bbi 06 2024 ePaper

What makes you stronger?

Catalina Mihu, Editor-in-chief

Your commments or suggestions are always appreciated: e-mail: mihu@foodmultimedia.de

‘What doesn’t kill you makes you stronger.’ Looking at the industry from the other side of crises with no ‘how to’ guidelines to navigate, and while still powering through a slew of ongoing challenges, the saying resonates with the baking industry. Bakery production prices are an accurate reflection of this volatility: in France, they surged by over 30% between Q4 2021 and Q2 2023 alone, for example. In Europe, this cost was higher by 26.1%, on average (Eurostat data), putting a dent in profits and forcing bakeries to increase prices. IBIS World estimates a 5.8% dip in revenues in 2024 in Europe’s landscape, which counts around 193,000 bakeries, industrial and artisan.

Although not without losses, Europe’s baking industry remains resilient. Growth is in sight, research estimates show. The market is steadily increasing: Gira expects it will reach 101% of the volumes consumed in 2019 by 2026. Again, growth comes with shifts on several fronts. Bake-off should gain more ground, while fresh bakery consumption is anticipated to remain at only 99% of 2019 volumes in 2026, for instance.

To add to the list of challenges in need of solutions, Mintel Global New Products Database (GNPD) highlighted an unsettling finding: innovation is at a nearly 30-year low. “So far in 2024, only a third (35%) of global consumer packaged goods launches were genuinely new products, while two-thirds (65%) were renovations of existing products or brands,” Mintel calculates.

We are hopeful as we are looking at a new year coming close. The question, for 2025 and beyond, is how to balance sustainability, efficiency, savings, supply chain troubles, bottlenecks, ingredient prices, margins, R&D, and innovation? Without a doubt, losses and challenges make us stronger as we explore new directions forward, walking, stumbling and running. How to connect with consumers who are shaping their own identity and offer them exciting, tasty experiences? This is where sincerity and creativity will spark the kind of innovation that gains loyalty and drives businesses.

Before the year changes, we are proud to announce our own new development for you, an industry-first virtual resource library bringing all of the in-depth knowledge we’ve gathered about all aspects of baking, from technology to ingredients, products and markets, science and services. The doors of our library open soon, and I would like to extend our warm invitation to read and study together in our f2m library, from next year!

You can read more about our f2m library project, here: https:// bit.ly/f2mLibrary

In the meantime, the f2m team wishes you a holiday season full of joy. Here’s to new beginnings!

Catalina Mihu

COVER STORIES

“THE KEY TO SUSTAINABILITY IS TO THINK GLOBALLY”

Norbert Lötz, Managing Director of Production and Technology, talks about the challenges and obstacles on the way to sustainable baked goods production.

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“AI WILL FURTHER INCREASE PRODUCTIVITY”

WP BAKERYGROUP leaders share the insights of leading a diverse group of companies while looking at a ‘think process’ big-picture.

“PUT YOURSELF IN CUSTOMERS’ SHOES”

The Lesaffre Baking Center™ network, now counting 52 state-of-the art facilities all over the world, started in France. Today, the new Lesaffre Campus hosts it.

HIGHLIGHTS

EASY DOES IT!

The Kaak DrieM sheeting lines are designed to optimize every step of the process for large-volume dough production. The newest update to the sheeting system can now enable easy access to the portioner for thorough, convenient cleaning and maintenance.

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RELIABILITY IS EARNED

Spiral cooling and freezing systems have an unmatched capability to save space. For AMF Bakery Systems, the reliability of the line is crucial to every project, big or small, so the design and technology offered need to be simple, robust, yet highly customizable.

© Kwik Lok 34 THE MEDIUM IS THE MESSAGE

Automating packaging and coding not only streamlines the process but also checks all of the boxes – efficiency and transparency, material traceability and sustainability.

© Roayl Kaak

© AMF Bakery Systems

06 Harry-Brot: “The key to sustainability is to think globally”

12 WP BAKERYGROUP : “AI will further increase productivity”

18 Lesaffre Baking Center™, France: A knowledge network 50 years in the making

26 Royal Kaak: Easy does it! Hygiene-friendly sheeting

PROCESSES, SPIRALS

30 AMF Bakery Systems: Reliability is earned

CODING

34 Kwik Lok: The medium is the message

38 American Pan: Information is power

40 Reading Bakery Systems: Better snacks: science and creativity

44 Fedima: A clear approach for a complex issue in

“The key to sustainability is to think globally”

Sustainability is multi-layered and complicated, partly because it’s difficult to tackle the topic in isolation from other partners in the value chain. Germany’s largest baked goods manufacturer, Harry-Brot GmbH, found this to be true as it has been making strides with CO2 reduction, in-house and along the value chain for years. In this interview, Norbert Lötz , Managing Director of Production and Technology, talks about the challenges and obstacles on the way to sustainable baked goods production.

+Helga Baumfalk: Mr. Lötz, what do you understand by sustainability, as a baked goods manufacturer, and where did the idea come from to tackle the issue and determine the carbon footprint of all products first, and later, of that of the entire company?

Norbert Lötz: As an owner-managed company in its 10th generation, we have always strived to ensure the continuation of our company for future generations. Changes in society and current crises have prompted us, not only in management, but also among many employees, to ask ourselves what we can do even better in the future. Seven or eight years ago, sustainability wasn’t among the top priorities as much as today. However, we realized then that we had to change something and focus on it more. It’s less about how to cut costs or solve this or that problem, and more about ensuring the future viability of the company.

Baumfalk: How did you proceed in concrete terms?

Lötz: We asked ourselves where we stand in terms of sustainability. Where and how can we do things even better? Looking at what do we, perhaps, do we need to fundamentally rethink things? We have been dealing with the topic of energy for many years, but it was primarily from the perspective of cost savings. Today, the impact on a single product’s carbon footprint is taken into account. The narrative has changed and it’s become complex. Simply saving kilowatts by installing a better motor for a conveyor belt, for example, is no longer enough. We are thinking ahead, rethinking the size of our breadsticks, for example, in order to produce fewer rejects in the form of end pieces and thus save energy and raw materials.

Baumfalk: Have you received external demands for sustainability?

About Harry-Brot

Lötz: The initial incentive came from within our company. Requirements from outside came later, from our customers, other stakeholders and politicians. Sustainability was and is an ongoing process in our company, which has now gained considerable momentum.

Baumfalk: What expectations do consumers have?

Lötz: Consumers today want to know where the raw materials come from, how they are processed and what happens to by-products and waste. Awareness in this direction has increased significantly.

Baumfalk: How do you communicate sustainability?

Lötz: We talk specifically about topics such as the regionality of our raw materials, or the precise and therefore reduced fertilization of the grain and we are receiving positive feedback consistently. Occasionally, we are explicitly asked about certain topics, such as food waste. When we explain what we are doing in terms of sustainability, people are amazed at the extent of our commitment.

Baumfalk: Speaking of food waste, what are you doing about it?

Lötz: We see a very important point in demand-oriented production and packaging. This allows us to adapt to market demands with our daily fresh production and delivery and actively contribute to combating food waste.

Baumfalk: Are your efforts for more sustainability also seen by retailers?

Lötz: Absolutely! The retail sector itself has set up departments within the company that deal with sustainability. We are in direct contact with these departments.

Harry-Brot GmbH, headquartered in Schenefeld near Hamburg, was founded in 1688 and is now in its 10th generation of family ownership. With around 5,020 employees, Harry-Brot operates 10 production sites in Germany and produces sliced bread, toast, sandwiches and baked goods for ready-baking as well as a range of prebaked products for retail baking stations. In 2023, Harry-Brot GmbH generated sales of EUR 1,408 million. This makes the company the market leader in Germany.

Sustainability is a leadership matter

Baumfalk: “Sustainability must be a top priority,” you said in your presentation at the WIG conferences in spring 2024. Who is the driving force at Harry?

Lötz: Clearly, the management. They have to lead the way on this topic. But, we very quickly realized that many of our employees are just as committed to sustainability work and got actively involved. They are incredibly motivated to drive this issue forward.

Baumfalk: How do you define sustainability at Harry?

Lötz: Avoid, reduce and, if necessary, compensate! It is best not to generate CO 2 in the first place. The second step is dealing with lowering emissions and finding answers to the question, “What can we do better?”. One example: engines consume a lot of energy when starting and stopping. If you leave them running all the time, they also need electricity. Now the question is, what is better for the CO 2 balance, keeping them on, or shutting them down and restarting them? We decided to keep them running at a minimum speed. To do this, we installed frequency converters that operate at 15 Hertz in standby mode instead of 50 Hertz, so that they don’t consume as much power when starting up and as little as possible when continuing to run. It is important that we scrutinize the entire process in detail to look for better solutions. Admittedly, we don’t always find opportunities for optimization, but the search for them alone drives many people in the company to get involved.

Baumfalk: Can you give us more examples?

Lötz: We also looked into the question of why the flour has to be transported over such long distances within our production facilities. As a result, we are installing the silos in our new plant in Troisdorf above the production area. This shortens the distance to the kneader and reduces the amount of energy required for transportation. Another example: in the past, the goods were pasteurized to preserve them. Today, we only pasteurize in isolated cases and transport many of our products via clean rooms, which significantly improves the quality of the products and also saves energy.

Baumfalk: You mentioned the new plant in Troisdorf. Is sustainability an issue for building materials there?

Lötz: To a certain extent. We try to reduce the floor space by not only thinking in terms of 400 m long halls, but also considering how the material flow can be optimized. In my opinion, we have succeeded in doing this well in Troisdorf. In terms of the building materials themselves, we have less leeway due to the fire safety requirements. Nevertheless, sustainability was the focus of the planning. In the distribution hall, for example, we use underfloor heating that is sourced from waste heat. We have also installed large heat exchangers to preheat the air that is fed to the burners. We assume that this will also save a considerable amount of

”If we all only ate rye, our carbon footprint would look better. But, you can’t produce in a way that ignores consumer wishes. Nevertheless, there are also ways to emit less CO2 with wheat production. And that is exactly what we're working on.“

Norbert Lötz, Managing Director of Production and Technology, Harry-Brot GmbH

energy. We will be able to prove this when the comparative values are available.

Baumfalk: Do you see CO 2 as a kind of currency?

Lötz: Yes, but this is where it starts to get complicated. Sustainability is multi-layered. I would like to illustrate this with another example. When looking at our corporate carbon footprint, our CHP (combined heat and power) plant is currently under discussion. The problem is that it increases gas consumption and, consequently, our company’s footprint. However, it works very energy-efficiently, precisely because we can also use 100% of the waste heat. We save energy in many other places and even feed the rest of the waste heat into the city’s district heating network. The question is, which perspective on sustainability is the right one? It is crucial that we don’t think about sustainability on a small scale but in a global way. If we don’t, we are not actually changing anything.

Baumfalk: That does sound complicated. Can you explain your approach in more detail?

Lötz: If we use fossil energy, in this case, gas, to generate electricity and heat via our CHP plant and then achieve an efficiency of 93%, we can’t be blamed for the fact that we need more gas at this point. 93% efficiency – none of the electricity-generating power plants in Germany reach this, to put it into perspective. That’s why I would like us, in Germany, to take a more global approach to the issue. The fragmented nature of the decisions – federal, state, district – has an inhibiting effect. As a result, we want everything, but no one can implement measures to reduce CO 2 emissions. We must not penalize companies for doing something for the environment.

But that’s how it is at the moment. Companies that do nothing are not taking any risks. Those that do something are taking a high risk and may end up losing out if, for example, natural gas prices plummet and it was a bad decision to invest in sustainable energy. It must be ensured that companies that invest in sustainability are not disadvantaged. The CO2 price can play a role in this if it is implemented consistently.

Baumfalk: Specifically, what are the drawbacks of the CHP unit consuming more gas?

Lötz: It’s about pursuing the SBTi goals – the Science Based Targets Initiative. It calls for and defines methods for reducing emissions in line with climate science to achieve climate neutrality. The CHP plant means that we consume more gas and therefore do not achieve the target set at this point.

Baumfalk: And what does that mean for you?

Lötz: I examine SBTi targets with a very critical eye. They require us to save 4.5% on energy every year. But, we don’t have a perpetual motion machine. The 4.5% savings have

to be achieved every year, even if a company produces more goods. However, a company that is growing cannot do this. The crux of the matter lies in the calculation with absolute values: there is no reference value here. A manufacturing company cannot be climate-neutral per se. When formulating targets, achievability should also be taken into account at a global level; otherwise, these targets quickly appear to be window dressing.

”Sustainability was and is an ongoing process in our company, which has now gained considerable momentum.“

Norbert Lötz, Managing Director of Production and Technology, Harry-Brot GmbH

Baumfalk: So what would you propose?

Lötz: We urgently need to do something and use the available energy more efficiently globally. CO 2 emissions can only be reduced with greater efficiency, regardless of the process. We waste too much energy these days and are also unable to store it. Two years ago, I set the company target of 50% self-generated energy at the Soltau site. The Federal Ministry of Economics is supporting us at the state level to develop simulations for greater sustainability, which have also incorporated various ideas. However, many legal hurdles in regional politics may prevent the implementation of various options.

Baumfalk: Obviously, there is room for improvement in cooperation with and in politics. If we look at your efforts to advance your sustainability, did you have any role models from the industry?

Lötz: Both in the food industry and in other sectors, many great companies are taking an innovative approach to sustainability. I am very excited to see which concepts we could also implement for ourselves.

Baumfalk: What are your plans for Soltau now?

Lötz: We are currently investigating what we can implement. Wind power and biogas are important topics that we are looking at closely.

Baumfalk: Is an electrolysis plant for producing hydrogen, such as the one operated by MPREIS, an issue that Harry could consider?

Lötz: Producing hydrogen ourselves is not an option for us at the moment. However, we will need hydrogen one day and are active in various organizations that focus on the use of hydrogen. We can easily integrate hydrogen at various points in our production. Only the connection is still missing. However, the question arises as to who will pay the higher price for hydrogen compared to gas. If we make our bread 10 cents more expensive because we use hydrogen, for

example, that may be laudable, but in the end, we have to sell it and generate profits from it, which we can then use to invest. That is why I believe that there must be compensation payments from a higher level for those who reduce gas compared to those who do not. This brings us back to the issue of CO 2 pricing.

How is the CO2 footprint determined?

Baumfalk: How do you determine the CO 2 footprint?

Lötz: For our Corporate Carbon Footprint (CCF), we start with our raw materials and examine the emissions caused by cultivation, transportation to the mill and processing, based on information provided to us by the mills. In the next step, we include the entire production process, including direct and indirect energy consumption. We record all the values of our processes, even employees’ commuting and business trips. Finally, transportation to our customers is also calculated. The values in the various scopes are added together. TÜV then validates our calculations in the individual scopes. And since the framework conditions are constantly changing, we recalculate every year. The values for our CCF are derived from these calculations. For the individual product - the Product Carbon Footprint, we also take into account the line on which the product was manufactured and under what conditions. Developing

a CCF is a huge challenge, and one with a time limit, as the CO 2 footprint has to be constantly adjusted.

Baumfalk: In contrast to most other suppliers who use central warehouses, Harry supplies each individual store. What effect does this have on the CO 2 balance?

Lötz: There are significant differences. For example, reusable crates are used in drop shipments, while deliveries to central warehouses are packed in cardboard boxes, which have a higher CO 2 value. In this way, we produce considerably less CO 2, even though we include the gas for the journeys to and from the individual customers and the cleaning of the boxes. Nevertheless, our carbon footprint is around 23% lower than if deliveries were made in cardboard packaging. To be fair, I have to say that we set up driving routes to nearby stores. This means that one vehicle drives to many stores within a relatively small radius every day. If we only drove to one store in each region, we would get a completely different picture.

Baumfalk: Harry produces fresh and frozen products. Are there differences in the CO 2 balance here?

Lötz: Our frozen products are semi-baked, so we save energy during baking. Energy is then used in the form of electricity for freezing. In the end, the balance is not that

CONTINUOUS MIXING

different. At the moment, half of the electricity in Germany is green and half is black. Of course, we could consider using electric ovens, but gas prices are currently far too low to make it worthwhile. The Scandinavians, for example, are positioned differently. Because a lot of hydropower is used to generate electricity in these countries, electricity is comparatively cheap there.

Baumfalk: Would that be a model that would work well in Germany?

Lötz: If we want to get away from fossil fuels, we certainly have to think in terms of electricity, but it would have to be produced sustainably. At Harry, we are already thinking about how some processes could be converted to electricity use. However, this requires careful consideration of the advantages and disadvantages.

”We no longer need these high-protein flours, we need the right varieties.“

Norbert Lötz, Managing Director of Production and Technology, Harry-Brot GmbH

Baumfalk: 65% of CO 2 emissions come from raw materials used for baking, before baking even starts. How does Harry approach this topic?

Lötz: That is the biggest lever. If we all only ate rye, for example, our carbon footprint would look better because it requires less nitrogen fertilizer during cultivation. Nevertheless, there are also ways to reduce CO 2 emissions from wheat. This is exactly what we are currently focusing on. We see ourselves as part of the value chain and are working with farmers, a fertilizer manufacturer and a mill in a joint project to test how we can reduce CO 2 emissions.

Baumfalk: You are talking about your cooperation involving the use of green nitrogen fertilizer, right? Why did you enter into this cooperation?

Lötz: Because we want to show a way in which we can reduce CO 2 emissions. However, this path ultimately costs money and the question is whether consumers are prepared to spend a little more money so that a reduced nitrogen input from the outset lowers the CO2 footprint of the product. But, we also go further and ask ourselves what we need to do together with the farmers to ensure that the right varieties are grown that provide us with the baking properties we need. Ultimately, we want to get by with less protein and therefore less nitrogen fertilization. The farmers we work with are highly automated. They do not determine the amount of fertilizer required per field, but can use geodata and algorithms to fertilize specific areas. Fertilization is therefore more needs-based and much more targeted. It is a pleasure to sit around a table with such professionals and discuss what is feasible!

The green nitrogen fertilizer project

In 2023, Harry-Brot signed a cooperation agreement with the milling group Bindewald & Gutting and the fertilizer manufacturer Yara Germany. The collaboration aims to reduce the CO 2 footprint of grain cultivation. The vehicle for this is the production of the nitrogen fertilizer used in grain cultivation using renewable energy. Yara’s fertilizer is produced in Rostock using green hydrogen from Norway. Compared to conventional nitrogen fertilizer, it reportedly has a CO2 footprint that is up to 90% smaller

Baumfalk: What solutions did you take away from the discussions?

Lötz: We have identified wheat varieties that we believe require less protein from the outset in order to achieve the same product qualities. These varieties have now been cultivated in specially assigned areas. This is accompanied by studies and, among other things, the amount of nitrogen applied is documented. At the end, we calculate what we have achieved in terms of CO 2 reduction and yield. As we measured the values last year using conventional varieties and methods on precisely these fields, we can really compare them with this year’s results.

Do we still need high-protein flours?

Baumfalk: Do we still need wheat with a high protein content for baking bread? Is that still the right standard?

Lötz: No, it doesn’t need to be. Protein has always been viewed quantitatively, not qualitatively. This view has changed, certainly due to the fertilizer reform, the price increase, and other reasons. Today, I think we no longer need these high-protein meals, we need the right varieties.

Baumfalk: But farmers are paid according to protein content. How do we solve the problem?

Lötz: A reconsideration is needed here. A large proportion of the grain grown in Germany is exported. This means that a new approach must be embraced globally. I believe that we can certainly achieve this within Germany. However, I can’t speak for France or other countries. But, I know that some bakers in the Netherlands, for example, are prepared to scale back their demands on protein content. However, farmers must not be left out in the cold. The exciting question, and I have already mentioned this, will be whether we can achieve consumer acceptance. If this works, and if you, as a baked goods manufacturer, have the opportunity to label your product with the statement ‘this or that measure has reduced CO 2 emissions by 30%’, then you can also offer farmers corresponding contracts. The best example of how easy it can be for people to make a decision for or against something is green electricity. I am aware that it will be a long road to re-evaluate wheat and certainly not an easy one, but as they say – crises are always new opportunities. +++

“AI will further increase productivity”

With its portfolio of companies, the WP BAKERYGROUP covers every step of the baking process with dedicated and interconnected equipment. Jürgen Horstmann – owner, Horstmann Group, and Carola Landhäuser –WP BAKERYGROUP CEO, share the insights of leading a diverse group of companies and looking beyond individual production steps when designing solutions, to a ‘think process’ big-picture that shapes innovation in baking.

+Catalina Mihu: Earlier this year, we met at the AIBI Congress in Hamburg. What is your view on the baking industry’s latest approaches to current struggles throughout the supply chain?

Jürgen Horstmann: From a mechanical engineering perspective, energy efficiency, automation and artificial intelligence will shape the supply chain in the future. The goals of our new concepts are to reduce food waste, avoid disruptions, improve product freshness and ensure healthy production, in compliance with ecological standards. Today, WP uses automated modules in many different machines, in all the companies of our group. However, the area of control systems has witnessed even more significant changes. Here, we have succeeded in developing software concepts that can run on different platforms, or operate different devices. As a result, we are less dependent on hardware and are no longer tied to specific suppliers. Today, for example, we can use an oven computer for a dough divider and vice versa. The only thing that counts is the software, and we have that under control.

Mihu: Mr. Horstmann, you established WP BAKERYGROUP, but the company’s roots go back almost 150 years, growing together with the baking industry. What key moments would you consider to be the cornerstones of today’s group?

Horstmann: I am pleased to say that all companies in the group have developed very dynamically. I believe that the acquisition of the fat baking technology was a decisive step for WP Kemper (ed., In 2012, WP took over a provider in the field of frying business). In this area in particular, we were able to bring some special developments to the market, such as the thermal oil-heated industrial donut system, which helped us to achieve enormous growth.

Another key event is the development of the WP Digital Portal with all the associated apps. This is the entry into a new era of plant technology. In the future, digital solutions –with and without AI applications – will contribute even more than before to differentiating products from the competition and offer our customers added value that helps them earn money – bringing improvements to the productivity of a system as well as in maintenance and service.

At WP-L, alongside our strongest product, the Tewimat bread dough divider, we have established deck ovens as a strong automation alternative for larger artisan bakeries. WP Haton has focused very successfully on more precise

and, at the same time, more powerful bread dividers and has now expanded these systems to include new hygiene concepts in relation to the proofer. One of our latest developments at WP Haton is the Clean Proofer, which is particularly suitable for the production of gluten-free baked goods. WP-Riehle has now moved into process automation, developing and marketing fully automated solutions, for example, for the production of frozen pretzel baked goods.

And, a few years ago, WPI B, our industrial division, built the first thermal oil-heated continuous oven with two decks, which can bake toast quickly and in outstanding quality, thanks to its special turbo technology. This has significantly increased the productivity of our industrial ovens and at the same time considerably reduced the space required.

What innovation means at WP

Mihu: What innovations brought new solutions for bakeries and, in turn, translated into a step up for the group in the industry?

Horstmann: In addition to purely technical innovations, all of our developments are aimed at making our customers more flexible and efficient, so that they can meet the ever-increasing demands from retail and, above all, increasingly diverse requirements coming from their customers. Even large industrial companies have to be very flexible today because customer requirements change quickly. And our retail customers rely on differentiation through regional quality. We want to continue to build on this in the future and support them with special solutions where it makes economic sense.

One example is the KRONOS Kneader, a fully automated machine which, in conjunction with the MixControl feature, not only monitors the dough quality batch by batch, but can also be easily controlled by a non-specialist, even with fluctuating raw material qualities. In this way, the MixControl establishes the basis to further automate the entire process. In addition, with the new development of the SOFT STAR CT, WP Kemper has laid the foundation for innovations in the fat-baking sector. It is a high-performance 60-cycle dough divider and rounder with an unprecedented hygienic design. Milestones include the production of mini Berliners (8 grams) and mini donuts (15 grams).

In the WP Digital Portal, WP bundles all digital solutions to make service faster and more economical. New apps, such as augmented reality service support (FacelT} or a condition monitoring system (ControllT), which gives plant experts

access to machine data via a digital twin, are just the first examples of innovative new solutions. With the development of new web-based user interfaces (HMI), which are graphic-based and interactive, in conjunction with the WP Digital Portal, new solutions for improving operations and further automating systems will be possible in the future. The use of solutions incorporating AI and some completely new control concepts (for which we have already applied for a patent) will soon complete WP's range of services and take the performance of systems to a whole new level.

”The use of AI will further increase productivity and make production much more flexible. That is why we are investing in the development of new systems and technologies in this area in particular.“

Jürgen Horstmann, owner, Horstmann Group

The power of a cohesive group

Mihu: What is your view on the various ways of achieving company growth, including expansion, acquisitions, partnerships?

Horstmann: With the development of WP Kemper, we could and can grow quickly and sustainably through suitable acquisitions with truly complementary product portfolios. In my opinion, this is the only way forward. That is why we are constantly monitoring the market, and we are currently examining each of the many offers very carefully. I don't believe in simply merging companies into a group that is difficult to manage. I think it is ultimately more successful to grow more slowly, to take more time to integrate new companies and to integrate the new types of technology systematically from the outset, so that all companies in the group can learn from them and, of course, benefit financially.

Mihu: Please describe how the collaboration within the group is managed. What leadership style do you find works best, as a system provider with several competence centers in its structure?

Horstmann: Our management style demands and promotes commitment and creativity in order to enable rapid adaptation to new challenges and complex dynamics. This means that we cultivate a situational management style combined with agile elements in order to make quick and good decisions in rapidly changing markets.

Mihu: What are some of your favorite customer projects and key moments in the Group’s work, and what makes them memorable? Please share some examples.

Horstmann: One example would be the first OBER system, which we installed at a bakery in the Rhineland in

Germany, many years ago. Since then, the OBER oven-loading robot has now covered a distance equivalent to circling the Earth several times. It is a solid machine, which is why, over the past 25 years, we have only had to replace the cables and the starter, which were of course outdated. Also, the WPIB 2 thermal oil baking oven, which today bakes almost 10,000 kg of bread per hour in Sweden, was one such project, as was Kemper's first open kettle baking system in Spain, which bakes 40,000 donuts per hour. Special projects in the artisan sector also come to mind, such as the continuous tunnel vacuum cooling system for panettone in Switzerland.

Mihu: The HORSTMANNGROUP sees itself as a mediumsized group of companies with diverse specializations and an international reach, as described in its official presentation. Is this still how you envision the group’s future?

Horstmann: Good WP products have been in demand on the global market for more than 100 years. In addition to Europe, our most important markets are North and South America, but we are also focusing on the future growth markets of Africa and Asia.

Mihu: What are the unique values on which the company is run, which stem from it being family-owned?

Horstmann: In a family business, agility should be demonstrated through short decision-making paths, but the virtue of patience should also be taken to heart. Encourage and challenge managers – is what I promote; create a positive working environment that leads to responsible action.

Looking ahead

Mihu: In the baking industry, the Group has grown from starting with a single dough mixer to providing integrated bakery solutions under the motto ‘think process’. What does the future hold for the family-owned company in the development of process improvements for bakeries?

Horstmann: The shortage of skilled workers will remain a challenging problem for bakeries in most countries around the world. Concerns about the next pandemic, which is of particular importance in food production, remain omnipresent. In this context, I expect the automation of

“Think process”

The central element of our corporate philosophy is a networked way of thinking that stretches beyond the individual stages of production. We call it ‘process management’, the targeted management of the individual stages of production and the machines used within them – as fast and with as little loss of material as possible to achieve the desired result, even for small amounts – and the unlimited reproducibility of results achieved. And all this is combined with extremely high yield.

WP BAKERYGROUP

workflows and processes to continue, so bakeries can become more self-sufficient.

In the coming years, we will see many more collaborative robots in factories, we will see ovens and machines that will be able to make decisions previously left to the operators. The use of AI will further increase productivity and make production much more flexible. That is why we are investing in the development of new systems and technologies in this area in particular. I believe that, in the future, we will need much more software development, database technologies and augmented reality applications, in addition to the established areas such as production, design and electrical design. In order to adequately support our customers in times of a shortage of skilled workers, we need to become much more resourceful with digital solutions. We can only exploit the potential of these new technologies if we provide our customers with machine and process expertise at all times. 3D glasses, for example, will soon be an integral part of the service. We want to be prepared for this, work on it and grow with it.

Mihu: And how do these values shape its growth? What is your message for bakeries, long-standing and new partners, regarding the group’s next-generation leadership?

Horstmann: The values practiced by our management staff will secure the future of the WP Group. My daughter and her management team will work hard and innovatively to maintain the long-standing trust and loyalty of our customers for decades to come.

The next generation

Mihu: Looking at leadership succession into the second generation, how would you describe your own path leading up to it, and your approach to spearheading the Group into your new role, Mrs. Landhäuser?

Carola Landhäuser: I got my first management position in our group of companies 20 years ago. Since then, more and more companies have been gradually added; then, the WP BAKERYGROUP leadership, four years ago. Two basic things are crucial for me: to lead authentically and gain as much specialist knowledge as possible. This is the most goal-oriented way to get from A to B with employees.

Mihu: What challenges did you confront that have also influenced this path?

Landhäuser: It was and is challenging to constantly analyze and keep an eye on the WP Group and its individual organizations (GmbHs) in such a way that I can quickly assess strategic issues in any area, what the risks are and where I need to intervene and how.

This is not a trivial task, given the broad and multifaceted field that I have to cover, as decisions have to be made quickly and correctly. A second attempt at wrong decisions, which sometimes undoubtedly occur, is usually more timeconsuming and gives room to doubters and complainers.

Mihu: What unique value will the group gain from heading into a new chapter under the leadership of a woman?

Landhäuser: There are certainly stereotypical differences in the leadership of men and women. I find the mixture beneficial. I am very calm and level-headed, which helps me manage any situation, including dealing with the most headstrong personality types. You could say this is feminine or maternal. However, I also know male managers who act like this. And, there will always be employees for whom a louder and more direct approach is more appropriate. It helps me a lot that I have seven children, five sons and two daughters - nothing can shock me.

”There are certainly stereotypical differences in the leadership of men and women. I find the mixture beneficial.“

Carola Landhäuser – CEO, WP BAKERYGROUP

Mihu: What is your view on women’s representation and career opportunities in the industry? And how does the Group support it?

Landhäuser: Most industries are still very male-dominated. I don't believe in quotas for women. Tasks have to be accomplished and goals achieved. Whether you are a woman or a man, you have to take action and perform well. Due to the lower representation of women, the vast majority of men are simply not used to coordinating with women. But this can be trained. Unfortunately, I am convinced that this often leads to men opting for what they are used to, so yes - in my opinion, the chances are not equal for women.

Mihu: Expanding on this topic, since (the lack of) people is one of the most prevalent issues today, how can the industry tackle labor shortages successfully? What has worked for the group?

Landhäuser: As long as we can describe as precisely as possible the areas in which we are looking for support and what exactly we expect from the people who come to us, we will always be able to find new employees. We are an international company and we see our future growth largely in foreign markets. Therefore, we have been trying for some time to become more international in our recruitment. This is a change for our company and an important one, which we will continue to pursue consistently.

Fortunately, we now have the advantage that women are also interested in engineering and other technical disciplines, so the overall recruitment base has expanded. We have already made some adjustments to our working time models during the pandemic, for example, by enabling and maintaining home offices in many office departments. This is, obviously, not possible in the production areas, but here, too, we are trying to optimize assembly processes by

providing information on large screens and, as far as possible, communicating to each of our employees why we are doing things in a certain way and what the end-result should be.

A changing landscape

Mihu: Looking back at the baking industry over the past decades, how would you compare its main requirements, then and now?

Horstmann: While, years ago, it was all about producing as much as possible as cheaply as possible, today the focus is clearly on quality, product safety and variety. Yesterday's ‘plentiful’ has become today's ‘diverse’, yesterday's ‘affordable’ has become today's ‘fast’, and yesterday's ‘packaged bread with preservatives’ has become today's ‘safe, high-quality food for everyday use’, in environmentallyfriendly packaging and in small quantities.

Mihu: What new approaches to today’s production problems could help bakeries advance at this turning point in the world economy, politics and business – all intertwined?

Horstmann: Bakeries produce staple foods. The demand is high in some countries around the world, but the infrastructure is still lacking. Government-funded projects can help to improve supply here. We are now able to plan and develop entire bakery operations, from the floor of the building to the machinery and equipment, the laboratory and the test bakery, to the air conditioning on the roof (a comprehensive example of this kind is the Xazri bakery in Baku, Azerbaijan, which we supplied a few years ago).

Let’s look ahead, for example, to the situation in Ukraine when this unfortunate war is finally over. Everything will have to start from scratch again. Holistic concepts can help to rebuild supplies more quickly.

Bakeries are energy-intensive businesses that require considerable resources in the form of drinking water, cleaning water, electricity and fuel. At the same time, they are often easy to identify when coming to their immediate vicinity.

The smell of fresh bread wafts far and wide. In the future, it will not only be important to make the production process

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It is particularly easy to clean since the drive and dough processing areas are kept separate and all parts that come into contact with the dough are easy to reach. Flour collection drawers also contribute to making cleaning easier.

”Developments that can change the industry will only come about, in my opinion, if we give the teams the freedom to think outside the box, try new things and make mistakes, and to explore.“

Jürgen Horstmann, owner, Horstmann Group

more resource-efficient, but also to make the waste heat generated during the baking process available in local energy networks for heating or other processes and to neutralize odor emissions using suitable systems. Bakeries continue to pose a logistical challenge in terms of the 24-hour transportation of goods, both for incoming and outgoing products. We are seeing the beginning of a shift towards hydrogen trucks or battery-powered smaller delivery vehicles. While we are already seeing numerous approaches to optimizing internal logistics with autonomous AGVs in bakeries, external logistics are still largely handled traditionally with trucks. I think that we will see many changes here in the coming years.

Mihu: On the topic of today’s turning point, what is your view on practical approaches to sustainability – for you and for the bakeries?

Horstmann: As I mentioned, resource-saving processes, energy recovery, but also the export of waste heat, for example to urban heating systems, can provide ways to reduce overall energy requirements. A kilogram of bread will always consume around 200 Wh of energy before it is baked. We want to stick to this, from a food quality perspective. But, the way in which the energy is used to bake the bread can still be optimized. Then, there is the distribution of the goods, as I described. Even more important, however, is the last step in this chain, the collection or purchase of baked goods. After all, if the consumer drives to the bakery in the morning in their combustion-engine car to buy a bag of bread rolls and then drives home again, all efforts to reduce the ecological footprint of these 10 bread rolls are nullified.

Changes must also be made in the last mile if we are serious about protecting the environment.

Innovation that evolves with the times

Mihu: How does a technology/solution specialist remain innovative over time?

Horstmann: I am not worried that we will remain at the forefront of technology in Germany. We have a solid training program, making skilled workers and good engineers. As long as our management focuses existing capacities on the continuous improvement of our machines and systems, we will be successful. But, developments that can change the industry will only come about, in my opinion, if we give the teams the freedom to think outside the box, try new

things and make mistakes, to explore, so to speak. Of course, commercial success is needed to be able to finance such developments. That is what we stand for as an entrepreneurial family, it is part of our DNA.

Mihu: What emerging ideas that could bring significant process improvements in bakeries do you find the most promising?

Horstmann: Robotics in handling, AGVs in internal transport, machine learning in our control systems for ovens and machines and, last but not least, the sensory recording of all process steps and the integration of this information into a digital model, the digital twin of the roller, so to speak.

Mihu: What process steps are in your focus in particular, for next-generation advances in the production of baked goods?

Horstmann: Of course, we are particularly concerned with the steps in the process chain for which we manufacture equipment ourselves. These are dough production, dough

processing, proofing, bagging and cooling. We are working on the precise control of dough development in the kneading process and expect further, decisive optimizations here. In addition to hygiene measures, we are working on control mechanisms to avoid rejects during dough processing. We are working on the precise control and distribution of adiabatic humidification in the proofer. At the same time, we have now installed the first energy-network proofers, which are heated with the waste heat from their ovens. We are working on shortening the baking time by modulating the radiation wavelength emitted in the oven. We are working on cooling processes in a vacuum, both in batch and continuous processes, and expect to be able to cool baked goods gently while saving energy.

Many fields with many tasks, but also with great potential.

Mihu: We are looking forward to learning about the new developments as they are launched. Thank you for an insightful conversation. +++

i In both adiabatic and isothermal humidification processes, approximate 1000 BTU's per pound of water are required to change the water from a liquid to a vapor. However, in isothermal humidification, that energy is taken from boiling water, while in adiabatic humidification, that energy comes from the surrounding air (Source: JMP).

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“Put yourself in customers’ shoes”

The first Lesaffre Baking Center™ was opened 50 years ago, as a place where its specialists could not only put themselves in their customers’ shoes to understand their experiences – from baker to baker, but also roll up their sleeves and bake together to find product and process improvements. Since then, it has become a network of 52 Baking Center™ facilities (and counting), busy baking with manufacturers all over the world, from craft and industrial bakers to baking equipment makers and millers.

By Catalina Mihu

+This year, Lesaffre celebrates the 50th anniversary of its Baking Center™ network, which today spans the entire world, from Austria and Hungary to Brazil, the USA and Chile, from Egypt and Morocco to China. Each specializes in serving its region of residence, with its cuisine and baking traditions, techniques, flavors and perspectives on innovation. A multicultural team of more than 300 specialists with different fields of expertise make up Lesaffre’s dedicated teams at the Baking Center™ network. Information and knowhow are exchanged as a vast database is continuously built.

The concept

Lesaffre is developing its global network of Baking Center™ facilities to meet the needs of bakers everywhere, through joint projects. They are places where innovations are created, with practical research of each project stage, from concept to product, that can be seen, touched, smelled and tasted. They can tackle diverse issues, such as new product development, recipe improvements and technique finetuning. Bakers come here to test anything from technology innovations to processes and the implementation of new concepts into production. Lesaffre’s experts help develop solutions to specific needs and are researching market expectations and changing priorities.

At the same time, Lesaffre uses the centers to further its own expertise and develop and tailor solutions, with information it gathers from the vastly diverse food cultures and unique products from the world’s markets.

To celebrate half a century’s work on its Baking Center™, Lesaffre organized a suite of events throughout 2024, at each facility in the network. Internal competitions, baking demonstrations, inspiration sessions, workshops and training programs, seminars and international exchanges are among the events that created an engaging celebratory year. Several projects and communication campaigns shed light on the specialists’ work, including the publication of a new book, published in French: ‘Les Pains du Monde’ and English: ‘Breads of the World’. The book reflects a jouney in breadmaking, undertaken by Lesaffre bakers who have choosen 40 original bread recipes, selected for their originality and authenticity. It was a difficult selection to compile, given the breadth of available options.

The bakery experience

It was in France, Lesaffre’s home country, where the concept was formed, and the first and biggest Baking Center™ was developed. Led by Gaëtan Jegoux, Baking Center™

all pictures © Lesaffre and f2m

170

Lesaffre celebrated 170 years since it was founded, in 2023

13,000 sqm

The Lesaffre Campus is built on a 13,000 sqm area

51

The network currently counts 51 Baking Centers TM

600

50

The Lesaffre Baking Center TM network was established in 1974

1/3

Over a third of the research projects undertaken are carried out with partners, universities and start-ups. Lesaffre is currently working with more than 60 research partners.

The R&D team has 600 specialists, working in 62 applied science centers worldwide; 300 of them are a part of the Baking Centers TM

Director, the team here works together with visiting bakers for specific answers to any number of product, process, or concept questions. Six bakery laboratories have been set up as a part of the Baking Center™ in Marcq-en-Baroeul, each with a different specialization and corresponding equipment: bread, pastry, pizza, sourdough (the interactions between the bacteria with the strain of yeast are analyzed here), and a fermentation lab. The pizza testing bakery, for example, lines up all the equipment commonly set up by a pizza maker. Investigating every step, ingredient, timing, and parameter ensures a perfect pizza is systematically done. It is only complete when even the cardboard box is analyzed, along with a standard delivery bag, to ensure it arrives at the consumer’s door exactly as intended: in the best possible condition.

Everyone working at the headquarters in Lille has, at one point, paid a working visit and enjoyed a hands-on learning experience here, says Jegoux – meaning, a team of approximately 700 people. Given its rich, festive agenda, 2024 was an unmissable opportunity to visit the Baking Center and Lesaffre’s brand-new Campus in Marcq-en-Baroeul. For a full day of ‘VIP internship’, thanks to exceptional French hospitality, a working visit was an illuminating first-person contact with innovation at the source. For one day, the Center’s celebration event agenda also included baking with BBI magazine. From mixing to resting, sheeting and cutting, forming and scoring, rolling and folding, baking and tasting (and a bit of magic!) – the program included the preparation of four French staples: traditional baguette, brioche, croissant and pain au chocolat. The hands-on baking experience was complete with detailed formulations and information about every process step, as well as expert advice along the way, including ways to improve the products, courtesy of Gaëtan Jegoux and Alban Depierre, Baking Technical Advisor. The difference between writing

EUR 2.7 billion

Lesaffre’s turnover in 2023

77

Production facilities in more than 50 countries

11,000

Lesaffre employed 11,000 people of 96 nationalities in 2023

about the craftsmanship required to trace the perfect scoring on a baguette and actually doing it? Invaluable.

Bakers can work on many different projects here, ranging from customized training in the form of such practical sessions (and Lesaffre can also organize training programs at their facility), to seminars on anything from yeast and fermentation, to baking and freezing, or optimizing product shelf-life. Product sensory testing for potential reformulations or new developments is also possible on site, for example.

The Lesaffre Campus: ‘Le Baking’

Vibrant Lille, the third-largest city in France, was the European Capital of Culture in 2004, when it was also recognized as

Projects at the Lesaffre Baking Center ™ network

+ Product and process development

+ Technical support

+ Baking trials

+ Sensory analysis and product testing

+ Training, seminars (on location, at the bakeries, online)

Baking, anytime and anywhere

The Group’s products are available in over 185 countries. The company leverages fermentation innovation for its solutions, which are produced in 77 facilities and include:

+ Baking ingredients (mixes, sourdoughs, functional ingredients, yeasts)

+ Fermentation products

+ Nutritional solutions

+ Solutions for flavor and taste

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‘Ville d’art et d’histoire’ – ‘City of art and history’. Lille stands out for its music scene and hospitality, its Flemish-inspired architecture, and its renowned university center. It is also home to Lesaffre’s state-of-the-art Biotech Campus, opened in 2022. Brice-Audren Riché, CEO, Lesaffre, shared the Group’s intention to give innovation R&D a new home with the new Campus: “The inauguration of our Lesaffre Campus is a historic milestone in the Group’s development. This living space arose from a desire to express what we are: an innovative, eco-friendly and open-minded company that has strong local connections. It embodies the spirit of our Group, which has been working for 170 years to explore and develop the infinite potential of fermentation and microorganisms. Inaugurating our Lesaffre Campus illustrates our aim to accelerate the research and development of innovative solutions to take up the challenge of improving food, nutrition and health for tomorrow.”

The objective of the Campus was to gather everyone in one place: “When the group was growing, our offices were hundreds of meters from here. We had a factory nearby, and some offices here, but each team was, to a certain extent, separated into different groups. In line with our mission to work together to better nourish and protect the planet, it now starts by working together, literally. This was the concept behind regrouping everybody on the Campus, so we would all share the same place, value and project,” said Thomas Lesaffre, Baking Marketing Director of Lesaffre Group during our tour of the new complex.

In the building at the entrance to the Campus, an auditorium with an immersive lake view was set up, in line with a general preference for glass walls. Here, events such as seminars are organized. It can welcome as many as 250 people. In this building, the company’s motto is displayed: ‘Entreprendre ensemble pour mieux nourrir et protéger la planète’ (‘Working together to better feed and protect the planet’). This wall has already become an instantly recognizable landmark at the Lesaffre Campus, as it is the background for many of its developments, with their corresponding photo opportunities.

The buildings in the Marcq-en-Baroeul complex, in suburban Lille, span 23,000 sqm, 60% of which is space devoted to R&D, which is an essential department at Lesaffre, with plans to increase its dedicated budget by 10-15% annually in the upcoming years.

Envisioned as a 'co-construction' space, the Campus comprises 750 workstations and 600 meeting/project areas, as well as a learning center: the Léon Lesaffre pavilion. The facilities were developed as an entirely ‘green’ concept, inside and out: sustainable working spaces equipped with latest-generation technology, complete with buildings for dining and exercising, all pleasantly spread in a veritable

park. The well-thought-out architecture and layout were designed around transparency and ease of access, in a natural environment. All to support teamwork: to easily share good practices, build resource databases, create partnerships and share know-how. Convenient, yet unobtrusive parking spaces between the facilities, so the eye can immediately enjoy nature, from any alley, from any of the buildings: trees, plants, a farm, and even a lake with resident swans and other migrating birds that have chosen the Campus as their yearly home. The traditional farm was recently revamped to allow visitor hosting and events.

The facilities set up here allow Lesaffre to step up its research in food, animal feed, health, environmental protection, energy production and industrial biotechnologies. “Our R&D approach is based on these emerging state-of-the-art technologies supported by historical knowledge and especially by the expertise of engaged and passionate teams,” said Christine M’Rini Puel, Chief R&D Officer for Lesaffre.

Not far from the Campus, more ‘green’ upgrades are underway in Marcq-en-Barœul, reflecting Lesaffre’s sustainability priorities: two high-power heat pumps will be commissioned in 2025, for a heat recovery unit that will enable the heat generated by the fermentation process to be reused. It is installed in the Group’s largest yeast plant, Société Industrielle Lesaffre.

The sensory lab

The Campus also houses facilities dedicated to sensory analysis, where specialists and volunteers carry out tests designed by Lesaffre’s experts. Camille Dupuy, Sensory Baking Manager, is setting up product tastings in a sensory-

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controlled space, useful for various projects, including product differentiation, reformulation, or new product development.

An important project here, developed with the Baking Center™, is perfecting a common ‘language’ describing tastes, flavors and textures. The books not only catalog a complete sensory glossary around specific products, but also provide information about them, including recipes from around the world. Serving as a communication tool, several books that coin useful and practical terminology have been developed and make up an important, growing collection. <“Le Pain” in Words >, for instance, proposes an entire glossary of sensory terms that describe crusty bread. For clarity, this includes breads made with no added fat, or sugar, which have a brown crust, and are baked on a hearth, tray, hot plate, or in dry and steam heat.

From yeast research to robotics-run biofoundry

Advancements in work with bacteria here include the biofoundry, the biggest of its kind in Europe: a set of 60 specialized robots that simultaneously perform microorganism screening and analysis at high speed, to establish their profile and functional potential. From the test results, the best matches are selected for their properties and potential benefits. In this way, thousands of strains are tested every day, followed by advanced data processing. Thanks to the new robotics setup, it can perform 10,000 tests per day – a significant step up from the previous capacity of 10,000 tests carried out per month.

To put this work into perspective, for 100,000 screened strains to identify potential candidates, it can just be a selection of only 15, for example. These are tested for production viability, to check how well they scale up, in stages. If the process is replicated successfully to 1-2 m3 fermenters, a pilot yeast/bacteria variety has been obtained.

The R&D work at the biofoundry is also used by other departments on Campus, for in-depth, focused analyses related to biological processes. Studies around nutrition even include work with a model of a human digestive tract.

Lesaffre milestones

Louis Lesaffre and Louis Bonduelle launched a grain alcohol and Dutch gin plant in Marquette-lez-Lille in 1853. The first mill was acquired 10 years later, in Marcq-en-Baroeul, which became a distillery. The Société Industrielle Lesaffre was born. In 1923, the company shifts focus to yeast and malt, which goes on to drive its growth.

The development of the Saf-instant ® Dry Yeast in 1973, a dry yeast that didn’t need to be rehydrated before being added to the mixer, quite literally put Lesaffre on the world map: “It was quite a revolution in the yeast market. This long shelf-life product allowed us to export from France for the first time, to Africa and the Middle East. This invention was paramount to our international development,” emphasizes Thomas Lesaffre.

One year later, the first Baking Center™ opened with the motto, ‘From baker to baker’. “This is why then in 1974, we decided to invest in a Baking Center,” he adds. “We hired a baker, just to put our feet into customers’ shoes, and to begin to better understand their needs. And over a period of 50 years, we have been building approximately one Baking Center per year, around the world, which brings us to today, when we count 52, with different specializations: the Chinese teams are experts in steamed bread, the teams in Turkey master flatbreads, and in France, we have people who are experts in baguettes, while in North America, our experts excel in toast bread. Today, we animate this network from here, to leverage all these experts to develop new solutions.” Every year, more than 18,000 projects and events with customers are conducted in the Baking Center™ network.

The Group acquires Red Star Yeast & Products in the US in 2001, while also entering the Chinese market, with the purchase of the Ming Guang Yeast facility. In 2024, several new acquisitions expand Lesaffre’s capabilities in its four core areas: baking, health care, biotechnology and food taste expertise (baking being the main core business). This year, dsm-firmenich’s yeast extract business joined Lesaffre. The majority stake in Biorigin was also acquired this year. +++

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The Kaak DrieM sheeting lines are designed to optimize every step of the process for large-volume dough production. The newest update to the sheeting system can now enable easy access to the portioner for thorough, convenient cleaning and maintenance.

+In Dutch, ‘drie’ means three. True to its name, Kaak’s DrieM technology development started in 2008 with a team of three – where ‘M’ stands for ‘musketeers’. Since 2021, it became Kaak Dough Technology and consists of about 180 people. Also in line with the initial technology concept, the awarded DrieM sheeting lines, focus on the craftsmanship of the process and artisanal products. Today, DrieM lines can be found in bakeries all over the world, as they are designed to produce a wide variety of bread shapes, from fine to very open structures.

Kaak Dough Technology

Kaak Dough Technology has been a part of the Royal Kaak family for 30 years, following the acquisition of Benier in 1991 – a specialist with over 125 years of experience in the production of dough-handling machines. In 2021, Benier was renamed to Kaak Dough Technology to reflect the group’s new, consolidated brand image.

Kaak Dough Technology develops dough preparation systems such as Benier mixers, rounders, blenders, finishers, dividers, proofers and DrieM sheeting lines.

With a space-saving design, the layout and philosophy of the DrieM sheeting line are perfected for bread and pizza production to ensure that the dough remains stress-free throughout the process, so that no tension or shrinkage occurs. Complete process visibility was also a design specification. The high-capacity line enables complete control over the production process, thanks to easily adjustable parameters that ensure a consistent flow of the dough. This design makes the line excel at sheeting from low to highly-hydrated doughs as well as dough with fruit inclusions,

The Kaak Technology Center is also located in the same building as Kaak Dough Technology in Nieuwkuijk. The Kaak Technology Center includes all Kaak equipment, such as a high-speed mixer and Benier make-up systems for dividing, rounding, molding and intermediate proofing, as well as the DrieM sheeting lines – with more to be added soon. The Center is home to the complete collection of technology developed by all Kaak Group companies, including several types of ovens.

for example. With softer doughs, however, come higher cleaning requirements, since they will stick easier to surfaces. To accommodate cleaning procedures, the DrieM line has an open design and a special cleaning mode integrated in the HMI, among other features.

Cleaning made easy

In their work with bakeries, the Kaak specialists observed some challenges with cleaning sheeting lines, feedback they brought to the drawing board and helped design a new technology update that particularly targets one of the most difficult points to clean: the dough hopper and chunker system. Since it is placed high up above the sheeting line, it is harder to access for thorough cleaning and maintenance. Kaak researched ways to improve access and make it easier for people to clean the equipment. The solution the Dutch specialist perfected and is now launching is an ‘Easy Access Portioner’, which, as its name describes, enables faster and easier access to the portioner, without having to resort to any manual effort. Rens van Heesch, Product Sales Manager, Royal Kaak, explains why an automated solution made the most sense: “When parts are manually dismantled from production lines in industrial bakeries, there is always the risk that some are overlooked when placed back onto the line after cleaning, or they can get damaged, resulting in significant time loss. It takes longer to resume production if the reassembly is not carried out correctly. Besides, time is saved

for the sanitation process itself and production can resume faster afterwards.”

The Easy Access Portioner eliminates these issues, and the need to have many people assigned to lengthy cleaning tasks – another aspect the designers incorporated, taking into consideration staff shortages in addition to process convenience. To accomplish this, the designers mounted the portioner on a frame, creating a tailor-made lift.

For any maintenance and cleaning operation, the operator only needs to press and hold a button, and the hopper and chunker will automatically slide down the support system where it is hoisted, from above the line where it is positioned while running, to a vertical position parallel to the line, with slow, controlled movement. The space is calculated for comfortable access all around the portioning system when it is lowered. “This is a very good alternative for cleaning, because it makes the hopper and the chunker knives easily accessible from either side of the hopper, for thorough sanitation,” the specialist explains. The operator can easily go around the system, while it is vertically aligned and safely locked in place at shoulder height, for ergonomical and comfortable access from each side.

Additionally, the tilting movement improves accessibility for cleaning, not only for the hopper and chunker, but also for the underlying infeed of the sheeting line, which further enhances hygiene standards, reduces cleaning time, and lowers cleaning costs.

The space required on the side of the sheeting line for the support structure and the portioner, calculating ample room to go around the hopper when brought down, is around 2 sqm (21.5 sq ft), so the line’s overall footprint remains compact. Automating the portioner movement for easy access ensures downtime is minimized.

For maintenance, the chunker knives can be taken off for repairs/replacement in case of any damage, but they do not need to be removed for cleaning.

Automated movement

The conveying system moving the portioner up and down is essential to this automated solution. Although they handle the heavy load of the hopper and chunker, the timing belts that support the controlled movement match, at least, the lifespan of other timing belts normally used in a production line. They can even outlast them, since the tilting mechanism has a limited speed and low acceleration/deceleration speed sequences.

Moreover, “The number of tilting/releasing cycles of the Easy Access Portioner is quite small compared to other timing belt applications,” the specialist notes.

© Roayl Kaak

For guaranteed safety, the motorized tilting system keeps all the components mechanically and electrically connected to the line, the specialist underlines. Sensors are in place to control the movement of the hopper, the mechanical stop when lowered, and the correct alignment when brought up to start operating. “It's very important that the dough chunks are released from the portioner in the middle of the sheeting line. This is why we have a detection sensor checking the alignment and giving the system the green light to run,” van Heesch explains.

”The Easy Access Portioner is improving cleaning and hygiene standards, because it makes the hopper and chunker knives easily accessible from either side of the hopper, for thorough sanitation and maintenance.“

Rens van Heesch, Product Sales Manager, Royal Kaak

While improving access, hygiene standards, cleaning speed and safety, this elevator system also eliminates the need for staff training, and the risks involved in climbing to reach the equipment. During commissioning, Kaak provides training on how to clean the machine, as well as service. Cleaning routines depend on the dough’s characteristics –the more liquid the dough, the more frequently it should be scheduled.

While cleaning processes may vary according to the cleaning materials chosen and their usage instructions, as well as water use, the entire DrieM sheeting line can be washed down with water. “This all is, of course, according to the CE standards in Europe, to which we have some additional mechanical safeguards implemented as well, for the Easy Access Portioner,” van Heesch highlights.

Officially launched at the end of November 2024, the first Easy Access Portioner has already been installed and

DrieM sheeting line factsheet

+ Single-operator production line, through automation features

+ Complete process visibility for the operator

+ Capacities from 1,000 kg to 10,000 kg per hour. Higher capacities are possible for custom setups.

+ Industrial solutions available for bread and pizza production

+ Stress-free dough processing by eliminating falling heights for the dough sheet

+ Processing doughs with liquid ingredients percentage up to 92%

+ Provides several options for make-up processes for all types of products

+ Modular standard design, which can be custom-made and can be expanded at a later time

+ Unique cross-controller design

+ Optimizing dough sheet by minimizing rework and level measurement

recently started running in bakeries, and more companies have already placed their orders for the automated hopper and chunker. It is suitable for industrial operations, meaning sheeting lines with production volumes ranging from 1,000 kg to 12,000 kg per hour. The solution comes with new sheeting lines and it can also be retrofitted onto existing DrieM lines by replacing the current dough portioner with the new system – taking into consideration the floor space for the frame and access around it. “We will set up a plan on how we can disassemble and install the new equipment together with the customer, on a case-by-case basis,” the specialist says.

And, speaking of new developments, the Kaak Technology Center is soon having new equipment installed, for an even wider range of bread and pizza production lines. More information soon! +++

The entire DrieM sheeting line can be washed down with water

Roayl Kaak

Efficiency, transparency, flexibility – this is more essential than ever. IT will be the key to meeting your challenges. ERP, MES, subsidiary management, or intelligent planning software: the CSB-System is the comprehensive solution for bakeries. It enables you to optimize your production processes immediately, laying the foundation for the future digitization of your entire plant.

Find out more about our solutions for bakeries: www.csb.com

Reliability is earned

Spiral cooling and freezing systems have an unmatched capability to save space. For process consistency, they must also ensure even temperature distribution, and an uninterrupted conveying movement for minimum downtimes, while being easy to clean and maintain. Energy efficiency and scalability features are also important checkboxes for a reliable piece of equipment.

+Several types of cooling and conveying systems can be adopted, to automate controlled-temperature processes – from proofing to cooling and freezing. To maintain or even improve the quality of the products, in increasingly faster production setups, customization is key to ensuring process optimization. This is especially true in industrial bakeries. For AMF Bakery Systems the reliability of the line is crucial to every project, big or small, so the design and technology offered need to be simple, robust, yet highly customizable.

Looking at the big picture of a production setup and then ‘zooming in’ to the spiral solution helps to evaluate the cooling process needs in the context of the entire line, in terms of timings, volumes, speeds and space required. The flow of the line and the placement of equipment within a facility are critical considerations. To meet these requirements, AMF designs highly customizable solutions in terms of configuration and size. “We assess the flow of products entering and exiting our systems to ensure consistent handling. This approach not only reduces downtime for our solutions but also for downstream equipment. The precision in spiral manufacturing and the quality of product transfers,

tailored to the shape of each item, ensure proper alignment throughout the line, for enhanced productivity,” AMF specialists explain.

Smart systems

The AMF Spirals are highly automated to ensure continuous operation during production without the need for operator supervision. This system also ensures that the spirals continue to operate for as long as possible during downstream stoppages. Incoming products are monitored and the progress is displayed on the HMI, allowing for real-time tracking as they travel through the spiral. In addition to monitoring the products passing on the conveyors, the take-up motor output torque is being constantly monitored. “Through finetuning calculations, the motor’s speed is regulated to follow the main drum and keep the belt tension as low as possible, yet always tightly engaged to the drum. Special routines may apply with our spiral freezers to allow safe operations when the spirals encounter ice buildups,” AMF explains.

Various sensors—including those for vibration, temperature, humidity, and motor parameters from the variable

frequency drives (VFDs) – provide comprehensive insights into the operating conditions of the spirals. This data facilitates preventive maintenance and enhances quality control efforts.

Vesta spirals can combine technology creatively in setups for cooling and freezing configurations to minimize floor space while making full use of available ceiling height. AMF specialists illustrate: “We have, over the years, designed unique concepts to accommodate building restrictions or process requirements. From sizes that fit in a home garage to very large diameters and tall spirals containing thousands of meters of belt, we can connect many spirals together, even at odd angles, to avoid building obstacles.”

Optimizing the belt width with engineered feeding conveyors can also save considerable floor space (e.g., double pass spirals, or custom configurations that feed products into the spiral at different heights, or on the turning belt).

Spiral systems quite literally revolve around the conveying belts, so the adequate type and belt material for specific needs should be identified for each bakery, according to its product needs. Considering that they often come into direct contact with the products, which may, sometimes, be sticky, determines how this major component of a spiral system should look. AMF developed an extensive array of belt choices that can be incorporated in a spiral cooler/ freezer: “Most of our features and options are available with every belt, allowing customers to freely choose, based on their preferences,” its specialists say.

Process controls: spiral proofing and cooling

The path to customizing and design ing a technology concept is found together with the bakery. The condi tions that need to be met for the targeted product quality deter mine custom builds. This means the exact temperature and hu midity desired must be reached and maintained, regardless of daily or seasonal weather.

“For Vesta Spirals, this primar ily involves determining the optimal duration for the product to remain in an environment that maintains consistent temperature, hu midity, and airflow,” the specialist illustrates. AMF Vesta’s spirals are opti mized to meet any trav eling time required, so

that the product can rest while traveling through the spiral as long as it needs, while matching the production rates.

The humidity of the spiral proofer is mainly controlled through a gentle stream of steam added to the circulating air. Ventilation ducts will distribute the warm and humid air along the entire length of the enclosure. All ducts are stainless steel, with a slopped top and accessible for sanitation.

To ensure the desired cooling/humidity effect throughout the product’s time in the spiral cooler, AMF focuses on configuring the space to position fans and cooling coils in a way that provides optimal airflow around the products. Specific solutions are tailored to each design if needed, including the controlled intake of fresh air to effectively balance humidity levels, the specialist explains.

Spiral freezing

The Vesta Spiral Freezer uses the Blast Freezing System, with an enclosure designed to sustain the required airflow without blasting air directly onto the products, which would cause unwanted displacements. “Deep-freezing products often require heavy air movement. The enclosure subdivision, the fan and coil positions are a key feature in accomplishing a gentle yet rapid freeze, with a uniform and continuous airflow around each product,” the specialists highlight. It features an automatic defrost-while-running sequence. The defrost time may vary from one system to another, but the sequence is always planned so that one coil can defrost, dry and spring back into operation before another one can

all pictures

© AMF

Bakery Systems

initiate its own defrost cycle, with no influence over the system’s overall freezing capacity. “Cascading from one coil to another results in the uninterrupted operation of the Blast Freezer,” AMF notes.

Choosing the right refrigerant solution can also be flexibly selected: AMF can accommodate any commonly used refrigerants in the industry. Every system is analyzed with care, considering existing installations but also the cost and advantages of a new system. It is an integration challenge that is solved together with each manufacturer.

Sanitation and hygiene: built-in

Operating the machine is another important consideration. This is why the ease of maintenance and cleanability are crucial factors in the design of spiral systems. AMF spirals can be fitted with various access platforms to facilitate reaching the top conveyor or accessing the center drum. Additionally, “We provide automatically controlled oilers that activate only when necessary, minimizing usage and eliminating the need for manual intervention. Our programmable wash cycle, complete with a dedicated belt washer, enables effective cleaning of the product contact surfaces with minimal manual effort,” AMF specialists explain.

The Vesta spirals are designed to prioritize sanitation: the spiral structure itself is primarily built with open-frame components, preventing dirt accumulation and bacterial growth. This design allows for easy access and cleaning while ensuring that water does not collect. In addition, the patented cages are designed with single bars rather than having caps over a support beam, to further minimize areas where bacteria could build up. “Our mono-piece cage bar design was developed to achieve exceptional cleanability. While traditional designs typically use plastic

”Deep-freezing products often require heavy air movement. The enclosure subdivision, the fan and coil positions are key features in accomplishing a gentle yet rapid freeze, with a uniform and continuous airflow around each product.“

AMF Bakery Systems specialists

caps over a metal support beam, AMF has innovatively created a single-piece component that functions equivalently to caps, while being significantly more sanitary. Given that access to the cage bars is often restricted and in close proximity to the product, ensuring high sanitation standards is even more critical,” the technology developers explain.

The belt washer-and-dryer system also optimizes hygiene by integrating high-pressure water nozzles that cover the whole width of the belt, top and bottom. AMF explains how cleaning is carried out with minimum hassle: “Top and bottom air knives, which can also be easily opened and deep cleaned, will keep water drips coming out of the washer to a minimum. An easily programmable wash cycle can predetermine how many passes in the washer are required – often, one is enough – to meet higher cleaning standards.” Each spiral has its own wash box, so no installation is required to do the cleaning; all the preparation required is connecting the provided hoses from the pump and blower unit.

Continued consistency

Determining the right setup of the spiral system guarantees it will operate reliably and with optimum efficiency, for the exact product recipes, at the exact production volume and speed. The ease of use and of maintaining them are also optimized with new improvements, to meet the highest hygiene standards with the shortest possible time off from production. The prerequisites are met, for round-the-clock production. +++

The medium is the message

Automating packaging and coding not only streamlines the process but also checks all of the boxes – efficiency and transparency, material traceability and sustainability.

+Labor challenges have led Europe to be a step ahead in automating the packaging process according to Kwik Lok. Still, there is room for expansion in automation in Europe and beyond, especially since it encompasses proudly diverse markets.

Some traditional bakeries, for example, are still finding their footing in scaling the automation of their operations, packaging included.

In addition to eliminating the need for manual labor, automation also benefits predictive maintenance planning. Bakeries looking to improve their packaging practices are adopting fully automated packaging lines for their speed, convenience and efficiency. To optimize this step that truly adds the finishing touch to bakery products, the workflow throughout the process chain must work well. Packaging solutions such as those provided by Kwik Lok bring important benefits to the end of the manufacturing process, including cost-effectiveness, consistency, speed, versatility and ensuring food safety compliance. The bottom line: automating processes contributes to fewer line stops and shorter downtimes when they do occur (or are scheduled).

Moreover, it helps ensure that people with the skills to handle required, planned operations are immediately available, since these are known in advance.

The task and the solution

Packaging is more than bags filled per minute and per day: “To find the best automated setup, understanding where the customer’s output is today and where they want to go in the future is key,” explains Blair Chastain, Chief Revenue Officer, Kwik Lok. “Our staff will work with customers to understand their current needs and make a plan for the future which includes a cost-effective and scalable approach to equipment and automation integration,” he adds.

Targeted solutions for semi-automated or high-volume, completely autonomous operations are available, each being mindful of footprint limitations and surrounding machinery. A bakery targeting expansion can start with semi-automated packaging systems, which can be later upgraded to higher volumes and additional features, Chastain illustrates. In this scenario, the space the system occupies requires (today and in the future) careful consideration, and is optimized by Kwik Lok engineers.

Packaging and coding

Changing operation needs is one aspect that determines packaging setups. The contents of the message on the packaging are another, as they complete the identity of the product itself. As needs and preferences for the information displayed on bags evolve, adjustments to the overall packaging process follow. Traditionally used Universal Product Codes (UPC) come pre-printed on the bags before packaging, to which the batch code is added. This is where variables can impact the results of the printing process on the bag: the shape of the product itself, the environment in bakeries and variations in temperature or humidity, for example.

Kwik Lok has created a new solution to bypass these challenges: closure labels including data resources such as 2D bar codes, which can now be printed in-line as a step in the packaging process, for large-volume production setups, and with semi-automated systems for mid-sized/ smaller operations. Taking pre-printed bags out of the equation is more const-efficient, ensuring there are no leftover items with outdated messages.

The codes not only ensure the necessary information regarding the product is always available, but also provide new communication opportunities, in a simple yet effective way. Chastain explains: “We like to always emphasize to our customers how important it is to print on a flat surface. In cases where it isn’t possible, that's where Kwik Lok comes in. With our closure labels and our closures, we have an opportunity to print directly on a flat surface, to consistently deliver the necessary information onto the product.” Whether on the closure itself or on a closure label, a code that can lead to a generous amount of data can be easily added to the product.

Through these codes, the product’s complete history can be included in the information delivered to the consumer, down to tracking all the ingredients going into it, for complete traceability. In this way, transparency requirements for the manufacturer can be met, as well as people’s need to learn about the product. For packaged goods that need to

include the EU’s Digital Product Passport – a new initiative meant to advance sustainability and transparency, this solution is in the right place, at the right time. Implementing the code application is straightforward, with instant benefits. Kwik Lok can print that 2D barcode in-line to narrow down lot-level traceability to the item level – invaluable in mitigating product recalls, and damage to the brand’s image, for instance.

Label enters production

Fully automated packaging options mean that, instead of five people assigned to carry out manual operations, only one or two are needed, freeing up valuable hands for other operations upstream. The ‘all-inclusive’ systems provide, via a PLC, options for efficient packaging steps and predictive maintenance insights. The company’s automated equipment is label-ready, applying closures and labels on a single machine. Older models that might not offer this features can be upgraded to include it. A printer can also be added to the system, next to the closing machine, if one wasn’t in place already.

For the label, “We currently have a polypropylene-based option that uses less water, less CO 2, and a lot less plastic – for the closure and the label,” Kwik Lok’s specialist highlights. The label itself can also be ultrasonically added, meaning no adhesives are involved, making it great for recycling where allowed. For a complete communication message, the label can contain information about how to best recycle it and the closure, too, with targeted instructions to match the requirements and infrastructure in each country.

The integrity of the labels is ensured throughout their journey, from the factory to the shelf, from the store to the fridge,

”We like to always emphasize to our customers how important it is to print on a flat surface. In cases where it isn’t possible, that's where Kwik Lok comes in. With our closure labels and our closures, we have an opportunity to print directly on a flat surface, to consistently deliver the necessary information onto the product.“

Blair Chastain, Chief Revenue Officer, Kwik Lok

and until the product is consumed. Billions of them are manufactured by Kwik Lok every year and are delivered on reels, ready to be applied with the machines.

The ink used to print the codes is also carefully considered: “Our printer uses a thermal inkjet currently, to make sure that it works well in environments typically found in bakeries,” says Chastain. “As a part of our R&D process, we are looking into more sustainable inks we can offer,” he adds, which can align with sustainability initiatives while remaining cost-effective. These goals are shared by all Kwik Lok developments, from machines to tracing and tracking tools, and material science advances.

A code that’s worth a thousand words

The closure’s mission starts by protecting the product’s integrity and includes compliance data; a new opportunity is now added, by including brand messages and transforming it into a communication tool via the 2D code. It has “the ability to speak to the consumer in the store, on the way home and it can continue to engage with them every time the product is opened and closed. This is very unique to our label,” Chastain underlines, adding in this way a new dimension to product branding. Labels are a compelling vehicle for consumers to engage with brands, putting a digital spin on a traditional marketing concept, which ultimately elevates sales, Kwik Lok observes.

The closure-and-code pair is starting to be adopted across industries, and food items can certainly benefit, too, from ability to connect with the consumer digitally more than via the well-traveled roads of communication that are usually taken. It is the perfect solution to the Digital Product Passport requirements in Europe, for example. The information, which can include nutritional information, ingredient sources and special offers or promotion announcements, is not intrusively offered and the call to action is welcomed, since

The EU Digital Product Passport

Starting in 2024, the European Union implemented a new regulation requiring nearly all products sold in the EU to feature a Digital Product Passport (DPP), to advance transparency and sustainability. This initiative is part of the Ecodesign for Sustainable Products Regulation and aims to provide comprehensive information about each product’s origin, materials, environmental impact and disposal recommendations. The DPP is designed to close the gap between consumer demands for transparency and the current lack of reliable product data. The DPP will include essential details such as a unique product identifier, compliance documentation, and information on substances of concern. It will also provide user manuals, safety instructions and guidance on product disposal, according to the announcement made in September. “By offering a detailed

it’s a piece of information that has been actively requested by accessing the code. Kwik Lok notes that engagement rates can be 10 times higher than any other channel, which is a powerful tool for a very cost-effective label. And, as with all digital information, the content shared can easily be updated. Moreover, its performance can be tracked –for real-time monitoring of the effectiveness of the message. When campaign changes are made, visible results are

digital record of a product’s lifecycle, the DPP will enhance supply chain management, ensure regulatory compliance, and help companies identify and mitigate risks related to authenticity and environmental impact,” it said.

By making detailed product information publicly available, the DPP supports open data initiatives that emphasize transparency and accessibility. The EU anticipates this approach will improve product visibility and sustainability practices. At the same time, it will facilitate better data sharing and collaboration across the industry.

The EU moves toward full adoption of this new regulation, to enhance both the visibility and integrity of product information via the DPP, benefiting companies, consumers and the environment.

available to assess their impact, since analytics reports of the data usage are generated.

Complete solutions

In its work to provide the most suitable solution, the Americanbased company partners with different suppliers that can offer platforms for digital data management, as well as their seamless integration. The interface is easy to implement, utilize and maintain, when building and updating data to be shared. “We have dedicated engineering staff to make sure that all the different bakeries worldwide receive the solution matching their bagging preferences, taking into consideration the specifications of the bag manufacturers of their choice for consistent packaging results,” Chastain explains how packaging equipment is engineered, with corresponding coding features, for the desired materials.

Kwik Lok is also working with partners to ensure data management and safety, with no exceptions. Additional ideas on how to creatively use this kind of data are also developed through these partnerships, for a new spark of excitement in communication with the consumer.

To be continued

“Using a label as a marketing piece might be still in its infancy, but that is the future, and the amount of interest that we have in there already proves that,” Chastain summarizes the exciting new opportunity. As always, upgrades are built on perfect compatibility between all elements involved, packaging machine, label material and production flow.

It allows brands to experiment with what can have the highest impact, in their messages. Achieving this level of transparency in communication builds trust; with it, comes the willingness to pay attention to the product’s messages.

“We know how powerful a pretty simple interface can be, with just a coupon, a promotion or a sweepstake,” Chastain underlines. The window for creativity (and earnings) is wide-open, now with a digital interface for content management. And the time is now, as post-pandemic consumers have acquired the habit of scanning codes and researching items, starting with food products, for how they impact their health and safety, their sustainability positioning, and to verify that the brands they associate with validate their values. +++

Information is power

In the world of industrial baking, maintaining line efficiency and ensuring the longevity of bakeware and their coatings are paramount to delivering high-quality products consistently. American Pan’s SMART Pan Tracking ® System helps protect the product and the pan, with actionable information.

+ The key to efficiently achieving great products on an industrial line includes using good quality coatings and pans that are optimized for the product and the production line, material, size and configuration. A comprehensive tracking system ties together all these aspects, to optimize the bakeware use, the system’s operation and the final results.

American Pan developed a SMART Pan Tracking ® System providing data monitoring and insights concerning both the coating status and the line efficiency. “The pan tracking system is designed to provide actionable insights into these critical areas, ensuring streamlined operations and proactive maintenance,” states Jason Bowman, President of American Pan Europe & MENA.

”At American Pan, we are committed to delivering solutions that empower our customers to achieve greater efficiency and sustainability in their operations. The SMART Pan Tracking ® System reflects that commitment, combining advanced technology with practical insights to help bakeries reduce downtime, improve quality, and stay ahead in a competitive industry. “

Jason Bowman, President of American Pan Europe & MENA

The SMART Pan Tracking ® System is built around a straightforward record-collection framework, gathering the information necessary to continuously adjust operations for efficiency. Namely, it is gathering the following records:

1. Scanning time – The exact time each pan is scanned on the line.

2. Barcode identification – Unique barcodes on each pan for precise tracking.

The records are then analyzed to compile insights based on the measurements. These reports can immediately be used by operators to optimize coating usage, identify trends, and predict maintenance needs, ultimately reducing costs and downtime.

Smart installation, smart tracking

Incorporating the SMART Pan Tracking ® System into a production plant is a straightforward implementation. The system comprises a processing unit that can have up to three cameras, depending on the pan type and operation scale. This adaptable setup is designed to accommodate a wide variety of pan designs and baking operations. “Whether a facility manages a high- or low-volume production line, the system’s flexible installation ensures it meets diverse operational needs,” American Pan notes.

Real-time alerts: proactive maintenance and quality control

To help bakeries stay ahead of potential issues, the system can be set to issue customizable alerts. They can include: + High coating usage: Signals when the coating begins to show signs of wearing down.

+ Low read alerts: Indicates difficulties in reading barcodes, often caused by debris or wear.

+ Predictive Recoating Alerts: Notifies users when coating on pans is nearing end of life based on cycle counts and current usage rate.

The preset values for alerts can vary by coating type and bakeware, ensuring precise monitoring tailored to specific operations.

The system evaluates operation efficiency and predictive maintenance through indicators – coating stock usage and historical data trends. “Uneven usage or residue buildup can signal the need for maintenance. By leveraging these insights, operators can establish maintenance schedules, minimizing downtime and preserving product quality,” American Pan explains.

Flexibility in access and records display

The SMART Pan Tracking ® System is designed to provide system records as needed. To ensure data safety and convenience in accessing it, the information is available via a secure cloud login, which also makes it accessible from any location, regardless of the proximity to the line itself, or the facility. “Registered users can access an overview map of multiple facilities, with the ability to drill down into specific pans, production lines, or trends,” an American Pan specialist explains.

The system can automatically identify new pans when they are introduced into production without requiring an initial registration process. It adjusts its tracking parameters and compiles insights based on production volumes and types. “This adaptability allows the system to grow alongside production needs, providing comprehensive tracking across diverse operations,” American Pan specialist highlight.

Further enhancing its utilization flexibility, the SMART Pan Tracking ® System is compatible with a wide range of baking operations and types of pans (leveraging the manufacturer’s pan manufacturing know-how), by using standard Matrix barcodes. The system adjusts to various sizes, shapes, and coating types; in this way, the need for extensive customization is virtually eliminated. Moreover, the system can be incorporated into production lines of widely different capacities, for the same benefits in tracking efficiency and cost savings.

In time, as production volumes increase or new pan types are introduced, the SMART Pan Tracking® System also scales up, together with the operation: “A one-time configuration enables the system to recognize and optimize tracking for new types of pans, ensuring smooth integration and

The SMART Pan Tracking ® System

+ Provides detailed information on cycles/bakes, pan gaps, coating life, and theoretical yield

+ An intuitive dashboard displays data in charts, graphs and analytics

+ Is compatible with any operation and type of pan

+ Is mobile device-friendly

+ Can be used to provide a complete view of multiple pan sets, production sites and bakeries

+ Issues useful alerts and notifications when actions are (soon) required

continued efficiency,” the specialist illustrates. Together with bakers, American Pan designs tailored versions of the SMART Pan Tracking ® System, to fit their unique needs. Some challenges, however, are shared by all operations, such as barcode maintenance, for instance. Over time, barcodes may become scratched or dirty, which interferes with the machine’s ability to read properly. American Pan can provide expert advice: “Our team provides guidance on optimal barcode placement and maintenance techniques, ensuring reliable tracking and long-term usability.”

Tracking and more

When quality control and/or automation need to be heightened even more, the system can also come with optional features such as automatic pan rejection. This functionality ensures that pans failing to meet specified criteria are removed from the line, reducing human error and maintaining consistent product quality. Single and dual tags can also be implemented, to optimize the performance of various conveyor configurations. Data from multiple lines can be used, through an IoT unit, for even more insights and added control options.

All its features make the American Pan SMART Pan Tracking® System benefits extend beyond those of a simple tracking tool. “It’s a comprehensive solution for enhancing efficiency, maintaining coating quality, and enabling proactive maintenance. By integrating advanced monitoring and flexible features, this system empowers baking facilities to optimize operations, reduce downtime, and uphold the highest quality standards,” its manufacturer explains.

Data precision and smart use lead to measurable results improvements and welcome savings, proving that information is an extremely powerful tool in bakeries.

RBS SCIENCE AND INNOVATION CENTER

Better snacks: science and creativity

Providing excellent-tasting products is a must, but the eating experience is only one of the goals for successful snacks. The challenge lies in balancing health benefits, clean-label compliance, and manufacturing efficiency – all while meeting consumer expectations.

+ The challenges of clean-label snack development

Developing clean-label snacks is not a simple NPD project. Several challenges stand between a concept and a successful product. Clean-label recipes avoid artificial additives, preservatives, yet they must still deliver the desired shelf life, texture, and flavor. Achieving these qualities naturally requires innovative solutions and attention to market-specific certification requirements.

Sourcing natural ingredients adds another layer of complexity. Consistent ingredient availability and costs must be factored in, alongside consumer demands for affordability and great taste. Natural ingredients also behave differently than conventional materials during large-scale production. This calls for adjustments in equipment, processes, and formulations to ensure efficient manufacturing.

RBS’s

Science and Innovation Center: a hub for testing and development

At the RBS Science and Innovation Center in Sinking Spring, Pennsylvania, manufacturers can test and refine their products using advanced processing technologies. Complete production lines for baked snacks, crackers, biscuits,

”Our equipment features touchscreen controls for instant adjustments to speed, temperature, and airflow, allowing us to observe changes in the product within minutes. This real-time control is invaluable for fine-tuning product characteristics during trial runs.“

cookies, as well as batch and continuous mixing systems are available to optimize clean-label snack production.

Collaborative innovation

RBS specialists work with manufacturers from concept development to sensory testing of final products. “Clearly defining the goals for each ‘better-for-you’ concept is critical,” explains Cameron Johnston, Sr., Director of Innovation at RBS. “Whether it’s reducing sugar, sodium, or calories, or focusing on non-GMO and clean-label claims, each project is tailored to its target market.”

Cameron Johnston, Sr., Director of Innovation, RBS

RBS observes growing demand for baked alternatives to fried snacks, supporting claims such as ‘Baked, not fried.‘ For instance, international markets often prioritize non-GMO ingredients, while school-focused products lean toward natural sweeteners like fruit-derived sugars to meet ‘no added sugar‘ claims.

The development process begins with an ideation phase, where project goals are clarified. From there, the plan takes shape, incorporating cost analysis, trial phases, and adjustments for production challenges. Ingredient selection and equipment compatibility are carefully evaluated to ensure smooth production.

“Selecting certain ingredients can introduce processing challenges, such as stickiness or fragility in dough. Each piece of process equipment has unique features that address these issues, so we pay careful attention to conveyance, dough handling, and contact surfaces to ensure smooth production. These considerations guide the equipment setup and adjustments needed for a successful trial,” the Center’s Innovation Director explains.

No two development projects are the same; those involving formulation testing, production cost analysis, and market strategy planning can take up to one year to complete. “Once a recipe is developed that performs well on the process equipment, meets nutritional claims, and aligns with marketing objectives, we often move to produce a sample batch for test panel evaluations. These evaluations are essential for gauging the product's market potential and fine-tuning its appeal for a specific market,” Johnston highlights.

The testing process

Product development typically begins with small-scale trials to understand dough functionality. Once promising formulations are identified, they are tested and refined at the Science and Innovation Center. Adjustments to ingredients, water content, and processing parameters are made to optimize dough processability, flavor, and texture.

Trial runs monitor key metrics such as moisture levels, oven settings, and water activity. Real-time adjustments, enabled by touchscreen controls, allow for immediate fine-tuning during production trials.

“Instant control of speed, temperature, and airflow during trials is invaluable,” Johnston explains. “It lets us refine product characteristics on the spot.”

From pilot to full-scale production

Once a recipe is perfected, the transition to full-scale production begins. RBS uses the Scorpion ® Profiling System to gather all of the baking parameters. This makes it easy to replicate pilot oven profiles to the production system at commissioning. This ensures consistency in product quality and production efficiency.

“The Scorpion ® Oven Profiling System allows us to precisely match the pilot oven profile, ensuring a seamless transition to large-scale manufacturing,” says Johnston.

Successful südback 2024 concludes

The journey to creating clean-label snacks is a team effort. With RBS’s expertise and state-of-the-art facilities, snack manufacturers can develop innovative products that meet today’s consumer demands while maintaining production efficiency and profitability. +++

The 30th edition of südback welcomed 560 exhibitors, from established market leaders through to start-ups, from October 26 to 29, 2024. New ideas in working and operating technology, raw materials, sales promotion, services and other areas of interest to bakers were showcased. Close to 35,000 trade visitors attended, from Germany and beyond.

The focal point of südback 2024 was the joint development of the bakery and confectionery trades, reflected through live demonstrations, workshops and practical discussion panels. Visitors were able to experience new products and trends firsthand. Topics such as artificial intelligence, sustainable production processes and the recruitment of skilled workers through social media came under the spotlight during the Bakers’ Trend Forum. Practical live demonstrations and talks provided fresh impetus for the industry. “We want to do more than just keep the bakery profession going, we want to drive innovation and ensure its longevity,” emphasized Stefan Körber, Managing Director of the Southwest German Association of Bakers' Guilds. Andreas Wiesinger, Vice President of Messe Stuttgart, noted the sheer enthusiasm of the participants was evident: “südback is driving the success of the bakery trade, taking a variety of approaches to create a unique, informal atmosphere in which inspiration and exchange flourish. The trade fair proved this once again during the last four days.” +++

© Messe Stuttgart

Bundy Baking Solutions celebrates

60th anniversary

Bundy Baking Solutions celebrates 60 years in the industry, providing bakeware, coatings, and related services. Significant milestones in the company’s development include the launch of Pan Glo® in 1975, the founding of American Pan ® in 1985, the purchase of Chicago Metallic in 2005, and the introduction of Synova in 2019.

In addition, partnerships with global companies such as Cainco in Brazil (2014) and Turbelco in Turkey (2023), plus the acquisitions of Lockwood Manufacturing in Canada (2012), Cleanbake in the UK (2015), FBS Prestige in Romania (2017), and Runex in Scandinavia (2021), have expanded Bundy’s global reach to South America, Europe, and the MENA region.

“Celebrating 60 years is a testament to the dedication of our employees, the trust of our customers, and the strength of our partnerships,” said Gil Bundy, CEO of Bundy Baking Solutions. “As we honor our history, we remain focused on the future – continuing to innovate and provide unparalleled service to the baking industry.”

Hansaloy promotes Allen Wright to president

Management changes for backaldrin

backaldrin is expanding its management team from January 1, 2025, with the appointment of Martin Mayr and Wolfgang Mayer to the management board. With this move, the company strengthened its leadership, ensuring the transfer of central areas of responsibility.

Harald Deller, long-standing managing director, will step into the role of general director in January 2025. “Together with the extended management team, we will drive the company’s strategic development forward.”

“After 60 successful years, I am happy to say we have never been as well positioned as we are now,” said Kornspitz inventor and backaldrin owner, Peter Augendopler Sr. +++

Hansaloy announced Allen Wright is its new president. He was previously VP of sales and manufacturing and has been working at Hansaloy for 30 years. Wright is also vice chair of the IBIE 2025 committee. The company’s previous president of 15 years, Kim Brenner, takes on the role of executive director.

“Hansaloy has been providing bread and bun slicing blades and other products for 91 years from its Davenport, Iowa, location. We view strong, steady leadership as integral to serving that mission. To that end, Mr. Wright becomes the third president of Hansaloy in the past 34 years,” Brenner adds. +++

Middleby acquires Gorreri Food Processing Technology

The Middleby Corporation is acquiring Gorreri Food Processing Technology, a manufacturer of baking machinery for products such as cakes, pies, muffins, tarts and desserts. Gorreri is headquartered in Parma, Italy, where it runs a stateof-the-art, 50,000-square-foot facility, which was recently expanded. Gorreri has revenues of USD 20 million annually. “Gorreri is a highly respected brand recognized worldwide for premium-quality advanced industrial and semi-industrial baked goods solutions. This acquisition adds a broad line of complementary products to our food processing group, including turbo mixers, dosing, injecting, decorating, enrobing and ultrasonic portioning solutions. The Gorreri innovative end-toend solutions extend and significantly strengthen the current Middleby offerings as a leader in the cake and dessert categories, with meaningful growth synergies,” said Tim FitzGerald, Middleby CEO. +++

Bundy Baking Solutions

Gil Bundy, CEO, Bundy Baking Solutions

(left to right) Wolfgang Mayer, Harald Deller and Martin Mayr ©

backaldrin/Antje Wolm

Hansaloy

A clear approach for a complex issue

Sustainable packaging in the bakery sector lies at the intersection between EU regulations and industry commitments.

By Fedima

+In the food sector, packaging has both environmental and food safety implications. Fedima, as the voice of European manufacturers and suppliers of ingredients to the bakery and pastry industries, has identified sustainable packaging as one of the key priorities for a sector that strives to transition to greener practices.

The environmental challenges posed by the growing proliferation of plastics and their hazardous presence in nature are among the main reasons that prompted the European Union to intervene with rules to reverse this trend. The year 2024 has been pivotal in the EU packaging regulatory landscape, with the shift from the EU Packaging Directive to the new Packaging and Packaging Waste Regulation (PPWR). The Regulation introduces stricter, more comprehensive requirements for all businesses, including food businesses, and targets the reduction of unnecessary packaging, the increase of recyclability, and the minimization of single-use plastics.

Fedima’s Sustainability Committee, with its ad-hoc Packaging Taskforce, has made significant efforts to help its members welcome this regulatory scenario and shift to more sustainable packaging. Bakery ingredient manufacturers have already made progress in this transition process. Several Fedima members have been improving their recyclability rates in recent years, a sign of the sector’s eagerness to keep up with EU expectations.

Defining sustainability strategies

However, to best accompany bakery ingredient manufacturers in this process, Fedima advocates for a realistic approach: setting achievable targets and providing incentives to support sustainable practices throughout the industry are key prerogatives in these times of change.

In fact, reaching fully sustainable packaging comes with its share of challenges. For example, varying infrastructures for waste management across EU Member States hinder the uniform application of sustainability practices: in some European countries, advanced systems for waste collection and recycling are already established, while others lack the essential infrastructure.

”The harmonization of recyclability labeling requirements included in the Regulation needs to be further developed, as they are crucial to ensure a unified and effective approach to recyclability.“

It is also crucial to make sure that the body of legislation on packaging sustainability is balanced, carefully integrating environmental goals with the need to maintain food safety. For this reason, Fedima supports the goals of the new PPWR and particularly welcomes those provisions that exempt certain types of flexible packaging in direct contact with food from broad reuse requirements. While promoting the recyclability and reusability of packaging, food and consumer safety must remain a top priority.

Sustainable packaging and EUDR

The EU Deforestation Regulation (EUDR) adds another layer to the sustainability framework for packaging. Fedima supports the Regulation’s aim of fostering sustainable, deforestation-free supply chains but stresses the need for a balanced approach to avoid excessive burdens on

Fedima

businesses. With the European Commission's proposed delayed application date, and the provisional agreement reached by the Council and the European Parliament, the baking industry will focus on continuing preparations, building on the existing guidelines from Brussels. However, further direction and support from the Commission will be needed over the next year, to ensure effective collaboration towards increasingly sustainable value chains.

Achieving sustainable packaging goals in the bakery sector will require the continued development of harmonized rules and effective traceability tools to track progress toward recyclability and reuse targets. Investments in new technologies and consumer incentives will be essential, particularly in European countries lacking adequate infrastructures and regulation, together with support from the European Commission in ensuring that businesses are fully prepared by the time the PPWR takes full effect. Additionally, the harmonization of recyclability labeling requirements included in the Regulation needs to be further developed, as they are crucial to ensure a unified and effective approach to recyclability. Lastly, for our industry to reach good sustainable packaging results that are in line with the EU’s expectations, the entire bakery value chain needs to be activated. Sustainable packaging efforts need to take the front stage in all directions: upstream, among raw materials providers and packaging manufacturers, and downstream, among retailers and consumers. Regardless of which point of the supply chain we look at, the responsibility must be shared across all actors to reach key objectives: implement circular packaging systems, reduce overall waste, and promote environmentally friendly practices.

Looking forward, Fedima will continue to closely monitor relevant legislative developments and support its members in

EUDR: deforestation-free products

The EU introduced Regulation (EU) 2023/1115 to guarantee that the products EU citizens consume do not contribute to deforestation or forest degradation worldwide. It is expected to bring down greenhouse gas emissions and biodiversity loss by promoting the consumption of ‘deforestation-free’ products and reducing the EU’s impact on global deforestation and forest degradation. Under the Regulation, any operator or trader who places these commodities on the EU market, or exports from it, must be able to prove that the products do not originate from recently deforested land or have contributed to forest degradation.

Objectives – The new rules aim to:

+ avoid that the listed products Europeans buy, use and consume contribute to deforestation and forest degradation in the EU and globally

+ reduce carbon emissions caused by EU consumption and production of the relevant commodities by at least 32 million metric tonnes a year

joining the sector’s sustainability commitments, to enhance industry-wide collaboration, and support continuous progress towards sustainable packaging.

Through collaborative efforts, transparent guidelines, and balanced legislation, the bakery ingredients industry can make significant strides in reducing waste and fostering a circular economy that benefits both consumers and the environment. +++

Fedima calls on EU policymakers to:

+ Avoid regulatory overlaps and support the EU’s Design for Recycling criteria by 2030.

+ Develop an EU-harmonized labelling system to not only prevent market fragmentation, but also help consumers correctly sort their waste, simplifying choices and forming an integral part of waste management systems across all EU Member States.

+ Recognize the value of circularity in packaging while maintaining food safety and hygiene standards as a top priority.

Fedima supports the transition to a circular economy at EU level by:

+ Advocating for increased availability of waste collection, sorting, and recycling infrastructure at local level, alongside greater investment in collection and recycling systems.

+ Encouraging its members to adopt packaging reduction measures and achieve recyclability targets, while remaining committed to helping members enhance their data tracking capabilities.

+ Tracking its members progress toward achieving environmentally sustainable packaging.

+ address all deforestation driven by agricultural expansion to produce the commodities in the scope of the regulation, as well as forest degradation

Implementation

The EU continues to work with partner countries and companies to ensure a successful transition to a deforestation-free supply chain. Additional guidance documents were published to support preparations.

In response to concerns raised by EU member states, non-EU countries, traders and operators that they would not be able to fully comply with the rules if applied as of the end of 2024, the Commission proposed postponing the application date of the deforestation regulation by one year. As a result of their provisional agreement, the European Parliament and the Council put forth the new timeline: large operators and traders have to respect the obligations stemming from this regulation as of December 30, 2025, whereas micro- and small enterprises will have until 30 June 2026.

Source: European Commission, European Parliament

Source: Fedima vision paper, ‘Towards Sustainable Packaging in the Bakery Industry’ (December, 2024).

New CEO at Kwik Lok

Eric Hill is the new CEO role of Kwik Lok Corporation, since November 25. He took over from Don Carrell, who assumed leadership in February 2019. In his previous role, Hill was Regional Vice President and General Manager at Graphic Packaging International, a global packaging company with a strong emphasis on renewable, recycled, and recyclable materials. He worked there for 15 years.

“I look forward to joining the Kwik Lok family and ramping up the company’s ability to innovate and grow at the pace required by today’s market. Kwik Lok has a solid foundation as a market leader with a 70-year legacy of customer service, innovation, and growth. I look forward to overseeing the company as it moves forward to meet the challenges of today’s marketplace,” said Hill. +++

Bridor introduces Veganuary creations

Bridor is prepared to meet the ‘Veganuary’ trend with a selection of 100% plant-based pastries and bread specialties. Bridor’s vegan pastry products are prepared with a specially developed margarine with a melting point which is similar to butter. The margarine offers a great texture, a subtle taste and contributes to the finished color. It is used for croissants, chocolate rolls, raspberry croissants with a fruity raspberry filling and pink topping, and Danish Crowns (in cherry & linseed, orange & hazelnut and vanilla flavor & hazelnut variations) – all 100% vegan. In addition to pastries, Bridor also offers vegan bread varieties, including baguettes, bread with rye and lemon, wholemeal bread, Le Pochon, Le Céréalier, and bread with nuts. +++

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