baking+biscuit 2018-05 digital

The dough piece determines

Whether they are flours, liquid raw materials or fruit fillings and other miscellaneous goods, when raw materials are received into the production unit, sensors in the warehouse, in the silo or at goods inward determine whether they are of the quality that is required and was ordered. The system reports the results together with concrete handling instructions to the production manager and to Quality Assurance. After that, based on the collected data and supplemented by their own sensors, kneaders or mixers ensure that the plants stop automatically when the dough or batter has reached its optimum. All of this happens in real time, and the operator and/or line manager know(s) exactly what is happening on the entire plant. Artificial intelligence informs people about recommended actions, but in principle the plant controls and regulates itself, and purposefully influences the quality of the dough and thus of the finished baked article. The condition of the batter or dough is constantly recorded, accurate traceability is ensured through digitization, and as Dr. Mario Jekle of the Technische Universität München once remarked: the dough determines its pathway through the production operation. The product searches for it itself – whether it’s the right proofer with its temperature or air humidity, what is optimum for a decorative cut, or the baking time and steam input in the oven.

In the “Production facility of the future”, the optimum will be summoned from the corresponding raw materials without the personnel’s specialist knowledge. The required quality – whether it’s a baguette with particularly fine pores or a ciabatta with an artisan visual appearance, a high dough yield and an open pore pattern – the system can predict whether it’s possible, and can to some extent determine, influence and optimize. Various robotic systems also clean the plant and production facility automatically. Perhaps in the “State-of-the-art production unit”, delivery of the finished product to the customer will also be automatic – driverless logistics systems are already in use nowadays, e.g. to distribute goods within a factory.

At the same time, all the plants in the production operation are highly flexible to enable them to respond quickly to new customers’ requirements and product changes. Machines also communicate with one another and the proportion of reject goods is reduced, since the required baked products always leave at the end of the production line. The baked products always have the desired visual appearance, the required dimensions and desired weight, and the previously specified degree of browning.

It all sounds like pie in the sky – but a couple of systems like this have already been partly implemented today. Science and research, as well as the plant constructors, are already working on it, and the corresponding data is being collected and projects brought to life or have already been completed. However, there is certainly still a long way to go before we are at all able to fulfill the technical requirements.

Everyone knows that the baking sector operates using natural raw materials that are to some extent subject to large fluctuations. In the production facility of the future, however, human beings will play an ever-decreasing role, which will introduce enormous social challenges.

Regards,

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Production

08 Mecatherm: A unique oven for a changing world

12 Haas-Meincke: Diversity with a common denominator

21 Bundy Baking Solutions: Several new designs

24 Sancassiano: Hardware and software under one roof

26 Vandemoortele: Continuous investments

30 Zeppelin-Systems: A new CODOS and more

34 RONDO: Industrial bread line for artisan products 38 Tecnopool Group: From transport to process engineering 40 Handtmann: The next step

42 Reading Bakery Systems: Innovative baking technologies

94 Topos Mondial: New equipment is designed

iba

52 World trade fair: Innovations in Munich

Interview

16 Luis Videla: Pizza around the clock

92 Pierre Escarbelt: More baking cycles and higher temperature

96 Christian Tomasch: Europeanization at all levels

Raw materials handling

22 Cepi SpA: Automation and fermentation

44 Agriflex: From Trevira silos to tailor-made raw materials management

Packaging

32 Kwik Lok: Focus on food safety 86 Brevetti Gasparin: Specialists in slicing and packaging 95 Bettendorf Stanford: High speed slicing and bagging

Trays and pans

46 acs Coating Systems: New: HIFFICIENCY ® baking and roasting accessories 84 Precisma: Compact, efficient and universal Hygiene

48 Colussi: The de-luxe class from Northern Italy Refrigeration technology 78 Koma: Natural refrigerant

Inserts:

+ König Maschinen Gesellschaft m.b.H., 8045 Graz/Austria, + Kwik Lok Corp., UNION GAP, WA 98903, USA

+ MECATHERM S.A., 67130 Barembach, France

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TYPESETTING

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Introducing Hydrobond from Exact Mixing

Want superior hydration without adding excess heat to your dough? New Hydrobond technology delivers. Not only does it blend dry and wet ingredients with unmatched efficiency, it also:

• Requires no additional floor space

• Reduces your total mixing time

• Cleans quickly and easily

• Reduces heat attributed to mixing energy

• Allows you to mix more dough with same size continuous mixer

BY READING BAKERY SYSTEMS

++ Chilled coffee: a powerful revenue source in the UK

producing company founded by the Mauri brothers on the one hand, together with Burns Philp Yeast & Bakery Ingredients there on the other. AB Mauri in its present-day form was founded in 2004 and belongs to Associated British Foods (ABF) The Group also owns the former DSM in the Netherlands and a shareholding in the German Uniferm company.

++ Wiesheu: Changes in the senior management

The instore oven manufacturer Wiesheu’s new Management Board consists of Marcus Gansloser (CEO) and Alexander Herz (COO). As CFO, Harald Schrode will be responsible for the areas of Finance/Controlling. Volker Groos and Dieter Tacke have left Wiesheu’s Management Board with effect as of 1 July. Explaining the change, Marcus Gansloser said “It is very important to me that we continue to further our company’s development, and constantly improve the internal communications and collaboration of and with all employees to that end. All the staff are urged to play their part to enable our performance promises to be fulfilled. To allow this to be tackled with utmost emphasis, we have set a new course in the Management Board.” +++

According to the study “Project Iced Beverages 2018” in the Allegra World Coffee portal, cold coffee is a rising trend in the British coffee shop sector. A report in the online portal Food Service says the Study sheds light on the proportion of “Iced and Blended Beverages” in the British out-of-house market of the coffee chains established in that country. According to the Study, sales revenues from “Iced Beverages” last year amounted to 370 million British pounds (GBP, about EUR 417 million). Moreover, the Study is also said to predict strong growth: the analysts expect sales revenues exceeding GBP 421 million (around EUR 475 million) in 2018, and as much as GBP 660 million (EUR 745 million) by 2022. These drinks are said to be very popular with the young generation of millennials and generation Z. According to the survey questionnaire, the most popular brands for the consumption of “Iced Beverages” are Starbucks (29%), Costa (26%) and Caffè Nero (7%). For the study, Allegra carried out more than 50 expert interviews with representatives of industry and assessed more than 2,000 online questionnaires.

+++

++ AB Mauri buys Hogran/Fleming Howden

A second heavyweight in the yeast and fermentation industry is also acquiring further purchases. AB Mauri recently announced the takeover of two companies from the Rank Hovis milling group. Holgran, headquartered in Gainsborough, Lincolnshire, supplies malt products, seeds and various blends to the British baking industry. Edinburgh-based Fleming Howden, on the other hand, manufactures baking agents and yeasts. In January this year, AB Mauri had already taken over Specialty Blending Co., LLC in Cedar Rapids, which produces baking mixes. AB Mauri operates 50 production sites in 32 countries worldwide, and sales offices in more than 90. The nucleus was Fleischmann’s Yeast founded in the USA in 1868 and the Australian baking ingredients

++ A leadership change in FRITSCH

FRITSCH Holding AG announced a change in the chairmanship of the Management Board at the start of the second half-year: Kirsten Lange takes over at the company’s head. According to a communiqué, she already knows the Group through her Supervisory Board work, and looks forward to taking over responsibility for the family business on a temporary basis until a suitable long-term board member has been found. Lange’s most recent post was as a member of the executive board of Voith Hydro Holding, where she was responsible for the service, automation and digitization areas. Prior to that, she worked for 22 years in the Boston Consulting Group in Germany, the USA and China, and has advised more than 20 companies in the mechanical engineering industry. She is currently a member of the supervisory boards of Heidelberger Druckmaschinen AG and ATS Automation. She studied Journalism, Politics and Philosophy to degree level in Munich, and gained an MBA at the INSEAD in France. +++

++ New management board at FRITSCH USA Inc.

Anna-Maria Fritsch is the new President of FRITSCH USA Inc. Anna-Maria Fritsch studied “International Business” and worked in management consultancy companies for several years before joining the FRITSCH family business. She has comprehensively broadened her technical and technological knowledge and experience since that time. Fritsch has been responsible for the Marketing and Process Management departments during the past two years. In this function she focused her main emphasis on implementing strategic marketing processes and forming partnerships with reference clients. The CEO will move her residence to New Jersey next year, to be as close as possible to clients in the North American market. +++

© Allegra

A unique oven for a changing world

Mecatherm will present an entirely newly designed oven at the iba trade fair. Key advertised features include precision and flexibility.

+The French bakery machine constructor Mecatherm has its production facilities in Barembach near Strasbourg. However, drumbeats from the Vosges Mountains will be heard at the iba trade fair. One of these announces an entirely newly designed modular tunnel oven with which Mecatherm is spe cifically targeting medium-sized bakeries. The businesses in focus are those wanting to process a diverse range of products flexibly but without relinquishing a differentiated heat transfer profile consisting of radiant and convection heat matched to the respective baked goods. The engineers also promise efficient processes and precise control.

This oven is aimed mainly at major chain store businesses and specialty manufacturers in industrialized countries. Here in particular, according to Mecatherm President Olivier Sergent, there has been a large growth in the demand for high-quality variety. He says this is forcing companies towards a more complex, multi-faceted production organization and correspondingly modifiable technology, especially in the baking step of the production process. It is said to be still rather a niche activity at present in other countries, but a thoroughly attractive market due to the purchasing power existing in the middle classes. However, no matter how greatly diversity and an artisan visual appearance are valued in both markets, consumers nowadays are equally unwilling to give up adherence to their quality standards.

The company’s engineers are therefore said to have been given the task of developing an oven that guarantees excellent baking quality, is precisely controllable, and can be switched over from one product to another very quickly. The design of

operability and monitoring should be as simple and efficient as possible.

The outcome is an oven that not only looks markedly different to previous ovens from Barembach – including a contribution to better hygiene – but is also a kind of heating technology all-rounder.

To understand this, one must take a look into the modularly constructed oven in which each module allows a variety of heat transfer options from above and below.

A thick perforated plate heated by a stream of hot air is suspended in the baking chamber above the baked goods, and can emit radiant heat downwards. On the other hand, blowing warm air through the holes in this plate creates an air movement that carries heat to the products being baked,

Six different heat transfer options for each heating zone

+ Convection from above and below

+ Convection from above, radiant heat from below

+ Radiant heat from above and below, hot air brings heat to the products

+ Radiant heat only from above and below

+ Radiation and convention from above, and only radiation from below

+ Radiation and convection from above, and only convection from below

i.e. via convection. The two principles can also be used in combination. In the case of the bottom heat, on the other hand, Thanks to the new patented „mobile hearth system one can decide between radiant and convection. This yields a total of six different heat transfer possibilities, and thus the right baking program for almost every product at any point in time.

The oven is divided up into heating zones with a maximum baking area of 25 m2 each. Each zone can consist of a different number of modules. The most compact oven of this kind is 17 m long, including the entry and exit zone, offers three different heating zones controllable independently of one another, and provides up to 32 m 2 of baking area, depending on the oven width.

Heating is either direct using gas burners mounted above the baking chamber, or indirectly via heat exchangers and in that case with gas or oil, depending on the customer’s preference, or electrically.

Because not only can the type of heat transfer in each heating zone be regulated independently, but also the upper and lower heat can be heated by separate air flows, a fast response is possible and the oven can be operated with extremely productspecific baking profiles. The separate control over how and where the heat is brought to the product, to what extent and whether using radiation or air movement, gives the oven extremely fast mobility and reaction, especially as the burners are correspondingly dimensioned and deliver up to 80 kW/m2 According to Mecatherm, this avoids unproductive pauses between different products. Increasing the temperature by 100°C takes just 20 minutes, and a reduction of 100°C only 30 minutes.

Zeppelin Systems GmbH

Messenhäuser Straße 37-45

63322 Rödermark, Germany

Tel. +49 6074 691 - 0

foodtechnology@zeppelin.com

www.zeppelin-systems.com

PLANT DESIGN RUNNING IN OUR VEINS –YOUR FUTURE ON OUR MINDS

The architect of your visions

Plant engineering redesigned: We offer you the choice rather than ready-made kits – because we integrate processes, not just parts –for more efficiency, flexibility and security. Innovative plant designs from the plant architects. For a perfect dough all along the line.

++ The program runs at the press of a button, without the need to change slide valves or switches, which is beneficial to homogeneity when employing operators without much specialist training

Operating principle

Baking takes place optionally on a wire loop belt or a rod belt. Anyone who prefers to bake directly on the belt can on request have a belt preheating system to ensure that sufficient power is immediately available from below.

Each module comes with a steam inlet. For the air and steam extractors, the engineers placed value on the fact that no non-uniformity in the baking result occurs across the whole width of the oven.

Of course, even in this oven it is impossible to completely avoid a drop in temperature directly after loading the oven. But the combination of the use of a modulating burner that adapts precisely its operating rate and the rapid air change in the baking chamber ( 20 000 m3/H) permit a quasi immediate adaptation of the oven to the product load, and a very homogeneous baking even in case of partial loading;

An air management system ensures that equilibrium prevails between the air removed and the volume of inflowing air.

This is done thanks to seven regulators in total, four to extract air and steam and three for the air inflow. The automatic regulation system of the stack valve avoids both a downdraught of cold air through the flue and the blowing out of hot air into the production rooms. It goes without saying that the oven’s controller has provision for programming product-specific baking curves. The program runs at the press of a button, without the need to change slide valves or switches, which is beneficial to homogeneity when employing operators without much specialist training. To monitor the baking process, not only do the usual windows provide a view of the products being baked in the oven, but also anyone who wants to can arrange for this process to be relayed by camera to the controller’s monitor screen.

The engineers also thought it worthwhile to think about accessibility for cleaning and repairs. All the external panels can be dismantled without tools, allowing quick easy access to the baking chamber, and so can the belt drives at the be

ginning and end. +++

MECATHERM

++ Easy accessibility for cleaning and repairs; all the external panels can be dismantled without tools

++ For safety reasons there is a balustrade on top of the oven

Diversity with a common denominator

The competence of Haas-Meincke A/S extends from cookies to croissants – the common denominator being the ovens, especially the re-engineered IFC.

Haas-Meincke must simply love cookie monsters, since hardly anyone works so unstintingly as the engineers in Skovlunde just outside of Copenhagen on the question of how to manufacture particularly large numbers of cookies quickly and efficiently. They shape batters – even multicolored ones – on belts, cut hard cookies from laminated dough sheets, or use shiny molding rollers to give soft doughs the special appearance by which cookie enthusiasts recognize their favorite goodies. And they ensure that copious replenishments roll off the belt. Whereas in the past molded cookie lines had working widths only just reaching 1000 to 1200 mm, Meincke now offers plants with working widths up to 1800 mm, and even 2000 mm are no longer far off. With high speed, of course, the very latest hygiene designs and almost a flying product change, because in the cookie industry the combination of high line availability, perfect hygiene and simple control are also what decide a line’s efficiency.

The cracker lines are the second main pillar at Haas-Meincke. Sheeting lines, gauge rollers, cutters, recycling conveyors –and off they go like the cookies, off into the oven and, if required, after that into equipmentthat turns them into little sandwiches and/or decorates them. At the last Interpack Meincke showed a new „Jumbo line“: a very high-end equipment with massive production output (up to 6000 kg/hour) and the highest degree of sanitation and operability (open design/quick change over/on-the-fly set-ups).

But the product field for which Haas-Meincke works expanded long ago. Macaroons, soft sponge cakes, cupcakes and sponge cake rolls in all sizes are just as much their topics as crunchy cereal snacks, and they have already even helped a

Haas-Meincke A/S

The Danish company Meincke was founded in Skovlunde near Copenhagen in 1953 and has belonged to the Austrian Haas Group’s “Biscuit” division since 2009. Haas was in turn taken over by the Swiss Bühler Group in 2017. Haas brings together in this division the parts of the company dealing with cookies, crackers and cakes. Haas-Meincke produces industrial plants to manufacture soft and hard cookies, pizza, crackers, sponge cake rolls, bread, cereal products and fine pastries in Skovlunde near Copenhagen. The ovens are made in Rødkærsbro on the mainland of Jutland. The “Biscuit” division comprises two other factories in Leobendorf near Vienna and Etten-Leur in the Netherlands. The division’s sales in 2016 were approx. EUR 107 million, and it employed around 300 staff. The division builds and installs around 100 projects each year. More than 1,500 of the division’s production lines are operating worldwide today. There are subsidiary production works in Brazil, China and India.

++ IFC Oven with conveyor belt outlet

© Haas-Meincke

few bread products and bread-like products into a production line, regardless of whether it’s crispbread, cinnamon buns or bagels.

Their primary common denominator is their range of ovens, consisting of indirectly heated convection ovens (IFC) and all combination of hybrid ovens using directly gas fired and/or radiant sections in the first sections.

A fully newly re-engineered version of the IFC oven will be on show at the iba trade fair in Munich. The baking chamber’s insulation is reinforced by a layer of air, which ensures that the oven’s outer skin stays completely cold. Together with Copenhagen Technical University, they have also developed a new heat exchanger whose air dampers can now be adjusted independently of one another, thus allowing very efficient air flow control, which in turn considerably improves heat exchange.

All the ovens are supplied in working widths of 800 to 4400 mm and subdivided into sections two meters long. As a rule, a heating zone consists of several such sections. A blower draws air out of the oven to achieve a uniform distribution of heat in the oven. The exchange of air is in turn controlled via holes above and below the belt carrying the products, thus achieving a uniform baking result across the whole width of the oven. Fast temperature change and adjustment and thus efficient heat transfer is possible because air is blown directly onto the products. Haas-Meincke also offers a facility to control the air humidity in the oven as an option for all oven types.

Each 2-meter section is fitted with a large door for inspection, cleaning and servicing, and these are on both sides of the

oven at an oven width of 1500 mm and above. Depending on the customer’s preference, the oven’s cabling is either integrated into the oven or mounted externally.

For improved cleanability, the baking compartment height has been enlarged by 50 mm, thus creating more space under the belt. There’s no longer any need for anyone to suffer a dislocation to remove product residues that have fallen down and would otherwise be a fire risk. There is also a wash-down model of the oven, mainly for the US market.

The purpose of the gap control, an option available for all Haas-Meincke’s ovens, at the start of the oven is to raise the efficiency of the line (less waste and energy-saving). If the measuring instrument detects that there is no product currently running through the oven, all the flap valves are for example shut tight and are not opened again until product is on its way in. The energy recovery concept pursues a similar goal, including by ensuring that moisture leaving the oven with the hot air does not simply escape through the flue. Instead, the heat is transferred via a heat exchanger and into the incoming fresh air supply.

Again at the iba trade fair in Munich, Haas-Meincke is showing a high-speed wire-cut system that is not only able to process heavy doughs, but also leaves intact lumpy inclusions such as nuts or chocolate chips. The machine’s top, usually a fixed installation, is fully demountable on this machine and can be pushed onto a so-called roll-on-roll-off stand. This allows either a complete exchange or removal for cleaning to take place at lightning speed, which is an aspect that is important especially to safeguard against cross-contamination during a product change. With a 2-meter working width and 300 strokes/ minute, the 6110 is in the high-performance class among wire-cutters.

The subject of protection against unintended input of allergens is at the very top of the priority list in the cookie and cake sector, which is why some of the machines in Haas-Meincke’s pilot plant look as though they are still incomplete. But that’s not the case at all. In fact, when ordering a plant, a number of customers immediately include an extensive specification sheet dealing with sanitary design, and often this includes omitting covers and claddings that make no sense from the safety point of view. Visibility and accessibility for cleaning also top the priority list, and sometimes it’s even necessary to install transparent plastic or safety glass instead of steel doors and claddings. Then the easier accessibility frequently also has a beneficial effect during a product change, because now only complete assemblies are swapped. With the new GF3 rotary molder, a full changeover of the web can be completed in only 13 minutes, where 30 minutes is usually the „good benchmark“ level“. +++

++ Wire Cutter 6110 RoRo with Easy Clean function

© Haas-Meincke

SLICING AND PACKAGING SYSTEMS FOR THE BAKING

Brevetti Gasparin designs and manufactures systems for the SLICING and PACKAGING of baking products, with the purpose to satisfy and answer specifically to the customers needs to optimize production processes of end of line with reliable, functional and guaranteed solutions.

The company produces single machines and automatic industrial lines tailored and able to meet all market segments thanks to the personalization and customization of the systems according to the highest productive standards.

Founded in 1960, Brevetti Gasparin has matured on its over 50 years of experience a deep knowledge of the market able to guarantee for each product typology the right technique of slicing and packaging for an excellent result on the final product, with the interest in a continuous improvement abreast of the customer needs and the market evolution.

The study and design of specific solutions and the ability to listen and interact with its customers, enabled it to be on the market today to make the difference!

Pizza around the clock

f2m have spoken to Luis Videla , the CEO-Owner of Grupo Almar.

+Borchfeld: Mr. Videla, can you tell us more about the Grupo Almar?

+ Videla: Grupo Almar started in 2002 with 1 shop in Buenos Aires, close to where the bakery is now located. This area was an old private airport and we bought one of the hangars and converted that into a bakery. We started with producing cakes. Within the first 3 years, the company grew from 1 to 16 shops. Because labor was getting more expensive, we had to reconsider the business structure. Also, because we supplied products for different supermarket chains. By 2013, we had 700 employees in the plant. Because then we didn’t had production machines, our production capacity was limited. That was the reasons why we bought production machines: for Medialunas (Argentinian croissant) and Pizza, we bought a Rademaker Croissant and Pizza line. We also have a breadline from Mecatherm. This development made us increase the production capacity x10, while we could drop back the labor from 700 to 290.

Our last investments were a tin bread line, a bun line with a capacity of 9000 kg/hour and we upgraded our cake line. We now have a total product scope of 200 products. In 2014 we started franchise chain shops, and we now have up to 50 of these shops. In 2018 we will have a total of 80 franchise shops.

+ Borchfeld: Do you produce pizza around the clock?

+ Videla: We produce pizza in 3 daily shifts, and we have the Pizza line up and running up to 20 hours a day. Then

Grupo Almar bought from Rademaker a multifunctional Pizza line, that besides pizza bases, can also produce flatbreads and crackers. This way there are able to double their profits coming out of their Pizza line. Grupo Almar is a creative bakery that establish itself by getting more products out of a production line. In total Grupo Almar produces 200 different products. 8% of total production in the plant consists out of pizza products. Ice cream individual sticks is the company’s latest expansion.

++ Luis Videla, the CEO-Owner of Grupo Almar

++ The par-baked pizza's are tranferred towards the freezer, after which they are individually packed

© Grupo Almar

© Rademaker

between the next production run, we have 4 hours to cool down the oven and to clean the production line.

+ Borchfeld: How positioned the company itself in the market today and where can customers buy the pizzas?

+ Videla: Our philosophy is to produce a lot of volume at a low price. Our customers can by our pizzas at our own franchise shops and at Supermarkets. We supply pizza’s in Buenos Aires and other areas of Argentina. Our bakery is positioned in the middle of a civilian area and we have a shop directly at the factory. A lot of people from the area come here to buy their products.

Rademaker Pizza line information

After the mixing process, the dough batches are put into a Chunker low stress sheeter combination to create a continuous dough sheet. A Quick Reductor reduces the sheet’s thickness for the first time. The cross roller rolls the dough widthwise, to increase eventual its width. 2 Gauging Stations reduce the dough thickness further, before the dough sheet is transferred towards the Rademaker proofing system. Here the dough creates its cell structure and develops taste.

After proofing, the dough sheet is cut and pressed into Its final shape. Several sizes and shapes can be produced. The excess dough is automatically collected in bins and placed back into the dough mixing system. This way there is no dough waste.

Finally, the tomato sauce will be deposited onto the pizzas.

3 Stripes of sauce are deposited onto each individual pizza. The tomato sauce is spread over the complete pizza by a rotating sauce leveling device. The sauce is smoothened spread over the pizza, leaving the rim free of sauce. The pizzas now run towards the oven where they are baked for 80%. After baking, the pizzas are cooled down and packaged individually into transparent, plastics bags. Ready to be sold. +++

+ Borchfeld: What products do you produce and how much per year do you produce?

+ Videla: Like said, we produce a total of 200 different products. In total, we produce 1.200 tons of kilogram products per month. Our bakery produces both Fresh and frozen products. The pizzas that we produce, are what we call Pre-pizza, which are pizza bases topped with tomato sauce. These are pre-baked up to 80% packed individually and then sold. Customers can then top the pizzas and bake them their selves at home. This is the cheapest way for our customers to consume pizzas. The big difference to Europe, is that in Argentina a frozen, topped pizza costs around EUR 10,- in

© Rademaker © Rademaker

Silicone elastomer coating

PTFE / PFA / Ceramic / Fluoropolymer coating

the supermarkets which is for most Argentinians too much to spend on a mean. We offer customers the opportunity to consume pizza at a fair price.

+ Borchfeld: How do you describe the pizza market in Argentina? Is the market growing?

+ Videla: Topped pizzas (boxed) are for most Argentinians too expensive to consume. Therefore, the market for complete topped Pizzas is not so big as in the rest of the world. The freezer to freezer way of pizza distribution doesn’t sell here, par-baked, frozen and baked in the shop does sell. With our concept, we sell 200 pre-pizzas for one topped pizza in the supermarket. So, we think that we address the market the right way. It proofs when you look at our sales. And we still see growth in this way of offering our pizzas to the customers.

+ Borchfeld: Would you describe yourself as number 1 in Argentina, who are the competitors?

+ Videla: We would not describe ourselves as the number 1 in Argentina, but more as number 2. Our largest competitor is Bimbo.

+ Borchfeld: What products are particularly successful and why? What trend do you see?

+ Videla: For us as a bakery, the baguette line is most important, followed very closely by the Medialunas line. There for sure is a growth in the croissant market. Trends that we have here, are different than Europe. For example, there is no trend for clean label. Here in Argentina it is very much a price driven market; sell cheap or don’t sell at all. 95% of the population buys products that have a cheap price, and don’t choose much for quality products. To produce volume, you need to have a good price.

+ Borchfeld: Where do you see the company in 5 years?

+ Videla: We look ahead for 2 years with our bakery. And there we see an expansion that can feed a maximum of 80 franchise shops. At this moment, the traditional bakery and pizza market exists for 94% (mini family owned local bakeries) and only 6% out of large bakeries like Grupo Almar. But the market is slowly shifting as a natural growth of industry vs artisan

bakery is taking place. A local bakery is shrinking in floor space, a general of 100 square meters for a shop including the oven space. Therefore, we see a growth towards more market share and expansion coming up in the upcoming years.

+ Borchfeld: How did you come to Rademaker-Lines?

+ Videla: I met Rademaker on the IBIE show in Las Vegas back in 2006. From then on we had contact and started seriously talking about our plans and Rademaker’s contribution towards that.

+ Borchfeld: How does the cooperation with Rademaker from Europe works?

+ Videla: We can honestly say that it is very good, we are very satisfied with our co-operation with Rademaker. Rademaker has the best After Service in the market. I guess there is an estimate of 2 to 3 contact moments per year in which we update each other about what is happening, but on a service level we have more contact periods. Our technical department has direct contact with the Rademaker Service Direct department in case there might be a technical issue or spare-part need. As for the machines, we are operating in 3 daily shifts and the Rademaker machines have proven to be highly reliable, well designed. Maintenance is made easy due to good cleaning access.

+ Borchfeld: Mr. Videla, thank you for the interview. +++

++ The latest Groupo Almar shop in Buenos Aires

++ The par-baked pizzas are individually packed and sold

© Grupo Almar

© Grupo Almar

Several new designs

Bundy Baking Solutions is an American company with a family of brands that includes American Pan and Shaffer Mixer.

+Bundy Baking solutions is the USA market leader in the area of pans, trays, and coatings. American Pan manufactures stock and custom baking pans for foodservice, plant and industrial bakers. They offer their own proprietary coatings on their bakeware, including DuraShield, OptiShield, AMERICOAT, and Flexicoat. American Pan and offers pan refur-bishment services with four locations in Europe.

At iba, American Pan will be featuring several proprietary designs including:

+ TabLock Baking Screens : These screens are high strength steel frame with interlocking rib design that allows pans to stack while protecting the baking screen to increase the pan’s life. These baking panels are available in solid or any perforation pattern or size. These screens constructed using a tab-lock attachment system for easy and economical replacement of baking screens without rivets, drills or metal shavings. Most screens can be changed in less than two minutes.

+ ePAN designs : These are the strong and lightweight, while being energy-efficient bun and roll pans. According to American Pan, the ePANs reduce energy costs while improving proofer temperature control because they heat and cool faster as much as 25% faster pan rim cooling than traditional pans. This decreases the space needed for pan cooling. The high tensile strength of the ePAN’s aluminized steel minimizes the potential for pan damage and extends useful life. The light weight ePAN can weight up to 50% less than a traditional pan.

+ SMART Pan Tracking System : There will be a working model of the tracking system on site. This system is compatible with existing equipment and provides bakeries with valuable and precise data to monitor pan coating life and

efficiency. The pans are laser-marked with a unique 2D code and pan number. Pan sensors and tag readers are installed onto baking equipment and sends information to a database which is used to create usage and performance reports. Data collected provides reports on: line activity, pan coating life, product yield, and line efficiency. + Pan refurbishing services: with 4 plant locations in Europe (Spain, Romania and 2 in the UK), and others in the North and South America, American Pan has the ability to service global market. American Pan offers cleaning, straightening and recoating of millions of pans every year. Prolonging the life and performance of pans helps control costs in manufacturing companies around the world.

+ American Pan will also be launching their stock pan program for the UK and Europe.

Part of the Bundy Baking Solutions family includes Shaffer which manufactures horizontal dough mixers for industrial bakeries with batch sizes from 400 to 4000 lbs depending on the product. Shaffer offers triple roller bar mixers for bread, buns, and other yeast products, single sigma and double sigma arm mixers for cookies, crackers, granola, energy bars and many other products.

In addition to the American Pan products at iba, Shaffer Mixers will be revealing their new Select Series Mixers. These new designs have been precisely engineered to offer maximum value and durability. The all stainless-steel construction combined with watertight enclosures and an open frame under the bowl provides a ultimate mix of simple and sanitary design. The mixer’s single end drive system and simple operator controls are comprised of well-known, commonly-stocked components that make the mixer easier to operate and maintain. The tilt system can be configured for forward only or forward and reverse tilting of the bowl. Select Series Mixers are available in triple roller bar or single sigma arm models. +++

Bundy Baking Solutions

www.bundybakingsolutions.com Hall B1, Stand 201

© Bundy

Automation and fermentation

The Italian silo constructor Cepi SpA focuses on automation and the growing interest in fermentation plants on the part of bread bakers.

O utdoor monolithic silos, indoor silos, both made from panels and the patented Trevira silos, and a new metering system for small sized amounts of ingredients that meters from several hoppers into a fixed-position weighing pan, which grant a faster discharge and high precision in dosing, will be the hardware highlights on Cepi’s stand at the iba trade fair in September.

Fermentation plants and automation strategies are the second focal point. According to Sales & Marketing Manager Frida Lega, the company has been building fermentation plants for a long time. Up to now it has been a segment that has rarely taken center stage internationally in relation to customized project planning. According to Lega, it should come to the fore to a greater extent. She says the growing interest in high-quality artisan products on the part of industrial manufacturers beside the rationalization of the production have spurred the demand for fermentation plants. Cepi offers sourdough plants with a variety of cleaning systems. According to the project, they can varies between a pipe recirculation of product itself, or complete CIP technology with tank systems that flushes pipework and vessels with cleaning fluid and clear water. If required, Cepi can also supply a pigging system that removes adhering materials particularly thoroughly, especially from pipework.

Up to now, the Italian company has produced mainly bulk handling systems for the food, chemical and pharmaceutical industries, including patented antistatic Trevira silos, as well as stainless steel outdoor silos for food powders, with a vibrating cone or fluidized bed for complete extraction of product on the first-in-first-out principle. There are also sugar mills, metering plants for fat and micro-ingredients, and bread, both dried

Indoor Trevira silos made by Cepi, with an upstream sugar mill

++ Cepi plans a greater focus in future on the topic of “fermentation” because sponge doughs and sourdoughs are also playing an increasing role in industrial bread production

© Cepi

and liquid, or biscuits rework systems for the confectionery and baking industries. Cepi also supplies a flour-cooling system using pre-cooled air blown in silo through its fluidizing bed.

Most of the components and all kind of silos are fabricated in-house. Vertical production integration across all plant systems is currently around 60 %. Around 80% of sales, which reached EUR 25 million in the past year, were

Infinite possibilities

and to Asia. A worldwide sales and service organization has been established.

The company’s own electronic and electrical design department in which eleven programmers and designers work on automation solutions, together with ten designers and assemblers who are responsible for the layout of the electrical systems, should be helpful in this respect. The control system they have developed offers the ability to access and analyze the plant and

Endlessly unique. A whole galaxy of variety, with your success written in the stars.

++ Co ld metering: the plant can meter out cold butter, margarine or other fats at a constant and ambient temperature over a distance of up to 30 m

All the stars of the trade

Hardware and software under one roof

A few years ago, Oripan, a software house that could show one of the first Industry 4.0 installations, became part of Sancassiano group, the Italian mixer manufacturer. Sancassianos most conspicuous feature in hardware terms is the new bowl tipper.

+According to Andrea Agosti, one of four minority shareholders of the Italian mixer manufacturer Sancassiano, where he works as Area Manger: “The trend in the baked goods industry worldwide is towards diversified high-quality products and thus to precisely defined requirements applicable to mixing technology.” So Agosti sees growth potential for his own company to a lesser extent in continuous dough production, although Sancassiano also serves this market with its own continuous mixer.

Instead, in relation to hardware, the mixer specialists from Roddi, Italy, place greater emphasis on developing nuanced mixer types like the Kryos, built specifically for doughs that must not be exposed to a large evolution of heat. Other examples include the GRE (Revo) for cookie doughs and firm batters, or the new generation of planetary mixers. The most important innovation, however, is the new bowl tipper launched on the market last year, whose speed, drop height and emptying angle can be programmed for each individual dough. All four will be exhibited at the iba trade fair in Munich in September this year.

According to Agosti, the bowl tipper is an example of the way supposedly marginal changes can show thoroughly positive results. The dough transfer speed, drop height and

the rate at which the dough flows out of the tipper can all be programmed depending on the dough. There is also an option to specify if and when the emptying process is assisted by a scraper. To match this, for artisan products, there is a patented hopper that portions the dough downstream in large chunks with no degassing effect.

Taken altogether, according to Agosti, this reduces the stress on the dough, especially for doughs with a high dough yield and long fermentation time.

Ever since the “Genesi” design guideline came into force at Sancassiano in 2010, all the mixers made in Roddi have been built in such a way that the mobile bowls are interchangeable between all mixer types. The mixer tools are mounted in the mixer head without any visible screws or bolts, and are sealed in such a way that the mixer chamber can even be treated with a high-pressure cleaner. The mixers have also been provided with floor clearance and inclined rather than horizontal surfaces to ensure less contamination and easier cleaning.

©

Sancassiano

++ The Kryos mixer with cooling jacket and fixed mixing bowl was developed for frozen baked products, particularly firm doughs and doughs with a sensitive response to increasing dough temperature. Moreover, it can be operated under pressure or vacuum, which also allows it to be used for a Chorleywood process

All gearboxes have been banned from the mixer’s upper area and relocated to the region at the back to ensure a higher level of production safety without any oil reaching the dough. The spiral, twin spiral and Revo-mixers use an inverter to transfer power. “Wash-down” capability of the tools and mixer head is guaranteed in all cases. If the whole mixer is made from stainless steel, this even applies to the entire machine.

One exception to the interchangeable bowl style is the Kryos, a mixer that operates with a fixed-position bowl surrounded by a cooling jacket. The Kryos, which uses vertical mixing tools similar to the Hydra, is especially suitable for firm doughs with a TA (dough yield) below 155, such as pretzel or bagel doughs, as well as for frozen products including croissant, Danish or puff pastry doughs. Dough temperatures of 14 – 16°C can be maintained, thanks to the temperature control ensured by the double jacket. Because the mixer can also be put under vacuum or pressure, it is also usable for mixing based on the Chorleywood principle. According to Agosti, that’s one of the reasons why there is such a demand for the Kryos, particularly in countries influenced by the Anglo-American baking tradition that often worked using sponge doughs in the past.

The Revo mixer comes from a quite different area of work. Sancassiano developed it specifically for cookie and cracker doughs, thick batters and doughs in which little gluten development occurs, or none at all. According to Agosti, the market for these products also growing, and with it the demand for this mixer type, not least because the machine can use a wide spectrum of tools, from a cutter tool to a whisk.

One discussion topic on the iba trade fair stand will probably be the development already push-started by Sancassiano umpteen years ago when Oripan became part of the group. With support from the state and the scientific community, Oripan started an ambitious project with the purpose to integrate and to interconnect the production lines with the company processes according to the world wide standard Industry 4.0.

The system makes this data available to customers at a variety of processing levels. Based on a Guide, it shows line operators what is happening and where, and where action by them may possibly be needed. The data is also available to the production management for inclusion in the Manufacturing Execution System (MES) and to be linked to the Enterprise Resource Planning system (ERP). Agosti says: “It’s important to us that our customers, through the comprehensive analysis of their existing processes, can see and implement improvement potentials.” The first comprehensive installation has been operating in Italy for more than a year. +++

++ Sa ncassiano’s new bowl tipper. The angle with which the mixing bowl can be emptied, the drop height of the dough and the speed with which the dough is emptied out of the bowl onto a belt or into a cone are controllable. The way the bowl is to be emptied is pre-programmed with the recipe

++ A mixer for cookies, cupcakes, crackers and batters in which there is to be only slight gluten development or none at all

++ Th e new generation of planetary mixers, newly designed for enhanced interconnection with other equipment

© Sancassiano © Sancassiano © Sancassiano

Continuous investments

Vandemoortele is one of the leading manufacturers of frozen baked products. The works in Eeklo, Belgium, is among the company’s biggest locations, where 300 staff working 24/7 produce a wide variety of frozen baked goods.

+Vandemoortele N.V., Ghent, Belgium, is a company group employing a total of around 5,200 staff and pro ducing and marketing frozen baked goods together with margarines, cooking oils and fats in 35 production facilities in 12 European countries. Annual sales revenues are around E UR 1.4 billion, and the group is constantly expanding

For example, the company invested in a completely new fac tory in Kutno, Poland, in 2016/2017. However, a part of the company’s philosophy is continuous investment in existing production facilities, e.g. including in the works at Eeklo not far from Ghent, Belgium.

Site Manager Nick Clauwaert is responsible for more than 300 employees working at the latter site. The production facility was built on a green-field site between 1998 and 2000 and manufactures frozen Danish pastries and other laminated dough products, e.g. apple and nut turnovers or croissants in various weight ranges, on four lines working round the clock. The total number of different products is around 200. The Eeklo factory’s maximum production volume is up to 40,000 tons/year, the size of the total production area being around 16.600 m 2 with enough space for an extension.

Around 29% of the frozen baked products are exported to Germany, which makes that country the main outlet for products, followed by the consumer countries Belgium, the UK and the Netherlands. A proportion of the production, e.g. spicy Danish pastries with various meat fillings, is also exported to the USA.

++ Employees carrying out quality control of the croissant dough pieces produced

++ Employees manufacture a total of around 200 different products with various fillings, e.g. chocolate, and different weight ranges

© Vandemoortele

© Vandemoortele

HIGH SPEED BUN MAKE-UP LINE

Lower Your Cost of Ownership

•Hygienic Wash-down Design

•Lower Formula Cost (Scaling Weight & Dough Conditioners)

•Toolless Design Reduces Time for Clean Up & Changeover

•Up to 150 Cuts per Minute

• Lower Maintenance Cost

•Servo Driven

Burford’s seeders, toppers, sifters and pan shakers are a perfect match for our Bun Divider

We have been making Make-up Lines for over a decade. We listen to you, the baker, and innovate. Come & Experience the next generation at IBA 2018.

STAND B1-110, B1-111, B1-120.

Production

In total four lines are installed, physically separated from one another. The plants are supplied from a shared raw materials warehouse. Wheat flour is stored in five outdoor silos. Site Manager Nick Clauwaert explains: “The fact that the individual lines are physically separate has advantages, e.g. when cleaning the machines, since there is no need to interrupt or obstruct production in other areas. Installing new plants or components in the factory is really a challenge, however, because there is limited space in the existing production facility.” It goes without saying on the part of the Vandemoortele Group that there will be continuing investment in the existing works. For example, a new fine pastry plant made by a Dutch manufacturer has just been commissioned. Here again, the fact that the plant had to be installed in an existing building was a challenge, but Nick Clauwaert is pleased with the result. The Site Manager generally takes care to ensure that new plants are as flexible as possible, to allow them to adapt quickly to new requirements and to enable them to make the maximum number of different products. This is also why plants from a variety of different manufacturers are in use. The company has also invested in other production areas. For example, robots now help in the automatic packing of frozen dough pieces. These then go into the frozen food warehouse, which has capacity for 3,000 pallet storage bays.

Clauwaert has a clear answer to the question about market chances. There is a growing demand for mini-products weighing 25 g. Nowadays, many consumers ask about baked products with reduced sugar and salt content. To enable repeated fast adaptation to customers’ wishes, therefore, it is especially important that the Vandemoortele Group constantly invests in new technology, thus allowing it to continue to offer customers baked products with the best flavor, best quality and best service. +++

++ Around 300 employees operate four lines producing laminated doughs for a wide variety of frozen baked goods

Vandemoortele recorded a continuing positive business trend. 5.1% sales growth compared to the previous year was generated across the whole group of companies in 2017. The Recurring EBITDA was EUR 119 million, and the Recurring EBIT was EUR 63 million. Vandemoortele Germany increased sales in Germany and Austria by as much as 10% to EUR 220 million. The frozen baked products business area reached sales of EUR 871 million in 2017, which is a 5% increase compared to the previous year. According to the company, the positive result in the sector is reflected in continuing improvements in the entire added value chain, and was achieved through organic growth. It says the margarine, oils and fats business area also successfully increased its sales by 5% to EUR 549 million in a difficult market environment. About EUR 57 million was invested in 2017, including expanding and modernizing production facilities. +++

++ Site Manager Nick Clauwaert (l.) is responsible for operations in Eeklo, Belgium. Robert Maassen is Country Commercial Manager of Vandemoortele Deutschland GmbH

f2m

++ The production facility covers an area of 16,600 m2 There is enough space for expansion if required

© f2m

© Vandemoortele

A new CODOS and more

Zeppelin-Systems GmbH is an international market leader with regard to continuous dough mixing. The Rödermark-based company will present a new CODOS generation at the iba trade fair.

New drive technology, new cooling, Washing in Place, a nd of course also a new control system that communicates with Zeppelin’s higher-level automation and digitization software. Zeppelin Systems has granted the Codo a complete makeover, after more than 100 n ow, have been in service in baked goods production worldwide.

The previous asynchronous geared motor has been swapped for a water-cooled servo drive with a single gear reduction, which means not only a 40% weight saving but also a reduced installed length, i.e. space is saved and on top of that, energy consumption is reduced. Furthermore, with immediate effect there is an emergency stop function on all plants, which instantly brings it to a standstill.

The cooling system of the CODOS NT has also been fully redesigned. The efficiency level of the trough cooling has been improved considerably, which ensures better heat transfer. All the trough cooling assemblies will be positioned outside of the CODOS in future.

Moreover, with assistance of research at the Cereals Research Institute in Rehbrücke, the geometry and spacing distances of the mixing tools themselves have been optimized again.

According to Michael Piepenbrock, Zeppelin’s Business Unit Manager, Food Processing Plants: “That provides more power and performance with less energy consumption, and makes the CODOS scalable.” There will be a CODOS NT 160 with a dough production capacity of approx. 3 tons/hour, the

CODOS NT 200 with 4 – 5 tons/hour and the CODOS NT 230 with up to 8 tons/hour of dough. In 80% of all cases, a CODOS stage will be combined with a DymoMix that supplies pre-mixed, uniformly wetted raw materials to the CODOS. A two-stage CODOS solution is usually used when processing flours containing extremely high gluten levels.

Of course, Zeppelin is also moving towards digitization in its control technology. The very closely interrelated topics of automation and digitization will be combined under the MIRA brand name in future.

This means for the CODOS NT is that control will still take place via the existing Prisma Web system. However, the Prisma Web system will be incorporated into the MIRA concept in the near future. Topics, such as data analytics and cloud capability are already being developed. Whether it’s Cloud in the Web or a local solution can be chosen freely. The development focuses on the future solution’s easy applicability and scalability. Another important element are MES functionalities, which play an important role in MIRA. In concrete terms, that means input, output, energy consumption, process times, etc. are documented and can be called up and analyzed at any time. Moreover, a mobile terminal device can be used to view the documentation belonging to the Zeppelin modules, and spare parts can be ordered, if necessary. A remarkable aspect of all of this is that the Zeppelin landscape has no problems incorporating even components that do not originate from Zeppelin. In order to be able to use

© Zeppelin © Zeppelin

++ Left: The new family of rotary valve promises less air leakage as a result of a new bearing design. Right: The diverter valve’s pneumatic drive has been integrated into the housing. Applications have been filed for EHEDG (European Hygienic Engineering & Design Group) certification for both of the new components.

this technology also in already existing plants, it is sufficient to retrofit the plant positions in question with a “beacon” which records the corresponding data and feeds it into the system.

In future, the CODOS NT will be installed on load cells in order to carry out some measurements. On the Zeppelin both you can already experience “hands on” the entire MIRA system consisting of the MIRA Control and MIRA Connect.

“Simple” hardware improvements sometimes find it hard to gain a hearing with so much IT around, but looking into that area is also worthwhile, because they directly improve reality. For example, Zeppelin will show a new series of models of water mixing and metering devices, a new manual weighing station, a new diverter valve and a new rotary valve in Munich.

The new generation of rotary valves and diverter valves for the medium-pressure impressively show Zeppelin’s new design language, clearly and powerfully drawn, with lighter weights and more powerful performance than ever before, and EHEDG has not been forgotten either. In this respect, Zeppelin is consistently going down the road of digitally networking every component, and thus MIRA Connect (formerly: PLANT.GATE) is also on board as standard.

The rack oven.

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Bakes to perfection: core temperature sensor

Ergonomically brilliant: soft close door, remote display, large screen

++ Al l the components will be fitted with a “Beacon” as standard in future. This will record process data and forward it to a higherlevel controller. This data can then be evaluated. They can also be retrofitted to plants made by third parties and to existing plants. The “Plant.Gate” tool can be used to read out this data

Zeppelin is at the iba trade fair in hall B6, booth No. 351. The Italian machine manufacturer Tecnopool is right next to Zeppelin´s booth, and Zeppelin and Tecnopool will jointly present design concepts for entire production lines. +++

© Zeppelin

iba Munich. Hall A2. Be our guest.

Focus on food safety

For nearly 70 years Kwik Lok ® Corporation has created solutions to closing bags that has been used throughout the world in the consumer goods industry. This simple yet innovative little card seamlessly secures the end of a filled bag.

+The advantage of the Kwik Lok ® closure is that it is quick and easy to apply and reuse. With focus on food safety, sustainability and technology, Kwik Lok ® closures give extended reach beyond a simple bag closure, it also provides business-building opportunities.

Sustainability

The Kwik Lok ® Corporation is constantly working towards sustainability. The bag closure is designed to easily be reused and recycled. Kwik Lok ® is actively engaged in reducing its’ global footprint with clean process and environmentally conscience efforts to minimize energy demands. For example, Kwik Lok ® cools its extruders within a closed loop cooling system. Additionally, the closure does not use hardeners or additives in the plastic.

Food Safety

Kwik Lok® provides the technology to close bags, print required information on the closure, and apply label in one motion. These metal-free Kwik Lok® closures allow for the use of metal detection as the final step after packaging the product. The closure system can be combined with bag sealing machines to apply a weld seam, so both supplier and customer can be sure the product has not been mishandled.

Marketing

Kwik Lok® printing capabilities extend beyond UPC and matric codes – build a brand promotion with customized labeling and messaging to see measurable increases in sales. Tip Top

Bakery Brands saw a 15% increase in sales, with consumer recall of 85%.With easy application and high-resolution laser printing, increasing brand awareness is easy.

Manufacturing

In addition to ease of use, the machinery required to apply the closure to packaging is simple.The shape of this closure is what makes it work. The Kwik Lok® high-speed bag closure system provides customers with automation, speed, reliability and custom printed bag closure labels.Kwik Lok ® provides the technology to close bags, print required information on the closure, and apply label in one motion for up to 120 film bags per minute.

Kwik Lok ® also offers other equipment like conveyors, bag tensioner, closure printer separator for hand bagged products, and printing solutions for bagged packages. The company makes bag closures and equipment for fully automated packaging lines as well as semi-automatic and hand applied closures. In addition to film bags, the Kwik Lok ® closure systems can also be used on burlap and paper bags.

Additionally, Kwik Lok® offers a roll-in/roll-out stand for flexible use for their label capabilities. This mobile stand can be used to try out the equipment in the facility, providing ease of use and testing without major modifications to the existing facility.

iba

At iba, Kwik Lok ® will be demonstrating their new ink jet printer (Model 904) that features an easy to use touch screen. The high-resolution printer has the ability to print QR Codes and 2D barcodes. It features quick replace industrial sized ink cartridges. Additionally, it has the ability to print 120 closures per minute with only one moving part. +++

© Kwik Lok © Kwik Lok

Industrial bread line for artisan products

The Swiss company RONDO Burgdorf AG presented a new universal bread line to visitors at an open-house event in Schio, Italy. The plant can produce sliced/cut, long-molded and round-molded artisan breads and bread rolls.

R ONDO Industrial solutions, RONDO Burgdorf AG’s industrial division, organized an open-door day in Schio, Italy, for European production managers. The company presented the newly-developed ARTISANA bread line to the expert audience. The plant can produce sliced/cut, long-molded and round-molded artisan breads and bread rolls. As explained by CEO Dr. Michael Witzak during the practical demonstration of the plant: “The RONDObot is also the only system worldwide that can round-mold doughs with a dough yield of 180 or more.”

Mode of operation

The plant begins by forming a dough sheet, for which RONDO uses the ASTec design of the universal MIDOS dough sheeter (Multiple Industrial Dough System) supplied with dough via a bowl tipper. A roller system developed specifically for soft to firm doughs creates a homogeneous dough sheet without using process flour or process oil. This is followed by a satellite head, cross-roller and calibrating station to produce the required dough sheet thickness and width. A built-in automatic weighing device ensures that the weights of the made-up pieces are as accurate as possible. After cutting and spreading apart the dough sheet, and separating the dough pieces, the RONDObot comes into operation. This is the basic technology for a novel round-

molding system for dough sheeters, and its task is to prepare round-molded artisan and “ordinary” rolls and breads in a wide range of weights. The round-molding system consists of the RONDObot, an industrial robot with an IP67 design, novel interchangeable tools (these tools are changed automatically), and a special round-molding table. The RONDObot’s six degrees of freedom enable optimum matching of the round-

++ The RONDObot is used to round-mold dough pieces when required

in a weight range from 40 to 1,000 g. The RONDObot’s tools are changed automatically

molding process to the dough and end-product, and replicates round molding with 100% repetition accuracy.

Round-molding in the multi-phase rounding process is divided into individual phases, in each of which the molding movements are carried out in the same way as a baker would perform them manually. The plant enables not only the adjustment of the molding speed but also a definition of the changes in the eccentric movements and the pressure on the dough piece. All the parameters of the multi-phase rounding process are stored in the plant’s controller and can be called up again.

The plant can process artisan rolls and breads in a weight range from 40 to 1,000 g. It can also process wheat doughs and doughs with a proportion of rye or seeds. In particular, doughs with a long dough rest time can be made up through the plant. Thus, as was explained to participants during the event, the RONDObot is the only currently available rounding system that can achieve good molding results with doughs containing large amounts of water and with a prolonged pre-proofing time. Basically, the RONDObot can be integrated

ASTec lines

RONDO ASTec lines are designed to meet the highest hygiene requirements. Fast, safe plant cleaning is ensured by the hygiene-friendly design and construction, and by the use of high-quality materials. ASTec lines are cleaned according to a computer-assisted program individually defined for the respective production facility. The cleaning steps are logged and recorded for possible audits. ASTec lines are available in two versions: one for dry cleaning and one for wet cleaning. An advantage of ASTec lines is a reduction in cleaning times by up to 30% compared to other plants. On the one hand this leads to reduced costs, and on the other to increased production time. +++

++ Production managers from all over Europe were able to obtain on-the-spot information about the new line and the way it operates

© f2m

into existing or new bread and roll baking lines. This round-molding system is the RONDObot’s first application. Dr. Witzak explained that RONDO is currently considering automating additional dough processing steps. The RONDObot can also be bypassed to manufacture long-molded and cut/sliced products on the ARTISANA.

Industry 4.0

However, the new plant’s practical application was not the only thing that was presented during the event. The role played by the topic of Industry 4.0 in the RONDO company was also explained to the visitors. Dr. Witzak presented the RONDOnet, in which production and plant data are collected in a cloud. Users receive an overview, e.g. about system alarms, the operator or the plant’s capacity utilization. All the events are recorded online and stored in the cloud. Machine incidents, e.g. a plant start or stop, have a date/timestamp and a value. All the components can send warning or fault states at the same time. These messages can be forwarded to the internal service or directly to RONDO’s service team. According to Dr. Witzak: “If the system has an ERP connection available, these messages can also trigger an order for spare parts.” In this respect, RONDO supplies a servicing plan for each component, which should be complied with to guarantee faultless functioning. Moreover, the plant can be equipped with up to four webcams to monitor the progress of the production operation. An analysis tool currently being developed should, in the near future, allow the number of products and

their dimensions and color to be established. As Dr. Witzak explained: “Preventive maintenance with proactive alarms and online event recognition is the first step towards the target of nil downtimes for our customers.”

The open-house event in Schio allowed participants to take a look at the company’s new developments. More information about the industrial bread line for artisan products will also be available at the iba trade fair in Munich. +++

++ Overall view of the new Artisana plant

++ The new line is designed to be as flexible as possible. Long-molded products, for example, can be manufactured from a dough sheet, and can also be strewn with seeds if needed

From transport to process engineering

The Tecnopool Group, at one time mainly a conveyor belt specialist, is increasingly making a name for itself as a process technology supplier.

D oing one thing but not giving up the other – that’s how the development of the Italian mechanical engineer Tecnopool in San Giorgio in Bosco near Padua could be described.

Tecnopool is still regarded as a specialist in a wide variety of steel rod belts for product transport. For the past two years, however, Tecnopool has expanded its field of activity and built a thermo-oil-heated spiral oven in which hot oil circulates in pipes under the levels of the spiral. Due to the way the spirals are built, the pipes run under one level and above the next. This allows the products being baked to receive radiant heat from both. Whether the oven has a circular or oval construction, and whether the belt entry and exit are at the top or the bottom, is decided by the customer, and so are the oven’s height and thus the number of spiral levels. To achieve a specific time/heat profile for a product, the oven can be divided into temperature zones with separate oil circulations. If required, convection heat is provided by a heat-exchanger in the center of the oven, supplied with hot oil and with a blower.

Depending on the need and the customer’s requirement, each oven has its own heating plant, but central oil heaters are also an option. There is a choice between various steel rod belts to convey the items being baked, depending on whether baking is to take place directly on the belt, on trays or in pan clusters. The spiral oven’s possible performance spectrum is broad. Plants with a capacity of 500 kg/hour for

gluten-free products, and toast-bread plants with an hourly capacity of up to 4 tons have been built up to now.

Thus the oven builds on conveyor belt technology specific to Tecnopool, which is employed mainly in the global baked products industry where up to now as a rule it has been used in proofing and freezing plants or deep freeze. The aspect which makes Tecnopool’s belts rather special is that the drives are installed in an easily accessible position and do not need to be lubricated. In addition, they run really quietly and even in reverse if necessary, which also allows the plants to be used as buffer storage.

++ According to Tecnopool, the combination of a spiral proofer, spiral oven and spiral cooler occupies up to 600 m 2 less space than tunnel oven lines

Tecnopool

++ Spiral ovens also bake pan clusters

The secret is in the connections between the steel rods and what drives them forwards. The rods are welded to steel elements whose ends are attached to sliding elements that in turn run on rails. The shape of the guide track prevents the belts from jumping out of the guide. They are driven forwards by wheels that engage in the chain guide from the outside, one spiral and one drive wheel on a separate drive shaft for each level. This ensures that each level is pulled uniformly, and excludes jerky movements. The drive wheels are the only things that need to be serviced. Whether one or more motors is/are used depends on the height of the spiral tower.

This kind of drive technology frees customers and the designers from the need to build circular spirals in every case. Ovals are equally possible, as are systems in which the belt spirals upwards then moves downwards again inside the upward-moving first spiral, so the entry and exit are both located at the ends of the spiral near the floor.

The spiral oven is not the only thing that set in motion Tecnopool’s transformation to a process technology supplier. The company, still majority-owned by the founding family Lago, took over the Slovenian bakery machine builder Gostol-Gopan D.o.o. Tecnofryer S.L.U. in Valencia, Spain, which produces industrial fat frying plants, has already belonged to the company for some time. +++

Hall B6, Stand 230

© Tecnopool

The next step

Almost everyone in the industry knows the Handtmann dough divider from the VF Line. An add-on device that afterwards shapes the divided dough will be shown by the Biberach-based company at the iba trade fair.

A n outstanding feature of the VF dough divider is its precise pre-portioning of batters and doughs by a vane cell feed system in which a vacuum assists uniform product infeed. The doughs are afterwards gently conveyed as a continuous filling stream and pre-portioned at the same time.

The dough dividers are usable in combination with attachments to cut/divide, mold and meter a variety of bread types, e.g. from wholegrain breads made from rye, wheat and spelt to gluten-free baked products, pizza doughs, toast- and sandwich-breads, cookies, baked snacks, ethnic food such as naan breads etc. Gentle feed material conveying ensures that sensitive raw materials such as added olives, seeds and nuts are not crushed, and the structure of the dough is also retained undamaged.

At the iba trade fair, Handtmann will show how the VF 800 dough divider pre-portions dough and feeds it to the FS 520 molding system’s powered filling stream divider with its six outlets. The servo-driven filling stream divider ensures accurate weights for each row and product at the same time, thanks to accurate rotor revolution speeds. Products are molded into the required 3-D shape by a rotating perforated plate system with easy-change formatting attachments plugged on at the outlet. Possible options include spheres, cylinders, small rods, droplets or other 3-D shapes with a product diameter up to 65 mm. Products can be pre-portioned directly onto trays or even into a fat-fryer at a cycle rate of 45 pieces.

The product shape is displayed via the dough divider’s controller, meaning it can be chosen easily, after which the process parameters are calculated. Handtmann’s presentation with this combination at the iba trade fair will include processing gluten-free doughs, ryebread baguette rolls and “Vinschgauer” flatbreads, an Austrian regional specialty.

In another combination, Handtmann will show the VF 800 dough divider in conjunction with the SE 442 and SE 443 cutting systems. Doughs for which the SE 442 is suitable include those for naan bread, toast-bread and pizzas, as well as gluten-free doughs. It is fitted with a pneumatically-operated knife and can reach a high cycling performance that depends on the dough piece weight, dough consistency and the dough divider that is used. The 443 cutting system is normally used to fill tinned breads directly and precisely into baking pans. The VF 800 and SE 443 combination operates oil-free, thus enabling of low-viscosity doughs to be pre-portioned accurately.

Handtmann’s iba presentation is rounded off by various equipment for accurately weighed metering of fillings and toppings onto dough sheeter lines or into containers. +++

Handtmann

++ Free-form ryebread rolls deposited on a baguette tray in six rows ++ VF 800 dough divider with FS 520

Sveba Connect part of Middleby Connect - cloud solution.

New S-Series combination oven.

New Prover F500.

Updated rack oven C252 with core temperature.

Professional young bakers in the Sveba Dahlen bakery. Swedish ”fika” in the stand. Glimek Bread line.

V-Series rack oven updates. Middleby Bakery Group.

Innovative baking technologies

Reading Bakery Systems (RBS) is one of the world’s leading manufacturers of baking and process systems, especially in advanced high production cookie, cracker, biscuit, snack (baked chips, pretzels, expanded snacks, and bread snacks) and pet food systems.

Reading Bakery Systems brands include: Thomas L. Green, Reading Pretzel, Exact Mixing, and Reading Thermal. Reading Bakery Systems is also part of the Markel Food Group Company.

At iba they will be featuring several new baking technologies and innovative snack systems including a new Exact Mixing HDX continuous mixing system for buns on the show floor as well as and feature the new Thomas L. Green Servo Wirecut Machine, new Emithermic cookie oven and Reading Thermal oven profiling solutions.

Exact Mixing by Reading Bakery Systems

At iba, Exact Mixing will display an HDX (High Development) Continuous Mixing System for buns. The mixer is designed for manufacturing highly developed dough at low temperature like buns, breads, rolls, English muffins and other ultra-high absorption doughs. This two-stage system is designed to mix all ingredients in a uniform mass with a twin-screw mixer in the first stage. In the second stage, the dough is kneaded to the proper development level with a single screw mixer. The HDX mixer is shown to create more consistent color and height in buns and rolls, while reduce energy consumption

compared to batch mixing. This continuous system helps eliminate batch to batch variations. In addition to consistent product, food safety is optimized since dough is not exposed to environment during mixing. All of this and can handle dough production rates from 1,500 to 10,000 kg/hour.

Exact will also highlight other models available for a wide range of snacks and other bakery products including the new MX Mixer with Hydrobond Technology. The new Hydrobond Technology ensures instant, even hydration of a dry ingredient stream prior to entering the continuous mixer. Without adding heat to the dough, a uniform hydration is accomplished and results in shorter mixing time, therefore requires less energy. The MX Mixer is the most versatile mixer that Reading Bakery Systems offers and is suited for a wide range of products including: snacks, cookies, batters and pastes. According to Reading the MX Mixer is also an ideal first-stage mixer for processes that require creme up and pre-blended stages.

Reading Thermal Oven Profiling Solutions

Reading Thermal will be featuring the Thermal SCORPION® developed for bread and bun bakers. The SCORPION® 2 System provides measurement system to capture the 4 key baking

++ HDX mixer – MX mixer with developer for bread and bun type doughs

© Reading Bakery Systems

parameters: temperature, air velocity, heat flux, and humidity. In addition to tracking these parameters, it also simplifies the baking process kill step validation as it allows bakers to collect 5 product core temperature measurements and automatically generates a kill step validation lethality report.

The SCORPION ® 2 System includes the Pan+Dough Probe and the Temp+Airflow Sensor Array. To help bakers achieve consistent bake cycle S-curves, the Pan+Dough probe is a fixed position dough interface/core temperature measuring device to provide accurate and repeatable data. The Temp+Airflow Sensor Array is used to both profile temperature while also profile airflow across the width of large tray and grid conveyor ovens. The information gathered from this system are useful in adjusting a process to maximize product consistency and quality while reducing waste and improving baking efficiency.

Snack Products

Reading Bakery Systems will also feature several innovative baking technologies at iba used for cookies and other snack products including:

+ Servo Wirecut Machine- This new machine offers more control and flexibility as well as better safety features and easier sanitation. With up to 300 cuts per minute (cpm) it is designed for cookies, biscuits. Even with the speed it maintains high degree of accuracy and consistent

piece weights. Adjustments are made easy with an integrated touchscreen. Sanitation and maintenance improved with 50% less parts than standard wire cut machines. Wash down parts can be removed without tools. RBS SafeShield® Program is integrated to prevent injury including with light curtains that stop machine when curtain is broken.

+ PRISM Emithermic Oven Zone- This newly designed oven offers radiant and convective heat, with a humidity controlled product zone directly surrounding the product while baking. Particularly for cookies and biscuits, this provides better control over product development and spread and is more efficient than traditional recirculating heat and cyclothermic zones.

+ Low Pressure Extruder- This has been redesigned to improve safety, efficiency and ease of cleaning that is optimized efficiency and flexibility for pretzels and various shaped snacks. It features efficient and precise dough forming and piece weights. +++

From Trevira silos to tailor-made raw materials management

Agriflex s.r.l. is specialized in powder and liquid raw materials handling for the food industry. The solutions range from dry materials silos to sourdough production systems. Its patents include the innovative in line flour cooling system (patent nr.1401347).

T he company’s history began in Forlì, north of Italy, in 1975 when Luciano Agri founded the company to design and manufacture flexible flour silos made in Trevira Fabric. Presently, there are more than 8000 installations around the world.

Today Agriflex consists of three production plants, the head office in Forli with over 80 employees, the second Italian unit is a highly specialized production facility in the north of Ferrara, and a third in Oradea (Romania).

The solution range has expanded over time and now comprises the storage in 4 different types of silos, conveying and automated metering of all kinds of powder and liquid ingredients in macro ad micro quantities.

Installation takes place worldwide. Agriflex customers mainly work in the baking, confectionery, pasta, pastry, snack and pre-mixes industry.

The solid ingredients are conveyed pneumatically or mechanically, the liquids by centrifugal or lobe pump according to needs. Systems typically include weighed hoppers that allow batching according to pre-set recipes. Using operative and supervising software the system enables traceability of batches and lots, with the possibility of automatically transferring information to the ERP.

At iba 2018 Agriflex will present a new micro-ingredients unit able to automatically manage, without damaging them, difficult flowing raw materials such as: raisins, pine-nuts, candied fruit, almonds, pistachios, lecitine, almond flour, milk powder and all micro ingredients used in the food industry.

Relatively to sourdough production systems, Agriflex has lead pioneering research and investment for over 20 years. Nowadays Agriflex can offer stand-alone machines of up to 500 liters capacities as well as industrial integrated automatic systems with capacities of several thousand liters. Agriflex offers solutions for both white and rye sourdough using any type of starter. As side service, a food technologist can be

provided on site to assist during trials and start up in order to achieve the client’s required results in terms of final product, as fast and as best as possible.

The sourdough production process is automatic, thanks to the control of temperature and PH by the software. Agriflex supplies industrial systems complete with automatic control. Agriflex automation systems feature straight-forward graphics and intuitive controls, guarantee the control of an infinite number of production cycles, as well as the possibility to manage stocks, the traceability of production batches and the reliability and consistency of the entire production process.

One of Agriflex’s latest innovation is its patented and innovative flour cooling system, which can also be installed into existing systems. The flour cooling achieves a flour temperature reduction of up to 20°C, with a minimum flour temperature achievable as low as 12°C.

The system works by cooling and dehumidifying the air used in the pneumatic conveying line. This dry air is used to collect the flour from the silos, then flour itself passes through the heat exchanging unit where it is cooled down.

The system cools down the flour along the pneumatic line and ensures that the cooling agent, glycol, never comes in contact with the ingredients. The system regulates the flour temperature fully automatically and keeps it constant during the whole process.

The service network is present globally to serve the worldwide clientele. It includes the company’s own subsidiaries as well as, in other countries, cooperations with local dealers or other engineering companies. The service department in Forli is available on an analogue or digital basis for remote assistance. +++

Agriflex

S.r.L.

www.agriflex.it Hall B4, Booth 361

New: HIFFICIENCY ® baking and roasting accessories

DURAPEK ® and DURAQUARZ ® coatings from acs Coating Systems, absorb heat particularly quickly in the oven, distribute it well, and release it again quickly.

for this purpose and is patented. HIFFICIENCY ® perforated lye trays are available in all the usual baker’s sizes and with GN dimensions. Benefits: especially good baking behavior, no baking paper, increased efficiency.

Another special item is the patented HIFFICIENCY ® multibake tray. This is unperforated and has a convex geometry that allows escaping liquid to drain away quickly to the sides, where it is collected in a peripheral channel. The multibake tray is torsionally stiff, and the company says it does not distort in the oven. As a result, the baked products are crisper, ready sooner and have a smooth base. From pretzels to pizzas – the results produced in a circulating air oven are more like those from a stone oven. The multibake tray can also be given a lye-resistant finish. It is usable on both sides for everything that is baked, grilled or braised in an oven. Available sizes: ENBM, 1/1 GN and ½ GN. Benefits: excellent baking and roasting behavior, no baking paper, increased efficiency.

H ifficiency ® is from the English words “high” and “e fficiency”, i.e. these baking and cooking accessories are highly efficient. The reason can be explained quickly: the alloys with particularly high thermal conductivity used as the metal supports, and DURAPEK ® and DURAQUARZ ® coatings, absorb heat particularly quickly in the oven, distribute it well, and release it again quickly.

The coatings are designed so there is no need for baking paper that would adversely affect heat transfer. Moreover, baking paper becomes fully saturated with escaping liquid, which can lead to mushy results or lengthened baking times.

HIFFICIENCY ® products are always coated underneath as well, firstly to accelerate heat uptake and secondly to prevent abrasive wear of the aluminum.

According to Dr. Christoph Stecher, Managing Director of acs Coating Systems GmbH, Wilhelmshaven, Germany, this results in baked products being ready approx. 10% faster, in addition to which the oven temperature can often be reduced by approx. 10°C. No baking paper is needed. Thus altogether this yields a production efficiency increase of more than 10%, which quickly repays the slightly higher procurement price.

HIFFICIENCY ® perforated lye trays, which are fully coated with a 70 µm thickness of DURAPEK ® , are available for lye applications. In this process, the holes by which the trays are suspended during coating are tightly sealed with stainless steel rivets. The riveting technique was developed specifically

DURAPEK ® coating has undergone further improvement and now withstands approx. 300,000 scrub cycles in the wear test. That’s about ten times as many as for good triple PTFE coatings. It’s also suitable for all sweet products. Anyone who doesn’t want any polymers in their oven can be supplied with the ceramic DURAQUARZ ® coating. DURAPEK ® and DURAQUARZ ® contain no solvents and no PFOA, and are oven-safe without outgassing, and up to the highest temperatures without any limitations. HIFFICIENCY ® accessories have been developed and are manufactured by asc Coating Systems in Wilhelmshaven/Germany. +++

© asc Coating Systems

++ HIFFICIENCY® Multibake tray: crisp results, unperforated, multifunctional

++ HIFFICIENCY® perforated lye tray with no baking paper, even for the first lye dip

© asc Coating Systems

The de-luxe class from Northern Italy

Colussi Ermes is considered to be a supplier of de-luxe class washing plants. Word of this has spread around, not just in industrial businesses but also in the baked products sector.

The whole washing plant business that began in Casarsa della Delizia, North-eastern Italy, was for the high-class San Daniele ham made quite nearby in the Italian region of Friaul. The ham was followed by dairy processors, who asked Colussi Ermes to build washing plants for their cheeses, and finally pharmaceutical companies and all kinds of food manufacturers came knocking on the door. The baked products industry now appreciates Colussi’s hygiene standard, and does so worldwide.

There are several reasons for this. Colussi always builds its washing plants individually, according to the needs and space circumstances of the respective operation. The product range

has expanded over the years, and now includes washing plants for everything that needs washing in a bakery: trays, pans, crates, rack trolleys, bread trolleys, thermoroll trolleys and transport crates of all kinds. Cleaning in industrial operations is increasingly understood as part of the whole process chain, and is integrated into lines. That’s why Colussi built a plant equipped with 14 blowers to clean 130 x 130 cm peelboards for a frozen baked products manufacturer, which ensures a level of dryness so high that the peelboards can be loaded again immediately.

Although Colussi itself says it produces plants whose daily period of use is not finished in two or three hours but more

++ Cleaning that leaves no residues, even on complex pan clusters and cake molds

© Colussi Ermes

© Colussi Ermes

++ The crate washing plant’s centrifugal drying system ensures residual moisture is reduced to 2 g/crate, which is on the crates not as droplets but as a film that quickly evaporates

++ Contamination on rack trolleys is often particularly stubborn. Colussi’s rack washing plant is a specialist for this problem

© Colussi Ermes

++ A four-row folding crate plant with an hourly throughout of up to 10,000 crates like one or two shifts, that does not in any way limit its customer base to industry alone. The company also makes combination plants for chain-store businesses that can wash trays, pans, crates and even rack trolleys or other transport trolleys.

The fact that the plants are consistently fabricated from stainless steel, and not just pushed or screwed together but fully welded, is all part of Colussi’s standards, just like the special water sealing of the upper covers on tunnel oven washing plants. The hot steam condenses on the cover and runs into a channel carrying the seal. The channel is sealed watertight by the water, and only after the shift has ended is the channel emptied by the operator.

There are many details that boost efficiency. Thus many trolley washing plants are happily recessed into the floor, because in this way the water from the washroom can drain away quickly and efficiently, while at the same time there is no need for a ramp to wheel in the trolley. Another example is the externally mounted drum filter fitted with a scraper that removes coarse dirt from the water circulation. It extends into the water only far enough to trap the residues, and doesn’t repeatedly drag them through the water again but removes them

with the scraper as quickly as possible after they have been collected. Cleaning the plant itself is assisted by the fact that all the parts are accessible without effort, and/or can be opened or dismantled even without using tools.

New: 2000 crates uses 10 kW-hours

Based on experience from the fruit and vegetable industry, which operates plants that need to clean more than 8000 crates/hour in an energy-efficient way, Colussi recently built a plant for the baking industry that cleans 2,000 crates per hour, which it does with an average of 10 kW-hours of energy. A plant with only one centrifuge, which copes with 1,200 crates per hour, even makes do with an energy consumption of 5 kW-hours. Centrifuge drying reduces the residual water on the crates to 2 grams/m 2, on top of which it remains not in the form of droplets on the surface but as a fine film that quickly evaporates. To keep the energy consumption low, the braking energy released during centrifuging is fed directly back into the electricity network again. +++

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iba innovations

Numerous exhibitors will present their innovations in Munich. The editors submit a couple of novelties to give trade fair visitors an insight.

+Efficient snack production

Anneliese Backtechnik GmbH, Eschweiler/Germany, is considered to be the inventor of the Snackline, which is being constantly expanded. The plant consists of a worktable with a conveyor belt on which snacks are prepared. A wide range of accessories – from extension tables, catering tubs, attachment modules (for ingredients) and recipe holders to many other accessories, e.g. transport trolleys, is designed to make the preparation as efficient as possible. The Snackline is driven by maintenance-free, oil-free, gearbox-free drum motors. The electrical system is splash-proof. The only power supply needed is a 220 Volt supply socket. The Snackline is also mobile and can be moved on wheels. The conveyor belt is removable and easy to clean. The basic version is two meters long and can be expanded by adding various modules. In practice, this often results in lengths of up to eight meters. At the iba trade fair, for example, the company will also present a cutting module for the plant, to cut through or into bread rolls, bagels, cakes, croissants and other baked goods. There will also be a metering system to optimize sauce or dip dispensing.

especially suitable for use in hot climates such as the Middle East, Latin America and large parts of Asia.

The Accurist2.1 dough divider is also new. The plant now has a foaming and rinse-off cleaning system (by hose), and is supplied with a customized low-pressure spray pistol. Due to its servo-control, dough division is said to be fast and gentle. Another new feature is the TruClean three-roll dough sheeter for crackers and snack products. The TruClean design is said to significantly reduce the time required for a typical cleaning routine.

New sourdough ideas

The sourdough manufacturer Ernst Böcker GmbH & Co. KG present new product ideas on the subject of fermentation at this year’s iba trade fair in Munich. The innovations are as follows:

+ Pumpable quality sourdough pastes in 1,000-liter packs: automatically emptiable – to manufacture sprout and grain baked products in high-tech production units

SuperCool technology

At the iba trade fair, Baker Perkins, England, will present a technological innovation to optimize the precise temperature control of Tweedy mixers. According to the company, the process, called Tweedy SuperCool, fundamentally improves mixing bowl cooling. An improved design intended to ensure greater hygiene will also be exhibited for the first time. The new plant’s maintenance work is also said to be easier. The Tweedy can be used to make doughs for toast-breads, hamburger buns and pizzas. The Tweedy SuperCool is

+ Liquid, ready-to-use and microbiologically active sourdough products: for more flavor and a declaration advantage: “baked with sourdough”

+ Gluten-free sourdough products and special sourdoughs: for individually customized product solutions and quality optimization of gluten-free baked products

Moreover, the company is showing the range of purchasable, ready-baked special baked products under the brand name “Gluten-free from BÖCKER”. For example there is the new gluten-free oat bread (fresh with a longer shelf life or frozen) as well as gluten-free baking mixes and special flour blends

++ The new metering system for the modular Snackline

++ The developers have improved mixing bowl cooling on the Tweedy SuperCool

© Baker Perkins

© Anneliese

for amylase-trypsin inhibitor-controlled baking. As well as the iba, BÖCKER offers an individual applications advisory service, recipe folders, lectures and seminars, together with an opportunity to request test samples of products and advertising support.

A new dough extruder

Bühler AG, Switzerland, has added the ContiMix ™ dough extruder to expand its range of plants for industrial bakeries. This continually operating twin-shaft extruder combines two processes with mixing the ingredients and kneading the dough. The plant is suitable for preparing consistent doughs for laminated products such as puff pastry, flat products such as pizza dough, and molded products such as breads or toast-breads. The ContiMix ™ also has a recipecontrolled metering system for dry and liquid ingredients. There are also zones for treating doughs with vacuum or pressure, a cooling zone and easily interchangeable extruder shaft modules. Bühler says this allows fast, recipeaccurate configuration of the dough extruder to the required dough specifications. According to a company statement, baked products manufactured using the ContiMix ™ show in particular an improved volume and crumb structure, and are said to have a more intense flavor. It also says the continuous process enables the elimination of an additional dough rest and the associated handling. The dough goes forward directly into the next production phase, which shortens the entire production time.

We offer you the whole solution for the complete dough production and thus the most important process in the bakery production.

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Optimized construction

For optimum results with low consumption, the manufacturer Colged has now developed three washing machines with versatile uses: the IsyTech 36L-11GD, the TopTech 36L-23 GD and the TopTech 37L-23GD, in which there is space for a wide variety of kitchen utensils from spoons to baking trays. The wash liquor can be distributed uniformly by the innovative star-shaped combination washing arms supplied by a 700 W pump with Duo-Flow

++ The new gluten-free oat bread is available either fresh or frozen

++ The double-shaft extruder has zones to treat the dough with vacuum or pressure

© Bühler

© BÖCKER

technology. The company says significant savings are possible when combined with the UltraRinse3 post-rinse system. Furthermore, simple machine cleaning was emphasized to guarantee the necessary hygiene: Any deposits are easy to remove due to the deep-drawn, pipework-free interior with rounded corners. The models will be presented for the first time at the iba.

Colors from fruit and vegetables

Colourfood Professional, a brand of the BETTEC B.V. family business based in Vaals (Netherlands) is present at the trade fair with its coloring foods. Their philosophy is direct from field to bottle – pure colors from 100% fruit and vegetables. The company offers six intensely colored variants to produce colorful foods and drinks free from coloring agents and preservatives. The coloring foods are available as liquid and water-soluble variants in the color shades “Cherry-Red”, “Carrot-Orange”, “Spirulina-Blue”, “Grape-Violet”, “LemonYellow” and “Apple-Green”. As reported by the company, the products are generally very stable to temperature, light and acid. After opening, they can be stored for at least 60 days when cooled. The natural raw materials are processed using only physical processes and with water as the process medium. Colourfood Professional also avoids using organic solvents or ingredients of animal origin. Thus the products also satisfy the requirements for vegetarian and vegan foods.

Digital baked goods production

Digitization is progressing well in the baked goods industry. The sector specialist CSB-System showcases this in concrete terms. Its digital solutions presentation includes systems for incoming goods, production planning, price labeling, order-picking and branch connectivity. Trade fair visitors can gain an onthe-spot picture of how they can use smart technologies to optimize planning their production and resources and reduce their costs.

The centerpiece is the ERP system, which CSB offers in three different variants. The CSB Industry ERP is the sector ERP for companies in the baked goods sector who

are looking for a complete solution for their business. CSB Factory ERP is suitable for production works control in international groups and company groups that use a master-level group ERP. CSB offers the Basic ERP for SMEs: even in this basic version, the company says baked products businesses already have access to best practice processes that cover all the sector’s needs as standard. CSB is also showing new automation solutions and special hardware for bakery businesses. For example, the CSB Kompaktrack is used to record operating data and is suitable for fast weighing and labelling of goods. Industrial image processing promises big efficiency gains. It enables automatic data acquisition, analysis and further processing. The new CSB Recognition Unit for example, also on show on the CSB stand at the iba trade fair, can record baskets quickly and automatically: identification, counting, documentation – all these work steps are carried out simultaneously and with manual effort.

New generation of sponge dough and sourdough tanks

DAXNER is a full-service provider of high-performance plant and process technology solutions for bulk materials handling – all the way from raw materials reception to finished products. The company also offers sponge dough and sourdough plants with extensive accessories. These can be customized to integrate into existing production facilities, and offer solutions for high or low dough yields. The company’s product range comprises process technology solutions for every specific requirement: flours and groats, rye and wheat, cooled or uncooled, mobile or stationary, soft or firm processing, single stage or multistage, manual or automatic filling, and offtake via volumetric metering or weighing. The new generation of sponge dough and sourdough systems is designed to convince with more precise temperature regulation through large-area heat or cold transfer, increased hygiene as a result of conical openings and edgeless, joint-free transitions, flexible container heights and improved agitators. Daxner’s trade fair program also includes the daxDou continuous dough-maker to prepare sponge doughs and sourdoughs, together with special solutions for liquid components, e.g. in the shape of the daxRec scrap bread mixer.

e.CLEAN 500

DEBAG Deutsche Backofenbau GmbH is showing several new developments at the same time. The e.CLEAN 500 for example: a fully automatic oven cleaner with a 500-day refill cycle. Once the oven has been filled with cleaning agent, the stock lasts up to 500 days if the recommended cleaning intervals are adhered to. DEBAG’s customer service undertakes the handling. e.CLEAN 500 is available for the DILA and DECON instore ovens. The DECON multifunction oven will also be presented for the first time as a combined baking station at the iba trade fair – together with the newly-developed DEDEC hearth oven (DEcon DECk Oven). The DECONDEDEC combination thus unites the advantages of the three equipments in one: instore oven, combi-steamer and multideck oven.

++ Various new washing machine variants with star-shaped combination washing arms for kitchen utensils and baking trays

++ CSB offers various ERP-Systems for different requirements

Due to sustained strong demand, DEBAG has also developed further variants for the DECON multifunctional oven. This means every purchaser can now assemble his or her own individual DECON. The spectrum ranges from the DECON 5 (max. 5 trays @ 40 x 60 cm), the DECON 12 (max. 12 trays) and the DECON 5/5 (2 baking chambers with 5 trays each) to the DECON 12/5 (2 baking compartments, one with 12 and one with 5 baking trays). The loading system simplifies oven loading and unloading. The company offers a wide variety of subframes and proofers as accessories. The oven is configurable to the customer’s needs (space requirement, baking volume, product range breadth and depth) due to its modular construction. The plant constructor will present the expansion of its e.BAKE solutions at the iba trade fair. There is now a controller for two ovens. Operating expense is reduced, since both ovens can now be controlled from one display. The oven can now be operated by “touch” on the 7-inch graphic display, like a smartphone. The corresponding symbol is simply touched, e.g. “pretzel”, and the baking program starts automatically. DEBAG currently offers the one-touch controller for the DECON instore oven.

Mixers, starter cultures and fermenters

DIOSNA Dierks & Söhne GmbH has numerous products, and presents the DIOSNA A100 Ecoline as an example. This is a plant to produce soaked grain, hot-soaked grain, mash and AromaStück®. This compact three-wall plant with a water-bath jacket for all thermally managed sponge doughs with a dough yield ≥ TA 300 has a net capacity of 100 kg of sponge dough per batch. When using the AromaStück®, milled cereal products are heated together with water and special DIOStart flavor. After a defined development time, flavor components and natural maltose are formed, and develop an incomparable taste profile. The DIOSNA RW 650 HK-FU Compactline will also be exhibited. A rye and wheat fermenter with a cooling and heating unit and a frequency inverter. This compact plant with cooling or temperature control for all rye sourdoughs with a dough yield ≥ TA 220 and with a net capacity of 650 liters yields about 500 kg of sourdough. The RW 650 Compactline can also be used to manufacture a wide variety of wheat sponge doughs and sourdoughs.

In addition to mixing systems and wendel mixers, the company also presents the DIOSNA PSPVW 240 A TP/T/FU premium spiral mixer. A mixer with a touch-panel, frequency converter and interchangeable mixing tools. A special feature of the spiral mixer is the large-dimension mixing tool that is effective from the bowl wall to above the bowl center. Its special shape

ensures homogeneous mixing and intensive kneading. The special rotation speed relationship between the mixing tool and bowl is said to guarantee good mixing and kneading results. It can be used to process wheat dough, mixed bread doughs and even wholegrain doughs. The company promises optimum kneading of batches of any size, whether very small amounts or full capacities.

Visitors can also obtain information about various starter cultures, e.g. DIOStart wheat classic, DIOStart wheat strong or DIOStart wheat fruit.

Donut-Topper

The chocolate decorations manufacturer DOBLA wants to be even more deeply involved. For example, the Dutch family business will present the Fast Chocolate Experience at the iba trade fair. For this, the company will recreate its own American diner style fast food restaurant on its trade fair stand to show, for example, donuts with individual decorations or “Chic Shakes” (the chic version of the freak shakes).

Remote Maintenance

At the trade fair, the DÜBÖR company will present the latest innovations connected with control and regulation technology. The new machine generation has been given a user-friendly touch-screen for interactive operator guidance. Due to digital controllers, all the machine’s performance and consumption data are tracked continuously and assessed in the context of preventive maintenance. For instance, the new generation TSA 800 independently reports the need for maintenance depending on the intensity of use. It also has a recipe database through which a wide variety of spray quantity settings can be managed and called up at any time. The DÜBÖR company’s remote maintenance concept rounds off this digital system. Machines and technicians dial in via the Internet. This access is possible through all mobile terminal devices. Data exchange then also said to take place via a secure encrypted connection. A large proportion of malfunctions attributable to wrong settings or incorrect operation can be remedied quickly via the digital access facility without cost- and time-intensive on-site intervention. Machine availability is restored quickly and lengthy unplanned production downtimes are eliminated. The external access facility also enables the immediate adaptation of any processes within the production operation, as well as answers to operation and maintenance questions. The TSA 800 is rounded off by the new nozzle generation, which fulfills the highest hygiene demands through its clean-in-place design.

The intelligent plant

Soft doughs, especially doughs with a long dough preparation process are a special challenge in the manufacturing process, but there is an ever-increasing demand for products made from these doughs. That’s why FRITSCH has developed the new SDS (Soft Dough Sheeter) dough sheeting system. It is optimally suited for processing very soft doughs and large dough thicknesses with only minimum use of oil, and very

++ Wendel and spiral mixers together with various other systems await visitors to the trade fair

© DIOSNA

slight impacts on the dough structure. These are decisive advantages, since an increasing trend is developing towards processing ever softer, pre-fermented doughs with sponge dough and bowl fermentation. Thus the SDS is specifically useful for Mediterranean artisan bread and bread roll products with a dough yield of TA 165 and above (up to TA 190 depending on the flour quality). The capacity range extends from 800 kg up to 5 tons.

The advantages of the SDS at a glance:

+ for a dough yield (TA) up to 190 and long pre-fermented doughs

+ maximum possible retention of the original structure of the dough and pores

+ high weight and shape constancy of the dough sheet that is produced, for low scrap dough residues and minimum end-product weight tolerances

+ optimizing the entire production process starting with dough preparation and dough fermenting (batch size from 150 to 200 kg with container or bowl fermentation)

Another of FRITSCH’s topics will be the “Intelligent Retrofits”. The following benefits are offered in the first configuration stage:

+ Qualification balancing of operating personnel through intuitive plant operation

+ Increasing plant availability and prevention of unplanned plant downtimes through Condition Monitoring

+ Predictive maintenance through early warning messages when problems arise on critical components

+ Cost saving and efficient communication with FRITSCH Service, supported by the use of data glasses

++ The new Soft Dough Sheeter processes especially soft doughs with a long fermentation time

© FRITSCH

1+1= more than 2

The main aim of the merger between Haas and Bühler in 2017 was to create advantages for customers. Under the slogan “Creating Tomorrow Together”, the intention is now to illustrate the benefits. Innovative wafer, cookie and snack products, among other things, will be exhibited. There is also an Ideation Room. Machines like the Contimix or Eco-Oven can be seen live and in action. Visitors can experience other machines such as the CAIMAN and aeration machines in the Augmented Reality World, and can explore the processes on the 3-D table.

Flavors from Plauen

KAROW has 70 years of experience, and is now one of the leading flavor specialists in Germany and Europe. Specialist visitors to the trade fair will have an opportunity to get to know the product range, which comprises more than 250 articles. The liquid flavorings and pastes for baked product and dessert manufacture deserve special emphasis. The full product range contains as good as every flavor variety. The selection of flavors is supplemented with ice pastes, toppings and dessert sauces, basic materials for beverage manufacture, and coloring foods. Newly exhibited are the premium clean-label pastes in flavors including strawberry, raspberry, pear, cherry, cassis, sea buckthorn, mandarin, maracuja, lemon, orange, vanilla and lime. At least 95% of the flavorings come from the basic raw materials from which they take their names. The dosage is 30 to 60 g per 1,000 g of batter. The second KAROW highlight are the organic flavorings. These articles conform to the DE-ÖKO-001 Standard and carry the Bio (organic) seal of quality. The product range currently consists of: organic lemon zest paste, organic orange zest paste, organic lemon oil, organic vanilla bean extract, organic lemon flavor, organic bitter almond essence, organic vanilla flavor, organic invert sugar syrup, organic turmeric extract and organic egg liqueur with blossom honey.

The power of the four elements

Under the slogan “König Elements”, the Austrian plant constructor König shows how the power of the four elements Earth, Water, Air and Fire are pooled together in the machine highlights to enable this world’s bakeries to manufacture the best bread and the best rolls. The mechanical engineer will show a variety of innovations at the trade fair, e.g. the Easy Clean model of the Combi Line Plus bread roll plant. The trade fair machine will be demonstrated as the “plus” version with an 800 mm working width. This allows a performance

of 33 strokes/minute, corresponding to 11,880 pieces in 6-row operating mode. The Industry Rex Compact AW divider-rounder machine offers a balance between weight accuracy and gentle dough handling. By a variable division of the weigh-out stamp and row arrangements, this machine provides a weight range from 28 to 350 g in only a single compactly-constructed machine. A new user interface simplifies its operation for day-to-day production, as well as for program changes and servicing work. The new Combi Line plus offers the customary variety of round-stamped, long-rolled and molded dough pieces. In addition to stamped bread rolls such as Kaiser rolls and Czech housky rolls, the trade fair machine with a molding station provides the option to manufacture hamburger buns, hot dogs, half baguettes etc.

A multifunctional high-performance plant to produce bread rolls will also be shown. The plant consists of a direct weigher with a capacity of 100 strokes/minute, a proofer and a molding station for a variety of different products.

A cutting/scoring robot for precise, gentle decorative cuts is also new. To enlarge the product portfolio, König is cooperating with the Spanish company Simaupro to offer a cutting robot in the Smart system. This is used to make gentle, precise cuts into various breads, baguettes and rolls. Thanks to the built-in vision system, the exact position of the loaf of bread on the board is recognized and the cutting position is individually adjusted, regardless of the layout on the tray and even for doughs with a high water content.

++ New in the product range: Premium clean-label strawberry paste

++ The rack oven offers a potential energy saving of up to 20% compared to the predecessor model

© König

© KAROW

A more intense taste, a higher bake-off volume and an improved crumb structure – bakery products produced with the new continuous dough extruder ContiMix™ represent superior quality. Combining the mixing and the kneading process in a row, ContiMix™ eases the production process. And results in direct cost savings for bakery producers.

The compact G2000 bread roll plant will also be on show. This compact plant with an hourly output rate of approx. 2,500 items is a solution for small and very small businesses or instore bakeries. Up to now, this plant was already able to make stamped products, e.g. Kaiser rolls or folded-in rolls. As a result of additional builtin modules, e.g. with a cutter wheel, it is now able to produce split-top rolls, or with a driven upper belt, hamburger buns can also be made. Fitting a compact König coiler also allows the production of Kornspitz croissants or conical croissants. The plant has an adjustable-height, single-row exit belt for manual removal, and a proofer with approx. 100 loadable indented swing-trays and a proofing time of approx. 2,000 pieces/hour. The divider-rounder can be swiveled out for operation without a proofer, and a higher output capacity of up to 4,800 pieces/hour.

In the ovens area, the Roto Passat SE (Save Energy) rack oven will be exhibited. The main emphasis in its further development was on the “energy efficiency” theme. As a result, this oven offers a potential saving of up to 20% compared to the predecessor model. A newly-developed heating register is the basis for this energy reduction. The heating register, operated on the countercurrent principle, now offers a higher level of efficiency and better heat transfer.

Also on show will be the DW 240-H twin wendel mixer. The robust double-shaft mixer in a stainless steel version produces doughs with short kneading times and low dough warming. Thus this double-shaft mixer provides the basis for high product quality. Hygiene design type “H” has also been implemented for the double-shaft mixer. Thus the new DW 240-H is available as a fully washable model. The DW 240-H hygiene model has the following characteristic features:

+ Machine base-frame and machine top in fully sealed welded construction

+ Stainless steel claddings

+ Stainless steel switchgear cabinet

+ Drain holes in the baseplates of the machine base-frame and machine top

+ Friction wheel drive made of stainless steel

+ Friction wheel drive with spray water runoff

+ Dust-tight mixing bowl cover + IP65 touch-panel

The DW 240-H is especially suitable for wheat and fine pastry doughs, as well as for rye and rye mixed doughs.

Living Bakery

At the iba under the trade fair slogan “Living Bakery”, Korte Einrichtungen again emphasizes the fact that experience baking must not be just an empty phrase. The concept must be inviting and must convey an atmosphere of well-being, while at the same time being convincingly practical with a clear focus on increasing sales revenues and saving personnel costs. The sales counter plays a central role in this. Since the product range changes along with the sales focuses, a flexible presentation is the be-all and end-all. Korte’s sales counter technology takes into account and simplifies changing product ranges. With support by experts from bsc Concepts, the Kürtener experts on the stand demonstrate the versatile possibilities of their Tavola counter: whether it’s for a presentation of snacks, as a stage for confectionery products, as a buffet counter for fast customer service, as a tapas bar or – again together with the Giovanni L. ice-cream professionals on the iba stand – as the basis for a businesslike ice cream concept. The lighting is just as important as the counter engineering. Korte Einrichtungen has already been working for years with the options for intelligent, product-specific merchandise lighting. In this respect, the company is showing various different options for a modern, attractive presentation of breads.

Major innovations

iba 2018 will be the big event for MECATHERM. On a 750 m2 booth, the production lines architect will present three major innovations serving diversity and product quality. MECATHERM is launching a brand-new oven, unique on the market. Flexible, precise and efficient, this oven allows for optimal baking for a large selection of products, while allowing speedy changes to production, thanks to simple screen monitoring. A new intuitive divider, highlighting the French savoir-faire, will also be presented. Simple and precise, the new MECATHERM divider combines the best of existing technologies, associating the precision of a volumetric divider to the possibility of working with high quality dough thanks to lamination. This retrofittable solution will allow businesses to obtain hydrated, pointed, calibrated dough, to give the baguette back its authentic and historical

++ The hygiene model of the double-shaft mixer

++ At the iba trade fair, Korte Einrichtungen shows ideas for a modern, attractive presentation of breads

© Korte Einrichtungen

© König

value. MECATHERM will also present an intuitive, universal conveying system. This equipment is totally adjustable to the clients’ plant dimensions and allows modulation of the production rate. Designed around food safety, it permits homogenous, delicate handling of the products during the fermentation, cooling and freezing steps.

Exclusive coffee roaster

MEISTER KAFFEE, the exclusive coffee roaster, will give information about current market trends to experts visiting the iba and will present various different coffee concepts including the new “OUR

COFFEE” concept. “Café da Lagoa” farm coffee and the traditional “MEISTER KAFFEE” brand will also be center stage. The individualizing trend has also been taken up with the “OUR COFFEE” drink-serving concept. This involves implementing coffee packaging and associated advertising materials based on individual wishes and with the baker’s name. Forming an additional focus is the “Café da Lagoa” farm coffee, grown in Brazil and originating from the Fazenda da Lagoa, founded in 1764 and twice certified (UTZ and Rainforest Alliance).

All the way to special machine construction

Among other things, the product portfolio of the special machine builder Meyma includes the following: bowl tippers/ table tippers, strand shapers, intermediate cones, star dividers, dough feeder cones and belts, special machine construction, sponge dough cones, general overhauls and bread roll counting machines. The bowl tippers, for example, are developed and fabricated in their own works in Cloppenburg, Germany. Meyma bowl tippers are suitable for HACCP, are usable for any ceiling height and for all bowl trolleys, and are easy to operate. A laser scanner covers their aspects relevant to occupational safety without any space-grabbing systems. The laser scanner is also said to be inexpensive to purchase, needs no fences and requires no expensive cleaning. It is flexible in use at the same time, e.g. even in the oven’s loader area. The system is supplied with collision protection built-in. The company covers the small group component sector for retrofitting or conversions by components it develops and produces itself, e.g. in the form of forged bowl scrapers. The scraper is fabricated without a shoulder or transition, so thorough cleaning is accomplished quickly. The plant constructor can adapt the newly-developed scraper device to any bowl shape. Special sockets for the scrapers are developed in a 3-D design process.

HYGIENIC, FOODSAFE CONVEYING

From mixing to packaging – this process chain needs to be efficient and totally hygienic. Siegling Belting has an extensive product range to do just that.

■ With innovative belt types for all steps in the process and functions required

■ With HACCP types that sustainably support your hygiene concept

■ With reliable service and in uncompromising quality

Forbo Siegling GmbH · D-30179 Hanover · www.forbo-siegling.com · siegling@forbo.com

++ MECATHERM croissants production line

++ With their own coffee, bakery businesses can stand out from the competition

With customized front panel decoration

The MHS Premium touch S is right on time for the iba –the narrow “little sister” of the MHS Premium touch –available with the big model’s advantages. According to its own information, MHS had already developed the MHS Premium touch as the first bread slicing machine with an individually customized front panel decoration. The MHS Premium touch S adds a new variant to expand the series of models. Slicing speed has been increased to a maximum of 220 cuts. Upgraded cutting geometry combined with the newly-developed NEW-WAVE knife is also said to achieve maximum slicing quality. The operating system has also been completely newly developed. It now takes place via a SMART-TOUCH DISPLAY through which all the functions and information can be adjusted and accessed. When developing machines, MHS already emphasizes not only ease of operation and high reliability, but also time-saving cleaning. This is made possible through the MHS Hygiene Design. MHS has already focused for several years on separating the drive and electronic components from the slicing area, as well as on good accessibility through large maintenance openings. Cleaning is possible from the front, without needing to move the machine. The plant’s design has been completely revised and now offers an opportunity to match it to the shop-fittings. A décor or preferred color can be chosen in consultation with the shopfitter to integrate the machine into the shop visually as well.

Come and experience the next generation make-up line from Stewart Systems . The new High Speed Bun Make-Up line offers a variety of improvements. The most notable development is the detachable manifold assembly which can roll away and allow for easier cleaning. It is removed from the main divider body without needing tools. The manifold itself can also be cleaned by removing the inspection cover, also without needing tools. The main divider body essentially serves as a dough pump and can attach to a manifold assembly of the customer’s choice.

The exterior of the dough divider is now a hygienic wash-down design and the overhead proofer is easier to clean. Overhead side panels are removable with one simple tool for safety. Single swing-away bottom panels make it easier to dispose of accumulated flour dust. The molder is also updated with a redesigned indexer fitted with encapsulated magnets. Cleaning and part replacement are now easier than ever.

A wide selection

The Middelby Bakery Group will be present at the iba trade fair with Stewart Systems, Burford Corp, Baker Thermal, AutoBake, Hinds-Block, Sveba-Dahlen, Scanico and Varimixer.

Auto-Bake Serpentine

Auto-Bake is a global designer and supplier of fully automated industrial baking ovens and systems. Internationally renowned for its Serpentine technology, Auto-Bake’s compact, costefficient, continuous baking solutions are custom-configured for a diverse range of baking applications. Beyond cakes and pastry there are three significant growth categories where Auto-Bake is proving that its technology also excels; readymade meals, artisan/specialty breads, and pet food.

At IBA 2018, Auto-Bake will share booth B1-111 with HindsBock and Firex. Filling, deposition, pumping and portioning is the specialist area of the Hinds-Bock Corp., Auto-Bake’s strategic partner for over a decade. Firex, manufacturer of advanced cooking systems, will display its industrial sauce maker.

This year at the iba, Spooner Vicars will showcase the Vortex high speed, horizontal mixer for cookie, biscuit, cracker and

++ The plant’s design has been re-engineered and now offers an opportunity to match it to the shop furnishings

++ The new High-Speed Bun Make-Up line offers a variety of improvements

++ Spooner Vicars will showcase the Vortex high speed, horizontal mixer for cookie, biscuit, cracker and other similar hard and soft doughs

© Middelby

© Middelby

© MHS

Middelby

Spiral into control.

AMF Bakery Systems’ Spiral Conveyor incorporates the most sanitary design elements, including a patent-pending monopiece cage bar, for efficient cleaning and maintenance. Equipped with plastic modular belting using the Intralox DirectDrive™ System, the Spiral Conveyor eliminates product movement on the belt to minimize potential jams. This custom-configured solution is suitable for a variety of product applications including intermediate dough proofing, product proofing, cooling, and freezing.

Your bakery is our world.

VISIT AMF BAKERY SYSTEMS AT: MODERN BAKERY, MOSCOW FOOD & HOTEL ASIA, SINGAPORE BAKERY CHINA, SHANGHAI

other similar hard and soft doughs. Spooner Vicars’ unique sprag, a fixed stator inside the bowl, allows the dough to be folded, sheared and kneaded thoroughly. Research has shown this to reduce mix times significantly compared to other bowl/blade designs. Temperature is important and the sprag houses a temperature sensor to monitor this, while the bowl is jacketed to permit water circulation from an external source to maintain the ideal bowl temperature.

Capacities range from 350 kg to 2,400 kg and in the case of tough cracker doughs robustness is vital, and so is motor power and duty. The 750 kg mixer, for example, uses a 90 kW heavy duty Variable Frequency Drive with programmable speed and slow start ramps to handle torque when switching from low to high speed cycles.

On board software allows mixing to time, temperature or energy so that the baker can build a valuable history of mix parameters to accommodate flour variations and differing ambient conditions.

Sveba Dahlen

Sveba Connect – Smart Baking, part of Middleby Connect, cloud solution, is the recipe for successful business!

+ Monitor all the bakery’s connected ovens online

+ Better control of the oven’s energy consumption/statistics.

+ Increased operating reliability.

+ Central software update.

+ Save, distribute, download and share recipes between all your fleet of ovens and get or share recipes.

+ All ovens with the Sveba Dahlen SD-Touch panel (SDTouch panels made from 2012 to 2018) can get updated

free of charge during the iba. All subscribers before 31/12/2018 will receive 2019 free of charge. Thereafter, the subscriptions are charged annually.

Combination oven – S-Series

The success of Sveba Dahlens S-Series has made Sveba develop the oven further. Among other things, Sveba have reviewed the oven's footprint, and made an efficient oven whose footprint is only 990 mm. During the iba they will show three different combinations in the new color – black.

Deck combination oven

+ 3 decks

+ Turbo function heats up the oven quickly to set temperature

+ Each oven section can be individually controlled with separate settings of the top, bottom and front heat

+ Dual temperature sensors

+ Control panel

Flexible combination oven

+ Combination with rack oven, deck oven and proofer

+ All-in-one oven which bakes everything from stone baked bread to confectionery and ciabattas etc.

+ Very flexible baking station, with proofer, deck oven and rack oven, which improve flexibility in the bakery

Mini rack combination oven

+ Small rack oven with efficiency like a big oven

+ Fast, high-capacity and energy-saving, built-in steam system

+ IBS – alternately rotation of the racks for better baking results

+ Good overview of the baking process with large front window with heat-reflecting double glass and good lighting

++ from left to right: F 500, S-series flexible combination, C 252

© Middelby

F-Series Proofer

Sveba Dahlen has developed a new proofer, the F-Series. At the iba they will show the F500 with all its features and benefits.

+ Reliable, energy-efficient and user-friendly freezer-retarderproofer to lowest cost of ownership

+ Available in black or in stainless steel color

+ Demand-controlled fans makes sure that no more air than necessary is circulated. Parameters such as cooling, heating and humidity control the fans in each program phase, running the fan at just the right speed, which makes it quieter and more energy-efficient

+ Equipped with vertical presence-controlled LED lights inside for good insight.

+ Control panel which is easy to operate and with a really user-friendly GUI

Core temperature

Sveba Dahlen has developed a core temperature functionality suitable for all of our rack ovens. At iba the company will show it on a C-Series, C252, rack oven, which is also updated in black.

+ Core Temperature function measures the internal temperature of the dough and shows it on the control panel. It also shows the current temperature and notifies when the desired temperature has been reached. With the core temperature it is easier to achieve perfect baking results every time. Measures temperatures up to 120ºC.

Mini deck oven N-Series

Sveba Dahlen has developed a new neat combined deck and pizza oven, the N-Series.

+ Really high baking results with steam to a minimal cost and space

+ Stone hearth and hearth grid as standard

+ Same high-quality baking as in large deck ovens with a unique steam package system and top and bottom heat

+ Very small bench-top oven with outstanding flexibility, which makes it perfect for smaller bakeries, food courts, malls, supermarkets and stores

+ Easy to operate and can easily switch from making high quality buns and pastries to making pizzas with fantastic results

+ Plug and play oven

+ Control panel with touch screen and user-friendly GUI

+ Good insulation and triple-glazed window keeps the heat inside the oven and leads to high efficiency and a good working environment

Rack oven V-Series updates

+ Optimized airflow system and rotation speed for best possible baking results

+ Improved cutting and placing of the isolation plates inside the oven, improving the insulation and increasing thermal efficiency

+ The platform has improved material, providing robust stability and more

The wide spectrum of modern baking

MIWE will show the whole spectrum of modern baking at the trade fair. For example, a year ago the company presented for the first time the MIWE shop baking suite (MIWE sbs) –a tool that allows geographically dispersed systems to be managed in overview from one (or several) central point(s). The new MIWE sbs:assist module now also provides more security and digital convenience directly at the preparation area in the branches. This assistance system constantly provides employees with all the required information and instructions clearly and understandably, directly at the preparation point, in addition to which it carries out one or other of them fully automatically. This avoids mistakes, production quality increases and wastage due to rejects decreases.

A whole array of MIWE transport and loading systems ensures rational interlinking of the individual process steps in baked goods production. A small selection of these can be seen in live operation on the stand, from simple loading aids that mainly minimize physical effort and trolley oven feed systems like MIWE assist (in use live in conjunction with a MIWE thermo-static thermo-oil-heated trolley oven) to the MIWE athlet heavy-duty portal loading system (also in live use) that allows highly automated process lines to be implemented even for big throughput volumes.

Vacuum conditioning is a new addition to MIWE’s service portfolio. Via a cooperation project with Cetravac, MIWE has included vacuum conditioning into its portfolio in 2018 to allow it to meet the ever more highly differentiated technological requirements of many customers in an even better way. In the first place, vacuum conditioning in a production operation enables a significantly shorter baking process –with the same degree of browning and identical stability; therefore more moisture also remains in the crumb after conditioning. Secondly, it allows very much faster cooling (and thereby also the further processing) of baked products. With the new technology, a batch leaving the oven at approx. 90 – 98°C needs only 2 to 5 minutes to cool down to approx. 35 - 40°C. As well as speeding up the processes, it also yields longer shelf life and improved storage capability. With vacuum conditioning, pre-baked products attain a storage lifetime of 3 to 7 days at room temperature or when chilled. However, the product itself also benefits, e.g. with improved crispness, optimized volume and better shape stability.

Packaging solutions

MULTIVAC is exhibiting solutions to pack bread, baked goods, fine pastries and snacks. In addition to two chamber machines, the exhibits also include a compact thermoform packaging machine and a tray sealer. The R 085 e-concept thermoform packaging machine simplifies entry into automatic thermoform packaging. It enables the manufacture of product-appropriate packaging for a wide variety of baked products in small batches. The machine does not need a water or compressed air supply, with the result that it can be used flexibly in a production operation. The T 250 semi-automatic tray sealer is suitable for packaging baked goods and snacks in small batches. The model can be used flexibly thanks to its space-saving design and mobile castors – and according to the company its characteristic features are hygiene-appropriate

design and simplest possible handling. An automatic tray drawer ensures ergonomic working. MULTIVAC is showing two highly flexible solutions from the chamber machines area at the trade fair. The C 350 chamber machine has two sealing lines, allowing it to be used flexibly. Like all MULTIVAC’s vacuum machines, the C 350 is also easy to operate, clean and maintain. The evacuation and gassing processes is also said to take place under pressure control, thus guaranteeing reproducible packaging quality.

The BASELINE P 300 table-top machine provides a model that is especially suited to packing larger products, thanks to its spacious chamber (420 x 425 x 170 mm). The BASELINE P 300 can be used flexibly due to its compact dimensions.

Bakery machine specialist

At this year’s iba trade fair, the bakery machine specialist REGO HERLITZIUS will focus on presenting machines for artisan and semi-industrial suppliers. Following several years of major projects for the industry, the traditional manufacturer will in future concentrate entirely – and not just at the iba – on its core competence and on driving forward the development and production of machines for bakeries, confectioners and medium-sized users. The corresponding whipping and agitating machines, planetary,

++ The MIWE thermo-static thermo-oil-heated trolley oven with the MIWE assist loading system

++ The R 085 e-concept thermoform packaging machine for automatic thermoform packing

++ The latest generations of whipping and stirring machines are being presented in Munich

MULTIVAC © MIWE

stirring & mixing machines and the latest generation of bread slicers will be on show on the stand. REGO HERLITZIUS will exhibit at the iba together with MKW GmbH, which took over the industrial machines division of REGO HERLITZIUS early this year.

Tandoor bread

As it says itself, the Saltek company in Beirut, founded in 1977, is one of today’s market leaders for plants to produce naan breads, tandoor bread, lavash and other specialty breads. Visitors can obtain information about the various plants during the trade fair. For example there are plants with an hourly output capacity of up to 2,800 tandoor breads (28 cm diameter) or for 1,800 breads measuring 45 cm.

New developments

Sollich and Chocotech will be present on a corporate stand and will present new developments. The following exhibits will be shown:

+ A high performance enrobing machine type Enromat ® M6-1300 Magnum with a 1,300 mm belt width. The enrober is equipped with one curtain station and one blower unit and diverse accessories. The Enromat® M6 Magnum incorporates high technology when enrobing difficult products with chocolate. A built-in turn shaft with following turnover table allows high performance production of bottom-coated products.

+ Following the Enromat® M6 Magnum is a chocolate cooling tunnel of the Thermo-Flow plus type KSK 1300 with telescopic infeed table. The cooling tunnel is equipped with bottom water cooling and with new gullwing PU-covers for better accessibility of the cooling chamber. The complete installation is equipped with the “Fast Lane” remote control system.

+ An automatic 820 mm Decormatic ® type DC4 decorating device installed on a decorating belt and Minitemper ® MT 100 to feed the decorating machine. The machine will be on display with chocolate during the exhibition. The various decoration patterns are programmable, i.e. product change can be done very easily.

+ A Turbotemper ® type TE 1800 to feed the type Enromat ® M6 Magnum enrobing machine. The Turbotemper ® includes an automatic Tempermeter type Tempergraph.

Focus on ancient cereal types

In the iba year, SchapfenMühle is generally focusing on ancient cereal types, e.g. with the “Meine Mühle” (“My Mill”) product. This mill premix consists of the quartet of ancient cereals comprising spelt, emmer, einkorn and perennial rye. Additives such as baking enzymes, emulsifiers, milk products, wheat and wheat gluten have been consciously avoided. The ancient cereal quartet is the only one prepared in-house by a special milling method to ensure it possesses positive baking properties. The declaration-friendly mill concentrate is dosed at the rate of 35%. The original “Vier-Urkornbrot” is a fine-grained pale wholegrain bread and is suitable for a vegan diet. The mill blend is part of the Schapfen “My Mill –Baking close to nature”. The product can be used to bake other bread and roll variants by recipe adjustments. A bread roll production process via “chilling” also exists.

The first emmer mill blend on the market for bakery businesses is Schapfen “Meine Mühle” (“My Mill”) Emmer Urkorn. This is based on the cereal duo emmer and spelt, the entire emmer proportion being added in puffed form. The concentrate can be used to produce spelt-emmer baked products. The baked products are assignable to the “Meine Mühle” product philosophy according to which only declaration-friendly, consumer-oriented ingredients are used.

+ A Turbotemper ® type TT 100 B Airo for small capacities. The TT 100 B Airo is equipped with a heating reservoir tank and a feed pump, especially designed for tempering smaller chocolate capacities in a superior tempering quality. The integrated aeration system allows aeration of the mass.

+ A chocolate coating machine type Minicoater™ MC 420 with 420 mm belt width will be on display with chocolate, followed by a Thermo-Flow ® plus cooling tunnel type LSK 420. This machine is running very successfully at small and medium-sized companies setting new standards in the mini enrobing technology sector.

++ A highlight at the iba will be the Sollcofill/Sollcocap depositing line for refining biscuits

++ Tandoor bread plants are available for different sizes of bread and with various hourly output capacities

© Sollich

© Saltek

+ A special type CA 820 caramel enrobing machine with an 820 mm belt width for enrobing wafers or biscuits with caramel or – after slight machine adjustment – also with sugar icings.

+ A type KGS 1050 piston depositor to deposit fat masses, jelly or caramel.

+ A highlight at the iba will be the Sollcofill/Sollcocap depositing line to refine biscuits, e.g. fillings like caramel, fondant, nut paste, jelly, milk or yoghurt cream or chocolate can be deposited together with ingredients. The performance of the system has been greatly increased and guarantees high-quality production of sandwiched products. Products which do not meet the quality demands, e.g. a biscuit that does not match the shape, will be rejected automatically by the machine.

+ The combination of the Sollich machinery together with the Chocotech company’s cooking equipment to produce sugar, jelly or caramel masses allows customers to obtain production responsibility from a single supplier and thus also ensures production lines are commissioned efficiently and as quickly as possible

Best-In-Class Technology

The Tromp Group can fulfill all aspects in the complete process of baking: Mixing, Sheeting, Proofing, Baking, Cooling/ Freezing and Topping. These are the main items under the spotlight on the Tromp Group’s booth.

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All about Pizza

Three brands are represented: Tromp Sheeting & Depositing Systems, Den Boer Baking Systems and VanderPol Waffle Systems. Tromp will present “All about Pizza”, a concept to make the most optimal pizza production with our integrated process line. The concept is highly appreciated by the market due to its efficient way of working with modularly designed equipment.

The booth will also display a section from a Multibake HT tunnel oven. This is a directly heated oven with a stone floor for perfect pizza production. Furthermore, Tromp will show elements of a sheeting line and a topping line. Elements as hygiene, state-of-the-art and easy to use are visible.

++ The new Multibake HT tunnel oven

Fermentation, ancient cereals and vegan

UNIFERM will present the product innovations FermFresh ® Urgetreide (Ancient Cereal) and FermStar ® Langzeit (Long Time) at the iba trade fair. FermFresh ® Urgetreide is a new development from UNIFERM’s range of fresh products.

FermFresh® Urgetreide brings together the two cereal varieties – Emmer and Einkorn. UNIFERM’s own gentle multi-day fermentation process intensifies the natural flavor profile.

FermStar ® Langzeit bread roll baking agent is also new. According to the company, the bread roll baking agent, specifically with slower dough preparation methods, ensures a full flavor, good visual appearance and finely flaking crispness. Furthermore, during dough ripening, the special UNIFERM flavor yeast together with selected malts develop a flavor profile whose aroma and taste are said to be reminiscent of chestnuts and vanilla.

The new Royal Rühr® vegan will also be on show. It is suitable for the production of vegan tray cakes or muffin varieties.

New products

Vandemoortele is showing new products again at the iba trade fair, e.g. soft baguettes, rose-shaped rolls and Danish plait. The new rose-shaped roll has an artisan bloom. It weighs 90 grams and is available as a pale and a dark rose-shaped roll. The new soft baguette has an extra-soft appearance and a significantly longer shelf life. Due to its soft crust, the baguette does not crumble. The soft baguette is pre-cut, fully baked and ready for immediate topping to ensure uncomplicated handling. It weighs 105 grams and is available as a

white soft baguette and as a soft baguette with wholegrain wheat. The new Danish plait combines Danish pastry dough with a vanilla filling in a plait look. The Danish plait has a crème filling (vanilla flavor), is decorated with sugar and weighs 95 grams.

Think process

“Think process” – under this trade fair motto, the WP BAKERYGROUP presents a variety of innovative ideas at this year’s iba 2018.

The intelligent KRONOS DIGITAL mixer adapts independently to the condition of the dough and stops the mixing process automatically at the optimum point in time. This guarantees dough in reproducible, consistent dough quality, irrespective of the raw material properties and ambient conditions, as well as the training and experience of the responsible employees. The KRONOS is easy to operate: once started it performs all other tasks automatically. The mixing process is continuously controlled based on the measured dough properties. The blending and mixing phases are adjusted or ended automatically. And each measurement is also documented for the purpose of quality control.

The latest generation of the MATADOR STORE Color Edition instore baking oven will be presented at the iba with the new control system generation WP NAVIGO 3. Each oven has its own display, which is attached in an ergonomically optimized manner right next to the door for time-saving working. The EASY MOD display mode makes operation of the oven particularly easy and safe for sales personnel, as information on the product, the baking time and readiness for loading can be captured at a glance.

The advanced MULTIMATIC dough divider and molding machine is now suitable for an even more versatile range of applications. The number of rows can be adjusted, which means that the MULTIMATIC can be used very flexibly with a significantly greater weight range of up to 600 g. The MULTIMATIC has also been further developed in terms of hygiene. All belts, dough-handling plastic components and the hopper are in blue. This increases the safety of food production and saves time and costs when it comes to cleaning the machines. ROTOTHERM Green heavy duty: with a turning circle diameter of 1,560 mm

The heavy-duty edition of the ROTOTHERM GREEN is new. It offers space for two 600 x 800 mm rack trolleys or for one large single rack trolley requiring a turning circle with a diameter of up to 1,560 mm. The rotating table has accordingly been designed for heavier weights. It is suitable for high loads of up to 750 kg max. per baking cycle. The heat exchangers have also been enhanced to ensure even greater energy efficiency.

WP Bakery Technology’s tried and tested control system will be launched on the market in the third generation at the iba 2018. The WP NAVIGO 3 convinces with an optimized user

++ The new FermStar® Langzeit bread roll baking agent to bake small bread products

++ The new rose-shaped roll weigh 90 grams

Your Business Simplified with DirectDrive™ System

DirectDrive System spirals function the way spiral systems should function; with reduced belt tension, with improved product orientation, with increased load capability. This system eliminates overdrive and makes operation of your mission critical equipment reliably smooth, without interruption.

Reliable performance

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interface for all instore and production baking ovens, and many new features.

MAMMOETH, the first fully servo-controlled dough divider is

together with customers and suppliers. The MAMMOETH impresses with its Cleantec design with separate dough handling zone, and automatic cleaning options. The processing of the dough is particularly gentle thanks to the Pressure Response Position system. The servo drive controls the weight with maximum accuracy at a production speed of up to 10,000 dough pieces per hour. The dough divider is suitable for Industry 4.0 Cloud and 3DTwin. The 3DTwin principle will be demonstrated at the exhibition booth of WP BAKERYGROUP. For this, a virtual 3D copy on the display will be synchronized with a MAMMOETH at the stand. This principle enables clear and smooth communications between WP Haton and the customer – regardless of the location and combined with all advantages, such as data mining, training, service and remote process control.

VACUSPEED INDUSTRIAL: Fully automatic combination of baking in deck ovens and immediate vacuum conditioning. The fully automatic process combines batch-on-batch baking in deck ovens with immediate vacuum conditioning by the fully automatic OBER PRO II loading and unloading system. The fast WP OBER® loading systems series (up to 2 m per second) feature a central control of the entire system, in which the VACUSPEED® is also integrated. This allows reproducible and optimal mapping and control of process requirements.

++ Fully automatic combination of baking in deck ovens and immediate vacuum conditioning

At this year’s iba in Munich, WP Riehle will present the first robot module under the brand name WP ROBOT, coupled to the proven COMJET lye application system. The modular system with robotic module and camera systems sets new standards. Directly after lye application, the dough pieces enter the modular robotic module where they are sliced to specifications by state-of-the-art Autonox robots. Optionally, the cuts can be performed precisely by ultrasonic knives, water jet, rotating knives or fixed blade. The dough pieces are visually recorded in 3D by AKU camera technology using laser triangulation method and up to 78 cameras.

The new DLA 660 DONUT focuses on fast and professional donut production. The turning insert with one turning ensures an optimal result, and the cloth infeed table and base frame make the handling of the DLA Donut comfortable. The DLA 660 Donut features a display control with seven programs and the proven digital heating control of the DLA family, which ensures constant temperature and low-fat absorption.

Various innovations

Zeppelin Plant Engineering, Rödermark, will exhibit its various innovations at the iba. Visitors will discover new products and systems for use in various fields and designed by the dough production expert. Enhancements to the product portfolio range from process engineering components and automation concepts through to complete systems for mixing and kneading.

The continuous kneading system

CODOS has been entirely re-engineered and presents itself with a new design and a new name: CODOS NT. Thanks to its new drive system, performance has significantly increased despite its reduced size. The new CODOS NT lowers operating costs, is easier to maintain and its high availability will impress more than one. The new system in combination with the redesigned DymoMix dough production system will be presented to the public for the very first time at the iba. Its predecessor, the Codos, has already been installed more than 100 times.

++ The CODOS continuous kneading system has been entirely re-engineered and presents itself with a new design and a new name: CODOS NT immediate vacuum conditioning

For many years now, Zeppelin Plant Engineering has relied on a large-scale digitalization strategy which is now branded under the product name MIRA. Developments over the past two years have shown that plant automation is changing in the baked goods industry as well. In future, systems that allow for better scalability and are therefore suitable for both small and large plants will be indispensable. And topics such as connectivity and networking will also require implementation, which can only be achieved by breaking down the existing automation structure. At the iba, you will find out how Zeppelin Plant Engineering succeeded. The Prisma Web 3.0 system, which will be cloud ready and controllable via web servers, will be demonstrated live, together with a gesture-controlled manual weighing station.

©

Zeppelin

MIRA Connect automatically identifies components and provides specific information to mobile devices. It also provides precise information on specifications, spare parts lists, instructions for commissioning, operation, and maintenance and service intervals. Any product from any manufacturer can be equipped with it. Zeppelin has created a horizontal platform that enables customers to manage their plants’ service, maintenance and servicing at a glance. Front end by the technician, back end by the service or production manager. Access to HTML based machine control is also possible. MIRA Connect provides a gateway to all system components of a plant, transparency and an overview directly for the service technician or the machine operator.

The main advantage of MIRA Connect: it can be retrofitted to any component or machine of any brand and without the assistance of Zeppelin.

With MIRA Control, Zeppelin provides the trade fair visitors with a glimpse of the near future: in combination with commercial controllers, the software-based approach, which is state-of-the-art in other industries, will take control over each individual component and will be specially adapted to the bakery industry. MIRA Control is modular, open and IoT-ready for integration into any existing system. Furthermore, it is based on standards such as ISA S 88/ISA 95 and has standardized interfaces such as Profibus and Modbus. One of the benefits of using MIRA Control is that it will now be easier to configure the individual components. Operating and monitoring, for example, will be possible via laptop or smartphone thanks to MIRA Connect. It will therefore be much easier to see and adapt all relevant component parameters.

Higher performance diverter valves and rotary feeders

The low and medium pressure diverter valve and rotary feeder product range has also been entirely revised. The components are now more efficient, lighter, more pressuretight and come digitally equipped with MIRA Connect for lower operating costs as well as reduced weight and size. EHEDG certification is in the works for the hygienic design of these components. Rotary feeders and diverter valves that are already in use can be easily replaced by the new generation of components.

IT and checkout solutions

CompData, KMZ and OptimoBercher are showing IT and checkout solutions. Through this cooperation, the three partners form a basis for increased economic efficiency in bakeries. Efficient processes and optimized demand forecasts are ensured through end-to-end networking of the various business areas together with IT and checkout solutions.

Cruffins and creative baked products

Wolf ButterBack will have a presence at the iba with a wide range of frozen premium baked goods in the areas of croissants, sweet filled Danish pastries, snacks and deep-fried pastries.

Press releases about the iba continued to reach us until shortly after the editorial deadline. To inform our readers as fully as possible, the editorial department has attempted to publish as many releases as possible

Innovations will be on show on the manufacturer’s stand, and so will fantastic finishing ideas. Cruffins are an example of a novelty. As the name suggests, cruffins are a cross between a croissant and a muffin. Wolf ButterBack has taken it literally and has created a specialty baked product in two variants that combine both worlds in flavor and appearance. The two cruffins, vanilla-choc and cherry-choc, are made of a croissant dough filled with a chocolate-muffin batter with dark chocolate chips. The vanilla crème or cherry filling give the baked products an individual touch depending on the variety. Here again, great attention is paid to the quality of the ingredients. Thus one of them uses a boiled vanilla crème, while the other has a high-quality cherry filling with a 60% fruit content. The products are ready for baking, and are supplied in baking trays holding 12 items each. The trays are reusable, and can also be divided down the middle. This allows the required number of pieces to be baked off as necessary.

The apple basket is currently being revised, and so is its minivariant. As well as the adapted dough recipe, which gives the butter Danish dough a flakier character, the apple basket’s scoring is being changed to produce a more artisan-like shape. The company is making the new apple filling itself.

Wolf ButterBack has also created Winter Magic, a butter Danish whose cherry filling combined with gingerbread mousse is designed to satisfy consumer expectations. The homemade fruit filling is enhanced with cinnamon. The gingerbread filling with Persipan (apricot/peach kernel marzipan) and grated hazelnut contains lemon zest and orange zest together with various spices such as nutmeg, coriander, cloves, allspice and star anise. The almond flake decoration gives the baked item a slightly crunchy bite. This seasonal article is available from September to December –or as long as stocks last.

++ Cruffins and other new baked creations are on show in Munich

© Wolf ButterBack

Passion for Dough

Pizza calls for real

Passion

FRITSCH IMPRESSA pizza – for round, oval or rectangular pizzas, all cut or punched from a single dough sheet. Fritsch’s SoftProcessing technology ensures gentle sheeting and handling of soft doughs and doughs requiring long pre-proofing, so the individual dough structure stays intact. From Pizza Americano to artisinal Pizza Italiano – always the real thing, always delicious. Find out more at www.fritsch-group.com

We look forward

Belts for the baked products industry

Habasit offers a wide range of belts for the baked goods industry. The products’ features include the following:

+ Non-fray or fray-less fabric to improve product safety and avoid contamination risks

+ Belt designs that absorb moisture and withstand wetness

+ Special coatings with good release properties to increase yield and reduce waste

+ Blue-coated and colored belts for optimized, hygienic processes

+ Good air flow and temperature resistance to cool, proof and convey products at high temperatures

Fit for future

AICHINGER is showing, under the slogan “FIT FOR FUTURE”, how bakers can turn market changes and trends into opportunities and business success. New options for the sales-promoting showcasing of bread and baked goods are on show, together with new baker’s snacks and other innovations from the shopfitting area.

SlowProofing-Cold process

At the trade fair, on a stand shared with the HEUFT company, iceCool is showing bread, rolls and Mediterranean baked products manufactured by the SlowProofing-Cold process. Visitors can see the latest generation of “Sempra” automatic full proofers as a long tunnel version. Distinctive features include the full-color 12-inch touch-screen controller and low-temperature moistening of the “softSteam” type, which according to the manufacturer offers significant technological advantages, especially for slow-managed baked goods. In relation to the cell design, iceCool draws attention to other advantages, like the robust, hygienic magnetic strip door and reinforced “Longlife” stainless steel tank base without cover strips or hollows in the corners. The fabrication of the

entire cell construction is homogeneous, with rounded internal corner joints. Externally, the cells have no transverse seams at the butt joints between the panels, which gives the plants a high hygiene standard and particular security against external penetration of cleaning water.

Because iceCool is increasingly being asked about technology for the bake-off sector, it is attending the iba with an entirely newly designed branch outlet machine marketed under the “ShopMeister” name. Fitted with a 12"-touch-screen computer controller and softSteam evaporative moistening, the announcement says it sets new standards in quality, flavor and crust texture for bakeries in a branch location. The “ShopMeister” is fabricated from stainless steel internally and externally and is fitted with a magnetic strip door and viewing window. With a 90 cm (W) x 120 cm (D) footprint, “ShopMeister” fits into almost any niche. Its special secret is its future-proof refrigeration technology. Equipped with an entirely new refrigerant, the iceCool plant has almost no greenhouse potential, and thus already complies with European legislation from 2022 onwards.

In the plant control area, iceCool presents the iCom remote diagnosis and intervention system with a separate VPN tunnel. The advantage of this system is that iceCool plant information can be called up via an Internet access without iceCool needing to dial in through the network on the customer side in the process, which guarantees maximum security. Using this system, refrigeration plants can send information automatically to various recipients via the Internet. Moreover, access to the refrigeration plants from outside through a smartphone is possible from practically anywhere in the world.

Another highlight is the “IntraCart” rack trolley transport system, which enables bakeries to have their rack trolleys transported fully automatically through the various temperature zones without any human intervention. As well as saving working hours, the defined baked product quality and reliable reproducibility is an important argument in favor of this technology. A new aspect of the “IntraCart” is its great flexibility. The respective transport pathways can be operated fully or partly automatically. Manual removals after part-pathways are no problem!

The process heat necessary for proofer plants, proofing interrupter and proofing delay plants of the “Sempra” and “SlowProofer” type is a big subject for iceCool. With increasing numbers of iceCool plants, this energy is no longer generated conventionally using electricity, but instead with recovered heat from the refrigeration machines.

Buns and English Muffins

AMF Bakery Systems, a member of the Markel Food Group, offers its customers various bakery machines and fully automated production solutions. At the trade fair, the company will show new solutions from the bread, hamburger buns and English muffins areas of manufacturing. +++

++ AICHINGER will show new shopfitting ideas

Validate your kill step

3 Easy Steps to Prove Food Safety

The SCORPION® 2 LITE Data Logger with Temperature Interface and Product Probes simplifies the measurement of environment and internal product core temperatures. After collecting the data, the SCORPION® 2 Software (SV8) Food Safety Module makes it easy to calculate lethality and then generate a comprehensive report displaying cumulative log reduction. By combining this ease of measurement with robust data capture, the SCORPION® 2 System makes it simple to optimize your process while meeting food safety standards.

To learn more visit readingthermal.com or call 610-678-5890.

Natural refrigerant

The European Union has enacted an F-Gases Regulation (fluorinated greenhouse gases) that will slowly but surely have clear impacts on the baked goods sector, because nowadays the cooling and freezing area is markedly larger than the baking area, even in many artisan businesses.

Most refrigerants were and are partially fluorinated hydrocarbons, HFCs. The F-Gases Regulation is aimed at reducing their use by 80 to 95% by 2050. This has only a limited impact on industrial frozen baked products manufacturers, since as a rule they use ammonia as the refrigerant.

There are four significant dates for industrial cooling and freezing equipment, stationary refrigeration devices and central refrigeration plants with a refrigeration capacity of more the 40 kW.

Since 1. 1. 2015, the Global Warming Potential, GWP, must be stated for the refrigerant that is used. The GWP is also called the CO 2 equivalent. The figure states how much a greenhouse gas contributes to the Earth’s global warming.

From 1. 1. 2020 onwards, only refrigerants whose GWP value is below 2500 will remain permitted for use in new refrigeration or freezer plants. Continued use of synthetic refrigerants used up to that time will remain permissible only if they were recycled or reprocessed. If a plant contains more than 40 tons CO 2 equivalent of a previously existing refrigerant, it will no longer be permissible for refrigerants with a GWP greater than 2500 to be used even for servicing and maintenance/repairs.

From 01.01.2022 onwards, a GWP of less than 1500 will apply to industrial cooling and freezing equipment, stationary refrigeration devices and central refrigeration plants with a refrigeration capacity of more the 40 kW.

From 1. 1. 2030 onwards, recycled and reprocessed refrigerants whose GWP value greater than 2500 will be prohibited, even for servicing and maintenance/repairs. Whatever breaks down then, is forever broken.

The EU has clear ideas about the increments with which the disappearance of partly fluorinated hydro carbons from the market is to take place. Of the average 2015 consumption, only 63% should remain in use by the end of 2020. There is a stick and carrot policy to achieve this. Subsidy payments of up to 5% of the total investment are designed to make the switchover to other refrigerants palatable to businesses, while on the other hand manufacturers and importers marketing refrigerants with a GWP above 2500 must obtain quotas for them, which will probably restrict availability and force up prices.

Anyone investing in new refrigeration plants and freezers today can operate in an entirely legally permissible framework for the time being by using combinations of synthetic frigens and CO 2. There are a couple of unknown quantities, however, that could lead to problems, e.g. the suitability of such refrigerant blends throughout the whole spectrum of applications from chilling to shock-freezing. The specific characteristic properties of the individual components might possibly lead to a situation in which the Δ t is too great, which can damage sensitive dough pieces. Another imponderable is the development of prices, and not least the cost and effort required for the newly enacted leak-tightness requirements and monitoring obligations.

The operating principle of a propane/brine refrigeration circuit

Of course, a more ecological and probably also more futureproof solution is to use natural refrigerants such as propane, CO 2 and ammonia.

Propane-R 290 – has low toxicity but is flammable. Plants in which more than 50 kg of propane is used need a special license. Propane is often used for ready-to-plug-in devices whose requirement is considerably less than 50 kg. Propane is frequently used as the first cooling stage in combined systems with brine chilling or CO 2. In rare cases, both the lower and upper stages are operated using propane. To eliminate the risk of a fire in the bakery if there is a leak, manufacturers offer compact propane-operated plants entirely housed in a container set up outside of the bakery. The connection to the brine circulation in the bakery can be isolated at any time. Moreover, the container option has the attractive feature that it can be included in the move or sold if the production operation is relocated.

ammonia circulating within the refrigeration plant, ammonia is normally used in combined plants in which the second stage is operated using brine or CO 2. Thus ammonia is present “only” in the machine room.

Ammonia is a very pungent-smelling gas that can be fatal if inhaled. Therefore its use is subject to stringent safety requirements that are economically justifiable only in the case of very large installations. The advantage of ammonia is its very favorable COP value (Coefficient of Performance), which defines the ratio between available cooling and the consumption of electricity. To avoid the danger due to the ++ CO2 unit

The operating principle of a propane/brine refrigeration circuit

CO2 Refrigerants

CO 2 is the third natural refrigerant that comes into consideration for newly-installed plants. If one wanted to retrofit existing plants to use it, the entire refrigeration engineering would have to be replaced, and only the shell would remain. It is neither flammable nor toxic, and is colorless and tasteless. However, high pressures occur when CO 2 is used. If a leak occurs, however, there is no resulting climate damage, and the plant simply needs to be fixed and refilled. Another point that must be taken into account with CO 2 plants is the interference caused by sub-critical or trans-critical outdoor temperatures. If temperatures at the gas cooler drop far below 31°C, the gas completely liquefies in the gas cooler. If outdoor temperatures lie too close to the so-called triple point of 31°C, the gas no longer liquefies. Thus it depends on how the plant is designed and where the gas cooler is

Trade fair calendar 2018

installed, and/or whether it is water-cooled if necessary. Incidentally, for commercial bakeries there are refrigeration plants operated using CO 2 and housed in a container to save space by setting them up outside of the bakery.

CO2 can be used in combined plants using CO2 in both stages, or CO 2 with other natural refrigerants, e.g. propane or ammonia. However, CO 2 can also be used in a booster, for example as recommended by the Dutch refrigeration specialist KOMA. CO2 is then used as the refrigerant in the entire system and is compressed in two stages. The advantage of this is that CO 2 in a bakery does not present a hazard source, and there is no need to install an additional brine circulation. This makes the plants more attractive from the price point of view. +++

2018

NOV

September 5-8, 2018

Riga/Latvia

Riga Food 2018

www.bt1.lv/bt1/rigafood/?link=10000000

September 15-20, 2018

Munich/Germany

iba 2018

www.iba.de/en

October 14-16, 2018

Riyadh/Kingdom Of Saudi Arabia

SIBPE 2018

www.sibpe.com

O ctober 14-17, 2018

Chicago/USA

Pack Expo Chicago

www.tradefairdates.com/PackExpo-M1809/Chicago.html

October 21-25, 2018

Paris/France

SIAL Paris www.sialparis.com

November 6-8, 2018

Dubai/UAE

Gulfood Manufacturing 2018 www.gulfood.com

Rise above the competition with GEA Bakery Equipment

With 100 years of combined experience, GEA Comas and GEA Imaforni have been engineering high quality solutions for the baking industry. With that kind of history behind us, we have gained world-leading knowledge and expertise to offer you complete production solutions, from dough making to packaging and everything in between, customised to suit the precise requirements of your line of products.

Our range of baking equipment ensures you maximum productivity whilst maintaining the best product quality. With fully automated plants able to run non-stop, we reduce the need for human interaction, thereby reducing the risk of human error and product contamination.

You can also take full advantage of our new Bakery Experience Centre where you’ll be able to test your own products on our equipment, and utilise the knowledge of our specialist food technician to help refine your recipes or make a new product. Experience for yourself the winning combination of our equipment and expertise. After all, the proof is in the pudding. Enquire now at gea.com/bakery

We look forward to meeting you at iba 2018 Hall A6 – booth 211 in Munich, Germany from 15 – 20 September 2018.

Organic baker advertises technology

Norway’s biggest organic artisan baker advertises that it uses vacuum cooling.

+T he married couple Katrine and Jon-Frede Engdahl together with Jon’s sister Jorunn Engdahl founded Kolonihagen in 2004. They wanted to work for “a better life”, which includes organic foods just as much as species-appropriate life for animals and a good, meaningful life for farmers. Bio plus is the name Jon-Frede Engdahl gives to the philosophy of the company which he still manages, even though the three founders sold it two years ago to Rema 1000, one of the country’s biggest food retailers.

Kolonihagen consists of a total of five lines of business whose activities are interwoven: a bakery, restaurant, brewery and a delivery service for what are called “green boxes” in Germany but are available from Kolonihagen in various formats depending on whether there is more fruit, more vegetables, more luxury foods or more baked products – everything organic of course. Line No. 5 is rather more unusual.

In this division of the company, Kolonihagen develops products for the food retail, from raw materials and

processes to packaging. Measured in terms of sales, No. 5 is the biggest part of the company, followed by the manufacture of baked products.

Kolonihagen’s bakery employs 15 staff and is thus Norway’s biggest organic artisan bakery. There are a few other organic bakers in the country, but they limit themselves to producing baked goods, are smaller, and not many of them also sell their bread through the retail.

Kolonihagen markets its baked products through forty selected food retailers in Oslo. The remainder goes to caterers, restaurants and canteen operators, and into “green boxes”.

The bakery commissioned a vacuum cooler from Cetravac AG in Switzerland nearly three months ago. The reason for it was quite pragmatic. Production volume had risen constantly over the course of time, and customers suddenly began to complain about the deteriorated quality, although nothing had changed in the raw materials, the recipe or the manufacturing process. The bakers investigated the issue thoroughly and discovered a really simple cause. The increased production volume had not only lengthened production time, but had also increased the temperature in the bakery, because the breads were allowed to cool down in the bakery. The higher temperature not only made the cooling process longer, but also caused the breads to dry out slightly, which was what the customers were complaining about.

++ The fact that there is a search for a technical solution is one thing, but immediately communicating it vis-à-vis customers as well is quite another

© Kolonihagen

©Kolonihagen

The fact that there is a search for a technical solution is one thing, but immediately communicating it vis-à-vis customers as well is quite another. In fact, it’s even a matter of course for Jon-Frede Engdahl: “In Kolonihagen, we believe transparent communication to customers is important. Therefore we also spoke openly about the problem and explained that we wanted

to try out a new technology. What ecological production means to us is not manufacturing foods as was done a century ago. On the contrary, for us ecological production also means being open-minded in relation to improvements and new technologies. We have kept our customers constantly in the loop about investments and their benefits ever since the first breads that passed through the vacuum chamber went onto the market. The benefit for customers is a more succulent bread with a longer shelf life, while the benefit to us and the environment is the energy saving, and the benefit for the bakers is the lower temperature in the production premises.”

Communication with customers runs through all channels. First of all, customers were informed through social media. Then stickers carrying the message “New baking method. Vacuum technology for more succulent bread” were distributed, and finally Kolonihagen reduced the price of its bread for two weeks to allow customers to test it and to win back customers who had stayed away due to the excessively dry bread. A film is currently being made, designed to explain the technology in an understandable way, after which there will be information campaigns for specific target groups and a big advertising campaign at the start of the school year in August. According to Jon-Frede Engdahl, customer feedback so far has been extremely positive and the sales of bread are increasing week by week. +++

++ Jon-Frede Engdahl

© Kolonihagen

Compact, efficient and universal

The new BELT-OILER-R combination machine enables baking trays to be cleaned and oiled in a single operation.

+As it says itself, Precisma GmbH in Sipbachzell, Upper Austria, is one of the leading tray cleaning specialists. The designers have now developed the BELT-OILER-R, a new combination machine (an all-in-one cleaning and oiling machine). This involves a baking tray cleaning plant combined with an oiling plant specifically for profiled trays. After the cleaning and oiling process, a return conveyor takes the tray back to the starting point. Only one person is needed to operate the plant. The company adds that the machine can dry clean and oil almost all kinds of baking trays. Trays are cleaned by novel belt brushes that can fit into tray contours, recesses and corrugations. Release agent i s applied by special sensor-controlled Airmix nozzles to ensure economical consumption.

Versatile

The BELT-OILER-R is usable in a wide variety of areas: flat trays with up to four edges, baguette trays with and without frames, perforated and unperforated trays, coated and uncoated trays – with widths of 600, 800 mm or 1,000 mm. According to Precisma’s announcement, an hourly capacity of up to 1,200 trays is possible. The plant is said to be easy to operate, and service expenditure is low.

As well as the new BELT-OILER-R, the company offers a large number of bakery plants: the BELT series of baking tray cleaning plants, the OILER series of release agent application plants and the POWDER series of strewing plants are individually custom-fabricated. The bakery plants can be seen at the iba 2018 trade fair in Munich (Stand 337 in Hall B2).

++ Sensor-controlled Airmix nozzles apply the release agent

© Precisma

Indonesia

Specialists in slicing and packaging

Brevetti Gasparin comes into its own when slicing and packing baked products for large artisan businesses and the baked goods industry are involved. They are also revealing a series of innovations for the iba trade fair.

B

revetti Gasparin was founded around 60 years ago in Marano Vicentino, Italy, the Brevetti part of its name indicating that the company owns numerous patents. Gasparin is the founder’s family name. The company, which now employs 30 staff, began at that time with classical bread slicers for artisan bakeries. Then, more than ten years ago, it reoriented towards a product range focusing on the needs of major businesses: machines that automatically cut and slice bread, baked products

and cakes, pack them into so-called flow-pack bags and close the bags with a metal wire reinforced clip.

In addition, cutting and packing in cushion-shaped big packs is available mainly for the bun industry. Something that sounds so simple is actually quite varied. The buns can be cut into from one side, cut through, cut into from both sides, cut into from the top etc. Just as there are no limits to imaginative ideas where positioning the cut, there is equal flexibility with respect to the number and arrangement of the buns in the bags.

“Nowadays,” says Brevetti Gasparin, “we start our product range where it used to end. The cutting technology extends from reciprocating and band blades to the circular saws used for croutons and focaccia, for example.”

According to Brevetti Gasparin, as a rule the company supplies tailor-made fully-automatic plants with a supervisions system that gives customers the ability to monitor functions online. Three quarters of all their equipment is exported,

++ New continuous band blade industrial slicer, model 1900

++ New continuous mechanical clipband closure system

Brevetti Gasparin www.gasparin.it Hall A1, Stand 251

© Gasparin

© Gasparin

principally to other EU countries, but sales are also flourishing in the Arabian region, in North and South America and in Asia. In addition to the BulkPacker for buns, Gasparin will present at the iba trade fair in Munich a new model of a continuous band slicer that cuts up to 3600 breads per hour. Cutting takes place using endless bands running over two rollers, one of which is driven. Tension in the stainless steel or Widia steel guided bands is regulated pneumatically. The infeed belt is available with a maximum width of 600 mm with an adjustable lateral guide and forward feed speed, also adjustable. The upper conveyor belt can be adjusted by a handwheel to allow the bread to be pushed towards the slicing belts.

A new mechanical bag-sealing machine that closes bags with clips (clipband) and which they will be exhibiting at the iba trade fair also achieves the same hourly performance of 3600 packs per hour. The filled bags are transported to a clipping unit positioned at a 90° angle with an inclination angle of 20°, 30° and optionally at 45° or 60° degrees. The clipping unit moves automatically, and a belt that is independent of the other

As a rule, feeding is manual on two belts which converge and bring the product to the cutting head. Cutting height and depth are adjustable, of course, and the band runs at a maximum speed of 18 m/minute. +++

Nowakowski 4.0

The Nowakowski family has operated baking businesses in Poland for four generations. In the process, the family acquired a remarkable flair for the development of European markets. The most recent business produces artisanal, additive-free frozen products in wood-fired ovens.

Head of Production Waldemar Jaczewski and Łukasz Nowakowski, who is responsible for sales , currently focus on four product ranges: hearth-baked breads, small panned breads, yeast-raised cakes and hand-topped pizzas with a diameter of 1 4 and 28 cm. The incentive here, namely to opt for quality equal to that of handmade products and to bake specialties instead of mass-produced goods, originated from the market. As in the whole of Europe, there is also a class of consumers in Poland who want to return to authentic baked goods made from selected raw materials, a significant reduction in the use of yeast and in salt content, and of course entirely free from additives, including enzymes. There is also a group of buyers, as there is everywhere in Europe, who are also willing to pay a higher price than for ordinary

mass-produced products. Retail groups operating throughout Europe also know this.

When Nowakowski Piekarnie commenced production just over a year ago in Kolonia Kepaczka, a small town three hours’ drive southwest of Warsaw, 20,000 m2 of production space was available to them, plus a frozen food store for 5,000 pallets. It contained four lines for the four product families, leading to two large wood-fired ovens, with the exception of cakes. The two cousins inspected various bakeries before making the investment. A wood-heated tunnel of this kind is used by a baker in Baden near Zürich, who is noted far beyond Switzerland’s borders for the quality of his products. They also adopted his plea for artisan manual work at the important points.

++ Łukasz Nowakowski (Jacek Nowakowski’s son), Production Manager of Nowakowski Piekarnie, Mariola Janczewska (Jacek Nowakowski’s sister), owner of the Cukiernicza MW Janczewscy confectioners, Jacek Nowakowski, Chairman of Nowakowski Piekarni Bakery and owner of the Nowakowski Gorąco Polecam store chain, Waldemar Janczewski, Vice-chairman of Nowakowski Piekarnie and responsible for sales, and Jacek Nowakowski Jr., New Business Development Manager

++ Du rum wheat bread has an artisan bloom

Novakowski

f2m

++ Pl ain rye bread without yeast, baked in a wood-fired oven

f2m

MIXING SOLUTIONS

for bread, pastries, cakes and snacking industries

A company of

Gas is used to heat up the ovens before production starts, but baking takes place exclusively using Polish oak and beechwood. The baking surface in the oven consists of volcanic rock, which withstands even the temperature of nearly 400°C needed for pizzas. The selected wheat and rye flours originate from Poland, and the cousins check the entire supply chain back to the farmer to ensure compliance with their quality standards. They have the raw materials for durum wheat bread with its artisan gold-yellow crust delivered to them from Sicily. The doughs are baked using various sponge doughs and sourdoughs, and have often undergone 24 hours of fermentation time before being made up. This also allows 1.1 kg of water to 1 kg of flour to be achieved.

The heaviest bread in the range is a one kg loaf made from rye and wheat baked with poolish and sourdough, and usually cut into pieces on shop counters and sold by weight. The remaining hearth-baked breads vary between loaf weights of 300 and 500 g. The five types of small panned bread, each weighing 450 grams, are aimed at single households and caterers. Slices cut from these have an edge length of approx. 8 cm. It’s a full range of very varied breads, all based on traditional Polish recipes: plain rye bread baked entirely without yeast, rye bread with buttermilk, potato-onion bread, sunflower seed bread, and a small, sweet milk roll for Sundays – a perfect breakfast buffet assortment.

Word of the insider’s tip from Kolonia Kepaczka has not only spread in their own country, it has also already been talked about in the Czech Republic, Germany, Slovakia and Hungary, but the Nowakowski family would not be doing justice to their own tradition if they didn’t think beyond it as well.

BRC (British Retail Consortium) and IFS (International Featured Standards; Food) certificates are available. +++

++ A lot is done by hand, like dusting breads with flour before baking ++ or putting crumble on cakes as shown here

© f2m © f2m

f2m

The Burford® Smart Servo Twist Tyers deliver the #1 consumer preferred closure at a lower cost per package. With critical components designed to last even longer, the Smart Servo delivers years of dependable service with less maintenance. For optimal performance a minimum bag thickness of 1.25 Mil is required.

Model 2200M shown with optional digital display, package detection system and conveyor

More baking cycles and higher temperature

Sasa Demarle Groupe introduces a new silicone coating for bakeware. baking+biscuit international talked with Mr. Pierre Escarbelt , Sales & Marketing Director of the Industrial Business Unit of The SASA Demarle Group about the advantages.

+bbi: Dear Mr. Escarbelt, SASA is promoting at the iba a new silicone coating, called iNFiNiUM 6001. Can you please indicate to us, what the difference is between this new coating and existing silicones?

+ Escarbelt: SASA, well known for its state-of-the-art silicone coating iNFiNiUM ® 601 specially designed and manufactured for industrial bakers, has developed a new generation of silicone – the iNFiNiUM ® 6001 – with greatly improved characteristics, whether on abrasion or on temperatures, for reducing the CAPEX and OPEX of the industrial bakers as described above.

The iNFiNiUM ® 6001 can withstand more than 5,000 baking cycles whereas the previous iNFiNiUM ® 601 could reach 3,500 baking cycles in the same operating conditions. The iNFiNiUM ® 6001 can also withstand operating temperature up to 260°C, easily competing with other type of non-stick coating chemical formula (e.g. PTFE or PFA), whereas the iNFiNiUM ® 601 was limited to 240°C.

+ bbi: What kind of bakeware can this coating can be used for?

+ Escarbelt: Non-stick coatings have a limited lifetime, depending on many ageing parameters, such as temperature and mechanical wear (abrasion). In heavy duty environments, typically the use of non-stick coatings on automatic baking lines for bakery and pastry, the progressive loss of non-stick characteristics of the baking trays will first engender production losses, which can be massive until the replacement of the trays by new or renovated ones.

The iNFiNiUM ® 6001 is intended to be used in heavy duty environments such as automatic baking lines for bakery and pastry where the lifetime is of utmost importance.

SASA Demarle uses the iNFiNiUM ® 6001 on all stamped trays, fluted trays, soft trays and tin straps for intensive industrial use.

+ bbi: Does it work for sweet dough with raisins and sugar?

+ Escarbelt: The iNFiNiUM ® 6001 is a very versatile non-stick coating, which can be used with many recipes, e.g. French baguette, brioche, milk bread, croissants, madeleines, sugary products, glazed products, etc. It adds the non-slip capability to the non-stick property, which is keeping the baked products perfectly in place. The iNFiNiUM ® 6001 can be used to produce industrially cakes with raisins & sugar.

+ bbi: Have there been any scientific tests carried out and you can publish these results?

+ Escarbelt: SASA Demarle has its own chemical labs and chemical engineering team. We have conducted scientific tests internally. Since there is NO standard test sets existing on the market, we have written our own internal procedures. We are not willing to publish these results since they cannot be compared to what another lab can do (no standard tests).

+ bbi: Up to which oven temperature can the bakeware with the new coating withstand?

+ Escarbelt: The iNFiNiUM® 6001 can withstand more than 5,000 baking cycles whereas the previous iNFiNiUM ® 601 could reach 3,500 baking cycles in the same operating conditions. The iNFiNiUM ® 6001 can also withstand operating temperature up to 260°C, easily competing with other type of non-stick coating chemical formula (e.g. PTFE or PFA), whereas the iNFiNiUM ® 601 was limited to 240°C. In order to even further optimize the efficiency of the new silicone, SASA has changed the colour from light grey to charcoal grey, giving the iNFiNiUM ® 6001 an improved thermal performance.

+ bbi: Are there any restriction about how often the trays and tins can be recoated with iNFiNiUM ® 6001?

++ Pi erre Escarbelt, Sales & Marketing Director of the Industrial Business Unit of The SASA Demarle Group

© Escarbelt

+ Escarbelt: Trays and tins coated with iNFiNiUM ® 6001 can be recoated 3 to 4 times (from experience). The recoating is only limited by the wear of the metal sheet, which can become too thin for re-use. Compared to other coatings (PTFE, PFA), the cleaning before recoating is softer for the metal.

+ bbi: What about the price of the new silicone compared to usual solution from SASA and the price of recoating?

+ Escarbelt: The price of trays coated with the iNFiNiUM ® 6001 is slightly higher than the previous iNFiNiUM ® 601 but it has a better Return-on-Investment (ROI) thanks to its much longer lifetime. It is always a more competitive offer than the PTFE or PFA that are more expensive.

+ bbi: Where is the silicone produced, where is the recoating center located and how long does it take to recoat the tins and pans?

+ Escarbelt: The silicone has been fully designed in our own chemical labs and is produced on our brand-new silicone reactor, in Le Cateau-Cambrésis, France. SASA Demarle has made an investment of more than 1 million Euros in a new workshop. SASA Demarle is the only supplier of non-stick baking trays across the industry worldwide to produce its own silicone specially made for bakeware. The recoating center is in Le Cateau-Cambrésis, France only. There are very stringent environmental rules that we strictly follow for

the removal of the used silicone coating and for the waste treatment.

+ bbi: What will be the most important benefit for the baking industry - quality improvement, cost saving, hygiene or improvement of line efficiency?

+ Escarbelt: The replacement of non-stick baking trays on automatic line is a costly maintenance procedure on many aspects: availability rate of the line, handling of heavy pieces, costs of coating renovation and logistic costs. Hence, the first benefit is the extended lifetime of the coating, which improves the line efficiency. The quality of the end product and the hygiene remain unchanged compared to the previous iNFiNiUM ® 601, meaning that it is as good as what it was before.

+ bbi: Thank you for the interview. +++

XXV International Trade Fair for Bakery and Confectionary

25 Years in Russia

New equipment is designed

Topos Mondial Corporation is based in the United States with a manufacturing facility in the Czech Republic. With the ability to customize pieces of equipment for installation, they serve retail bakers and up to large industrial scale bakers.

+When revamping equipment design, Topos Mondial follows industry trends, especially in the USA with regards to sanitation. New equipment is designed to eliminate harborage places, cavities, and hidden crevices that are hard to clean places that could contribute to microbial growth and contamination. With the intent of making the job of sanitation crew easier, the equipment now has removed the need for tools needed for equipment tear downs by eliminating bolts for attachments. It is also designed to be sealed and can be washed down without risk of damaging electronics.

In addition to the equipment design that facilitates sanitation, Topos Mondial also offers a water driven bowl titler that raises the bowl from the ground and holds the bowl tilted while cleaning. This is electricity-free lift and is ideal for wet wash down rooms, providing a safe method for wet washing mixing bowls.

iba

This year Topos Mondial will be bringing several pieces of equipment to iba including their newest innovations in sanitary equipment design. Here is what will be on the show floor:

+ Open Frame Spiral Mixer with removable bowl: The T300 has been completely redesigned, the only thing they kept from the old spiral mixer is the mixing geometry. This heavy duty spiral mixer is built for easy cleaning as well as heavy production. It is made from stainless steel and other sanitary materials as necessary. This mixer can handle all dough types up to 300 kg.

+ Double Sigma Mixer: this is now designed with open frame for easy cleaning and sanitary design. This mixer is ideal for non-gluten products and sheering/creaming. The 110 degree overtilt horizontal mixer bowl is reinforced and features the double agitator design. The bowl canopy, main shaft, agitators and mixing bowl are all solid

stainless steel. The frame can be made from solid stainless steel as well, or from mild steel coated in “Steel It”. The mixing controls can be customized to the products mixing needs. Available in sizes 110 lbs to 2500 lbs of mixing.

+ Open Frame Horizontal Roller Bar Mixer – redesigned with the open frame has capacities from 400 to 800 lbs. The new design offers an easily removable without tools, stainless steel cover over both the drive gear-motor and hydraulic package side of the mixer for easy cleaning and maintenance. The advanced mixer bowl can be jacketed and insulated for bowl cooling. The bowl shape and roller bar positions yield shorter mixing times while mixing at slower agitator speeds.

+ Removable Bowl, Vertical Planetary Mixer (T750) is popular in the US Market. It has also been redesigned and optimized for sanitation with direct drive motor, easy to remove and clean covers with no tools needed. It has the capacity for 350 quarts (or 350 liter). It is ideal for all types of soft dough, batter, icing, glaze and fillings. The mixer features an integrated bowl scraper, and dual positive-locking implements which allow for maximum mixing versatility

+ Chunker – Is also redesigned. Only kept the cutting blades and everything else was redesigned for cleaning and simple assembly. The Chunker is available with 1000 lb or 2500 lb capacity and able to chunk up to 20,000 lbs per hour.

+ Single Sigma Open Frame Mixer: Sanitary designed with 110 degree overtilt horizontal mixer has from 600 lb up to 3000 lb mixing capacity. Mixing controls can also be customized your mixing needs. +++

© Marco Zamperini –123rf.com

High speed slicing and bagging

Bettendorf Stanford is a food slicing equipment company which was established in 1965 and is based in St. Louis, Missouri, USA. From blades to machines, they are constantly engineering new products to better the industry.

The company and its management are members of the Bakery Equipment Manufacturers Association since 1967 and Society of Bakery Engineers since 1969. Bettendorf Stanford manufactures a variety of high speed slicing and bagging equipment for loaf bread, hamburger buns, rolls, bagels, pound cakes and other products. The equipment includes: ultrasonics, servos, topping applicator and linear motors as well as proprietary mechanical designs.

Not only does Bettendorf Stanford manufacture slicing and bagging equipment, they have the advantage of being a bakery blade manufacturer. This offers unique view and understanding of how both the slicer and blade functions and means Bettendorf Stanford can troubleshoot slicing problems without directing manufactures back to the blade or slicer manufacturer.

New for this iba, Bettendorf Stanford has several new products that will be highlighted with videos at iba including:

+ High speed automated bun line (HS-ALPS): This is new for 2018. This bun line can group, slice, and bag buns at speeds of up to 65 packages per minute depending on product being bagged.

+ High speed bread slicer and bagger (BSI-75B/Hybrid 65 Bagger): This integrated line is capable of running 70 loaves per minute depending on the type of product, and typically runs 55-65 loaves per minute. The slicer is capable of running up to 90 loaves per minute on all types of product. The reciprocating bagger uses linear actuators for a 35% reduction of moving components.

+ High speed reciprocating slicer (RSC): This newly designed high speed reciprocating slicer works great for hard-to-slice products including: sticky products, gluten free bread, and cinnamon raisin/other fruit and nut type breads.

+ Frozen Sandwich assembly slicer: This new high speed slicer that will slice frozen rolls/buns that present the tops

next to the bottoms for sandwich assembly plants. This slicer utilizes proprietary frozen slicing technology to allow slicing of rolls/ciabatta/English muffins at high speeds. The machine removes the top and places it next to the bottom to allow operators or a robotic set-up to easily apply meat/egg/cheese to the bun. Single lane operation allows for speeds from 60-120 frozen rolls per minute.

+ Hand load baggers (Model B): Used for the semi-automatic bagging of rolls, buns, bagels and other product at speeds of up to 60 bags per minute (actual my vary based on product and operators ability to load).

+ Deluxe Hand Bagger: Designed for easy operator use including operator knee switch for consistent workflow. Used for hand bagging a variety of products such as breads and rolls. +++

Bettendorf Stanford

Bettendorf Stanford

++ BSI-ALPS: No rmal run speed of 45-55 packs per minute; model shown with 5 spindle hinge slicer, single band slicer, and servo stacker

++ BS I-75B Slicer/Hybrid 65 Bagger: Capable of up to 70 loaves per minute

Europeanization at all levels

The Oetker subsidiary Wolf ButterBack KG plans to combine conventional and new, and on the one hand remain a loyal supplier to artisan bakers through wholesale organizations, while on the other serving new sales channels as well as European countries abroad.

+This could be assisted by cooperation with another Oetker Group subsidiary, the recently acquired Diversi Food in Belgium.

+ bbi: Mr. Tomasch, you have been spokesman for the Management Board of Wolf ButterBack KG in Fürth for six years; how far has the importance of Europe as a whole for Wolf ButterBack’s sales changed in these years?

+ Tomasch: Wolf ButterBack’s business in Europe as a whole has continuously gained importance in recent years. Whereas exports as a proportion of sales were still below 25% six years ago, they have now grown to over 30%. Although our most important market is and remains Germany, we pursue a strategy of further internationalization, and aim to achieve half of sales in countries abroad in the medium term.

+ bbi: Which countries have gained most significance in this respect, and how do you see growth rates compared to the German market?

+ Tomasch: The good news is that we can grow both in Germany and abroad. In addition to our classical foreign markets, Austria and Italy, the strongest growth in importance has taken place in all of our immediate neighboring countries, e.g. France, the Netherlands or Belgium and Scandinavia. Growth in Germany in 2017 was just under 4%, while the overall growth rate abroad was 20%, and we were even able to double the level of sales in a number of countries.

+ bbi: How much has the expansion of sales influenced the product range policy, and how much more “European” have baked goods become? How many products can be sold in the same quality throughout Europe, or must the manufacturing operation use country-specific recipes?

+ Tomasch: Countries abroad have a very significant influence on our product range policy. Firstly, consumers’ taste preferences with regard to specific baked products in the individual European countries are becoming increasingly uniform. French croissants, for example, are in demand worldwide. Snacks based on Danish or puff pastry dough, e.g. savory loops or cheese-filled sticks, or even pizza products, can also be marketed well in the same quality throughout Europe. In this respect, Wolf ButterBack’s premium quality is also appreciated abroad, and we constantly find more sales markets that can pay the corresponding price for it. On the other hand, however, one must clearly recognize that a product range aligned purely to German tastes cannot succeed internationally. The preferences for various fruit fillings, or expectations regarding size, volume or baking

properties, are too dissimilar. There is a trend, especially in southern Europe, to ask for smaller baked product sizes, and baking takes place mainly without steam. That’s why Wolf ButterBack is also increasingly developing different product ranges for different European sales regions.

+ bbi: Has the growing out-of-house market changed the structure of the product range?

+ Tomasch: The product range structure actually follows the sales markets. The out-of-house market in Europe is booming. Consequently there is more-than-proportional growth in the savory snack market, and topped articles in any form have become more important. Nowadays any snack counter is unimaginable without fresh croissant-based sandwiches, for example.

+ bbi: Not only have customers’ consumption habits changed, so has their purchasing behavior. The food retail has gained market shares of the overall baked goods market. In the past there was a strong focus on bread and bread rolls. Significant increases are now observable with regard to fine pastries, snacks and cakes. How does that affect your business and how does Wolf ButterBack respond to it?

+ Tomasch: We monitor changes in consumers’ purchasing behavior very closely, and ultimately we also want our product range to follow consumers to wherever they demand our premium quality. The decisive factor for us in this respect is that we offer a quality with our baked products whose characteristic features are artisan manufacture, the use of butter and slow dough preparation, which all come at a price. That’s why the sales channels that come into question for us are all those that can serve a corresponding quality and price segment.

++ Ch ristian Tomasch (52), spokesman for the Wolf ButterBack KG Management Board

© Thimasch

+ bbi: How important to Wolf ButterBack is the food service market, and how significant for you is the growing importance of not only European but also international chains in this market?

+ Tomasch: The food service market is also developing dynamically alongside the European boom in the out-of-house market. To serve this market in Germany, we have cooperated for more than two years with our sister company Dr. Oetker Professional in Ettlingen, which markets a range of Wolf ButterBack articles through specialist food service wholesalers. However, artisan bakers, Wolf ButterBack’s core clientele, have also performed well as market leaders in the out-of-house market. Moreover, international chains and other customers in the transport catering area are also of interest, and we make contact with them through our presence at international trade fairs.

+ bbi: Wolf ButterBack is part of the Oetker Group, and not long ago took over Diversi Food in Belgium, a company which says itself that the conviction that “bake-off” is the future was the origin of its formation. Nowadays, as I see from their web site, the company aims deliveries to bake-off and the food service, together with supplying own brands to retail traders. Is there any collaboration or overlaps between Wolf ButterBack and Diversi Food, or even a competitive relationship?

+ Tomasch: Collaboration between Wolf ButterBack and Diversi Foods will be strengthened in the future under the umbrella of the Martin Braun Group. There is no competitive relationship, on the contrary, primarily they complement one another very well. For example, collaboration with Diversi Foods’ Belgian-Dutch sales organization is designed to strengthen Wolf ButterBack’s internationalization in these countries just described above. Conversely, Wolf ButterBack’s sales organization, e.g. in Germany, Austria and Italy, can achieve new turnovers for Diversi. The product ranges of the two companies also complement one another well, since Diversi focuses on bread and bread rolls, while Wolf ButterBack concentrates on viennoiserie and snacks. The Martin Braun Group’s frozen food product range is now developing into a full range of high-quality specialties as a result of the collaboration, and it now offers complete customer solutions.

+ bbi: Online product retail is currently an exciting topic. Your sister company Martin Braun is testing this at present, with the aim of a roll-out for other Oetker baking area subsidiaries. How close is Wolf-ButterBack to this topic, and do you see the opportunities for its application mainly in Germany, or in the export market as well?

+ Tomasch: It is clear that digitization will also take hold in the baking sector, and will always do so wherever it can generate customer benefit or efficiency, and of course across national boundaries as well. As a subsidiary company, Wolf ButterBack is included as an integral part of the digitization projects within the Martin Braun Group. We are working on the topic and are examining which options exist for us.

In contrast to Martin Braun, which can also deliver its orders generated in the online shop directly to customers through its own logistics, Wolf ButterBack does not have a logistics structure of its own and delivers via the trade, e.g. Bäko wholesalers. So for an online shop to make sense for Wolf ButterBack, it would be necessary for a wholesale stage to be incorporated. This still needs many discussions, and the creation of the technical prerequisites first of all. Automated, digitized ordering procedures, assisted by EDI (electronic data interchange) currently have higher priority for us and for our customers. 40% of our orders are already executed via EDI. However, the majority are still communicated to us via classical media such as telephone, E-mail or even Fax.

+ bbi: Europe as a procurement market, or regionality is trumps? What and how much is possible, and what can be communicated in view of the local patriotism increasingly invoked in all parts of Europe?

+ Tomasch: The reality includes both. On the procurement side, for some individual raw materials one is dependent on the world market in terms of both price and quantity. Nevertheless, we succeed in purchasing nearly 90% of our raw materials at least from regional or national suppliers. Marketing finished baked products with a regional connection is very successful. This balancing act can succeed only if regionality is played out through the recipe or through individual ingredients, e.g. fruits or fillings.

+ bbi: Europe’s baked products market – can you define Wolf ButterBack’s position in this respect a) today, and b) your targets for 2025?

+ Tomasch: We want to define our position in Europe’s baked goods market less in terms of size and much more via our positioning as the best supplier of high-quality butter-based specialties in the viennoiserie and snacks area and, in conjunction with Diversi, in the bread/rolls area as well. If our customers attribute this positioning to us, and this confers on us a place among the Top Ten in the overall European frozen product bake-off sector by 2025, we shall be grateful.

+ bbi: Mr. Tomasch, many thanks for the interview. +++

UK: Diversity and sustainability

As on the continent, the food-to-go market is a mainstay of the baked products market in UK and is steadily gaining importance.

+The market is determined by two big trends. One is the constant hunt for new ideas with which to set oneself apart from the competition – one might also ask what will be the next bandwagon to jump onto.

Suppliers are endeavoring to differentiate their product ranges throughout the day as well, and are also enlivening the evening business in addition to breakfast, lunchtime and a snack in between. Starbucks and Costa, for example, have obtained alcoholic drinks licenses for a series of locations to enhance the attractiveness of their shops in the evening. Combined with a flatbread with goat’s cheese and artichokes, or a cheeseboard and small salad, that can certainly be a tempting offer. Café W, West Cornwall Pasty Co, Soho Coffee and Esquires have also obtained alcohol licenses, and Black Sheep Coffee even converts its locations into a wine bar in the evenings.

Another route to more customer contact is the kind of cooperation some businesses are entering into with established retail houses. The Crussh company, which specializes in juices and health-food, has opened its first location at Sainsbury’s in London, and another project, also in the capital city, is ongoing with Debenhams, a store chain that sells clothing, cosmetics and gifts as well as furniture and electrical appliances. Joe & the Juice-Outlets has also been seen in several Debenhams stores for some time, and also in John Lewis stores, and the Eat format concluded a corresponding agreement with Debenhams during last year.

Costa plans to increase its presence in football stadiums and transport hubs this year. Greggs, and also the Scottish bakery Stephens, are trying via drive-through shops to reach those people who are unwilling to get out of their mobile armchairs.

Greggs and Subway are experimenting with delivery services for those who don’t even want to come on board.

Whereas product range differentiation and the search for cooperation is aimed mainly at reaching more customers and/or selling more to them, the other topic stirring minds in the British food-to-go market in the past year and right up to the present day involves greater social cohesion and thus sustainability. As in this country, coffee cups are a hot topic in this respect. One group is attempting to organize the return of used paper cups in its own shops, while another offers discounts to customers who bring their own coffee cups with them, but none of that is the perfect solution yet, so Starbucks, Greggs, Costa, Pret A Manger, Caffè Nero and others have banded together to form a working group tasked with developing a national recycling concept for coffee cups.

Costa is campaigning for coffee cup recycling, and promises 500 million coffee cups will be recycled each year from 2020 onwards. That corresponds to about the number of coffee cups Costa gives out annually. A national recycling company has recently started paying Costa GBP 70 for each ton of recycled coffee cups. Customers arriving with their own cups receive a discount of 25 pence per cup

© Greggs

++ Greggs, Great Britain’s biggest bakery chain, goes on the offensive with a delivery service