baking+biscuit international 2021 issue 06

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ASHWORTH PROVIDES INNOVATIVE SOLUTIONS FOR THE COMMERCIAL BAKING INDUSTRY www.bakingbiscuit.com

Production

Sustainability

Automation

A growing hub for pans and trays

Hydrogen fuels the future of the ovens

Industry 4.0 tackles fast industry tranformations

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WE ARE HERE EXPLORE OUR INNOVATIVE PRODUCTS

Oven System Solutions

TabLock Trays

ePAN® Designs

Specialty Designs

DuraShield® Coatings

With production facilities and sales offices located across Europe, we offer your bakery unparalleled design, expertise, quality, and service. From standard to custom sizes and designs for industrial systems, American Pan Europe will deliver innovative solutions for your bakery’s biggest challenges.

For more information on these and other design innovations, visit americanpan.com/innovation.

MANUFACTURING AND SERVICE LOCATIONS For sales office locations, visit our website.

Alexandria, Romania

Barcelona, Spain

Irlam, England

Skelmersdale, England

+40 247 306170 / 314245 jalbertsen@americanpan.com

+34 93 781 4600 sparra@americanpan.com

+44 (0) 161 504 0771 hdooley@americanpan.com

+44 (0) 1695 50500 hdooley@americanpan.com

EDITORIAL

Meaningful work

Food2Multimedia is a publishing house operating at an international level and specializing in researching and editing technical information for the baking sector.

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

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ASHWORTH PROVIDES INNOVATIVE SOLUTIONS FOR THE COMMERCIAL BAKING INDUSTRY

Hardcover edition: ISBN 978-3-9824079-0-6 PDF: ISBN 978-3-9824079-1-3

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Sustainability

Automation

A growing hub for pans and trays

Hydrogen fuels the future of the ovens

Industry 4.0 tackles fast industry tranformations

AUTOMATION – SCIENCE AND TECHNOLOGY

Price: 49 € incl. VAT

Production

06 21

AUTOMATION SCIENCE AND TECHNOLOGY

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Dictionary of bakery terms

The answers to two questions can provide solutions for each approach: what are the underlying reasons leading to this shortage, and how to ensure stability in production in the meantime (and in the long run)? The reasons identified on a case-by-case basis can offer immediate, practical solutions. Are night shifts one of the issues turning people away? Is it the tedious, intensive work among the reasons, or failing to provide the feeling of accomplishment? Another way to tackle the problem is to adapt the work to fewer people. A common denominator in both cases is technology: it can take over night shifts when certain processes are fully automated; robotics can perform the repetitive and tiring jobs; and people, unburdened of physically demanding tasks, can be provided with training to specialize, be inspired and deliver results in rewarding areas around the production facility. The good news is that it has become a better investment than ever to automate operations in bakeries - assuming the right balance fitting to each business is identified. And finding it is just one example of meaningful work people can do.

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France is not alone in this. These challenges are affecting the bakery and confectionery industry elsewhere as well, despite the sector’s recovery – supported this year by foodservice reopenings and enduring trends for healthy eating. Volatile prices and labor shortages are causing concern internationally. One of these issues, however, is unlike the others – in that it is not contextual and is not relatively short-term: labor shortage. It has been an issue for years. Analyses on attracting and retaining people in the industry were already among hot topics at IBIE almost a decade ago.

Catalina Mihu

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CMY

f2m food multimedia

French companies including bakery, pastry and viennoiserie makers have been struggling with spikes in their production costs. Reasons cited include a painfully acute scarcity of staff.

The Fédération des Entreprises de Boulangerie (FEB) voiced its members’ concerns early December regarding the rise in the price of raw materials, packaging and energy while, at the same time, facing a labor shortage. France is trying to adjust to a 10-20% increase in packaging costs over all types of materials, for example. The situation is causing supply disruptions, delivery delays, and its effect is felt in rising prices. On behalf of its members, the FEB relayed the message asking customers, from supermarkets, restaurants, to wholesalers and other sales channels, to join talks to mitigate the inflation.

Media to the global baking industry

Dictionary of bakery terms English

ENG

German

DEU

French

FRA

Glosario de términos sobre tecnologías de panificación

Spanish

SPA

Термины хлебопекарной индустрии

Russian

RUS

Ordbog over bageriudtryk

Danish

DAN

Japanese

JPN

Dictionary of bakery terms

Wörterbuch der Bäckereitechnik Dictionnaire des termes techniques pour la boulangerie

baking+biscuit international Our specialist journal concentrating on production professionals in large companies in the industrial and chain-store sectors.

Published six times a year in the English language.

Our Review series provides in-depth analysis of clearly defined issues. This involves market analyses and is a comprehensive, informative presentation of the state of the art in process engineering.

The f2m dictionary translates bakery terms into a mulitude of different languages.

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

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IMPRINT

© PhotoGranary – stock.adobe.com

CONTENTS

© American Pan

06 American Pan Europe: Alexandria – a growing hub for pans and trays

10 AMF Bakery Systems: Hydrogen fuels the future of the ovens

SUBSCRIPTIONS Viktoria Usanova usanova@foodmultimedia.de

42 Packaging: The best way to reach (or come close to) zero waste Robotics

DISTRIBUTION vertrieb@foodmultimedia.de

16 Royal Kaak: The right robot for the job

ADVERTISING dixon@foodmultimedia.de

Production

SOCIAL MEDIA Annie Dixon annie.dixon@foodmultimedia.de

20 Ashworth: Process automation with the SmartSpiral 30 FRITSCH: Software prevents input errors

LAYOUT/GRAPHIC DESIGN LANDMAGD Design aus der Heide Linda Langhagen, design@landmagd.de

Proofing MIWE: A world of proofing in a small, green footprint

PRINT Leinebergland Druck GmbH & Co. KG Industriestr. 2a, 31061 Alfeld (Leine), Germany

Automation 26 Mecatherm: Industry 4.0 for industry transformations

IT IT Consulting BRUNK Felix Brunk, felix@brunk-net.de

Cooling and freezing 28 Reading Bakery Systems: Gentle and fast ambient cooling for crackers

BAKING+BISCUIT INTERNATIONAL is published six times a year.

Single copies may be purchased for EUR 15. Subscription rates are EUR 75 per annum. Students (with valid certification of student status): EUR 40. (All rates include postage and handling, but not VAT).

Research 32 Functional salt substitute: Salt reduction in bread using choline chloride 36 VR technology: A virtual new world in consumer perception studies New raw materials

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Address subscriptions to the above stated distribution department.

38 Enzymes: Better-for-you baking, with enzymes Gluten-free 44 Diosna: Free-from innovation for taste

Claims will not be accepted for any copies not received or lost copies due to reasons being outside the responsibility of the publishing company. This magazine, including all articles and illustrations, is copyright protected. Any utilization beyond the tight limit set by the copyright act is subject to the publisher’s approval.

Markets 48 Commercial Baking: Translating culinary trends into the bakery aisle

Regulars 03 Editorial 14 News 24 News

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

COPY EDITOR Annie Dixon annie.dixon@foodmultimedia.de

Sustainability

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PUBLISHER James Dirk Dixon dixon@foodmultimedia.de

EDITOR Helga Baumfalk baumfalk@foodmultimedia.de

Visit

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PRODUCTION

VISIT

A growing hub for pans and trays American Pan’s facility in Alexandria, Romania, is the company’s main European operation head-

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In Europe, American Pan works with a staff of 520, out of which close to 400 people are employed at the factory in Alexandria alone, with plans to increase their ranks by an additional 50 before the end of the year. The Group’s sixth pan manufacturing center, in addition to its three facilities in the U.S., one in Brazil, one in Sweden, has ambitious plans, all on-trend with the dynamics in its surrounding markets. The industrial pans made in Romania are mainly specialized for the production of buns and rolls, the company’s core segment in Europe, and breads – which has been a growing market over the past few years. Baguette trays are being added to the product portfolio at the facility in Alexandria.

Bakeware has been the growth driver for American Pan’s facility in Romania, which was first established by the acquisition of FBS Prestige just outside Bucharest. Together with it, came its promising market share, valuable know-how, ideas and people. The facility managed to triple its market share in Europe in its first year alone and it is looking at a multiple of that for the following years, anticipates Thanos Rizoglou, American Pan’s Vice President of Operations for Romania. Operations maintained a steady level throughout various restrictions caused by the pandemic, with some segments even enjoying growth, such as the DuraShield coating, which is a non-stick fluoropolymer coating that helps bread and rolls easily release from pans, including

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quarters for bakeware, with investments worth EUR 10 million planned over the next five years.

gluten-free products. The coating’s productivity and longevity proved to be convincing arguments everywhere in Europe.

Moreover, the plant even made significant strides into mainland Europe’s highly competitive markets. As its own operations expand, American Pan Europe observes, in parallel, the growth trend among the region’s bakeries and their increasing needs for bakeware: while they might be

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somewhat decreasing in numbers, they are becoming more centralized and are expanding with distribution centers in different countries.

The COVID-19 measures did bring changes in the products in demand, more than anything: requests for pans for buns and rolls stayed low, in line with the fluctuating operations of the QSR bakeries using them. Products for bread markets and all confectioneries commonly sold in supermarkets, however, experienced massive growth for over a year, Rizoglou shared; “A rush of inquiries that we have not seen for a very long time.” The level of demand now hovers above that recorded before the pandemic.

The facility also launched a new service this summer, a stock bakeware program with online ordering. Bakeware in standard sizes such as 400x600mm and 600x800mm can be shipped from Romania, options including bread tins and lids, baking trays, baguette trays, bun trays, muffin trays and pizza trays.

Refurbishment services are increasingly being requested as well, a possible consequence of the pandemic.

Sound investments All signs seem to indicate a strong year and that demand will remain high and to support this the company has invested in developing its existing lines and equipment lineup, to increase its flexibility. Since the pans are vastly different in sizes, shapes and designs, they are hand-made, for the most part (and made by a staff comprising women, in the majority – an HR strategy both notable and laudable). A certain type of product may be produced in the hundreds, for example, after which the line would need to be set up again, meaning all new tools, dies and presses would be needed. The company also aims to increase its automation levels. Projects that are already on the drawing board in this regard will upgrade the spraying process and robotic welding. In line with the spike

© f2m

© f2m

PRODUCTION

in orders, increasing production speed and capacity is also in the works, with investments into newer equipment. The way the internal engineering and design departments work contributes to speeding up work, as the NPD process can be time-consuming: “Our engineering teams work as a group, internationally. We do compare notes regularly to see if new ideas have come to fruition for projects such as new designs for dies, for example, and if so, whether they can be implemented in all production sites. This is the beauty of being part of a big group, being able to continuously learn from each other,” Rizoglou underlines. Entire lines and workflows that were proven to perform well in a certain setup in the U.S. were entirely replicated in Romania and Brazil, for instance.

Having lines dedicated to producing a certain type of bakeware is the goal, but built as flexibly as possible since all the resulting pans need to be essentially custom-made.

Safety is also among priorities and it dictates replacing most of the equipment that can pose any risk in operation. This has been an ongoing process, for the past three years. The factory has also been working on expanding its capabilities in the dimensions of the pans it can manufacture, due to incoming requests for bigger pan sizes, in line with the market trends in the design of new production lines. To meet such requests, the company invested in presses; mechanical limitations aside, variations that were hard to conceive not long ago are now being produced – with the presses to support it. As bakery lines grow in size, so do pan production lines, to match corresponding bakeware. One of the recent impressive projects, in this regard, was a tray measuring 1.3x1.2m. This is a huge undertaking to produce a single pan that is fully closed without external welding, certainly a seamless pan in the superlative. The design and supporting software helped achieve a sturdy tray, that maintains its shape and integrity over time. The only challenge is in handling a tray of such a size (exclusively automated with either mechanical grippers

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PRODUCTION

The facility in Alexandria, Teleorman county, was recently expanded by 3,000sqm ROMANIA Alexandria SERBIA

Bucharest

BULGARIA

GREECE © f2m

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or magnets, conveyor lines, etc.), and not necessarily in manufacturing it, the specialist concludes. One handling recommendation American Pan offers when using heavy pans is not to stack more than 60, and to stack them on the strongest part of the design.

infrastructure hasn’t been a problem at all, as the roads remained mostly clear of traffic. On-time delivery is successful up to 95% of the time, the rest being the effect of unexpected events that can occur anywhere in the world (late deliveries, supply chain bottlenecks, driver-related, etc.).

Employees also represent an important investment, not just in their numbers, although a considerable team of 50 is now being added, but in attracting, training and keeping them.

Specialization is gained in-house to provide the quality and services needed on the job. New facilities for the workers are also among priorities, including new lunch and break areas.

Training and promotion opportunities are showing results: employees are staying with the company for the long run.

Safety measures were put in place for the teams during the pandemic, and investments were also made for remote work, wherever possible. The company also organized several vaccination campaigns, and booster shot support will follow.

And thorough research To maintain and grow the business, American Pan Europe is looking beyond simply pan designs and is aiming to ultimately simplify processes for bakeries. Continuous support with customers’ everyday operations to identify improvements is also a priority. Sustainability and the longevity of the products are key for manufacturers, the specialist summarizes. Various solutions can provide answers to these goals, the use of hightensile strength steel being one of them. Helpful features include the ease of stacking and handling.

The facilities will also be expanded by an additional 2,500sqm, following another recent expansion of 3,000sqm, bringing the production site to a total of approximately 16,000sqm (working space).

Calculated risks Geography, labor force, existing market share, networks, growth potential - these are some of the arguments making Alexandria, a town just outside Bucharest, a strategic pin on American Pan’s map to conveniently serve Europe and the MENA region. One of the challenges that also comes with the location is the infrastructure. Highways linking the plant with the capital and with Europe’s major transportation routes are scheduled to be finalized in the next years. In the meantime, logistics take into consideration up to two extra days for deliveries, until the products reach the borders.

However, during various pandemic measures, the

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Copyright © Free Ve

Samples are built to develop special solutions, including molds and designs solving specific manufacturing problems. New designs are conceived for specific requests, which are made into samples when approved. The samples undergo lab testing, then live samples are prepared for trial runs on the production lines. Once the specifics are agreed upon (e.g. pan height, width, radius, indentations, materials, the shape and the way it travels through the conveyor, etc.), the company begins building the dies it will need for production. This process varies; it is simplified if a similar solution is already in American Pan’s database somewhere in the world. But, given the product variety in certain markets and even regions in those markets, development can start from scratch. One such example is a Romanian specialty – the cozonac, a type of cake traditionally baked around holidays, somewhat similar to the panettone. There are countless variations of the cozonac.

American Pan developed a type of tin specifically for its industrial production, after extensive market research, testing various coatings and finishes to test product characteristics

PRODUCTION

including color and release. After the sampling, a larger trial was performed by a bakery, using about 100 tins. The bakery now has several thousands of this type of tins, to use for seasonal sales. The top three bakeries in Romania are now all using them. “The most difficult part is to thoroughly understand what the customer needs, and crystalize that on a piece of paper with everyone agreeing. After that, a drawing and a sample take around two-four weeks to be produced,” Rizoglou outlines the R&D steps. Depending on the product, projects can take up to a few months to develop. A thorough understanding of the bakery machinery is a given, to optimize the use of pans, the specialist shares. In this regard, European markets have not yet reached full maturity.

TECHNOLOGY MEETS BAKER‘S CRAFT. FOR YOUR PERFECT BUNS.

A special project The local manufacturers that source their pans from American Pan include one of the Romanian leaders for packaged bread. It operates a manual production line in its facility located just outside Bucharest. In recent months, the bakeware specialist designed a lighter-weight pan for the bakery, which also helps achieve a better product color and save energy in the oven. The pan needed to be as light as possible, as it is manually handled by an operator, and extra weight means more and faster damage inflicted on the pans. In addition to the design, the materials also played an important part, needing to be sturdy enough to preserve the integrity of the pan.

Reaching the optimum solution meant going through the R&D steps, with trust and reliability also contributing to the collaborative workflow, from the bakery's perspective.

The collaboration succeeded because the information was shared both ways, a process in which he saw a partnership rather than simply a sale, the plant manager recalled. Three standard sizes were sampled to achieve better baking results in a lighter configuration. The new pan, the first of its kind in Europe, features additional holes, making it also cheaper and providing better air circulation. As the input and output are manual operations, it is more likely to have problems with the pans due to nesting, the plant manager explained.

The development of the new tins was finalized over approximately two months – and that at a time of a global metal shortage.

König QualityVac Vacuum Technology

With König vacuum technology, breads, cookies and pastries (e.g. Danish pastry) can be cooled and stabilized for further use in just a few minutes. This enables enormously improved product quality in terms of freshness, crispness, volume and stability, immediate further processing of the further processing of the pastry and optimization of your operating processes.

EASILY OPTIMIZE YOUR PRODUCTION ADVERTISEMENT

Despite a double crisis (COVID-19 and spikes in energy costs) affecting the Romanian market, the bakery business has grown to produce 32% more volume than it did at launch, in 2009. The plant in Romania anticipates high-volume production next year, aiming to have one toast bread in every house.“When we succeed, the market is mature,” anticipated the plant manager. The differentiation point of the breads this bakery makes is that no preservatives are used and the shelf life is extended thanks to pasteurization alone.

The bread maker uses double packaging, which also contributes to the product’s shelf life, freshness and safety. +++

THE SYSTEM FOR OPTIMIZED PRODUCT QUALITY

Koenig Group Baking Equipment 8045 Graz · Austria info@koenig-rex.com · koenig-rex.com

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S U S TA I N A B I L I T Y

Hydrogen fuels the oven of the future With the world’s first zero-emissions baking oven, a tunnel oven made by Den Boer, AMF Bakery Systems unlocked the opportunity for baking technology that is entirely environmentally sustainable. Times are now catching up with this next-generation technology, in finding ways to source and use green hydrogen.

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The futuristic oven concept running on hydrogen is also a literal nuts-and-bolts, working technology residing in the AMF Tromp Innovation Center in the Netherlands. The modular Multibake ® VITATunnel Oven effectively eliminated emissions commonly produced by baking ovens by using green hydrogen to activate its burners.

Color-coded hydrogen To clarify the different color codes used to describe hydrogen, it should be understood as an energy carrier. Gray signifies that natural gas is used to obtain this hydrogen, a resourcedemanding process that also results in CO2 as a by-product.

Research also shows that considerable amounts of methane escape into the atmosphere as natural gas is extracted.

Hydrogen is labeled blue when the CO2 generated from steam reforming (the gray hydrogen, known for years) is

captured and stored underground (85-95%), through industrial carbon capture and storage. Green, however, means that this type of hydrogen is produced by splitting water via electrolysis; it is ‘clean’ hydrogen. This produces only hydrogen and oxygen, with no negative impact on the environment, as electrolysis can be powered by renewable energy sources, such as wind or solar power, to steer clear of any CO2 emissions.

Deep green baking Hydrogen is a viable energy source to support baking technology, as AMF assessed and demonstrated by designing the technology. Since many bakeries are using natural gas for their ovens, another type of gas could be an easy switch for them, the company theorized. Hydrogen was discovered decades ago but had not been considered a potential energy

© AMF Bakery Systems

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© PhotoGranary – stock.adobe.com

S U S TA I N A B I L I T Y

source for baking ovens. In line with its own sustainability goals, AMF Den Boer built the technology that can support bakeries to truly bake ‘green’. Burning green hydrogen only creates water/steam as a by-product and no CO2 emission; it is also able to reach relatively high temperatures, which are vital to baking.

Efficiency optimization can turn a theoretical model into day-to-day working technology. In this case, “It can be reached by having a large network and availability of hydrogen, so more bakeries can connect and reduce the use of natural gas/ propane,” AMF highlights a potential solution that would also be a welcomed alternative to ever-increasing natural gas prices. Such large networks are currently in a project stage: earlier this year, RWE, Uniper and Bosch have announced large-scale projects for hydrogen research, while the European Hydrogen Backbone (EHB) initiative proposes a hydrogen network of 39,700 km by 2040, which can be further developed in the long term. In turn, the German government has allocated EUR52 million for hydrogen research. Electrolyzer systems are already available in many shapes and sizes, to produce hydrogen on location or at production sites. If electricity is generated via solar or wind energy, green hydrogen can be generated.

direct gas-fired Den Boer ovens recently delivered, are H2READY and can be rebuilt to use the hydrogen burners in a matter of days,” AMF highlights.

Hydrogen availability is growing in the world, especially in the EU region, AMF observes: “The EU has started many initiatives via Hydrogen Europe, where producers, users, governments and lobbyists are gathered to build a new, sustainable future in Europe and beyond. AMF Bakery Systems is also a part of Hydrogen Europe and contributes to this stream of upcoming projects.”

Burning hydrogen with a baking oven is, in a way, comparable to natural gas and propane. But, using it sustainably means doing it right and safely; that is where AMF’s new technology comes in, the specialists point out. “Burning hydrogen creates water or even steam when temperatures are very high, so this

© AMF Bakery Systems

In the near future, bakeries will be able to generate their own green hydrogen with renewable resources. Potential solutions include companies working together to have an Electrolyzer, or hiring a party that produces hydrogen on-site, and transports it to their facility, just like local gas stations or gas-pipelines work. AMF points out that subsidy plans are also evolving, so funding will soon become available as well.

In the meantime, AMF can mix H2 with natural gas (NG) and still reduce CO2 emissions by about 30% without changing the current burner design. “It should be noted that the

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stays inside the oven and circulates, which is perfect for baking. Many bread, pizza and cake products look and taste even better using a bit of steam,” AMF explains.

implementation of the hydrogen-burning technology. The reason for that is that the burners heat the product, respectively on the oven belt directly, just like the blue flame burners do when fired with natural gas. The specialists outline some benefits of the direct-fired principle: + Dependable, adjustable heat transfer from bottom and top + Moisture monitoring and steam injection as an option (less needed with hydrogen) + Heat transfer from the combustion gases of the burners towards the product is direct without any transfer losses

For the development of the burner capable of using hydrogen, small, lab-scale tests were first trialed. A mini-tunnel oven was the next step, after feasibility was demonstrated with the pilot tests. Currently, AMF displays a working, full-size production oven running on hydrogen in its Dutch Innovation Center in the Netherlands. It can be seen up-close running baking cycles to produce anything from bread, to pizza, flatbreads, buns and more, on a stone sole oven.

The maintenance of a H2-fired oven is no different to that of any otherDen Boer oven. Regular inspections, remote support and replacement of wearing parts will extend its lifetime, which can be as long as half a century. Features supporting increased sustainability can be used with it, such as the Smart Oven app, which can help gain savings of up to 30%.

Sustainability efforts trending in bakeries

+ Reduction of energy consumption + Increasing production efficiency + Reducing CO2 footprint + F inding new energy sources like hydrogen + Minimizing transport/movements needs + Efficiency programs supplying consumers + Managing scrap to have less waste + Hygienic design + Minimizing water use + Digitalization and the use of smart technologies

Hydrogen burning technology at the ready All AMF oven models from the last years are H2-ready.

Hydrogen heating can be retrofitted into existing oven models. What the process entails is determined on a caseby-case basis, since many ovens in production have been custom-designed. But, most natural gas/propane burners in Den Boer ovens can be easily replaced by new hydrogen burner systems and software, in a matter of days, depending on the size of the oven: top, bottom and pre-heat burners can all be switched to be able to use hydrogen. “Combination, hybrid models are also an option, where only a part runs on hydrogen, to take the first steps towards more sustainable baking,” AMF elaborates. With that in mind, it is important to note that it is the Den Boer Multibake-D, a direct-fired oven, the model the specialists consider to be the best for the

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© AMF Bakery Systems

© AMF Bakery Systems

S U S TA I N A B I L I T Y

Source: AMF Bakery Systems

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The patent is pending and expected to be granted at the begining of 2022. The technology used for burning hydrogen was invented by the AMF Den Boer engineering team, and tested and approved by the notified body KIWA. It is designed to reach for efficiency with consumption vs. high-capacity capabilities in mind, to maximize potential savings. “From a chemical point of view, hydrogen is the lightest element.

As it generates heat, more hydrogen (volume) is needed than natural gas to reach the same results, but it comes with the invaluable benefit of enabling carbon-neutral production 24/7,” AMF specialists weigh in. The engineering team of AMF Den Boer has a combined experience of over 100 years in the baking industry. And they are not stopping with this innovation: “Our goal is to have more smart and sustainable products for our customers, based on the demand of the market and the fact that worldwide the desire to become more sustainable is also urgently needed.”

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Reference 1

https://www.weforum.org/agenda/2021/07/clean-energy-green-hydrogen

2

https://www.eia.gov/energyexplained/hydrogen

AT THE PEAK OF TEMPERING QUALITY

TURBOTEMPER® www.sollich.com

30.01 . – 02.02.2022 KÖLN · COLOGNE

U N I Q U E FO R YO U R N EEDS

NEWS

Ingredion launches natural flavor modifier

© Ingredion

PureCircle™ by Ingredion launched a new solution, namely NSF-13, that delivers sweet taste at scale, with a natural flavor claim. It was developed to deliver sweetness across a wide range of applications including bakery and dairy. It is made with sugar-like steviol glycosides, including Reb M. PureCircle™ NSF-13, which is classified as a ‘flavor preparation’. It will increase some targeted flavor tonalities, notably brown notes, while reducing potential bitterness on top of its core sweetness quality contribution, the company detailed.

Sue Bancroft, Ingredion Category Lead, Beverages, commented: “This new addition is our highest performing natural flavor modifier when we compare the typical attributes required to round off sweetness quality, reduce linger, bring out zesty notes and enhance brown notes across a wide range of food and beverage categories. Produced through PureCircle’s most advanced technologies, NSF-13 carries a consumer-preferred ‘natural flavor’ label and is organic suitable.” +++

Anuga FoodTec 2022 gears up for a special edition

RBSConnect platform adds new options

Anuga FoodTec anticipates its upcoming April 26-29, 2022 installment will be a ‘special edition’, held both in-person, in Cologne, and via the digital platform Anuga FoodTec @home.

The product segmentation has also been revised and structured to include solutions throughout the supply chain. “In this way, supply and demand can be brought together in an even more targeted manner,” Koelnmesse announced, in a press conference.

The segments are now as follows: Processing, Filling & Packaging, Digitization, Automation, Intralogistics, Safety & Analytics, Environment & Energy, Science & Pioneering. Among the new entries, Intralogistics deals with the internal flow of materials and includes, for example, product groups such as conveyors, large containers, storage systems and industrial trucks. The Energy & Environment will offer approaches to solutions and innovations at various levels across all process stages, while Science & Pioneering focuses on the future more than any other segment. Here, the experts are expected to identify solutions that will be ready for the market in the next 5 to 10 years and overall industry directions.

Anuga FoodTec @home promises virtual visitors access to the relevant players in their industry, while at the same time providing exhibitors with a digital extension of their trade fair presence.

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© Anuga FoodTec

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Reading Bakery Systems (RBS), expanded the capabilities and services offered by RBSConnect, their proprietary Industrial Internet of Things platform for custom-designed control systems. RBSConnect facilitates communication and coordination of the operations while collecting and analyzing data. These systems allow real-time information monitoring and provide preventative maintenance information, key performance indicators, alarm history and trending.

“RBSConnect offers a full suite of innovative solutions to empower customers to maximize their system controls, optimization and management. It’s an exciting blend of manufacturing automation, intelligence and analytics, resulting in customers achieving tomorrow’s baking systems performance goals, today,” said Shawn Moye, Vice President of Sales, RBS. RBSConnect offers two service levels: a full suite of IIoT capabilities ‘out of the box’ for traditional baking requirements, as well as RBSConnect 2.0 for companies with more advanced operational needs. +++

NEWS

Panera Bread announced its commitment to remove more carbon from the atmosphere than it emits by 2050. The company is pursuing the following 2025 short-term targets to reduce its footprint by increasing the percentage of Cool Food Meals to 60% of bakery-cafe entrees, transitioning to packaging that is 100% circular - reusable, recyclable and compostable, and using green, renewable electricity for at least 50% of its operations.

Reaching this climate positive goal equates to removing approximately 2.4 m metric tons of CO2 equivalents each year, compared to Panera’s 2019 greenhouse gas baseline. Since 2017, Panera has already reduced emissions from its operations by 15% per square foot, meeting its 2022 target one year early.

“Climate change is one of the greatest humanitarian crises of our time, and we must act now for our planet. We embrace the responsibility to take immediate and relentless action to create positive change and hope that our industry will follow us. We are sharing our vision for a climate-positive future to inspire both our industry and our supply chain partners to take urgent, decisive and clear action,” said Niren Chaudhary, CEO, Panera Bread. +++

BACKFACTORY tests innovative self-checkouts

Bremen-based BACKFACTORY introduced self-service checkouts where customers can scan their own purchases and pay cashless.

Thanks to AI-based technology, terminals no longer need item recognition barcodes to record and identify an article. Even unpackaged, unlabeled snacks can be processed.

The guest places the item of their choice on the corresponding counter of the selfcheckout and starts the checkout process with a single touch of the display (‘tab to start’). On the terminal display, guests can take a photo of the item and the checkout process begins, displaying the corresponding prices. The purchase is finalized afer requesting a confirmation. When support is needed, shoppers have the option to call the store employees on the display. Payments can be made via an NFC card reader. +++

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© BACKFACTORY

Panera Bread announces goal to become climate positive by 2050

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© Kaak

ROBOTICS

The right robot for the job Automating labor-intensive, repetitive work in bakeries by use of robotics helps perform complex movements and round-the-clock tasks.

+

Besides the packaging area, where robotics are well established, production lines can similarly automate processes including storage, scoring, depanning and dough resting systems. Kaak develops robotic applications specialized in performing different types of tasks along the bakery line. The company started building 3D vision guided scoring systems using robotics and expanded the use of robots on the bread processing line for all kinds of handling automation.

Fueling this development are the recent shortage and rising costs of personnel.

for products that are perfectly aligned on defined positions in carriers and scored in fixed patterns by a series of knives.

This solution works well for mono-product lines. However, demands for a large variety of different luxury products with complex scoring patterns is growing, since it is a powerful way to reflect the brand identity and make products truly unique. This is where robots come into play. “Scoring is a very complex movement that was only done by humans. This is the clear advantage of the robot,” Michiel Dix, underlined.

Traditionally, the baker ‘scans’ the product to determine how deep and where to score. The recognition of different products, their curve and height, as well as the cutting movement itself, is now also done by the Kaak robotic scoring systems.

3D-vision technology is instrumental to this. It recognizes the product’s position, orientation and shape and sends this

Scoring with robots Dough scoring has been vastly automated in industrial bakeries, observes Kaak; the company has installed around 200 robots. Conventional, xy-scoring systems were mainly used

Key points driving the use of robotics in bakery

+ Robotics provides simple solutions compared to more complex alternatives

+ Covid has fueled discussions on automation and

robotization. Limited availability of personnel and rising personel cost have triggered many bakeries to further automate their production processes using robots

+ Robots simplify production planning due to the

www.bakingbiscuit.com 06/2021

for Kaak's scoring aplications

Source: Kaak

absence of variations in availability of personnel.

+ Fast return of investment, e.g. as fast as 2-3 years © Kaak

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ROBOTICS

THE Peelboard © Kaak

Suitable for all industrial baking lines.

information to an industrial computer, where the logistics of assigning the robots tasks are handled. From the computer, the robot receives the information related to the product command about the movement it should perform, Teun Verkerk detailed. “A robot is by definition suitable to make such complex movements, guided by 3D-vision to follow the contour of the dough piece.”

1

Excellent non-stick effect

1

Perfectly hygienic

1

Stable & durable

Scoring is a process that requires skill and shows the baker’s experience when done manually. Alternatively, as labor is becoming harder to find (and then keep), robots can efficiently take over the task; they will never need to stop and will perform constantly over time. As the trend for artisan-style products is growing, the concern might be raised whether the resulted products would all be identical, ‘robotic’. Of course the scoring will be uniform and perfect for each individual product, despite differences in shape and position of the dough pieces. Dough is a living substance. If scoring is constant, when the bread is being baked, there still will always be small differences between each product, maintaining the artisanal look and feel.

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Kaak has installed many 3D controlled cutting systems over the last six years, operating in various combinations anywhere from 1 to 12 robots, depending on the requirements. There are different kinds of scoring tools available that best suit the product properties of each bakery. For example: the scalpel knife, the rotating knife, and the water jet. They have quick-release systems, so the operator can swap them by simply using a handle or it can be done automatically.

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

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ROBOTICS

© Kaak

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The recipe programming is designed to be intuitive and user friendly. Input of the scoring parameters is made easy as the input data is visually represented on the screen for quick recognition of the scoring pattern. The HMI also provides operational information of the performance of the scoring application.

Robotic handling There is also a growing demand for robotics for storage, Kaak observes. In bakery processing lines, the Dutch company sees a vast array of applications in which robots can be of added value over traditional equipment. These robots can perform complex movements in a very flexible and efficient way, resulting in higher output and efficiency of the production line. In addition in applications where tedious, repetitive and difficult tasks are performed by humans, robots can perform these tasks cheaper and more cost-effectively. Examples of these applications include depanners, carrier storage, dough resting systems and many more.

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Carrier storage applications As an example, Kaak sees a growing demand for robotic storage automation, handling baking trays, straps and lids.

“Besides the fully automated gantry systems that Kaak has been building for many years, we see a growing demand for more flexible and smaller sized robotic storage applications.”

Automated storage systems using robots are a simple and cost-effective solution for mid-sized production lines, where flexibility is key. This means robots that can correctly identify, pick, and place carriers, keeping them and their coatings safe from any damage while handling them. All solutions are custombuilt, according to production requirements and the floorspace available, to seamlessly integrate their work on the line.

Future-ready Kaak keeps investing in further developing robotic applications in the following years in those areas where tedious, repetitive and difficult tasks are better off assigned to robots. The goal is the complete integration in the total line control, to increase process efficiency. +++

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PRODUCTION

© Ashworth

20

Real-time is the right time Every aspect of the process and its related equipment is closely analyzed to identify new ways of increasing efficiency. When proofing, cooling and freezing bakery goods, this means constant monitoring to prevent unplanned downtimes. For this, smart tools are the key.

+

A versatile piece of equipment that can be used for all processes requiring controlled temperatures is the spiral.

For this technology, Ashworth developed the SmartSpiral® Monitoring System, an application that provides real-time monitoring of multiple spirals, even over different facilities.

It manages maintenance to identify performance issues, prevent failures, consequently minimizing downtimes and service.

calculated, the 3 sigma limits are noted on the graphical displays,” he adds. Moreover, performance parameters are defined within preset limits, to trigger warnings when parameters are outside of these presets. When it encounters deviations, the system automatically sends a notification as soon as an alarm is registered. Data is recorded and analyzed for such ‘alarms,’ which are saved for an evaluation of the overall status of the system. Data is monitored for the bottom bearing, the cage drive, the outfeed drive, temperature, and belt tension. Sensors can also be added and monitored based on specific process requirements. In addition, up to three more sensors can be added to the system, upon request.

The system is designed to monitor parameters that are difficult to monitor in harsh environments, such as a freezer during operations or a bottom bearing on a Lotension spiral cage, for example. The SmartSpiral ® monitors trends over time as well as instantaneous changes. Various kinds of data can be obtained and managed The evolution of the trend graphs indicates with the SmartSpiral® , depending on the the health of the system. Trend data is system and its requirements. “Every system graphically available on the connected is unique, so we establish a baseline for smart devices to monitor the system’s Follow the QR-Code to watch each monitored parameter as a step of the operation in minute detail, to maintain/ the video installation,” explains Chris Trinch, Senior increase process efficiency and to identify Product Engineer for Ashworth. Data is areas that may require adjustments or continuously collected, with a data point established every intervention. As it monitors basic parameters, the Smartthree minutes. These data points are used to establish Spiral ® uses the data to create an image of the entire system’s performance which becomes the backbone of predictive trend graphs. “Over time, the system calculates SPC data to maintenance. provide +/- 3 sigma ranges for all monitored sensors. Once

www.bakingbiscuit.com 06/2021

© Ashworth

PRODUCTION

Valuable data The working environment of a blast freezer is inhospitable for most operators. The SmartSpiral ® Monitoring System is particularly suitable for cooling and freezing conditions because it is built to withstand harsh environments, including below-freezing temperatures. It transmits system data to the smart devices it connects with for safe viewing, outside the freezer.

Motor power, temperature, and bearing noise are among the process parameters that are frequently monitored. Motor power brings insights on how hard the system is working, bearing noise levels indicate whether the bearing needs lubrication or replacement, and temperature changes can show in detail the efficiency of the cooling systems as loads change. All the data acquired helps to effectively plan production schedules and accurately anticipate all routine operations needed, from cleaning to maintenance or any intervention that might be required to continuously improve the processes.

of the facility. Information is provided online, via a webpage, as well as via weekly performance emails. As the system operates independent of a company’s Intranet, no access to company servers is necessary, so company data is never at risk.

In this way, it can help minimize or entirely prevent spiral system malfunctions such as bearing failures, high belt tension, improper maintenance, motor failure, gearbox failure, etc.

The SmartSpiral allows the operator to determine predictive maintenance priorities, thanks to the data reports it compiles.

It clearly shows when parts of the system are changing, so that they can be addressed. For example, a failing bottom bearing can be seen via the reported alarms and be replaced before failure.

“It enables planned downtime versus unplanned downtime that creates havoc with employees, product, and profits,” Trinch highlights.

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wo

The SmartSpiral System sets up a baseline for the system and looks for deviations. How to handle a case of a false alarm, though?

“False alarms can sometimes occur, but we do our best to minimize them.

Because data is presented in trend graphs, false alarms should show as ‘outliners’. Should multiple ‘outliners’ be present, an investigation of the issue should follow to verify the correct operation of the sensor,” the specialist recommends.

©A

Smart and safe data The system notifies plant engineers and managers about potential system failures before they actually pose a production problem.

The messages issued include information about the fault identified, the date and time of detection, as well as the system ID and the location

r th

While it performs ideally for conditions such as freezing temperatures, the SmartSpiral®’s use can be adapted to fit the needs of other processes, too. This is why it was designed as an open platform. “For example, a user could elect to monitor an oven with various temperature sensors and a sensor on the main drive motor,” Ashworth’s specialist illustrates.

The solution can be retrofitted and implemented to match the production parameters and it immediately contributes towards minimizing unplanned, costly events that could disrupt operations. +++ www.bakingbiscuit.com 06/2021

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PROOFING

A world of proofing in a small, green footprint Advancements in proofing technology are focusing on obtaining the best possible product and on flexibility for all possible process needs.

Fully automating the process is the next step, and then doing so sustainably, over a small © MIWE

footprint.

+

E

There are several options for versatile elements that can be quickly removed for refrigeration solutions in bakeries, cleaning,” Matthias Burkhardt, CSO, MIWE, for any dough fermentation needs – from illustrates. forced, controlled proofing to proofing interruption and retardation. Space is The MIWE GVA e+ is fully automated in performing tasks required in bakof the essence in bakeries of all sizes, ery refrigeration. This includes all which means that this is the type of processes from proofing, proofing reequipment for which ‘more-in-one’ tardation, fast cooling, up to proofing features are a valuable asset. The interruption, or dough stiffening. Every MIWE GVA e+ unit is an example of such versatile equipment, covering temstep or every combination of steps can be peratures ranging from -20°C for freezing, configured in freely selectable time segM E at IW t hi to +40°C for forced proofing, and anything in ments.

M , as B u rk h a r d t, C S O between. In addition to these temperature settings, any humidity patterns can also be applied, in any Depending on production and process needs, custom proorder, and in freely selectable time segments. The adjustable grams can be created. Once it has been defined, a program relative humidity that can be reached is up to 98%. The runs from start to finish, without the need for supervision or result: ideal proofing profiles, consistently reproduced time intervention. By automating this, night work done manually after time. is no longer needed and baking can be carried out immediately at the start of the morning shift. Besides, every function Unlimited possibilities with automation of the MIWE GVA e + can be controlled remotely, via the browser-based MIWE remote. “This innovative service tool There is more to the design of a truly effective bakery refrigeraoffers flawless monitoring and – if needed – remote control tion solution than stainless steel housing and refrigeration of the entire system, 24 hours a day, 7 days a week, 365 days machinery, to truly be able to effectively assist with a wide a year. In addition to remote monitoring and online diagnosis, range of processes. An in-depth understanding of the charthe MIWE GVA e + is under the complete control of the acteristics and behavior of dough is required. Every func+ operator, just as though they were standing in front of it,” tionality of the MIWE GVA e comes with slightly different requirements reflected in its design.“The seamless and Burkhardt highlights. easy to clean flooring in our refrigeration, for example, was Dough pieces need very specific humidity conditions dependdesigned with the special hygienic needs of a bakery in ing on the product, proofing state and temperature interval. mind. We also include impact protection on all sides and High-end refrigeration systems can accurately monitor and an air management system made of hygienic stainless-steel ©M IW

22

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PROOFING

All process steps With the MIWE GVA e+ in its various configurations, products can go through all processes until baking. Up to 99 programs can be stored, each with a maximum of eight process steps.

These phases can be any combination of the five key functions (proofing, proofing retardation, fast cooling, proofing interruption and stiffening), for any user to build their own programs. This is possible because the individual phases in the climate-controlled processes (i.e., programs) are not preset as fixed processes in a predefined order in the MIWE TC control system. Any combination is therefore possible and they can be carried out more than once within the same program if necessary.

The layout of the MIWE TC displays all parameters in graphic and/or alphanumeric form. The proofing curve is mapped on the MIWE TC, displaying black blocks – individual phases with the respective setpoint setting – and a yellow graph showing how the MIWE GVA e + converts the setpoint values into actual temperatures in real-time. A blue graph on the display shows the humidity.

The perfect setting for each step highly depends on the type of product and the baker’s individual idea of taste and volume of his goods. The MIWE GVA e+ also features integrated fan

control, so users can regulate the fan individually for every process step. By doing so, the ideal enzymatic development of dough pieces can be achieved.

The unit handles numerous processes, but it also helps simplify complex sequences. “The MIWE GVA e + is built to make a baker’s life easier. Its control systems will help eliminate potential sources of error, speed up product flow through the process and optimize workflows by also making them safer to use by all workers,” MIWE's CSO summarizes.

More features Optionally, more features aimed at increasing process efficiency are available. The MIWE GVA e + comes with many features and possible configurations such as a wide temperature range, adjustable relative humidity, storage capacity from one trolley to almost any size needed, touch controls – to name some of its core functions. There are also additional features that can be added to provide additional support to special processes or to increase efficiency in terms of energy use and energy consumption. The MIWE GVA e+ can be equipped with floor heating, MIWE eco:proof, MIWE eco:floor and MIWE eco:defrost features, all making use of existing energy to generate heat for proofing, defrosting and floor heating (to keep the floor dry, safe and clean). Moreover, MIWE eco: recover is a heat recovery tool that can reuse heat for the unit itself or direct it to other pieces of equipment.

No small plus Hygiene and energy efficiency are particularly important for these demanding processes. MIWE gave the GVA proofing unit the e + seal of energy efficiency for the savings it can achieve as a result of incorporating enhanced fans, injection electronics, continuous insulation, LED lights and the intelligent TC control system, making it a high performer in terms of energy

© MIWE

control the relative humidity in the cooling chamber. This proofing unit comes with an active moistening system, providing steam immediately at any time. It takes a combination of art and science to find the perfect settings, in Burkhardt's view: “The art of baking consists of skillfully manipulating temperature and moisture to achieve the perfect color, aroma, taste, volume, etc. to create the end product, and by maintaining a harmonious balance of yeast and enzyme activity.

Therefore, there is no single special setting to achieve a set goal, but many individual settings, which are always dependent on many different aspects (such as time, temperature, dough, the kind of product, etc.) to manipulate the outcome.”

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PROOFING

efficiency and machine intelligence. Only systems that use energy efficiently and “make a lasting contribution to sustainable energy conservation” are granted this attribute, Burkhardt shares.

The energy consumption of the MIWE GVA e + can vary according to many different factors, from the storage capacity, the amount of dough inside up to the design of the program.

With the MIWE eco:proof using warm water instead of electrical heat, energy savings are around 20%, depending on factors such as these.

MIWE's specialist explains an optimum process flow, for each product or user of the MIWE GVA e+: A case study could look like this: the dough is cooled quickly in phase 1 and then frozen in phase 2. During the third phase (the storage phase), the yeast remains inactive and enzymatic processes are halted. The dough is then defrosted again.

During the proofing retardation phase, the dough develops its flavor at +4°C. After 6 to 8 hours of retardation, the dough must be proofed within 2-3 hours. Optimum settings will, as always, be defined individually for each bakery’s setup and needs. +++

In collaboration with major French players in the industrial bakery industry, the MEDEF International confederation has developed a 3D application called ‘Virtual Modern Bakery’. The tool offers an immersive experience, allowing users to discover the latest equipment and services from a network of French providers.

The user has access to a complete production line through smartphones, tablets or computers, in the form of a 360° virtual tour. The app is designed as an online, multilingual customer experience. Solutions include equipment for industrial and semi-industrial operations, by type of process: storing, dosing ingredients, kneading, baking, packaging and office design.

The 12 companies that took part in the project were: Mecatherm, VMI Mixers, Shick Esteve (Rians), BFR Systems, Bongard, CFIA, Clauger, Eurogerm, Hopi Consulting, JAC, Panem International, and Sorema. MEDEF is the first private French network for the promotion of French companies in emerging and developing markets. +++

© Mondelez

South African food producer and retailer AVI Ltd announced it was in talks Mondelez International to explore the potential sale of its snacks and biscuits business. The Choice Assorted biscuits maker had been hinting since September that it had entered into negotiations, without providing the name of the other party or any details, according to Reuters.

AVI's Snackworks division houses biscuit maker Bakers and chip brands Willards and Baker Street Snacks, which make cheese curls chips, Jumpin Jack flavored popcorn and Tennis biscuits.

The division brought in revenue USD 270.17 million in the year ended June 30 and contributes about 32% to the group's revenue. +++ www.bakingbiscuit.com 06/2021

SternEnzym develops improver for gluten-free wafers

SternEnzym developed a new compound, Sternzym GA 31077 GF, to support the production of gluten-free wafers. This improver makes gluten-free wafers as stable and crispy as standard wafers.

Gluten contributes to achieving stable, thin baked goods. The flour used for high-quality wafer sheets typically has a protein content of 9-11%. If it’s lower than that, the wafer becomes too soft and fragile.

Values any higher than that would make the wafer become too hard.

These fluctuations can in principle be compensated for with enzymes, SternEnzym explained. The complete absence of gluten presents a greater challenge when making wafer sheets, because gluten is an important ingredient that gives dough more elasticity and provides a better structure.

Gluten also improves mixing tolerance and gas retention ability. +++ © MoldyVintage Photo from Pexels

South Africa's AVI in deal talks with Mondelez

Computer © RAYBON – stock.adobe.com

French companies launch together first 3D virtual bakery

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AU TOM AT I O N

Industry 4.0 has the answers to fast industry transformation The pace of change has only become faster over the past years, and its rippling effect is also felt in the baking industry. How do industrial players ride the changes while also increasing efficiency?

The first change is in the mindset, and then in finding the right solutions. The key word is agility.

+

The changes in the industrial bakery market have not escaped anyone’s notice. Trends in consumption are evolving rapidly and, in many places, what is massively popular one day is no longer so the next. This inconstancy, for an industrialist, could easily be considered as instability as it is not part of the industry’s DNA to offer custom-made products. By definition, the industry seeks to massify production to make economies of scale and benefit from the experience curve acquired through repetition. However, consumers, and therefore industrial bakers, are increasingly demanding products that are differentiated according to location, time, special occasions, etc. To equip oneself intelligently, it is essential to take a step back and understand the issues at stake in this paradox that is currently affecting the bakery industry. Indeed, Aristotle stated that it is not because humans have hands that they are intelligent, but because they are intelligent that they have hands. Applied to industry, this premise indicates that thought and strategy must always precede equipment. For a worker, the tool is only an extension of their hand, which is itself an extension of their vision. This is how Mecatherm’s vision is at the origin of the equipment it develops.

www.bakingbiscuit.com 06/2021

© Mecatherm

26

This tension between the necessary consistency of the industry and diversification exists within companies themselves.

Numerous businesses sometimes observe this opposition between a marketing department that would like to develop its commercial offer by diversifying continuously and the production staff who know the human, technical and financial cost of such variations. However, the market is always right, consumers have the last word. The reality is imposed on manufacturers and the question is no longer whether to integrate flexibility into its production, the question is how. It is possible, however, to consider this challenge not as a leak to be permanently plugged but as an opportunity for differentiation and growth. There are conditions, though. First of all, agility must be thought of as a way of listening to the customer, and this must permeate the entire company, from the manager to the operator, including engineers and sales staff.

From a management point of view, this has its own challenges.

Managers have the challenge of always focusing on one thing, which is to lower costs, whilst listening attentively to the customer. More than 40% of Mecatherm’s work is carried out on the customer’s premises, from installation to after-sales

AU TOM AT I O N

27

Volume vs. identity In any case, the overall picture is clear. The bakery industry must be able to cope with a market split into two main trends: standardized products manufactured in very large quantities and storytelling products corresponding to more specific demands. In Kinshasa, in the Democratic Republic of Congo, Mecatherm lines produce three million identical baguettes per day. In Russia, Mecatherm lines run a wide range of products such as garlic breads, pastries, stuffed breads, buns, etc. for the growing middle class that enjoys eating a range of more Western-style products.

Agility consists precisely in this capacity to set up solid and steady industrial processes, while giving them the ability to adapt to local and specific demands.

To meet the challenges of polyvalence, Mecatherm has developed a dedicated line, MECAFLEX. More than 60 units have already been installed in Europe, Asia, Africa, North America and South America. Versatility has been the guiding principle behind the entire design of this line, which is based on three fundamental elements: equipment flexibility, architecture and software. Firstly, the equipment must be flexible; the MTA Oven was included, as each of its modules can be operated in cyclothermic or impingement mode. The high power of these ovens allows a quick change of all baking parameters (heating mode, temperature, etc.). The humidity can also be accurately controlled and monitored for each module. The vertical M-UB Proofing system is very flexible as well, allowing fast changes of cooling, proofing and freezing settings. Secondly, the architecture must enable this agility, which is essential for operators who want smooth handling of the line. The processes may vary since recipes differ greatly depending on whether the product is pre-proofed, par-baked, fresh, frozen, sliced, etc. All these features are included in the design of Mecatherm’s lines with easily interchangeable modes.

Smart software Finally, and perhaps most importantly, the software is the key element of these systems. As the lines become more and more sophisticated, a poorly designed software system would

© Mecatherm

service, so the customer is there and their demands are naturally heard. To reconcile these industry principles such as massification or planning with the versatility required by the market, the key word is agility. Agility consists precisely in this capacity to set up solid and steady industrial processes, while giving them the ability to adapt to local and specific demands. To achieve this business philosophy, Mecatherm first listened intently. Operating in a vacuum does not allow for this 360° vision.

make the operators’ tasks too arduous and would not allow the reconciliation between versatility and industrial consistency. A clever computer should only allow those in charge of planning to choose the best daily sequencing for instance. To this end, Mecatherm has developed a specific digital tool dedicated to planning, which simulates different scenarios, thus making the efficiency of the line optimal. Operators are always concerned about the quality of the finished product, the maintenance of the machines and their overall performance. However, human resources to operate such machines are sometimes scarce. Hence, manufacturers must offer turnkey solutions for these operators. Mecatherm uses an advanced software to inform, train, and assist operators with intuitive and efficient applications.

Digital solutions are central to the evolution of the industry, in Mecatherm’s perspective, because they allow a worry-free approach to the increasing complexity of manufacturing processes. Industry 4.0 offers the capacity to simultaneously advance the sophistication of manufacturing processes and the ease of operating them.

As the French philosopher and entrepreneur Gaston Berger said in the 1950s, “We are not living in a new world, which can at least be described, but in a mobile world, which means that the concept of adaptation must be generalized in order to remain applicable to our accelerating societies.” This observation about society and the economy is particularly relevant to the industrial bakery sector. To adapt, our industry must reinvent itself, without forgetting its fundamentals or pretending to be something it is not. The technology developed

by Mecatherm is endeavoring to meet these requirements, but it will only be the extension of the hand and the vision of the industrialist who will unlock its relevance and effectiveness.

+++

Olivier Sergent, President of Mecatherm

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COOLING AND FREEZING

CRACKERS

Gentle and fast product cooling As crackers exit the oven, the cooling process is important to guarantee product quality and a long shelf life. A gentle cooling process will ensure the delicate product’s integrity until it is ready to be consumed.

+

Prior to entering packaging, crackers must be cooled down to a specific temperature. If the crackers are too warm, condensation can occur in the sealed package.

Alternatively, if they are too cool, the crackers will be brittle and become stale faster. The moisture level of the final product is critical to achieving and preserving the desired texture, which also results in a long shelf life of the snack. Crackers are baked to a low moisture content, usually between 1.52.5%. This doesn’t leave room for errors. Any form of stress on the product needs to be carefully avoided, including from the product’s cooling process.

New improvements A decrease in both moisture and temperature occurs as the crackers are transferred to the cooling conveyor. If these values change too quickly, cracks can appear on the product surface. The new cooling tunnel system from Reading Bakery Systems (RBS), however, can handle the process quickly and efficiently, while avoiding product distortion or checking.

This new machine is designed in modular form to flexibly meet any space and capacity requirements. “Customers can add multiple sections to suit their plant or process needs.

The modules are equipped with upper and lower fans, each with individual speed control. This allows operators to adjust the amount of air blown across the top and bottom of the crackers,” Reading Bakery Systems details. Operators have access to make the adjustments they need on the touchscreen control interfaces for quick and easy changes.

www.bakingbiscuit.com 06/2021

The goal of the newly designed equipment was efficient cooling in a smaller footprint. This was achieved by directing the air onto the product, and adding independent upper and lower speed differentials for the air moving across the crackers.

This cooling conveyor is also designed with access doors along the entire chamber. This allows for easy cleaning and maintenance. Operators can use either brushes or vacuums for cleaning out cracker fines.

The temperature of the environment is taken into consideration and even channeled to help the process: the equipment features fresh air intakes on the top of the cooling chamber to provide adjustable flow over the products.

Compared to a previous design, the air in this new ambient cooling conveyor is more directed towards the product, and access to the air filtration cartridges and air handling blowers can be handled without ladders. Cartridges can now be changed or cleaned without the use of tools. “The modular sections also greatly improve the time required for installation,” RBS underlines.

A new lineup The cooling technology it incorporates uses direct impingement air nozzles with independently controlled air handling blowers; a makeup that also helps achieve space savings on the production floor. By adding forced ambient air cooling, the amount of cooling space needed is minimized. “Reducing the equipment’s footprint means the space in the plant can be utilized for other items, or the plant, in general, can

© RBS

COOLING AND FREEZING

be designed with a smaller overall footprint, which costs less to heat and cool,” RBS points out.

More compact sizes of cooling tunnels can be designed, in custom configurations as well. While the modular sections are designed in 4.7m lengths, as many sections can be added

as the specific process requires. In terms of widths, the cooling conveyors can be designed between 1.0m and upwards of 2.0m wide. The crackers are often shingled before being brought to the cooling conveyor; they are then transferred onto a separate conveyor that transports them to the packaging systems. +++

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PRODUCTION

Software prevents input errors To make operation as simple and intuitive as possible, FRITSCH has developed a new,

© FRITSCH

performance-related control system.

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The equipment manufacturer supports the digital transformation in the bakery industry by continuously developing its systems; for example, in machine control, digital services and remote maintenance have seen upgrades.

The objective is to offer manufacturers of all types of baked goods the possibility of producing goods with fewer and fewer employees. This is also necessary, says FRITSCH, because it is becoming increasingly difficult for many companies in the industry to find suitable personnel. “The shortage of skilled workers increases the risk of malfunctions and unplanned equipment downtime due to operating errors,” explains Michael Gier, head of FRITSCH World of Bakery.

“After all, you need qualified personnel to understand the interaction of the various components of a bakery line and to be able to control the numerous parameters.”

To ensure that good results in terms of both quantity and quality can be achieved on the lines of medium-sized manufacturers, the software specialists and dough technologists at FRITSCH have developed a new control system for the industrial IMPRESSA series but also for the PROGRESSA series, including the LAMINATOR 700, which is designed for medium output requirements. “Our goal is to make operation as simple and intuitive as possible,” says Wolfang Stegmaier, project manager for digital development at the company. “The prior knowledge required for operation should be reduced to a minimum and input errors should be prevented as far as possible by the software itself.”

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© FRITSCH

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Performance-based management The new concept means that the system is controlled according to output. “For example, if a customer wants to produce 5,000 croissants per hour, he simply enters this performance specification on the display and the system then calculates all the necessary parameters to achieve this result,” explains Michael Gier.

PRODUCTION

CREATING TOMORROW’S SOLUTIONS

Until now, the settings were technically based, meaning that the operating personnel had to know exactly how the laminating line works and how adjusting a parameter affects the overall result. “With the new control system, numerous basic programs and corresponding performance parameters are available for different products, where only a few parameters, such as the roll gap and layer numbers, need to be readjusted to achieve the desired result,” says Gier.

According to him, the combination of three operating levels, of which the operator only needs to master two, and the preset basic programs have another advantage: any operating errors can be detected more easily and rectified more quickly. This reduces downtime and increases the overall efficiency of the plant.

Clear division of the operating levels To be able to produce an optimal dough sheet for each product, numerous parameters can be set and components adjusted on the LAMINATOR 700.

“After discussions with customers, dough technologists and software developers, we came to the conclusion of setting up three different operating levels,” explains Wolfgang Stegmaier. The first level provides a general overview of the system. The second level contains the various components of the line, which can be monitored and adjusted by the staff during ongoing production.

The third level is used for fine adjustment and is primarily intended for dough technologists. Michael Gier: “For the operators, the first and second levels are primarily relevant; on the third level, our experts or those of the customer make adjustments for fine-tuning the products that can be produced on the line.”

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Visualization creates transparency The developers attached great importance to the fact that all working components networked with each other. For example, the drives are connected to the control system via a bus system. “Operation is via a 15-inch screen that is permanently installed on the LAMINATOR 700,” reports Wolfgang Stegmaier.

“The concept provides a clear overview of the individual components of the system.” The visualization on the display of the system enables the respective user to quickly control the required operating level and to clearly recognize the individual machine parts”, he adds.

Baked goods manufacturers can grant their employees personalized access to the operating levels and components via a log-in. “In practice, we have found that the master password for a system was sometimes known throughout the company,” says Michael Gier. “With the new control system, the user can log on to the machine using his ID card.” The operator is assigned the required access rights with his badge when he is created in the control system. They are therefore clearly defined. This increases the safety of the system and reduces operating errors.

FERMOPURE® L-cysteine is based on starch fermentation and has compelling advantages: • Non-human, non-animal origin • Vegan, kosher and halal • Utmost purity and safety • Highly dose-efficient For more information visit www.wacker.com/cysteine-bakery ADVERTISEMENT

Drives coordinate with each other To further simplify operation, the programs for producing dough bands are preset for specific products. “This means,” explains Wolfgang Stegmaier, “that when a new recipe is created, not all parameters have to be reset. The employee only has to set certain specifications such as the line output, the number of folds as well as the roller gap.” This significantly reduces the time required for setting up a new product. In the process, the software checks whether a desired performance change is even feasible. “The drives virtually coordinate with each other in terms of their performance and, if necessary, regulate themselves to that of the smallest drive.” According to the company, this ensures high and consistent product quality. +++

L-cysteine is an effective dough conditioner that facilitates various baking processes. The flour enhancer softens the dough and increases extensibility, creating high-quality baked goods.

Wacker Chemie AG, Germany food.support.europe@wacker.com www.wacker.com/cysteine-bakery Follow us on:

RESEARCH

A MULTIFUNCTIONAL SALT SUBSTITUTE

Salt reduction in bread using choline chloride As one of the basic food staples around the world, bread also contributes to the daily salt intake.

Lowering dietary sodium chloride levels is a priority worldwide, but its vital role in bread’s quality should not be overlooked when lowering and replacing its levels.

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Bread is one of the oldest foods in the world. It is a part of the foodstuffs that are the basis of many people’s diets due to its nutritional value and the low price, a reflection of both the raw materials used and the technology applied.

Nutrition experts define bread as an essential part of the food pyramid’s base due to its rich content in carbohydrates, fiber, proteins, B vitamins and mineral salts, and its very low-fat content (Silow et al., 2016).

Salt (sodium chloride) plays a major role in bread making. It contributes to bread palatability, water holding and also to setting a visco-elastic network. All steps of the bread-making process are impacted by salt. Fermentation, for example, is delayed due to osmotic stress, resulting in reduced yeast activity. Salt also contributes to the shelf life of bread, which is extended with increasing salt content. Finally, salt contributes to the organoleptic qualities of bread.

Nowadays, the dietary sodium chloride intake is higher than the daily-recommended levels, especially due to its prominent presence in food products. This may cause an increase in high blood pressure leading to cardiovascular diseases. In most European countries, bread is the most important source of salt, its contribution to salt intake ranging between 19.1% in Spain to 28% in France (Gebski et al., 2019). Considering a standard bread recipe (60g water, 2g salt and 100g flour), the aqueous phase contained in the bread has the same salt content as seawater (ca. 33g/l); in other words, eating 100g of bread is the equivalent of an intake of 38ml of seawater (in terms of saltiness intake); quite shocking, isn’t it? Salt reduction is, therefore, a great stake for all health authorities over the world. However, salt is a critical ingredient in bread making, and its reduction can have a negative impact on bread quality (Codina et al., 2021).

This paper presents an investigation carried out during the Ph.D. project of Doina Crucean under the supervision of Dr.Patricia Le-Bail (INRAE-BIA-Nantes-France), Prof. Alain Le-Bail (ONIRIS-GEPEA Nantes-France) and Dr. Gervaise Debucquet (AUDENCIA-Nantes-France), with the objective of developing bread reduced in salt using choline chloride (CC) and to assess the consumer’s acceptance of such bread.

The challenge of this strategy is to solve the technological and sensory problems caused by sodium chloride removal from bakery products recipes.

CC is able to act as a substitute for salt (NaCl). Choline (E1001) is presented as an emulsifier in the additive list of the EU commission. It also includes B4 vitamin. Nutritionally, choline chloride is an essential nutrient of vital biological importance.

Choline holds 3 European Health Claims (UE 432/2012); it “Contributes to the metabolism of homocysteine”, “Contributes to lipid metabolism” and “Contributes to hepatic function”.

It is thus an ingredient beneficial to health. Choline is marketed under different salts, such as choline-chloride (CC) (E1001iii), which has been used for this project. CC is temperatureresistant (melting temperature 247°C) and is therefore adapted to baking. It is acknowledged as ‘Generally Recognized as Safe’ (‘GRAS’) by the FDA. The impact of Choline Chloride on the main characteristics of bread Locke and Fielding (1994) first pointed out the interest of CC to reduce salt in food. Le-Bail et al (2013) showed that 50% salt reduction was possible in pizza dough by adding 25% of nominal salt. Based on this study, a similar recipe has been used in this project (Figure 1).

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© Veronika Haberzettl – stock.adobe.com

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RESEARCH

Source: Locke and Fielding (1994)

REC I P ES

Figure 1: The CC Bread was reduced in salt by 50%

shown in Figure 2 below showing the interest of CC in improving the softness of bread using CC in their formulation.

Other tests were done with a mixing cell (SETARAM, Caluire France) used in differential scanning calorimetry (DSC) to measure the thermal effect of water, salt and CC on starch during mixing. This technique made it possible to determine not only the heat of rearrangement of the amylopectin molecules of starch, but also the energy related to the dissolution of choline chloride at room temperature, and to conclude that in the presence of choline chloride in the mixture, CC took priority over the starch in front of the water.

Impact of Choline Chloride on the sensory and societal acceptability of CC bread On a sensory level, it has been shown that there is an increasing trend in the perception of salty taste with the increase in the content of choline chloride (Figure 2). However, the amount

Figure 2: Left Evolution of the retrogradation enthalpy of amylopectin during storage at 4°C. Right Evolution of the texture of breads during storage at 4°C

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Source: Locke and Fielding (1994)

Choline chloride allowed a significant reduction of salt and had less impact on yeast activity than salt. In an aqueous solution, the CC behaves like an ionic liquid and causes a reorganization of the internal structure of the starch grain.

The staling study highlighted the positive effect of CC on bread texture and the retrogradation of starch. Indeed, the CC restricts the recrystallization of amylopectin due to less availability of water in the medium and decreases the staling kinetics of the bread. Choline chloride may also act as an anti-staling ingredient since it behaves as an ionic liquid in an aqueous solution and may contribute to starch depolymerization. An in-depth study was done to assess the anti-staling effect with different levels of CC concentration.

Several technics were used (X-ray diffraction, calorimetry) with a kinetics approach to assess the impact of CC on starch during mixing, baking and storage/staling. The impact of CC on staling (evolution of the amount of retrograded amylopectin during storage) and evolution of texture of bread are

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RESEARCH

Product Formulation

Figure 3: Sensory ranking test: the impact of choline chloride (CC) on the perception of the salty taste of a reduced-salt bread with 50%. Values are given as a % of nominal salt (% NS) which corresponds to 1.8g of salt per 100g flour

Source: Locke and Fielding (1994)

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of choline chloride used in the recipe seems insufficient to fully satisfy the consumer looking for the salty taste identical to the reference bread (Crucean et al., 2019).

The acceptance of CC bread, investigated in focus groups, identified three groups of consumers likely to consume it: health-oriented young people, young parents who want to educate children to engage in a healthy lifestyle, and people broadly sensitive to nutritional information. In terms of acceptability, the nutritional qualities of this bread appeal to consumers who favor health in their food choices and those aspiring to strong food education. Alternatively, among consumers who are very sensitive to the traditional values associated with bread, the ‘functionalization’ or ‘nutritionalization’ of this food constitutes a major obstacle to its consumption (Crucean et al., 2019).

Conclusion The use of choline chloride as a salt substitute has the potential to provide improvements in breadmaking, due to its effect on the gelatinization of starch and its power to increase the perception of salty taste. So far, only two studies have demonstrated the possibility of using choline chloride to enhance the salty taste of foods (Locke & Fielding, 1994; Le Bail et al., 2013), and no study had been carried out on its use in actual production.

Among the main results, we note that choline chloride causes a reorganization of the internal structure of the starch grain; it restricts the recrystallization of amylopectin due to the reduced availability of water in the medium and decreases the rate of stale bread. On the sensory level, it increases the perception of salty taste, but in a moderate way. Thus, obstacles to the acceptability of CC bread were found on the sensory level and also on the cultural level. As an example, the labeling 'choline chloride bread' appeared suspicious to consumers thinking that CC is an additive whereas it is an essential nutrient, and the alternative labeling 'bread containing vitamin B4' was understood by some consumers as a medicinal bread which appeared also as suspicious.

This work constitutes an original scientific contribution, with a real technological stake and obvious industrial applications.

Indeed, the theme aims to respond to the demand for reducing the consumption of salt in processed products, as recommended by the health authorities and the World Health Organization, but also to an increasingly strong societal demand to consume products with less impact on health.

In conclusion, CC is a relevant alternative to salt that combines technological and sensory benefits; its success will depend on the consideration of issues related to social acceptability. +++ Acknowledgments: This project was co-funded by ONIRIS (Ministry of agriculture), INRA-BIA and ONIRIS-GEPEA within the ID4FOOD program.

Authors P. Le-Bail

a,c

, D. Crucean

b,c

G. Debucquet d, A. Le-Bail a

, C. Jonchere

a,c

, B. Pontoire

a,c

,

b,c

INRAE-BIA, UR-1268 Biopolymères Interactions et As-

semblages, rue de la Géraudière, 44316 NANTES, France b

ONIRIS, GEPEA, UMR CNRS 6144, rue de la Géraudière,

CS 82225, 44322 NANTES CEDEX 3, France SFR 4204, Ingénierie des Biopolymères pour la Struc-

c

turation des Matrices et des Matériaux (IBSM), 44316 NANTES, France d

Audencia Business School, 8 Route de la Joneliere, BP

31222, F-44312 Nantes, France Corresponding author: patricia.le-bail@inrae.fr

Reference Crucean Doina, Thèse Ecole Doctorale SPIGA, 4 Avril 2019, Univ. Nantes.

Crucean D., Debucquet G., Rannoux C., Le Bail A., Le Bail P. (2019) - Vitamin B4 as a salt substitute in bread: a challenging and successful new strategy.

Sensory perception and acceptability by French consumers. Appetite, 134, 17-25.

Le-Bail, A., Billard, T., Domingue, K., Jousselin, L., Leray, G., Della-Valle, D., …

Chevallier, S. (2013). Impact of salt and choline chloride on dough mixing, crumb staling and sensorial perception of a model pizza dough. In 2013 CIGR Section VII International Technical Symposium on “Advanced food processing and quality management.”

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Locke, K.W. and S. Fielding (1994) "Enhancement of salt intake by choline chloride." Physiology & Behavior, 55, 1039-1046.

Silow, C., Axel, C., Zannini, E., Arendt, E.K. (2016). Current status of salt reduction in bread and bakery products – A review. Journal of Cereal Science, 72, 135-145.

Gebski, J., Jezewska-Zychowicz, M., Szlachciuk, J., Kosicka-G˛ebska, M. (2019).

Impact of nutritional claims on consumer preferences for bread with varied. Food Quality Preference, 76, 91–99.

Codina, G.G., Voinea, A. and Dabija, A. (2021). Strategies for reducing sodium intake in bakery products, a review. Applied sciences, 11, 3093.

© elenabsl – stock.adobe.com

RESEARCH

A virtual new world Packaging has a significant impact on consumers’ purchasing choices. Using Virtual Reality technology, scientists at Campden BRI recently ran a virtual supermarket technology experience to better understand which on-pack sensory claims motivate consumers to purchase products.

+

The immersive study reproduced a real-world supermarket setting to ensure the participants’ choices reflected those they usually make in their shopping routines.

The Virtual Reality (VR) store created by Sodalight Creative contained multiple versions of a product’s packaging, each version with a different on-pack claim and accompanied with the product’s price. The resulting simulation allowed participants to interact with products in a way that has not been possible in previous consumer studies, Campden BRI scientists explain. This was also a way to continue research in this field as extended restrictions caused by COVID-19 are limiting opportunities for face-to-face studies.

To recreate the shopping experience, sensory and consumer research scientist Marleen Chambault, who led the consumer study, ensured the environment was virtually the same, including the minutest of details. Even background supermarket noises were added, to further immerse the participants.

Using a computer, the test required respondents to travel down virtual supermarket aisles towards the breakfast cereal

and orange juice product displays. Here, they chose one product from a selection, each displaying different on-pack claims.

“For each of the tested products, breakfast cereal and orange juice, we evaluated the impact of nine on-pack claims on the purchasing intent,” Chambault tells us. The claims were selected based on previous activities conducted by Campden BRI as part of a two-year research project on sensory claims; some were sensory-related, but others were not. The

Claims tested for breakfast cereals

+ Low in sugar + Source of protein + 100% British grains + Improved recipe + Great taste + Crunchy texture + Tastes better than the leading brand + Tastes as good as the leading brand + Now even tastier

Claims tested for orange juice

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+ Freshly squeezed + No added sugar + Bottle, label & cap 100% recyclable + From organically farmed oranges + Sweet & Smooth + Deliciously smooth + Great taste + Tastes better than the leading brand + Now even tastier

RESEARCH

researchers created their own packaging designs for this study, inspired by those commonly found on the UK market. Each product variant displayed a different claim, 18 in total.

Nutrition claims such as ‘No added sugar’ appeared to have a particularly strong impact on the consumers. The study showed that sensory claims also had a high influence, particularly those focusing on the specific sensory characteristics of the goods, such as ‘Sweet and smooth’ or ‘Great taste’, for example. Such sensory claims can be powerful marketing tools, which highlight the unique selling point of the product, the study found. “The challenge for food business operators, however, is knowing whether the claims they’re using are making a difference and motivating consumers to purchase their products,” Chambault explained. She added that “Typical consumer studies often lack the real-world element, yet context plays a pivotal role in determining how consumers behave.

We used VR to overcome this issue.”

The best claims to have depend on the specific product, the study showed. Consumers were not consistently motivated by the same claims, as they rarely chose both products from each category, cereal or juice, with the same type of claim.

Across all products tested, the claims relating to nutrition (e.g. ‘high in fiber’), clean label (e.g. ‘no artificial ingredients’, ‘100% wholegrain’) and sustainability (e.g. ‘100% British grains’) generally performed the strongest, all of which are relevant baked goods as well. Further testing would determine the best claims for bakery goods. This shows the need for food manufacturers to test specific claims with their products, the researchers concluded. VR provides useful tools to test the impact of different claims, to identify which claims manufacturers should use on their packaging to influence the consumer’s likelihood of purchasing their goods.

Virtual Reality to map consumer interest The study lays opens a door to future consumer research using VR, with a multitude of further applications to be trialed, such as the impact of a product’s shelf positioning or packaging designs on the consumer’s intent to buy, for example. To test bakery goods, the researcher recommends to first make sure the claims for testing are relevant to the product categories they are attached to. Recruiting consumers who specifically purchase the types of products investigated is also recommended, for better results.

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About sensory claims A sensory claim is defined as ‘a statement about a product that highlights its advantages, sensory or perceptual attributes, or product changes or differences compared to other products in order to enhance its marketability’ and includes statements such as ‘The UK’s favorite’, ‘Great taste’ and ‘Creamier than ever!’

to optimize their retail space, layout and shelf positioning,” the project’s leader explained.

Such consumer behavior studies are not without challenges.

Perhaps the biggest one to manage is technical – how to make the overall shopping experience as realistic as possible.

This includes recreating the products on offer, the look and feel of the supermarkets and the auditory experience, illustrates the researcher. The VR application should also be thoroughly tested to ensure it runs smoothly, since the experience is key, and that it is fully compatible with the available hardware. “We also found that a thorough briefing of the consumers was essential as the technology was new for some of them. We did not want the technology to be overwhelming or a distraction from the task at hand,” Chambault explained.

Claims relating to health, wellbeing and sustainability could perform strongly after the pandemic, depending on the type of foodstuffs considered. “Plus, not all claims appeal to the same people. For instance, those following a vegan diet may be motivated by claims that differ from those following a mixed diet,” the researcher points out. A new VR-based project would also be an interesting analysis, if the findings are maintained once most pandemic restrictions are lifted.

When competition is high, products featuring specific claims can appeal to consumers more. So bakery manufacturers, like any other manufacturer, could benefit from using consumer tests using VR technology. +++

© Gresei – stock.adobe.com

“With VR, we can immerse consumers in a typical retail environment and assess which products are looked at and selected more often. From what consumers choose to buy, we can derive conclusions about their drivers for purchase, for example, shapes, colors, claims (in our case), positions on the shelves etc. Manufacturers can use such information to design more attractive products that have a greater chance of being purchased; retailers can then use such information

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N E W R AW M AT E R I A L S

Better-for-you baking, with enzymes Naturally present in baking ingredients, enzymes play an important role in food processing.

Inspired by nature, modern solutions developed with enzymes mark the silver lining between goals coming from the R&D laboratory, restraints coming from the bakery facility and the tastes and experiences consumer prefers.

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The demand for softer breads that stay fresh longer is not new. Egyptians added oil and honey to their breads to achieve this. Later, ingredients like fat, eggs and sugar were used to create a softer crumb that would stay fresh longer. Until the beginning of the previous century, the most common ingredient that was added to breads was barley flour, resulting in a softer bread with a longer shelf life.

French chemist Anselme Payen discovered in 1833 that there were enzymes present in barley, which broke down starches in the flour into sugars for the yeast to consume. This inspired bakers and biotechnologists to get a better understanding of the use of enzymes in bread.

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+ The strength, tolerance & workability of the dough + The volume of baked goods + The freshness and shelf-life of baked goods + Process optimization, to minimize waste in production

Enzymes, produced by fermentation, are present in every living organism and naturally present in flour, yeast and bakery ingredients. In modern days, nature inspires Puratos to look for the best fitting enzymes that make bread stay fresh and soft while offering a texture experience for consumers.

Puratos aims to meet the consumer demand for clean(er) label by utilizing the benefits of enzymes. Here are the most common ‘better-for-you’ claims the specialist lists: + Enzymes offer the opportunity to create excellent baking products with a shorter and clearer ingredient list; Enzymes are proteins, produced by fermentation, present in every living organism and naturally present in wheat, flour and yeast. Enzymes are denaturated during the baking process and as a result, are not functional in the bread sold to final consumers.

Fat reduction: certain enzymes can lower fat contents + without compromising on the softness and texture of the baked goods.

Today, the most common driver for the usage of enzymes in baked goods is refining texture. According to Evelien Agache, Director of Business Unit Bakery Improvers & Mixes at Puratos, this implies improving:

Enzymes deliver a range of functional benefits in baked goods, such as wholegrain bakery products, which are fast gaining traction among health-conscious consumers. Enzymes that help delay staling and produce baked products that stay fresh

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N E W R AW M AT E R I A L S

Putting enzymes to good work Each enzyme has a specific functionality and finding the right blend is a delicate procedure. Enzyme reactions can be affected by changes in temperature and pH that may take place during food processing. Although the functionality of an enzyme is relatively well known, the optimal dosage can vary, especially when combined with other enzymes. “Factors such as the recipe, type of flour, process used and required shelf life of the product can affect the recommended dosage and combination,” van Peij explains. Other considerations, such as customer needs and preferences, also vary and should be considered at the very start of the product development. “For instance, a soft, high volume, moist white flour-based bread with at least three months’ shelf life is popular in certain regions and will require a different set of enzymes when compared to wholewheat, high fiber, organic bread with a shelf life of seven days, which is preferred in other parts of the world, DSM’s specialist details.

Enzymes will only work on the substrate they can interact with. Some enzymes work on the gluten network, others will interact with the starch, lipids, all present in the flour. They are sensitive to temperature and when heated above a certain temperature for an amount of time, they become ‘denatured’ – no longer functional on the final product. Puratos shares an interesting example in this regard: a unique, new family of xylanase enzymes was discovered in an expedition to the Antarctic. Coming from a cold region, these enzymes have optimal activity at much lower temperatures compared to regular enzymes. This means that their strength and tolerance properties will come into play even in cold doughs.

Puratos Intens Strength is made with this enzyme, making it especially suited for improvers in frozen bakery and related applications.

Salt is often used to extend the dough development time and increase the dough resistance, elasticity and extensibility.

The dough is strengthened due to the decrease in water absorption of the flour when salt is present. So, it can be challenging for bakery manufacturers to formulate products with reduced sodium levels in the creation of betterfor-you products, as it will negatively affect dough behavior during processing, and will influence the shape and volume of baked bread. DSM recommends: “To better control texture and volume without adding salt, gluten hydration needs to be addressed. Here, a hemicellulase enzyme hydrolyzes both water-unextractable and water-extractable arabinoxylans. Arabinoxylans make up 75% of the wheat endosperm non-starch polysaccharides and have a major effect on the water absorption of flour in a dough. Arabinoxylan disturbs both the gas retaining properties of dough and the visco-elastic properties of the gluten network. A hemicellulase enzyme, such as present in the DSM’s BakeZyme® enzyme portfolio, is able to partially break down arabinoxylan, resulting in proper water management, improved dough handling, improved tolerance and stability and improved dough volume.” ato s

When it comes to better-for-you claims, bakery manufacturers are increasingly searching for enzymes to reduce levels of sugar, fat, salt and acrylamide, as well as options to replace ascorbic acid. Additionally, they are now also seeking out enzymes that help lower levels of FODMAPs (fermentable oligosaccharides, disaccharides, monosaccharides and polyols) to promote good digestive health.

Better-for-you and good, too Maintaining dough elasticity, volume and texture in healthier products is the result of understanding the science behind the enzymes and knowledge in combining them. Depending on the type and quantity of enzymes combined, Puratos can manage the texture and volume for the different types of baked goods: for instance, a certain combination of enzymes could provide superior sheeting characteristics to the dough, supporting the creation of layered products. Some enzymes, like Puratos Intens Strength, include the qualities to deliver tolerance to the fermented dough and a great shelf-life in freezing temperatures.

©P ur

for longer, with lower levels of emulsifiers, are particularly in demand as sustainability rises to the top of the consumer agenda, observes Judith van Peij, Innovation Manager Baking, DSM Food Specialties. At the same time, there is a growing trend, driven by today’s health-conscious consumers, for fortifying baked goods with vitamins, minerals and fatty acids.

DSM, for example, can provide solutions for fortification with nutrients like vitamin D or omega-3s.

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Moreover, a lipase enzyme can further help improve dough tolerance and baking performance in baked goods. DSM’s KOENIG Motiv4 NTS 91x53.qxd

12.02.2007

11:10 Uhr

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N E W R AW M AT E R I A L S

© Igor Meshkov – shutterstock.com

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Panamore® Spring lipase has been developed to imitate the functionality of synthetic emulsifiers like SSL and CSL to help create products with an appealing crumb structure and softness. Meanwhile, the Panamore® Golden enzyme can be used as an alternative to DATEM to help improve volume, stability, crust opening and overall appearance.

Enzymes also provide manufacturers with the means to reformulate bakery products to have lower fat or sugar contents.

For example, Puratos Puraslim contains a patented enzyme found in Yellowstone National Park that can provide a more pleasant short bite by being active during the baking process of the breads. Puratos researchers discovered this enzyme and its ability to improve the texture of bread through its Innovation Inspired by Nature approach, which focuses on enzymes as a natural resource in developing better-for-you bakery solutions. This technology helps to reduce up to 50% of in-dough solid fat in sweet breads and pastries without compromising on texture or taste. This latest innovation can be applied to rich applications, such as brioches and other kinds of sweet buns, Agache (Puratos) notes.

New developments DSM’s established products include its Panamore ® Golden and Panamore ® Spring lipase ranges, which can be used to improve baking processes for a variety of bread and cake applications. “Panamore ® Spring is an enzyme preparation developed for a wide variety of crumb-rich soft bread applications and morning goods, offering a cost-effective alternative

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of SSL and CSL for more consumer-friendly labeling,” van Peij says. During mechanical processing, it can improve dough tolerance and enhance dough handling properties and machinability, in a similar way to the use of traditional dough conditioners. It can also improve crumb softness, while adding a low amount of fat further improves baking performance to result in enhanced softness.

Puratos knows that enzymes are key for delivering all of the benefits bakers are seeking, including the clean(er) label trends for the big industrial bakery players. Health and well-being are some of the key priorities for the specialist.

“Our latest innovations contain gluten-free mixes and organic improvers for soft baked goods.”

An important aspect in the work to perfect enzymes is having them meet specific requests, so specific that only the manufacturer who needs it can make the most out of it. To achieve this, collaboration is a must. Puratos worked with one of the biggest brioche producers in Europe, for example, on finding the solution that could help with two things: make the end product healthier and better for the end consumer and make sure it counts towards a nutriscore improvement on the front of pack labeling. “Puratos Puraslim was the perfect solution for that challenge. We have developed an improved nutriscore product with reduced fat and calories, without impact on the texture of the final product. On top of that, the customer could still keep the ‘pure butter’ claim while reducing the recipe cost,” Agache illustrates.

N E W R AW M AT E R I A L S

In its own collaborative work, DSM carries out extensive market research and baking trials, including sensory panels, to evaluate mouthfeel, shape, volume and softness. The findings are shared to help manufacturers create high-quality, great-tasting and consumer-inspired baked goods efficiently, with the use of enzymes.

Enzymes support sustainability Enzymes enable manufacturers to produce baked goods more sustainably, by using less energy than alternative ingredients.

These solutions can also help to make locally-sourced raw materials suitable for final applications, DSM emphasizes.

At the same time, enzymes enable bakery producers to reduce food waste by maintaining the freshness of baked goods once they reach the consumers’ cupboards without compromising on their preferences for shorter, more recognizable ingredient lists. With roughly one-third of the food produced globally for human consumption (approximately 1.3 billion tons) lost or wasted every year, tackling food waste remains a key sustainability challenge 1.

For bakery producers looking to further elevate their sustainability credentials, replacing or reducing an emulsifier like DATEM with an enzyme, such as DSM’s BakeZyme ® PH 800 BG and the Panamore® range of enzymes, can help reduce a company’s local carbon footprint. “This is because enzymes, which are added in very low amounts, require much less energy than emulsifiers to achieve a similar effect,” van Peij explains. Plus, adding specific combinations of xylanases can reduce the baking time of biscuit or wafer production, by decreasing the volume of water needed.

With less water, these types of products require shorter baking times, which reduces energy usage.

Enzymes contribute to reducing waste through freshness retention. “Bread is one of the highest food waste categories; we have seen that a large amount of bread is wasted throughout the supply chain,” Puratos illustrates. For example, according to an article by NRC Handelsblad, 25% of all bread in the Netherlands ends up being discarded. “If we can extend the shelf-life with freshness enzymes solutions, it can surely help to reduce the waste,” is the conclusion from Puratos.

1

Food and Agriculture Organization of the United States, SAVE FOOD:

Global Initiative on Food Loss and Waste Reduction http://www.fao. org/save-food/resources/keyfindings/en/

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Enzymes boost process efficiency, which results in lower energy consumption: “For example, our enzyme solution Double Bake Color, an enzyme solution specially designed for parbaked bread, can reduce the bake-off time up to 60% resulting in energy savings,” adds Puratos. +++

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S U S TA I N A B I L I T Y

© Chaosamran_Studio – stock.adobe.com

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The best way to reach (or come close to) zero waste The concept of zero waste packaging has become all the rage recently. But, is it really possible to achieve such a goal, especially in the baking business? To answer this question, we need to first define a sustainable package.

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Typical definitions of what sustainable packaging entails revolve around recyclability, the use of recycled or bio-materials, or compostability. The problem with these is that they ignore the key functions of a baked goods package, which include protecting the freshness of the product inside, maximizing shelf appeal in the store, and maintaining taste appeal at home.

Given this definition, and the fact that wasted food is a far bigger environmental issue than its packaging, the concept of zero waste should really be focused on the product rather than the package. In fact, studies are showing that sometimes the best way to reduce food waste is actually to increase the amount of packaging used, and thus the amount of packaging discarded.

When you consider that the food inside the package produces up to 20 times the environmental impact of the package itself, the role of packaging is far more important than people realize. To put it simply: Food waste is a significantly bigger concern than packaging waste.

So, after you have designed packaging that minimizes product waste by maximizing product protection and appetite appeal, what options can be pursued when working to minimize packaging waste?

Given this reality, my definition is a bit more holistic: Sustainable packaging delivers the full value of the product(s) contained within and does so with the least amount of negative economic, environmental, and social impact throughout its lifecycle.

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Recyclable materials Oftentimes, the term ‘recyclable’ is just a theory. Virtually anything can be recycled for the right investment. The key is to focus on materials with a proven record of being collected and reprocessed. Paperboard, PET and HDPE come to mind.

Some flexible or ‘soft’ plastic packages may be an option,

S U S TA I N A B I L I T Y

especially those using newer mono-layer technologies, but this is highly dependent on local regulations and available facilities.

The reason for the preference for recycled materials is that it generally takes less energy, and thus generates fewer greenhouse gases, than using virgin materials. This is a key point: reducing energy consumption is actually a more important sustainability goal than the choice of materials.

Packaging made from recycled materials Even better than simply using recyclable materials is the use of post-consumer recycled (PCR) paper and plastic materials. By definition, they are both recyclable and recycled, generally with the most preferred environmental profile. It should be noted that it is important to specify PCR, as industrially processed materials, such as regrind, are generally deemed to be part of the typical production process and are not considered to be recycled.

Industrially compostable packaging This type of packaging makes sense if your products are sold into restaurants and institutions where industrial composting facilities are part of the waste management equation. This is because it can be hard to separate packaging from wasted or spoiled food, or if food residue would contaminate packaging that could be recycled.

High barrier packaging A good example of where more packaging, or non-recyclable packaging, may be required is preservative-free baked goods.

Modified Atmosphere Packaging (MAP) is probably needed to provide a barrier that will deter the growth of yeast and mold in these products. And, according to well-known food packaging expert Dr. Claire Sand, while freezing products in paperboard or film may be an alternative to MAP packaging, it does not work well for some baked goods due to starch retrogradation.

Conclusion It should be noted that zero waste is an aspirational concept, and that waste minimization is the real objective. From both an environmental and economic standpoint, the best way to achieve this goal is to start by ensuring that your products are safely transported, displayed, purchased, and consumed.

Whether you then decide to use packaging that can be recycled, is made from recycled content, or uses significantly less material than other types of packaging, is up to you and the preferences of your customers. +++

Non-recyclable packaging If the goal is to minimize waste production, there are times when packaging that is not being widely recycled can be a good option. Let’s consider 0.5Kg of dinner rolls, in one case packaged in a paperboard box, and, in the other case, packaged in a heat-sealed LLDPE bag. The box is made from 35% post-consumer recycled content and is easily recycled.

The bag is made from virgin plastic and is not readily recycled.

Even when you factor in the relatively high recycling rate for the box, it still generates four times the amount of waste than the non-recyclable plastic bag! This is because the weight of the bag is significantly less than the weight of the box. It is also because polyethylene is very efficient to produce and requires relatively small amounts of energy to do so.

© kyrychukvitaliy – stock.adobe.com

Keep in mind that for retail applications, where your products end up in consumers’ homes, compostable plastic packaging is not a recommended option. There are two reasons for this: Firstly, even if the packaging biodegrades to EN or ASTM standards, it does not produce anything of value. There is no compost or humus, nor are there soil conditioners. Further, the lack of complete biodegradation can lead to microplastic residues. Secondly, the biodegradation of these materials produces powerful greenhouse gases that include carbon dioxide and methane or ammonia. Thus, even if a material completely biodegrades in the composting process, the final result is environmentally negative.

About the author Robert Lilienfeld is the Executive Director of SPRING, The Sustainable Packaging Research, Information, and Networking Group. He has been a sustainability consultant to the packaging industry since 1994 and is a regular contributor to baking+biscuit international.

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GLUTEN-FREE

Free-from innovation for taste Many bakeries use other cereals and pseudo-cereals such as amaranth, quinoa and buckwheat, looking to add new sensory experiences to their range. The gluten-free label is an added benefit, but it is not always a straightforward claim to earn.

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To guarantee gluten-free products stay clear of any accidental contamination (measurable values under 20ppm), the safest way is to produce them separately from the lines running regular products. Ideally, separate raw material and packaging storage should be set up, in addition to isolated production facilities and production rooms. The safest option also represents a high investment, however, and trying to avoid it only leads to putting more effort into processes, cleaning and controls, while the contamination risk is never zero. In the production area, gluten-free products should be regarded as an independent product category. The reason stems from the characteristics of gluten-free doughs, which are different from those made with raw materials such as wheat, spelt, or rye, for example. Short and sometimes very plastic, is how gluten-free doughs can be described. This is precisely what makes production somewhat more difficult, as many manufacturers of conventional baked goods are not used to these properties. Experience is required to design or adjust the machines to these kinds of dough characteristics.

Working with pre-doughs that also need to be pumpable is even more challenging; entire machinery can break down during production if the raw materials and additives are not correctly balanced. Flours can separate during fermentation, causing the starch to sink to the bottom and block the mixing tool, the specialist illustrates.

Replacing functionalities Gluten forms a three-dimensional network when energy is supplied. This is the essential core that must be taken into account. Wherever the gluten is pulled, stretched or compressed, gluten-free products cannot directly keep up.

However, there are raw materials like fibers and additives, for example, thickeners that can build up and significantly improve the structure of gluten-free doughs. This makes gluten-free doughs very similar to wheat doughs.

In general, baked goods gaining their sensory characteristics thanks to the presence of gluten are harder to replicate technologically through processes and/or the selection of raw materials, in the absence of gluten. For example, a baguette or ciabatta with its open, partly coarse, soft and yet thin pore structure will be very difficult to imitate. Cakes and biscuits, on the other hand, are very easy to imitate, especially if gluten is a hindrance or even undesirable. In addition, the more the crust-to-crumb ratio leans towards the crust, the easier it is to handle its gluten-free production. A pizza, for example, is not technologically very challenging compared to the ciabatta described above.

By using raw materials such as fibers e.g. psyllium, additives such as thickeners e.g. guar gum, hydroxymethyl cellulose, xanthan and/or modified starches, the properties of gluten-free doughs and products can be significantly improved. The use of the Indian psyllium husk (Psylium) alone improves the quality of the doughs and baked goods enormously. Because

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GLUTEN-FREE

45

Comparison of CO2 Equivalents Process

Wheat products

Gluten-free products

Water absorption

Gluten 1.3g and starch 0.4 H2O/g

Starch 0.4g H2O/g

A 1:1 ratio of flour to water is often used for

When using rice starches or similar materials,

the pre-doughs. The flour ingredients in

the starch content in the raw materials

combination with water make it a mass that

predominates. During long fermentation, the

flows well, which is shear-stable and pumpa-

phases separate and the starch sinks to the

ble. These properties remain stable during

bottom, which can destroy the pre-dough

fermentation.

strands. Therefore, it is recommended to use

(separated, main part) Pre-dough

propeller systems (pre-dough systems) for such applications. The mold must be controlled separately, to always keep the starch in suspension.

Mixing

Source properties

Through the flour contents in protein or

It can be done without adding raw materials

gluten, starch, pentosans and other compo-

such as fibers. If rice flour is used, for exam-

nents, a viscoelastic dough is produced under

ple, the dough becomes more like a mushy

the influence of added mechanical energy.

mass without stability and ideally plastic.

Depending on the type of dough or baked

Alternatively, the swelling of rice flour can only

goods being produced, there is a high degree

be determined based on the proportion of rim

of swelling due to proteins, xylans and

husk: the darker the flour, the more water can

pentosans.

be absorbed. This also applies to wheat, but in the case of rice flour, this is the only component.

Dough development

In a classic wheat dough, energy must be

In contrast, the dough of e.g. rice flour is only

added to be able to develop a three-dimen-

mixed to form a binding mass, if necessary,

sional gluten network. However, it is not only

which is composed of cellulose, xylans and

the linkage of gliadin and glutenin that needs

other thickening ingredients.

to be taken into account here, even though this is the largest part, but also protein-starch and protein-xylene compounds. This combination makes the viscoelastic dough, which must be intensively mixed in a mixing machine for a few minutes.

Shaping the dough

The viscoelastic dough can be shaped as

Shaping the dough is only conditionally

desired after short rests. It is for loaf bread,

successful with 100% rice flour bread; breads

freely set bread or for small pastries.

have to be baked in boxes, in most cases.

Fermentation tolerance Once the dough has been mixed out, the

The doughs in the box have a supporting box

dough, the gluten structure, holds the gases

wall, which adds to the stability. These doughs

and thus forms a loose dough structure, which

or masses are very stable, but usually cannot

can also be held well over the proofing time

hold well without this supporting wall, as they

and beyond.

would otherwise collapse. Therefore, the fermentation tolerance is good, but only

Gas holding

Furnace drive

As with fermentation tolerance, mixed doughs

Due to the viscous mass, the rather compact

have a good gas retention capacity, as the

doughs can hold the gases that are neverthe-

proteins (gluten) can hold the gas even when

less kept, but this is also limited, as with the

slightly agitated.

wheat doughs.

In the oven, the yeast gives another gas boost

In gluten-free doughs, the starch generally

and the gases also expand somewhat. Here,

takes over water absorption and structure

the gluten must hold the gases well before it

formation right from the start. As a result,

denatures and the starch takes over water

many gluten-free products tend to be more

absorption and structure formation.

compact.

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© mizina – stock.adobe.com

possible in the box.

GLUTEN-FREE

© DIO SNA

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of this outstanding use of the raw material psylium or other fibers, they are also often used in organic products. The use of transglutaminases is also often discussed, but, compared to the fibers, it is often too expensive and the effect is rather small compared to the costs.

A patented gluten-free starter The DIOStart rice liquid starter is a starch culture for rice application. They are special lactic acid bacteria that are adapted in the medium specific to rice. Sourdough can be produced with these starters; if this sourdough is then added to the dough, the properties of the baked product are improved in the form of freshness, aroma profile, crumb stability, crumb adherence and mold protection in the end product.

What’s more, the addition of lactic acid bacteria initiates a controlled fermentation, which can then be maintained individually. Besides, depending on the amount added and the raw material used, the starter prevents the starch from separating in the matrix and sinking to the bottom. This in turn is ideal for fermenter systems.

The lactic acid bacteria likes a temperature of 30-34°C, but a temperature over 40°C should be avoided. The higher the temperature, the more yogurt-like it tastes and the baked goods will have a milder taste; temperatures under 32°C will make the sourdough stronger and somewhat more acidic in taste. The temperature should not fall below 28°C.

Fermentation is completed after 34 hours but can be extended up to 48 hours. After 48 hours, the sourdough is completely leavened, whereas at 34 hours it is still very active. If the sourdough is to be reused, a starter quantity of 30% is recommended. When preparing the first sourdough, a starter quantity of approx. 2-5% is required, depending on the raw materials used. The ratio of flour to water should be 1:1-2 depending on the recipe. This sourdough can then be added by 10-30% to the bread dough (calculated on flour).

Sourdoughs can help reduce thickening additives that can often be used in gluten-free products. It should be noted that psyllium is not a food additive, but a fiber. In general, the first studies show that lactic acid bacteria can convert fructans in flour (in combination with water), but further research is needed to ascertain whether all lactic acid bacteria can do this or only certain ones. What is clear, however, is that lactic acid bacteria and yeasts in pre-dough can contribute to the degradation of FODMAP with long fermentation.

Depending on the fermentation process, the resulting baked goods are easily digestible, present a juicy crumb, soft nonstraw crumb, are slightly sour (yogurt-like) to sour (kefir-like) or even aromatic sour.

In the development of the rice starter, the difficulty of raw material diversity, applications, parameterization and machineability came into play. The newest version of the starter is organic-capable. The rice starter should also be universally applicable, always offer an individual solution so that the baker can achieve a variety of products. In addition, sourdough can always be produced with machines without much manual handling. The patent Diosna was granted is based on these concepts, including example recipes and parameters so that a rice bread can be made and baked safely. The patent is intended as a guide for gluten-free use.

© DIOSNA

The application possibilities for the rice starter and rice sourdough are manifold, including rice cakes, rice bread, rice hamburgers, or wholemeal breads; grain-on-grain breads ranging from sweet to savory can be developed with it. +++

Author Florian Paschen, Head of Science and Education, Diosna

www.bakingbiscuit.com 06/2021

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© Pots & Co

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Chef Talk – Translating culinary trends into the bakery aisle In 2020, dining in became the new dining out. As the restaurant and travel industries reopen, new culinary behaviors acquired in that year have varying degrees of staying power that will influence bakery and snack product innovation.

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Comfort and indulgence were hallmarks of the pandemic, which triggered growth across nearly every baked good category. It also drove consumer proclivity to the familiar – with a twist – that could well maintain its stronghold. A recent survey conducted by the Harris Poll suggests that 28% of Americans are eating more baked goods, with 42% citing a sense of comfort and 41% citing a way to induce happiness as their reasons, respectively. And flavors like chocolate, fruit and citrus – those with nostalgic familiarity — are also resonating with consumers, especially when elevated to a fine dining-like experience in quality of ingredients and execution.

Such is the case for London-based Pots & Co., which sells its products in Costcos across the US. The company crafts Michelin-quality desserts in its signature ceramic pots using single-origin Fino de Aroma chocolate sourced from farms in Colombia. “We’ve translated a basic fine dining philosophy to our products: Keep things simple and search the world for the best possible ingredients,” said Pots & Co’s founder, Chef Julian Dyer. “We know that people want the classics done really well. Our products tend to be a bit more expensive because of that, but that’s the tradeoff for raising the bar.”

Bringing these small luxuries into consumers’ homes is also a factor driving innovation at Richmond, CA-based Brioche Pasquier | Galaxy Desserts. One of their newest products, Freezer to Oven Croissants, was crafted by Master Pastry Chef Jean Yves Charon and doesn’t need proofing. They can be baked straight from frozen, which provides both convenience and indulgence.

However, consumers are also counterbalancing their desire to indulge with their interest in consuming functional foods that contribute to overall mental and physical health and wellness.

The plant-based “revolution” is now mainstream — both in restaurants and home kitchens – and plays directly to that

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consumer need. According to the Specialty Food Association’s State of the Specialty Food Industry 2020-2021 report, the category is expected to increase 10 to 20% annually through 2024. And SPINS data showed that the total plantbased market is growing 29% year over year, nearly double the 15% growth rate of the food-and-beverage market as a whole.

The chip category has been an innovation leader of plantbased alternatives (think Tia Lupita Catus Tortilla Chips, Plant Snacks Beet with Vegan Goat Cheese Cassava Root Chips, and Farmhouse Culture Kdill Pickle Kraut Krisps Snack), but desserts and snacks are untapped opportunities for plant-based alternatives, though product innovators are aware of the potential in the space. “The plant-based trend is one that is really powerful and picking up across categories,” Dyer said. “In baking, we’re seeing experimentation with alternative milks like coconut and oat, and even plant-based chocolates.”

Brioche Pasquier | Galaxy Desserts is also exploring vegan alternatives to eggs and dairy, as well as new chocolates. “As a principle, we are trying to integrate American trends into our French culinary expertise and create unique and tasteful new products,” said Guillaume Perruchet, R&D Manager.

Mushrooms are one ingredient taking full advantage of the plant-based culinary trend, though they have not yet reached their full potential in the baking space. Adaptogenic mushrooms, known for their functional benefits like improving cognitive function, stress and immunity, have been prized among health circles for years, but the culinary world is starting to take note as well, with many hailing them as the “it ingredient” of 2021. Data essential information revealed that on 80% of restaurant menus, mushrooms are one of the top appearing ingredients. And the functional mushroom market is expected to grow 8% by 2024 per a recent Reporterlinker.com report.

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Commercial bakeries looking to take advantage of this trend would be wise to explore the use of mushroom powders and mushroom extracts in their baked goods. For example, Earthlight Whole Vitamin D, which is produced under PLT Health Solutions, is a mushroom powder that delivers 1000 μg (40,000 IU) of Vitamin D per gram and has received approval of its Food Additive Petition from the USDA for use in a broad range of products including breakfast cereals and baked goods.

Chickpeas are also having a moment thanks to the interest in all things plant-based. The legume, which is rich in protein and fiber was singled out by Whole Foods Market in their Top Food Trends for 2021 as “the new cauliflower,” noting its versatility for use in snacks and baked goods.

According to the Mintel Global New Product Database, the number of US product launches with chickpeas increased 74% in 2019 versus 2018. The number of launches fell 22% in 2020, when compared with the same time in 2019, though that decrease likely has more to do with innovation cutbacks in light of the pandemic.

Siete Family Foods introduced Chickpea Flour Tortillas, which gives consumers a convenient way to add nutritional value to favorites like tacos and wraps. Biena Snacks now offers a variety of both grain-free and keto-friendly Chickpea Puffs in the baked snack category. And 34º recently released Snaps Baked Chickpea Thins, which include 3 grams of plant-based protein per serving.

In addition to plant-based, global flavors are expanding their reach and becoming more approachable as bigger CPG players introduce products that push the culinary envelope.

According to Dataessential, one-third of consumers are looking forward to trying new global foods and/or flavors this year, and 42% are seeking out spicy foods.

Latin flavors still enjoy popularity in the US, and according to Mintel, many of the flavors that gained traction — spicy, smoky, and citrus — are already foundations of Latin cuisine.

Additionally, more than a third of consumers also expressed interest in trying foods from lesser-known regions such as Oaxaca, Peru, Brazil and Argentina.

This trend for greater diversity in taste exploration expands beyond Latin flavors. “I’m seeing more prominence and appreciation of regional ingredients from parts of the world often overlooked, specifically an interest in West African ingredients and cuisine,” said Dawn Padmore, VP of culinary marketing and events with Karlitz and Co. Take fonio, for example. The ancient grain from Senegal is gaining traction in the western world. It can be prepared similarly to couscous, cooking in about 5 minutes, and can be ground into a versatile (gluten-free) flour for use in a variety of baking applications. Founded by chef, restauranteur, and cookbook author Pierre Thiam, Yolélé is one such company.

It works to connect smallholder farmers with global markets and offers a product line that includes fonio pilafs and chips.

El tiempo es ahora!

With Hispanic and Latino Americans accounting for almost 20% of the current US population and expected to comprise nearly a third of it by 2050, brands and businesses of all types need to start thinking – or think more – about these ethnic groups today.

For the baking industry, this means not only creating specific products that appeal to different ethnicities but also, perhaps even more importantly, developing recipes that allow these consumers to incorporate grain foods into healthy, culturally appropriate eating patterns.

I have dedicated most of my career to developing such recipes and promoting them to diverse audiences. I’ve always focused on making these foods accessible to as many people as possible and also helping Hispanic and Latino consumers retain their traditional cultural foodways while helping industry partners attract and build brand affinity with their customers.

For example, when working with the Grain Foods Foundation (GFF) during its recent research on the nutritional value of whole grains and enriched refined grains, I developed the Refried Bean Breakfast Flatbread Wrap. It uses a flatbread, but consumers can use any grain food as the base and whatever toppings fit their taste or dietary choices.

Promoting your baked goods with recipes that are delicious, authentic, nutritious and appealing to diverse audiences will be good for them and you. iBuen apetito!

— Sylvia Melendez-Klinger, Award-winning author and global nutrition entrepreneur Sylvia Klinger is founder of Hispanic Food Communications, a nutrition communications and culinary consulting company, and member of the GFF Scientific Advisory Board.

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MARKETS

McCormick & Company’s Flavor Forecast 21st Edition also identified “Humble Nosh” as one of its four flavor themes for innovation this year. The theme is “inspired by the Yiddish word ‘nashn,’ meaning to nibble on, and combines rising global flavors with the means to ‘travel locally’ via our plates.” And according to the report, a few key flavors to keep top of mind include the Indian spice blend chaat masala, pandan kaya (Malasian jam) and crisped chiles. © Anna Demidova – stock.adobe.com

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28% of Americans are eating more baked goods, with 42% citing a sense of comfort and 41% citing a way to induce happiness as their reasons, respectively.

For companies looking to expand their culinary flavor offerings in a global sense, the snack category could offer a low barrier to entry. Consumers are snacking more than ever and are more willing to experiment with new flavors and ingredients in the category, due to a limited cost commitment, according to Mintel’s Regional and International Flavors and Ingredients November 2020 report.

Health trends also remain top of mind for restaurants and chefs. Kimpton Hotels & Restaurants’ seventh annual Culinary & Cocktail Trend Forecast for 2021 expects a shift from the comfort food that so many turned to in 2020 to a renewed interest in healthful eating.

“We know that diners’ needs have changed,” said Scott Gingerich, Kimpton’s Senior Vice President of Restaurants & Bars. “The COVID-19 pandemic has brought out the foodie or at-home chef in many of us. While diners first leaned into comfort and nostalgia, heading into the new year we’re seeing a return to health-and-wellness-inspired culinary and cocktail creations.”

Clean labels and “free-from” packaging claims are still top of mind for consumers. Four in 10 Americans (43%) say it is important to them that a food or beverage includes only a few ingredients, and 54% say it is important the ingredients not have “chemical-sounding names,” per the 2021 International Food Information Council’s Food & Health survey.

Foods and beverages carrying a “lifestyle” diet claim grew 13% in dollar sales for the year ending Dec. 27, 2020, per IRI data.

Products like Scotty’s Everyday Keto Bread Mix, which was developed by a food scientist/pastry chef, contains zero net cards and is free of nuts and gluten is an Amazon bestseller, and Partake Foods’ popular 5-in-1 Baking Mix is not only multi-purpose, but it doesn’t contain gluten, dairy or any of the top 8 allergens. (The Specialty Food Association also notes that baking mixes and flours are a COVID-influenced category that will continue to grow.)

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Consumers remain wary of sugar and are increasingly looking for alternatives when it comes to sweeteners. According to IFCI, the number of Americans limiting or avoiding sugars in their diet is holding steady at 72% since 2020 (only a slight dip from 80% in 2019), though some expect this to become even more important as the pandemic recedes. “‘Sugar as the devil’ will become a more prominent message in 2021,” said Clara Park, corporate chef of culinary innovation for Chelton House Products. We will continue to see a decline in the levels of sugar in foods and drinks and an increase in the availability and popularity of alternative sweeteners like monk fruit, keto-friendly sugars and coconut sugar.”

In the past few years, Briess Malt & Ingredients Co. launched BriesSweet Oat extract and Organic Innosweet whole grain oat powder, both of which offer product developers more options when it comes to sweetening commercial baked goods. And Specialty Food Live! 2021 Trendspotter panel members took note of the number of new products that relied on natural sugars from carrots, jaggery (a cane sugar popular in Asia) and dates.

In looking at overall bakery and snack trends, it might seem there is a strong disconnect in consumer behaviors influencing culinary trends in new product development. Do they want to indulge or eat more healthfully? Do they want familiar comfort food or new and exotic global flavors? Individual brands will have to make the call as to how to stay up-to-date with the latest trends, ingredients and flavors that best fit their unique audience. But in this space, there is more than enough room to play. +++ Content provided by Commercial Baking magazine (Avant Food Media)

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