5 minute read
Trays with a mission: Cake production
PART II
Trays with a mission: cakes
One product, infinite possibilities: cakes come in all shapes and sizes, with unique concepts to mark memorable events or casual experiences. To create the cake that will stand out, the tray is the limit.
+Having a clear idea of the cake ranges on the to-bake list, there are several considerations to help determine the choice of cake pans. American Pan uses its proprietary ePAN aluminized steel together with aluminum to combine the benefits of both materials: it is up to 2.5 times stronger than standard material while weighing less. To optimize their structure design, ePAN cake pans are manufactured with aluminum cups and aluminized steel frames, as aluminum heats and cools faster than aluminized steel, but is not as strong and resistant to damage. However, the ePAN material does also heat and cool faster than standard aluminized steel due to the fact that it has less mass. This characteristic of ePANs, and a very timely one at that, contributes to energy savings at bakeries. Some American Pan customers that use ePANs have reported decreasing baking times up to 45 seconds and decreasing oven temperature by up to 21°C. In one case, a bakery saw nearly 8% energy savings from one year to the next using ePANs.
Depanning methods also factor in choosing a new pan, as they may require different construction features depending on the type of depanning used (the best depanning method for various cakes can include anything from gentle depanning to needle depanning and slam depanning). “Depending on the stress that is put on the pans during this process, they might require additional strengthening features such as the type of panel used for the cups. They can be built with a standard panel, or a ‘channel frame’, for added strength,” Jason Bowman, President – American Pan Europe & MENA, explains.
Jason Bowman, President – American Pan Europe & MENA
© American Pan
The shape of the product will, of course, dictate that of the pans. For example, products such as large muffins, which need deeper cups during processing, benefit from having these cups brought together and attached to a frame, for process efficiency. American Pan has addressed the issue of metal fragments breaking loose from these frames when welded and is using a seaming method to put them together instead of welding, which results in a stronger bond and eliminates this concern. In addition, American Pan also developed methods to place the cups closer together and increase the number of molds per pan, for higher production volumes. To strengthen the structure of these pans, cross supports can be built into them, which will also protect the cups against impact damage.
Product consistency is always a priority, especially for industrial operations. To ensure consistent results, the American specialist uses a shielding for the inner molds on pans, which supports similar product browning. This shows its role particularly well when used in the production of blonde or light cakes: “Using metal strips to shield cups in the center of the pan will prevent them from browning faster than the products in the cups on the outside of the pan, which are shielded by the outer rim of the pan,” Bowman explains.
Coating and cleaning considerations go hand in hand with cake production, too. American Pan recommends the DuraShield coating for its crumb-release properties. A silicone glaze requires using release agents, if selected as a coating solution. As many cake pans are washed after every production cycle, American Pan provides design and material options to minimize the risk of corrosion. The design of the pans also includes holes in the top panel to allow water to drain properly.
Special cakes go in special trays
The creativity put into making cakes puts forth a wide variety of (delicious) products. The same goes for the pans in which they are made: they have to suit the product and the production line in every aspect: “The shape, design and size have to lead to the best baking results, and the coating has to create enough no-sticking effect so that the cake is easily depanned, with no damage to its integrity,” Guido Kempf, CEO, Kempf, explains. The German company develops a custom solution for nearly every project, including designing unique shapes, such as those required by the famous Austrian Gugelhup cake or special designs for tartlets, for example.
The company takes into consideration the usual suspects in threatening the lifespan of trays used for cakes: unsuitable cleaning with aggressive chemicals or overheating the pans and/or the coating, and designs them with high-quality materials, to extend their lifetime. Ingredients can pose challenges to the integrity of the pans, too: “The most “The shape, design and size have to lead to the best baking results, and the coating has to create enough no-sticking effect so that the cake is easily depanned, with no damage to its integrity.”
Guido Kempf, CEO, KEMPF
challenging ingredients/toppings are egg wash and dough with high sugar content. If the sugar content goes up to 15% or even higher, it becomes difficult to find a coating solution to provide a sufficient non-stick effect. Of course, we have several options available for such cases, in our high-quality coating portfolio of KG-Flon coatings,” Kempf explains. They were developed to provide an excellent nonstick effect and to be resistant against routinely occurring abrasion. Alternatively, when the sugar ratio is even higher, only a combination of high-grade non-stick coating doubled with greasing is successful, according to Kempf.
When using these trays to bake cakes, vacuum depanning should be considered as a method that will protect both the cake and the pan coatings, Kempf recommends. Using this process where applicable will improve the lifespan of the non-stick coating.
For cake trays of any shape and size, the right cleaning processes are key to a balance between optimum hygiene and ensuring the pans’ protection. Ease of cleaning is included in the design of the pan, Kempf highlights: “The right design will eliminate any gaps that are very difficult to clean.” To optimize cleaning, the company always recommends using a continuous inline cleaning solution, because only hot water is used in most cases (no detergents).
The ongoing question remains: what original and unexpected creation will be popular with the consumer? Solutions to support production are therefore available – or can be perfected. +++
