might need to consider certain aspects in your bakery, such as any curves in the conveyor system, for limits to the sizes you want to have,” the specialist recommends.

Larger pans may not be able to move smoothly across the conveyors and can cause damage to pans, loss of product and jamming of the system.

© Kempf

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Moreover, smart pan tracking is increasingly becoming a necessity when raising the bar in automation in the bakery.

American Pan’s SMART Pan Tracking uses a Laser tag that is counted every time it passes the sensor, usually placed after depanning (i.e., on a cooling conveyor system). The information is sent to a website where it can be accessed and analyzed to estimate the coating status and anticipate the need for recoating or replacement.

The fewer parts, the better For baguette ranges, American Pan has upgraded its TabLock trays (EU patent pending), to eliminate the need for any rivets, drills and eliminate the hazard of metal shavings.

Having rivets would mean drilling them out and this would be necessary in order to replace the screen; this would pose the risk of having metal shavings in the frame, and potentially

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PRODUCTION

metal contamination of the products. By using the rivet-free TabLock system, these extra steps and risk factors are removed from the to-do and to-manage lists. “It just takes a simple tool to remove the screen, and then a simple tool to reinstall the screen,” explains the specialist. The added benefit is that the replacement can easily be done in the bakery, so that production cycles will not be missed while they are shipped to a service facility, and back. Aside from saving time, this means they can be replaced one at a time, as needed, and save costs significantly.

The process also factors in the coating selection; if the pans are handled roughly, the coatings may be scratched prematurely. Depanning is the most likely process to scratch the coating, which greatly reduces the lifespan of a non-stick coating like the DuraShield. Some of the more gentle depanning methods, for the product as well as the coating include using suction cups wherever suitable (i.e., for breads, buns, rolls, cupcakes, muffins and many other bakery products), the specialists at American Pan observe, to avoid metal touching the pans altogether. Another handling step to be carried out with care to protect coatings is pan stacking.

Protect the product, protect the pan: coatings An entire line of coatings is the next step to the closest match to specific needs in terms of custom solutions, including: + Fluoropolymer coatings are the go-to for challenging doughs or various product and/or process restrictions. OptiShield, for example, will require minimum to no release agents for a wide range of products and will consequently be easier to clean, which makes them a cost-effective alternative. The DuraShield is designed to deliver longevity, meaning less maintenance is needed, less downtime, and fewer costs: the coating’s ROI is less than a year, according to the manufacturer’s research. “The DuraShield and OptiShield are among the more popular products in the European market,” the specialist underlines. These products come in several variations depending on the product and will specifically Bakeware designed for allergen management

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Removal tool for a TabLock tray

address handling sticky dough, and even product ranges: for buns, they minimize the rings on the bottom; pretzel doughs, muffins are improved by using less oil, which saves expenses and will not affect the nutrition or flavor profile. + Rubberized silicone coatings are great for baguette pans, baking screens and perforated trays and can deliver up to 1,500 baking cycles before recoating is needed. In this category, the FlexiCoat is also a sustainable choice as it helps minimize scrap and oil consumption for an environment-friendly, longer-life use. + The Americoat silicone glaze is used on all American Pan glazed pans as any type of product can benefit from it. It contributes to lowering manufacturing costs, thanks to its release properties that decrease requirements for oils and other release agents. Its added benefits come from hygiene, process efficiency, and improved product quality.

Coatings can be also ground zero for allergen management: “Our allergen-management coating is a DuraShield, a fluoropolymer-type coating, which we’ve colored to make it stand out. If you see a purple pan in any bakery, you know not to use that with any product that contains flour or any other allergen. The visual aid is more helpful than placing the freefrom only pans in a certain cabinet, for example,” they point out. DuraShield excels at hosting stickier dough through processing, another reason to favor its use for gluten-free products, for example.

In addition, the group recently launched the Bundy/FME Continuous Pan Cleaner at IBIE, which uses tools such as brushes, vacuum and air to ensure the thorough removal of by-products including protein washes, seeds or loose toppings, using an inversion conveyor to move pans through a multistage cleaning process. As aluminized steel corrodes, water is not among the viable cleaning options, even if coatings help with this. Using four different sets of interchangeable, easy-to-change, cleaning heads, it is programmed to clean pans every time they go through the system.

Specific solutions are designed to suit the needs of the bakery’s profile for any bakeware requirements throughout its life cycle. +++

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MIXING

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PRODUCTION

Pigs in a blanket In the USA they are called ‘Pig(s) in a blanket’, in Germany ‘Würstchen im Schlafrock’ (sausages in a certainly in demand internationally. However, solid fillings pose a challenge for the coiling process.

+

The semi-automated production of Polsehorn on a large scale – that was the task with which a Danish company approached the bakery machine manufacturer FRITSCH. The development team at FRITSCH was asked to come up with the right solution.

More grip when hammering in “To enable the customer to produce this special product on a LAMINATOR 300 with Pig(s) in a MULTICUT, we have further blanket (in developed our CSV compact croissant dough) vacuum winder, which is also used for the production of filled croissants.

We have additionally placed motor-driven knitting belts on the wrapping cassette with wrapping hooks, which hold the sausage so that it does not roll away during wrapping and remains in a straight position,” explains Alfred Ströbel, dough technologist at FRITSCH. “The basis for this solution was created years ago when we added the catch rakes to the croissant coiler for a Swiss producer so that they could coil croissants around whole chocolate bars,” says Uwe Benz, Sales Director Line Solutions.

While unfilled croissants are relatively easy to roll in, firm fillings such as a sausage present a real challenge for the

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coiling process. The impact claws ensure that the dough is lifted slightly and can be guided and rolled over the inserted product more easily. To hold a sausage in position, for example, a notch is also pressed into the dough piece – at the point where the sausage lies. This notch serves as a physical barrier. In this way, the sausage remains in the desired position.

The additional fuse Because the sausages – unlike standardized chocolate bars, which have a straight contact surface – roll away more easily, additional securing is needed during production.

This is exactly what the fixing belt provides.

While the vacuum fixes the dough piece, the belt provides more grip when the sausage is wrapped. “In addition, chains on the mats and the coiling mat serve as a weight to exert a certain pressure on the dough piece so that the sausage is tightly wrapped in the dough piece,” explains Uwe Benz.

The coiling system can also cope with crooked, irregularly shaped sausages. According to the manufacturer, the same applies to products with a soft consistency such as a minced piece or a vegetarian sausage alternative. +++

© FRITSCH

dressing gown), in Russia ‘Sosiska v teste’ and in Denmark ‘Polsehorn’. Sausages wrapped in dough are

© FRITSCH

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PRODUCTION

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Vacuum coiler with additional benefits

The processes of diapering 1 Fixing the sausage on the dough piece: For this purpose, a motor with a moving belt has been installed. It is located on the coiling cassette and ensures that the sausage is precisely fixed before coiling and can no longer slip.

© FRITSCH

+

The FRITSCH CSV compact is a vacuum coiler that fixes the dough pieces or the dough pieces cut into triangles on the belt by means of a vacuum, which prevents them from slipping whilst coiling. Ideally, the machine is used downstream of a FRITSCH CTR or a MULTICUT. Both filled and unfilled products, such as croissants, chocolate croissants, various croissants and also pigs in a blanket can be produced on the machine. For the latter, only the coiling cassette and the vacuum template need to be changed. The coiling cassette is placed on the existing locks of the CSV compact. Tools are not required for the product change.

Vacuum coiler CSV compact

2 A coiling cassette with a scribing hook grips the piece of dough and the first impact is made so that the sausage starts to rotate.

3 Subsequently, the hooks are released and by means of the coiling mat with the piece of dough remaining in motion. The other windings follow.

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PRODUCTION

© FRITSCH

The snack product with yeast dough, with the demand particularly growing in Eastern Europe

The most critical process steps 1 The first impact with the scribing hooks: Here the sausage must be brought into rotation in order to be able to carry out the further coiling cleanly and precisely.

2 The transfer of the dough piece after the first wrapping from the cassette with the wrapping hooks and thus the infeed into the coiling mat is another critical step. The seamless transfer of the product must be ensured so that the speed can be transferred to the further rotation of the coiling mat.

sausage, the higher the risk of cavity formation. This must be prevented.

The number of coilings The number of coilings that can be wrapped around the product depends on two factors: the product size and the individual customer requirements. One to three wraps are possible without any problems.

What dough parameters to follow When using the coiling cassette and making sausages in a dressing gown, the same parameters should be observed as for a croissant. This includes, for example, the correct amount of flour below the dough band. With regard to flour, always use as much flour as necessary, but as little as possible.

The best results are obtained with a dough thickness of 2.53.8 mm.

What pressure the product subjected to?

With this coiling system, very little pressure is applied to the product. This is very important; after all, the product should retain its shape. The greater the pressure acting on the

The performance of the coiling cassette The performance of the sausage coiling cassette is mainly given by the placement of the sausages. The coiling cassette itself manages up to 80 cycles (i.e. rows per min, in industrial lines up to 6-row cassettes are possible). In a semi-automated solution, where the sausages are placed on the dough pieces by hand, the limit is about 60 cycles.

Cleaning process The vacuum coiler is suitable for ‘wash-down’ cleaning, which FRITSCH says ensures fast and thorough cleaning. +++ Helga Baumfalk

FRITSCH MULTICUT with vacuum coiling CSV compact

The first impact with the scribing hooks: Here, the sausage must be brought into rotation in order to be able to carry out further coiling cleanly and precisely

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© FRITSCH

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PRODUCTION

All on deck Deck ovens provide such reliable and flexible configurations that they can be conveniently used for a wide range of products, all in a design that is space mindful.

+

The goal is the same as with any oven: achieving the best baking results possible. The difference is in the details, and for deck ovens, in particular, this means they must also be easy to operate and provide consistency regardless of variations in the bakery (skills, shifts, ingredient sources, etc.).

Volume for money Some of the specifications Sveba Dahlen’s customers are prioritizing also include energy efficiency, including insulation properties – covering both environmental concerns as well as the cost of baking. The company also sees an uptick in requests for cloud-connected, smart deck ovens: “This is why we have also implemented the new SD Touch II panel on our deck ovens as an option,” the specialist says. The installation time is also important when it comes to replacing old ovens, aside from the always-in-demand custom oven footprint, to fit different premises.

The company is reviewing its D-Series deck ovens and the N-Series pizza deck ovens for new developments. The entire small bench oven is brand new, in the N-Series range.

“What’s special with this oven is the high-quality door gasket and well-insulated oven compartment that retains heat more effectively. Reliable heating elements have a turbo function that quickly and efficiently brings the oven up to the right temperature. This results in the N-Series oven baking as perfectly as an industrial oven or pizza oven. But, the volume is very small, of course,” Sveba Dahlen highlights.

The D-Series is available in five widths and up to five decks.

This oven is also modular which means that another deck can be added when production volumes rise. The newest innovation for the D-Series is the new digital SD Touch II panel. “The panel has important functions that make

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everyday life in the bakery easier. Also, it is possible to connect to the cloud solution, Sveba Connect, with all those benefits,” adds the specialist. The SD Touch II panel provides increased recording functionality: “Instead of making a program for a product manually, you can just bake it as you would normally and make the changes you want throughout the bake. When the bake is finished and you are happy with the result just press ‘save the previous bake as program’, enter the name of the product and that’s it! Next time you want to bake the same product, you can just go to your recipe list and select the product,” we learn.

Independent decks As far as operating autonomy is concerned, the D-Series packs almost unlimited possibilities, including combinations of higher and lower decks, for example; double glass doors or solid ones, or high-temperature and standard decks working simultaneously. There are three different types of control panels to choose between.

Complete control is provided: “It’s possible to control both element effect and temperature separately for both top and bottom heat throughout the bake and the elements are covered by a radiation cover to give gentle and perfectly dispersed heat for delicate products.”

To optimize baking for best results, Sveba Dahlen recommends planning the baking to minimize the idle time between cycles and using the automatic ‘eco mode’ to save energy for extended stand-by durations. Moreover, “If you are using different temperatures in different decks, use the top decks for high temperatures and the bottom decks for the low temperatures.

This way, it will be easier to maintain the ovens and will give you a better baking result.”

© Sveba Dahlen

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PRODUCTION

e-Bake DEBAG answers the trend for smart equipment with a wide range of intelligent solutions and adaptations to meet the diverse challenges coming from bakeries. “They are all bundled in our e.Bake. solutions, our platform for customization”, highlights Georg Schulze, Head of International Sales. DEBAG aims to provide highly automated baking options, which is why all ovens offer preset baking programs, for consistent product quality.

uniform radiated heat from top to bottom.

Baking is done directly on a stone slab, to give products the unique and traditional texture of a handcrafted product.

© DEBAG

The company’s HELIOS product family consists of four different deck sizes, with an additional option to increase the inner height of any deck. Up to five decks can be stacked, which are all individually controlled. “Also available with a scratchproof black finish ‘Nostalgia’, it is the eye-catcher in any shop fitting,” Schulze notes. Alternatively, it can serve as a serious option for production in just up to 5sqm (baking surface). HELIOS is the ‘classical’ deck oven, working with

37

From the MONSUN series, the SM model is particularly versatile for flexible baking needs. “Offering all advantages of the ‘MONSUN’ principle, this is a rack oven and a deck oven in one,” DEBAG’s specialist explains. The ‘MONSUN’ principle stands for a gentle baking atmosphere, achieved with sophisticated and directed airflow, operating at the same time with low airflow speed, Schulze adds.

The company’s approach to finetuning the baking process for best results is to accompany the bakers from the very beginning of their projects, from planning to delivery, installation and giving support if necessary.

+++

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TRAINING

Knowledge pays off Rademaker aims to build on and share the knowledge it has acquired through the years, and its Technology Center is proof of that. Since 2015, sharing knowledge has been expanded with the Rademaker Academy, built around teaching the fine points of production technology and maintenance.

+

The Rademaker Technology Center (RTC) features several pilot lines, full-scale, certified production lines that meet the latest standards, which are available for testing. The company believes knowledge is an investment worth making, and invest it did: over the past two years, the RTC has been developed to more than twice its starting size, to its current 2,400sqm. In addition to the pilot lines that can run any type of bakery products, its equipment lineup also grew to add kneaders, proofers, ovens and freezers – to replicate all production steps.

Wiep Bergsma, the head of the RTC, estimates the workload carried out at the Center: “We run tests at the RTC with our production lines for around 60 to 70 customers each year.

Some of them visit us for a day, others stay for five days. The number of tests varies enormously, but averages at two or three tests per customer. Besides that, we also demonstrate our machines and processes for prospects and run tests for research and development. Ultimately we do around 350/400 tests each year. So, that's quite a lot.” It’s not just about training either: RTC specialists have been working

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© Rademaker

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together with the R&D teams more and more recently, for new developments around market demands and requests from customers. The technologists report issues they encounter, for example, and resolve them with the R&D specialists.

New tools are then developed for the specific situation, which are tested at the RTC. “In terms of sustainability, we mainly focus on the more targeted use of raw materials, which is all about wasting less. In addition, our customers want to achieve optimal efficiency and create minimum failure. Weight accuracy naturally plays an important role too,” adds Bergsma.

How to test and develop Rademaker works together with the Dutch BoulangerieTeam at the RTC to come up with new and improved products and processes. It is a team of highly professional artisan bakers, winners of the international bakery contest 'Bakers in the city' 2020 in Italy.

The Dutch BoulangerieTeam and the specialist from the RTC recently sought out to make the best possible version of

a ham-cheese product, for example. Preliminary research by Rademaker showed that the croissant would actually be the worst shape to do justice to the flavors of ham and cheese.

To change the product, they first looked at the properties of the fillings: ham contains a lot of moisture which rises in a product, and cheese contains a lot of fat, and that sinks. “In a croissant, therefore, the water vapor goes up, creating a large air bubble above the ham and cheese. The fat sinks to the bottom of the product, which makes that part difficult to bake, if at all. Also, the ham and cheese must be encapsulated in a regulated way, because if you put those ingredients on top of the dough, they dry out and you lose the flavor,” Bergsma illustrates. We worked with those issues and developed a snack. The working team discovered that the best flavor comes from using ham and cheese blocks measuring 1x1cm and 5mm thick. The carrier they chose was ragout, to bring out more flavor from the cheese. “This way of filling is perfect for a snack/swirl. The cheese bakes towards the top and the fat sinks slightly so that it gets a deep-fried bite. The resulting products were ultimately rated 9+. This is a perfect example of what we already do and want to do more at Rademaker: working with the Dutch BoulangerieTeam to improve and change products. In this way, we are all challenged even more to come up with new and better products and processes,” underlines the head of the training facility, noting that they can adapt the technology to the properties of the product.

Some of the trends with clear interest going forward include vegan products and bite small bite-sized premium goods.

Handmade is another claim we can expect to see more of, and which is on the research list at the RTC: “By partly adding manual work to create authenticity, companies can claim that a product or process is handmade. This can be done, for example, by adding traditional processes to the production process, such as a wood-fired oven, to give products a unique character. I think that this will be a growth area in the long term,” the specialist anticipates. Rademaker provides input related to not just developing products, but also entire concepts.

© Rademaker

© Rademaker

TRAINING

Investment in training Since its opening in 2015, the Rademaker Academy in Culemborg has set out to maintain and share the company’s time-earned knowledge.

Engineers and operators who want to learn about production lines come for training at the Rademaker Academy. The teaching and training location is complete with a teaching room, a practice room with a fully operational two-section laminator and universal line, and a virtual reality lab (VR lab).

On-site training is also an option using a mobile VR setup.

Rademaker offers basic and advanced training in both operating as well as maintaining company machines. The basic training begins with a broad explanation of the machine and focuses on building on the basic knowledge of dough technology and production technology required for optimal operation of the machinery. The advanced training focuses on more specific and in-depth content. On a technical level, the training could address fat pump or dosing machine maintenance and in a technological area, training can relate to specific actions in the production process.

Kasper Rozeboom, Aad den Braven and Jan Willem Jansen are the educators at the Academy. Rozeboom says about their work: “With the new, well-equipped location in Culemborg, we have taken a huge step in offering an even better service to our customers. When knowledge is passed on by people who understand the practice, this offers true added value.”

Den Braven adds: “I sometimes compare it with obtaining a driving license. You can only drive a car as it should be driven if you have a driving license. It’s the same with our machinery. The users obtain their ‘driving license’ at the Rademaker Academy, which ensures that they can operate the machinery optimally in their own environment.”

The Academy has a designated space for training purposes.

The course participants come to Culemborg, where they can focus entirely on safe, hands-on training. “First production steps in this training line match the large production lines

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TRAINING

© Rademaker

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RTC technological support The development process starts in the Rademaker Tech-

The production capacity in the RTC is identical to actual

nology Center (RTC), featuring several production lines

production conditions. To closely simulate the manufac-

for all types of bakery products, whether bread, donuts,

turing process, it is also equipped with kneaders, proofers,

puff pastries, croissants, pizzas and flatbread, gluten-free

ovens and freezers from renowned suppliers.

or specials.

The RTC team consists of over 15 technologists.

During 2019/2020, the RTC was renovated and expanded.

Services: demonstrations and tests, recipe and product

In terms of surface, it has more than doubled to 2,400sqm.

development, sample production.

that participants use in their workplaces. The big difference is that it’s OK to make mistakes. After all, that’s how you learn. Moreover, the small group size means that everyone has attention. As trainers, we adapt the training to the group’s needs,” Jansen explains.

The VR lab Rademaker has been offering part of the operator training with the help of virtual reality for the past year. Rozeboom finds VR provides “A fantastic way to practice operating a production line reliably, without waste or financial consequences. Initially, it takes a while for people to get used to walking around with a VR headset. Once they’re used to it, the participants are all very enthusiastic. We’ll certainly be developing this further.”

The teaching location in Culemborg and the on-site training, with or without virtual reality, provide a foundation for growth at the Rademaker Academy. New production lines are arriving and existing lines continue to be developed all the time – this means new training is needed. “The operation screens used in the lessons must always match the screens that customers use in their production lines. VR will replace some of the theory and practice, and the online training that we developed in connection with COVID-19 is also here to stay. We see these different types of training as a fantastic addition to our range,” Rozeboom estimates.

Training on offer A team of technological and technical trainers developed two training themes focusing on the efficient operation of the Rademaker production lines. The training themes,

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operating and maintenance, both have a basis and advanced training module. Training is given in English, Dutch or German.

Operating 1 Basic operator training.

For operators, managers and line managers. The theoretical training will consist of unit descriptions, cascade, synchronization, virtual reality training and touch panel explanation. The practical training will consist of running training doughs on the line, troubleshooting and cleaning training.

2 Advanced operator training.

For product developers, managers, technologists and line managers. Customer-specific training content that focuses on specific units, ingredient information and product and process knowledge. Teams can resolve production line problems after this training.

Maintenance 1 Basic maintenance training.

For maintenance engineers and managers. The theoretical training contains of unit descriptions, cascade, synchronization, virtual reality training and touch panel explanation. The practical training contains belt tracking, greasing, troubleshooting and cleaning training.

2 Advanced maintenance training.

For maintenance engineers and managers. This customized training focuses on specific units, electrical systems, the process and advanced mechanical knowledge. After this training, teams can resolve the bigger problems and maintain the production line correctly. +++

MIXING SOLUTIONS for bread, pastries, cakes and snacking industries

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ADDITIVES

Safety first: food additives Titanium dioxide (E 171) is no longer considered safe for consumption, according to the updated ESFA evaluation. Rigorous methodology and new data helped fill in data gaps and conclude that genotoxicity concerns cannot be ruled out. potential genotoxic effect of a substance to conclude on its safety. Prof. Matthew Wright, both a member of the FAF Panel and chair of EFSA’s working group on E 171, said: “Although the evidence for general toxic effects was not conclusive, based on the new data and strengthened methods, we could not rule out a concern for genotoxicity and consequently we could not establish a safe level for daily intake of the food additive.” An Acceptable Daily Intake (ADI) cannot be established for E171.

Scientific evaluations In the framework of EFSA new risk assessment on E171, new knowledge on the characterization of the food additive E171 and updated guidance for the Risk Assessment of materials containing a fraction of nanoparticles has led to the broadening of the toxicological database, including a significant amount of new evidence from studies obtained with TiO2 nanoparticles.

EU according to Annex II of Regulation (EC) No 1333/2008. Risk managers at the European Commission and in the EU Member States have been informed of EFSA’s conclusions and will consider appropriate action to take to ensure consumers’ protection.

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EFSA has updated its safety assessment of the food additive titanium dioxide (E 171), following a request by the European Commission. The assessment took into consideration many thousands of studies that have become available since EFSA’s previous assessment in 2016, including new scientific evidence and data on nanoparticles.

Prof. Maged Younes, Chair of EFSA’s expert Panel on Food Additives and Flavorings (FAF), said in a statement: “Taking into account all available scientific studies and data, the Panel concluded that titanium dioxide can no longer be considered safe as a food additive. A critical element in reaching this conclusion is that we could not exclude genotoxicity concerns after the consumption of titanium dioxide particles. After oral ingestion, the absorption of titanium dioxide particles is low; however, they can accumulate in the body”.

Genotoxicity refers to the ability of a chemical substance to damage DNA, the genetic material of cells. As genotoxicity may lead to carcinogenic effects, it is essential to assess the

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© Michael – stock.adobe.com

Titanium dioxide (E 171) is authorized as a food additive in the

It is important to note that in EFSA’s food additives assessments, genotoxicity is considered a standalone toxicity endpoint. Data from TiO2 genotoxicity testing provide information about potential irreversible DNA damage that may result in heritable or degenerative diseases. The available data on genotoxicity have excluded the potential for TiO 2 to cause gene mutations but could not rule out concerns for other adverse effects on the genetic material of the cells, EFSA's Engagement and Cooperation Department tells us.

Although the majority of the genotoxic effects were reported with TiO 2 nanoparticles, they were also noted with TiO 2 particles greater than 100nm. Therefore, the data on genotoxicity do not allow EFSA’s experts to set a clear threshold with respect to genotoxic effects and the size of the particles that cause these effects. Different modes of action could be responsible for the genotoxic effects according to the available data. However, the data do not allow EFSA to identify a dose below which these effects do not occur. This is what leads to EFSA’s conclusion that it is unable to exclude concerns around the genotoxicity of TiO2 nanoparticles, EFSA explains.

The methodology The assessment was conducted following a rigorous methodology and taking into consideration all evidence that has become available since EFSA’s previous assessment in 2016, including new scientific evidence and data on nanoparticles.

Concretely, in the first instance, EFSA carried out an

ADDITIVES

EFSA is a European agency funded by the European Union that operates independently of the European legislative and executive institutions (Commission, Council, Parliament) and the EU Member States.

extensive review of the literature (nearly 12,000 publications) published between January 2015 and November 2020. After a first screening, EFSA identified around 200 in vivo studies and 300 in vitro studies as potentially relevant for this evaluation.

“TiO 2 is a particulate material, meaning that it is composed of particles of different sizes. TiO2 used as E 171 contains at most 50% of particles in the nano range (i.e. less than 100 nanometers) to which consumers may be exposed. The characterization of E171 was evaluated by EFSA’s FAF Panel in its opinion from 2019. According to data received from food business operators, the Panel noted in that opinion that there are different types of E171 on the market containing different amounts of nanoparticles. Generally speaking, the percentage of nanoparticles can vary from 5 to < 50% depending on the type of E171. For this reason, in the safety assessment of E171, our scientific experts applied the principles specified in the 2018 EFSA Scientific Committee Guidance on Nanotechnology.

During the re-evaluation of food additives, we review all available data, from public literature and data submitted to EFSA by interested business operators, from which conclusions are drawn regarding the safety of the food additive. With that knowledge, we produce a risk assessment and, based on EFSA’s scientific advice, the European Commission and the Member States then decide whether to change the conditions of use for a food additive or, if needed, remove it from the EU list of authorized food additives to protect consumers.”

Based on the available data, EFSA determines the level below which the intake of the food additive can be considered safe – the so-called Acceptable Daily Intake (ADI). At the same time, EFSA also estimates, based on the occurrence data (reported uses and use levels and analytical data), whether this ADI can be exceeded. In case the ADI will not be exceeded, the use of the food additive is considered safe.

ADIs are usually expressed in mg per kg of body weight per day (mg/kg bw/day). The ADI can apply to a specific food additive or a group of food additives that have the same moiety (e.g. an acid and its salts). When re-evaluating previously authorized additives, EFSA may either confirm or amend an existing ADI following a review of all available evidence.

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ORGANIC MARKET

Bio Breadness: A good step forward Premium bakery products are the business segment of the organic wholesale bakery Bio Breadness.

For 2021, the Pandriks Group, to which the German subsidiary belongs, expects total sales of EUR

© Bio Breadness

80m. Approval as a Demeter operation now takes the company to the next organic quality level.

ss

philosophy and what is behind it. In addition, it is a clear step towards fulfilling our social mission and working towards an agricultural turnaround. It is a good cooperation not only for our sales, but also for our inner attitude.” © Bio B re ad ne

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Despite Corona and the 2020 lockdown phases, Bio Breadness is well positioned with high-quality organic bakery products and a focus on the trade. Managing Director Andreas Swoboda expects a positive sales development for the coming fiscal year. He sees a slight Corona-driven push effect for organic. “We are finding that quality with a health connection is boosting sales.”

In January 2021, the first two SlooOW rolls in Demeter quality were launched on the market. A conscious decision was made to An When people shopped less frequently in the use two items that can be placed as a‚ ‘double.’ a dre a s Swob o d initial 2020 lockdown, buying momentum shifted “The pastries are a real innovation,” explains downward, and so did organic bakers’ sales in the short Swoboda. “We work with Demeter quality, with long-term term. Bio Breadness managed the dip with Corona well management and we bake on stone. We have created a through the summer. One of the products that got a boost modern item that is also attractive to young people.” Initial was MAP-packaged organic baked goods for baking at home. reactions from retailers have been positive. As to whether “Our SlooOW brand is performing well in the market,” more products will be added, the CEO doesn't want to commit. explains Andreas Swoboda. “Its appeal lies not least in the “We'll decide six or eight months before the next harvest if we opportunity for consumers to stock up on top-quality organic can increase the amount of Demeter-quality raw ingredients.” baked goods.”

With organic breads, organic baguettes and organic rolls for the bake-off stations of the trade and MAP-packed for end With organic, I'm doing something good; consumers, Bio Breadness has a narrow range. It has said it tastes better to me and it’s good for me. goodbye to organic toast, still part of the range until fall 2019. “We have had a relatively dynamic development and That's the spirit we try to convey with our have had to focus. That has done us good.”

products.“

Andreas Swoboda

To add momentum to the upward trend, Bio Breadness decided to partner with Demeter. “We appreciate the quality

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Families, 50-year-olds and the Millennials Among organic buyers, Bio Breadness identifies two major consumer groups: on the one hand, families with young

ORGANIC MARKET

children, and consumers with an average age of around 50.

Meanwhile, another large group is emerging, on the other hand: millennials, which also has to do with the fact that Bio Breadness has a strong presence at retail customer’ self-service stations, he says. “We see a growing consumer group of young people here who are open to sustainability and organic. They are a crucial target group for future sales development,” he adds. “To reach them, it takes products that are perceived as cornerstone items of daily consumption, not exceptional pastries. We need to focus on such items to reach young people in a relevant scope. That is our goal!

We want organic to reach the middle of society.”

fluctuations are higher than for conventional baked goods.

But there is more at stake. Andreas Swoboda: “If we want to offer value-for-money organic that everyone can afford, it must not be cheap, but value for money.

We pay particular attention to our own efficiency in the company and in the trade, so that we can pay the farmers appropriate compensation for their performance.”

Differences in Europe The organic markets in Europe differ – and not only in their scale. Bio Breadness points out a noticeable dynamic in France, Denmark and the Netherlands, among others, as well as in Eastern European countries such as Poland. For bread in particular, he says, organic demand often depends on how packaged goods are accepted. “In the Netherlands, for example, people are more used to buying prepackaged bread. There, the increase in MAP-packed goods in the first lockdown was, in my observation, even greater than in Germany. Germans already like to buy their bread unpackaged.” In general, it can be said that in the regions of Europe where people have a good handle on their primary needs and are concerned about the environment and the future of our planet – especially from the youth movement – support for organic food is strong.

Organic Breadness Bio Breadness, based in Fulda/Germany, has been part of the Dutch Pandriks Group since 2016. The latter bought the company from the WEG Foundation almost five years ago – at that time still under the name ggg (gutes gut gebacken GmbH). An artisanal mill near Bamberg/ Germany secures the supply of raw materials.

When it comes to plastic packaging, Bio Breadness is on the lookout for alternatives. Swoboda: “The whole industry is on the lookout. Although there are various packages based on renewable raw materials, on cellulose or on corn, the problem is the same for all of them. You can’t get the compatibility of sealing and barrier properties and the necessary low oxygen content right immediately, it takes time.”

© Bi o Br ea dn

es s

Price developments on the organic market follow their own laws. Organic raw materials are in limited supply, and price

ea dn © Bi o Br

Bio Breadness supplies organic breads, organic baguettes, and organic rolls to retailers and specialty retailers in Germany and six European countries. The organic wholesale baker makes 80% of its sales with bake-off products; 20% is contributed by MAP-packaged organic bakery products, which run under the SlooOW brand. The range includes five buns and baguettes in organic quality; since the beginning of 2021, it has also included two small baked goods in Demeter quality. Frozen household packs, which the company recently launched, are not yet relevant to sales.

With a total of 100 employees in five teams, Bio Breadness produces 24/7. Everything runs in close coordination with the Dutch parent company, which has also been certified organic since 2020. The fact that ‘Bio’ can be produced not only in Germany but also in parallel in Meppel creates room for more flexibility, and it shortens delivery routes. Organic customers in Benelux are supplied from Holland.

At the end of December 2020, Pandriks put an extension into operation. 13,000 square meters of production space, a line for the production of bread for bake-off and a cold storage facility with 12,000 pallet spaces were added at the Meppel headquarters. Currently, the possibilities for expansion at the German subsidiary are being reviewed. Andreas Swoboda: “There is also room for expansion in Fulda. We are looking to see to what extent we can take a step further.”

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Helga Baumfalk

In Demeter quality: the two new products in the SlooOW range

www.bakingbiscuit.com 04/2021

es s

R AW M AT E R I A L S

Technology makes the perfect pizza experience Made fresh by hand or industrially par-baked and served with different toppings, there is a whole world of different types of pizza in the market. Recent trends have broadened the pizza landscape, expanding both the producers’ and the consumers’ options. At AAK, it’s the fat flakes that help

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deliver the perfect pizza experience.

The flaked fats, or flaked shortenings, developed by AAK are designed to enhance the texture, flavor and functionality of the pizza. They do that by opening the pizza’s internal structure and making the surface less even, for an artisanal look, or by improving its flavor profiles, appearance and overall fat control.

Flavor and color By precisely incorporating minor ingredients, AAK delivers a whole series of benefits to specific production processes.

The flakes have a homogeneous distribution of flavor and/or color, which helps eliminate the risk of deviations. Flavor is encapsulated in the fat until the product is baked and the fat starts to melt. Encapsulation means less of the aroma is released during the production process, and the flavor of the end product is enhanced.

They also help products maintain their shape, both during production and after baking. AAK flakes help reduce shrinkage by over 43%. When producing pizza, two key parameters are the extensibility and elasticity of the dough. A certain degree of each attribute is beneficial to the production process; too much of either is detrimental. Tests are undertaken to optimize both.

Crust texture AAK flaked fats have a positive impact on the texture and mouthfeel of both thin-crust and deep-pan (thick-crust) pizza.

Shortness of bite, toughness and crispiness are all attributes that can be measured with a texture analyzer.

Thin-crust pizza Extensibility is used as a parameter for the textural analysis of thin-crust pizza, correlating with the crispiness of the pizza, which is a key determinant of mouthfeel. It tells us what

“Making Better Happen ™ ”

© AAK

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degree of force is necessary to achieve a penetration depth of 40mm into the baked product. This value is then used as an index of extensibility for thin-crust pizza. When the dough’s elasticity limit is exceeded, the pizza breaks. This limit is known as the ‘maximum positive value’ (see graph 1).

Once the ‘trigger’ force is attained, the graph plots how the pizza responds to tension. It is stretched and, when its elasticity limit is exceeded, it breaks. The force and the distance required to break it indicate the extensibility of the sample.

The lower the maximum positive value, the crispier the

AAK specializes in plant-based oils that are the value-

25 regional sales offices, 15 dedicated Customer Innovation

adding ingredients in many of the products people con-

Centers, and with the support of more than 20 production

sume. The company makes these products better tasting,

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oped together with its customers. Its 3,900 employees support the close collaboration with customers through

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Happen™” for 150 years.

R AW M AT E R I A L S

Graph 2

sample. The greater the distance and time taken, the more extensible the sample. A particular melting profile will give the correct degree of crispiness.

Generally speaking, steep melting profiles have a positive impact on the mouthfeel of thin-crust pizza. As shown in the graph, the pizza crust produced with the correct flakes has a lower maximum positive value in comparison to the pizza crust produced without flakes. This difference is attributed to the frying effect of the flaked fat in the thin-crust pizza.

This results in a crispier and flakier crust, which is less tough and therefore more pleasant to bite into.

Deep-pan pizza For deep-pan pizza, toughness is used as a parameter for textural analysis, evaluating what the crust is like to eat, and at the same time, measuring the crumb softness of a deep-pan pizza. At the start of a new measurement, the sample is torn apart. The positive area under the curve indicates the shortness of the sample. The lower this value, the softer the pizza.

However, a softer pizza is not necessarily a good thing. A pizza that is low in fat will have a dry mouthfeel. This can be overcome by increasing the fat content, but doing so will also increase the softness of the crumb.

To get the best of all worlds, producers can swap out part of their usual added fat for AAK flaked fats. The result is a pleasant mouthfeel (moist crumb) combined with a crust that has the desired shortness in bite (see graph 2).

Appearance also has an impact on the artisanal experience and flaked fats can be used to make pizzas more visually appealing, as they create clear air pockets and an attractive open dough structure. Different flake thicknesses are used following the thickness of the crumb. Research has shown that neither the SFC % (solid fat content) curve nor the SMP (slip melting point) has any impact on the size of the air pockets. While small, thin fat flakes (<0,5mm) enable a better texture in thin-crust pizza, thicker flakes (>0,5mm) lead to the creation of large air pockets that are evenly distributed throughout the crumb.

Source: AAK

Source: AAK

Graph 1

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Flaked fats also offer a significant advantage for pizza transport, usually done in cardboard boxes while the pizza is still warm. The amount of oil that migrates to the cardboard box can be drastically reduced simply by choosing the right size flakes with the right melting point. This not only prevents oiling out, but also gives the crust a better texture.

What’s more, avoiding oily fingers is an added benefit for anyone who likes to eat pizza with their hands. +++

By AAK Bakery (bakery@aak.com)

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19.04.21 11:15

INTERVIEW

Digitization leads the way DIOSNA uses its pharma expertise to stay ahead of new trends in bakery, while also taking advantage of the latest digital tools in all aspects of their work, from training, everyday operations, customer interface, to cloud-based workspace management, as explained by Henrik Oevermann, DIOSNA Managing Director.

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Oevermann: In many cases, we can deliver complete solutions from raw 2018? materials up to the finished dough; Henrik Oevermann: First of all, I aimed we have integrated track-and-trace to bring a clear focus on technology to systems, so that we cover all proDIOSNA’s agenda, which is emphasized cesses – from raw material handling by the motto we adopted a few years ago, to conveying, fermentation, mixing ‘The Dough Experts’. We invested heavily and proofing, including the comin technology and highly specialized soluplete interface management. On the tions, which from our perspective moved one hand, this reduces complexity for beyond classical mechanical engineering to our clients, but, on the other hand, it encompass a focus on the technology, the process also makes it easier for us as specialty comH en rik O ev e r m a n n itself and its implementation. With our starter cultures panies, as we work with established project for fermentation processes under the DIOStart brand, we even teams where everyone knows each other and there is full supply many demanding customers in the field of biotechnology. trust. We also benefit from the respective strong presence in the Service and after-sales are also very much in focus, which, for home market of our companies. This creates trust and makes us, means being close to our customers. To do this, we have it easier for customers to decide to invest in our products. built up loads of subsidiaries and decentralized structures in Mihu: What direction will planning take after a year like 2020? our organization: for example, we have daughter companies Which priorities have changed and which have remained the in Russia, India, and one in the Americas – which is jointly same? shared with Shick Esteve, our Linxis Group partner. We also Oevermann: We took advantage of the level of digitization have a subsidiary in the Czech Republic as well as local teams in our company. We had already been working with decenin the UK, South-East Asia, China, Latin America and other tralized software before pandemic measures brought changes parts of the world. We aim to be physically present, close to in workflows everywhere. We have cloud-based workspace our customers to provide good service and after-sales. We management in place, with all our employees around the world have established this way of sharing our knowledge and soluworking via their own accounts. It was very easy for us to tions to build customer intimacy. This is particularly important mirror the office desktop in private at-home computers in this to us at DIOSNA and as a member of the Linxis Group. way, and the transition was made without any interruptions.

In bakery, we are observing a growing trend towards quality We also made use of new software capabilities. We created standards, which have been established for many years in the complete Digital Twins of our industrial systems, for example, pharma industry. Internally, we have also reshaped our busito allow customers to train and familiarize themselves ness by merging several previously disconnected departments with the machines remotely, even before they arrived at the in Pharma and Bakery. The knowledge and the technology production facilities. we already have in Pharma is a valuable asset for Bakery, where we have become a leading provider of hygienic solutions, Mihu: In bakery, DIOSNA presents itself as ‘The Dough with extensive knowledge in everything related to hygienic Experts’. What does innovation mean to the company in this design and production. In the pharmaceutical industry, the respect?

FDA regulation and the GMP standard are acquired practice, Oevermann: At the very beginning of a new project, we ask which are increasingly being transferred to the food industry. for the pain points. In many cases, they are known to the Of course, Pharma standards are not replicated in their customer; but, sometimes, the pain points or their root entirety in the bakery industry, but we do see a tendency in this causes are not understood. This is where we step in, for a direction that can only benefit our customers, particularly thorough analysis of the entire process and facility. When a with our Pharma background. customer is planning a new product or production line, they require not only product trials but also support with product Mihu: How does being a part of the Linxis Group help DIOSdevelopment. In this case, we provide consultancy as well.

NA’s R&D work in providing technology and services?

SNA

Mihu: What changes have you brought to DIOSNA’s business strategy since

©D IO

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www.bakingbiscuit.com 04/2021

INTERVIEW

For bigger projects, we always start by analyzing the flour and the other raw materials used, once the recipe is defined.

If it isn’t, the project begins before this step. We then design the process that best fits the particular needs we have identified. Customer trials are performed after that, which can imply huge product variety. In some cases, the customer may want to rebuild their marketing campaign and market a new product with a 30-hour production time (slow baking, long dough resting and proofing). This is a different story to just removing additives (Clean Label) or increasing product shelf-life (BBD).

Once the customer has a clear image of the process, it is only then that we start designing the best match for the production line. A lot of work precedes the actual technology design, in order to produce the optimum version that will fit both into the customer’s budget and into their facility.

In addition, we know the current requirements and the pressure that our customers are subject to, with regard to hygienic manufacturing practice, for example. That is why we have developed a hygienic design line alongside our hygienic concepts, which is constantly expanding. In the area of our pre-dough technologies, we are developing starter cultures (DIOStart) to satisfy today's consumer trends.

It is particularly exciting for us and also for our customers when we can offer cross-divisional solutions. For example, our universal mixer is used for the production of protein powder because the mixing results are extremely homogeneous.

However, it is more important to customers that these can be achieved in 3-5 minutes. Our advantage here is that DIOSNA can produce not only the protein powder but also the bar mass. This means we can offer everything from one source.

However, many other granulates are also used in the food industry, such as solid flavourings, spices, enzymes...etc.

Alternatively, our spiral kneaders, are used in the food supplement industry, where producers are often pharmaceutical companies – to name just a few examples.

Oevermann: The next step will be towards an integrated approach, which is typically when we step in. We analyze the complete process and try to optimize it by adjusting and improving the dough production. For example, you can do proofing in the final proofer after post-mixing and post-makeup. This so-called piece fermentation is necessary, but experience has shown that it is the most expensive type of the dough development process. The fermentation of a pre-dough in a closed stainless steel container, as well as the so-called boiler fermentation in the bowl trolley directly after kneading are, in our experience, the more efficient way.

With an investment in these technologies, the recipe can also be optimized by removing improvers (meaning that clean label can often be claimed), but savings can also be made on additional expensive equipment, which is otherwise needed after mixing. We are looking into this holistic approach.

In addition, our experts have managed to optimize our kneading efficiency to a maximum, keeping dough heating low and the process gentle at the same time. This enables our customers to produce a perfect dough containing either fruit or chocolate. The energy and water input is optimized. A dough of this quality not only makes a better end product, but also has its advantages on the line. This prevents dough sheet tears on the processing line, which ensures high productivity for industrial companies.

Mihu: How can big companies stay at the top, once they have established themselves?

Oevermann: I think they have to continue to change day by day; small steps that will amount to big changes in the long run. Willingness to change and invest is required, as well as the ability to fund and lead those changes. Small, fast-growing bakery businesses are showing accelerated innovation, by comparison. I believe big players stand to win from clean labels, for example, and investing in sustainability, innovation and marketing. There is always a risk when investing in change, but I believe the risk is higher if you don’t. At various large industrial bakeries, you can see how quickly profitability declines if you are too hesitant to invest. They will face fierce competition from dynamic newcomers who will make these investments.

Mihu: How can waste be minimized? What role do solutions for scrap dough and leftover product play and how do you anticipate their use will evolve?

Oevermann: Avoiding waste has always been an important topic for us. For this, the solution we established and have used for more than 30 years comes from bread fermentation: when there is over-production, the dough can return to closed stainless steel vessels and restart a thermally controlled fermentation process with starter cultures. We have solutions in place for rye bread fermentation and we have recently started to commercialize a solution for the wheat bread fermentation process. Another solution is the liquefication of over-processed dough, which can typically be used for scrap dough resulting from sheeting and cutting dough.

With or without fermentation, this process will always result in zero residual material and it will also increase the consistency of the product tremendously. We also offer an option for leftover bread recycling.

Mihu: How can efficiency be taken to the next step in handling and mixing dough?

Mihu: Where could dough handling efficiency typically be improved, from your observations?

Oevermann: When one of our Master Bakers visits a customer’s site, they frequently find that the kneading parameters are not optimized, even when they are using DIOSNA equipment. There are ways of speeding up the mixing process for existing DIOSNA machines with frequency inverters to optimize the mixing curve. Both product and energy waste can be avoided in this way. Usually, the dough also has higher water absorption after optimization by our experts.

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49

INTERVIEW

I believe big players stand to win from clean labels, for example, and investing in sustainability, innovation and marketing.

Henrik Oevermann

© DIOSNA

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Mihu: Please highlight your thoughts on sustainability in bakery and DIOSNA’s efforts in this regard.

Oevermann: We have always invested in sustainability at DIOSNA; you cannot survive for 136 years otherwise. As it’s part of our DNA, it is also part of our machine design and process optimization. We equip solutions for pre-dough production or for mixing with frequency inverters, which helps save huge amounts of energy. In some cases, we are able to produce electricity and feed it back into the system.

To illustrate, our machines have a motor driving the bowl and one for the mixing tool. There is a point in the mixing process when the bowl is driven by the tool – the motor that typically drives the mixing bowl is then used as a generator.

It is a similar operating system to the braking of an electric car.

Mihu: What is the most challenging type of dough to control, and why? How are DIOSNA’s solutions designed with such challenges in mind?

Oevermann: An issue typically faced by our customers has to do with spontaneous and uncontrolled fermentation processes, which is a ground for the multiplication of unwanted micro-organisms, typically pathogens. Our solution for this is to regain control over the process, with our DIOStart starter cultures, which gives controlled, natural fermentation with organic-only micro-organisms. We also offer solutions for the production of gluten-free products.

In another example, the handling of cereal bars is notoriously difficult to process due to their sticky structure, and often, a lot of manual labor is involved, or extended downtimes are a common issue in automated production. We have developed a solution that can provide a very consistent transfer of the bar mass on conveyors. We have also redesigned our mixing tools and optimized the removal of the mass from the mixing

www.bakingbiscuit.com 04/2021

bowl to feed it into the system with a consistent flow. To achieve this, the mass is gently broken down into pieces.

This is a new, patented innovation that has not been shown at a trade show yet.

Mihu: And what specific, case-by-case problems are you encountering that require custom designs? Please illustrate with some examples from DIOSNA’s installations.

Oevermann: Examples are many and typically linked issues surround molding, shelf-life, and the proofing equipment.

We also receive requests for softer products, fewer additives, and gluten-free dough. We have a dedicated solution in place in each case.

Mihu: What priorities are on the agenda of the R&D team for improving existing technology features?

Henrik Oevermann: IoT is one, as we are working with the DIOSNA app with our customers; it will be released by the end of this year. Another important R&D topic is our focus on hygienic design.

Mihu: What opportunities do you see for online work in previously in-person areas?

Oevermann: We are investing heavily in using all available online tools for training, seminars, or everyday work, from Digital Twins, to Google glasses – you could say many things are in use. There is no other way of getting around measures such as the travel bans, but we will be stronger after it and we will reach a more balanced level of in-person visits and travel. Also, as we will travel less, IoT solutions will be adopted more and more.

Mihu: Thank you for an illuminating interview. +++

© carl-heyerdahl-unsplash.com

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This is pizza innovation While pizza restaurants are hard at work to regain their footing, pizza brands are riding the innovation wave as they busily launch new offerings that meet diverse preferences, lifestyles and diets. Many try to replicate the authentic, almost elusive dining-out quality, while better-for-you options explore all sides of what ‘better’ stands for.

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The universal choice for comfort food, pizza, is enjoying a generous uptick in innovation.

Retail brands, bolstered by the newly-found interest of home-bound consumers, are revamping the preparation process and recipes to replicate the quality of restaurant and delivery pizzas. Innovation has centered around trying to bridge the quality gap between retail and foodservice options by flagging up quality and authenticity credentials on the packaging and thereby raising consumers’ expectations, according to Mintel research.

Crosta & Mollica Pizzeria Bosco marks its packaged pizza with restaurant-quality claims in the UK, for example. The Wood-Fired Sourdough Pizza with Mushrooms and Truffle & Garlic Cream Sauce features a traditional sourdough baked in a wood-fired oven for an authentic pizzeria taste.

Plant-based goes with everything Improved nutritional profiles also spell quality, and the research company finds that consumers are open to trying better-for-you pizza, opening the door to a vast new range of possibilities. “Brands are enriching recipes with nutritious ingredients that provide protein, fiber or functional benefits.

Similarly, vegetarian and vegan brands are highlighting the nutritional benefits of plant-based ingredients,” Stefania Apostol, innovation analyst with Mintel, weighs in. Consumers are looking for healthier pizzas and pies: since the COVID-19 outbreak, 74% of Spanish adults have found pizzas with healthier toppings to be appealing, as European consumers are willing to try better-for-you products made with healthier ingredients, Mintel research reveals. Innovating around functional benefits can also appeal to health-conscious consumers. “Pizza and pie brands have an opportunity to tap into this consumer interest in healthier alternatives by highlighting functional claims, or nutritious and healthier ingredients, like wholemeal flour or vegetables used as toppings and in crusts,” the analyst adds.

Plant-based pizza maker One Planet Pizza launched the No Clucks Pizza for National Fried Chicken Day in the UK in July, in partnership with vegan chick*n brand VFC. The pizza is topped with VFC’s vegan southern fried chick*n popcorn

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pieces and features One Planet Pizza’s secret family recipe tomato sauce. The producer estimates that one chicken’s life will be saved for every 20 No Clucks Pizzas purchased instead of a regular chicken pizza, and 50p from every purchase is donated to the Big Red Rooster Cockerel Rescue. “Around 150m frozen pizzas are consumed in the UK each year and approximately 7% of these are chicken-based, so that’s just under 10m chicken pizzas bought each year,” says Mike Hill, co-owner, One Planet Pizza.

When selecting ingredients for their pizzas, the most important aspect is the taste for One Planet Pizza: “They have to taste as good, if not better, than meat and dairy alternatives. Once we’ve nailed the taste, the aim is to make them as healthy and sustainable as possible. Our pizza range has, on average, at least 25% less salt, sugar and saturated fat compared to meat and dairy alternatives, and the last time we measured our carbon footprint, each pizza had 40% less than the traditional leading brands,” Hill details.

Little Caesars is bringing its own spin on plant-based pizza ingredients with another July launch, the Planteroni ™ Pizza (the plant-based claim is limited to the pepperoni ingredient only). It is made with the new Field Roast ™ Plant-Based Pepperoni as a new alternative to America’s popular pizza topping. It is the first pepperoni substitute on the market to be made with pea protein, not soy, crafted with fresh spices including whole pieces of fennel, cracked black pepper, garlic and paprika, Little Caesars says.

© California Pizza Kitchen

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Everything is possible Toronto-based GA Pizza caters to the Canadian flexitarian consumers with its own plant-based launch: the naturally-leavened, New York-inspired Impossible Pizza, a collaboration with Impossible Foods. Its recipe features housemade tomato sauce, Impossible product made from plants and seasoned with chili, garlic, and toasted fennel seed. Fresh anaheim chilis and thinly shaved white onions complement the fennel-spiced plant-based protein. The pizza is finished with three types of cheese: premium fior di latte, grass-fed mozzarella, and grana padano.

product. “Shoppers are actively searching for a gluten-free pepperoni pizza bite alternative that actually tastes good and is made with clean ingredients,” Junea Rocha, co-founder and CMO of Brazi Bites explained. The development team also considered the most frequent demand it receives from its consumers over the past 18 months: a pizza bite option.

This summer launch is also a collaboration: PepsiCo’s Frito-Lay and Papa Murphy’s® co-developed Fritos® Outlaw Pizza, a new and limited-edition pizza innovation that combines classic BBQ flavors with the crunchy texture of Fritos corn chips. It is made with a crispy, thin-crust, garlic sauce, whole milk mozzarella, Texas brisket, onion mix, sweet BBQ sauce, and topped with crunchy Fritos (that are said to remain crispy after baking).

Health-conscious consumers are also invited to an entirely new taste experience courtesy of a multitude of benefits combined by California Pizza Kitchen (CPK) in a new veggie-based, glutenfree, lower carb, high in protein and fiber chickpea crust. Introduced in June this year, the new crust is made with premium chickpeas, chia seeds and honey. The company is building on the serious business momentum it has gained following the pandemic year with this launch, recognizing the rising demand for plant-based food.

“Chickpea Crust represents the very best of CPK culinary – first to market, creative, and most importantly, the product brings new health benefits while maintaining the incredible Californiainspired pizza taste our guests love,” says CPK CEO Jim Hyatt. from 1 to 4: © Mintel Global New Products Database; picture 5 © Frito-Lay North America

Better-for-you can also come in Latininspired flavors as Brazi Bites proves.

The company known for its gluten-free, healthy offerings, introduced this summer Pizza’nadas, an extension of the brand’s popular Empanadas line. This frozen pizza is made with a Brazilian cheese bread base made from clean ingredients such as tapioca flour, eggs, cheese, and milk, stuffed with fresh mozzarella, uncured pepperoni, and tomato sauce. Brazi Bites capitalizes on the white space it identified in the market, combining two growing trends – frozen and nostalgic categories, with the better-for-you, gluten- and grain-free

New launches everywhere In September 2020, Zizzi, the chain of Italian restaurants in the UK and Ireland, partnered with Sainsbury’s to launch its first at-home pizzas, following the closure of a number of its restaurants due to lockdown measures. The range Mintel analyzed is based on the restaurant’s popular hand-stretched Rustica pizza and includes Piccante Pepperoni, Margherita Classic and Vegan Jackfruit Pepperoni. The pizzas are said to feature restaurant-quality ingredients.

Pizza and pie brands are exploring better-for-you features in both meat and meat-free products. Using healthier ingredients like wholemeal flours, vegetables as toppings or for the crust, or calling out the functional benefits, manufacturers can attract health-conscious consumers.

The plant-based trend keeps reaching new heights, and vegetarian and vegan pizza brands are on board, as they switch dairy cheese out and find exciting topping combinations among vegetables and plant protein. Asda’s Plant Based Chargrilled Veg Flatbread Pizza (UK) is a vegan product that is low in

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Number of pizza restaurants by country in 2020

Other

56,386

United States

90,302

© Kalim – stock.adobe.com; Source: BoldData Food Database

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Germany

13,529 Brazil

32,283

Italy

42,288

saturated fat. It contributes to the maintenance of normal blood cholesterol levels and is a source of fiber. In the Czech Republic, Mintel singles out Pizza Natura’s Super Green Pizza, made with spinach, courgette, cyanobacterial spirulina and seaweed chlorella. The vegan product features a reduced content of fat and sugar and is rich in fiber. An interesting high-protein option is sold in Germany: Trattoria Alfredo’s Lentil Curry High Protein Pizza is made with fava bean flour and cooked red lentils and provides 50g of protein. The vegetarian product boasts a nutty and full-bodied flavor.

A cause for pizza Ethical and environmental claims continue to rise on the pizza aisles across Europe, with consumers’ concerns about the climate crisis intensifying. Mintel finds that 44% of UK consumers say that the amount of packaging used for ready meals puts them off buying them more often. As a result, there has been an increase in launches with ethical and environmental claims in recent years, mainly driven by environmentallyfriendly packages and recyclable claims. “This relates to the Mintel Trend Rethink Plastic, which outlines how plastic in itself is not bad, but our throwaway culture of it is. Brands and consumers are therefore reviewing their own behaviors to prevent plastic pollution,” the analyst details.

And there’s more: environmental awareness is another driver found in this segment; as consumers are becoming more aware of the negative impact of packaging on the environment, fully recyclable and plastic-free packs debut. Mintel illustrates notable new entries on Europe’s markets: Mix Créateur de GoûtPizza del Gusto! Goat's Cheese, Walnut & Honey Pizza retails in a partly recyclable pack made with 100% recycled carton and printed with vegetable ink in France, while in the

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UK, Pieminister Gluten Free Moo Beef Steak & Ale Pie has been repackaged in a newly-designed plastic-free, fully recyclable and biodegradable pack. The window of the pack is made from wood pulp.

Is the out-of-home pizza party over?

The U.S. is home to the largest number of pizza restaurants worldwide, with 90,817 pizza restaurants last year, more than the top four markets combined (88,100), BoldData research outlines. Italy comes in second, with 42,288 pizzerias, and Brazil completes the top three with 32,283 pizza places.

Australia, ranking eighth on the list, is an interesting mention with 5,598 pizza restaurants that amount to one of the highest numbers of pizza places per capita. Statistics from the data specialist highlight that the number of pizza restaurants in America has increased by a whopping 39.2% over the last five years. It was poised to reach the 100,000 mark this year, but COVID-19 bought the growth to an abrupt stop in 2020, when only 581 new restaurants opened.

Interestingly, however, Germany continues to see growth.

This is, in part, due to many chains opening stores there.

Close to 700 restaurants have opened since 2016, bringing the total count to 13,521 this year. Berlin is also the country’s pizza capital, with almost 500 stores, more than twice the number of those working in Munich (232). Cologne (225) and Hamburg (213) are the other major pizza centers with more than 200 dedicated businesses each.

As foodservice picks up the pace all over the world, pizza maintains its reign in consumers’ choices, and plenty of selections it aims to offer, to be experienced either at home Catalina Mihu or at the pizza restaurant. +++

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