2022
www.foodreview.co.za
Journal for bakery and confectionery professionals
REVIEW
The evolution of the bakery industry
Healthier ingredient options | Stepping up food safety | Sustainable packaging solutions
DIOSNA mixers in hygienic design for excellent dough production with reduced downtimes at fast recipe change.
DIOSNA Innovative Mixing in Hygienic Design
For dough at its best The Wendel Mixer of the Hygienic Design series connects high performance mixing with an open construction to allow easy cleaning, and thus a very fast switch between different recipes. As it is typical for DIOSNA Wendel Mixers the method of gentle processing of the dough by folding allows perfect dough development in shortest possible time, avoiding crushing of seeds and fruits if used in the recipe. The WH240 ”A” model allows fast succession of batches by the easy change of mixing bowls. DIOSNA enjoys worldwide recognition as specialist for dough processing and pre-dough fermentation on a large scale. Machine equipment and biotechnology represent the ideal interaction for best results in food production.
→ → → → →
Ideal for all types of dough, masses and bars Gentle dough and ingredient processing Optimal integration in existing line production Easy cleaning - reduced downtimes Hygienic design mixers with changeable bowl or direct ground discharge
4 EDITORIAL Editor: Tennille Aron +27 (0)73 995 5599 tennille.aron@newmedia.co.za Layout & Design: David Kyslinger
ADVERTISING Sales Executive: Anita Raath +27 (0)82 976 6541 anita.raath@newmedia.co.za Sales Executive: Carla Melless +27 (0)83 260 6060 carla.melless@newmedia.co.za Sales Executive: Candida Giambo-Kruger +27 (0)71 438 1918 candida.giambo-kruger@newmedia.co.za
CIRCULATION Circulation Manager: Felicity Garbers +27 (0)21 701 1566 felicity.garbers@newmedia.co.za
PUBLISHING TEAM General Manager: Dev Naidoo Group Account Director B2B: Johann Gerber Production Controller: Mandy Ackerman Art Director: David Kyslinger JOHANNESBURG OFFICE Ground floor, 272 Pretoria Avenue Randburg, 2194 POSTAL ADDRESS PO Box 784698, Sandton, Johannesburg 2146 Published by New Media, a division of Media24 (Pty) Ltd.
8
News Two novel flour blends New colouring on the market A naturally white colour solution Reducing food wastage in the bakery industry
AD INDEX
Eggless baking solutions
7
10 Solving bakery supply chain challenges 14 Overcoming the challenges of hygiene management 17 The best steel bake oven belt in the business 22 Popular bakery packaging trends 24 Top ingredients for all your bakery needs 28 Choosing the best partner for your bakery business 30 The sweet alternatives to baking with sugar
CO NTENTS 2022
AECI Food & Beverage OBC
www.aecifoodandbeverage.com / aeciworld.com
Arbonia www.arbonia.co.za
Cama Group 23
www.usspactech.co.za / www.camagroup.com
Cereal & Malt IBC
cerealandmalt.com
Chemgrit SA 31
www.chemgritsa.co.za
DIOSNA IFC
www.diosna.com
Ingreto 29
www.ingreto.co.za
IPCO International 21
ipco.com/bake
M-Bake Bakery Equipment 9
www.mbake.co.za
Prac-Pak 5
www.pracpak.com
Savannah Fine Chemicals 25
www.savannah.co.za
SUPREME Flour 13
www.supremeflour.co.za
Synercore Food Holdings 11
www.synercore.co.za
MANAGEMENT TEAM MANAGING DIRECTOR: Aileen Lamb COMMERCIAL DIRECTOR: Maria Tiganis STRATEGY DIRECTOR: Andrew Nunneley CHIEF FINANCIAL OFFICER: Venette Malone HEAD OF HR: Ruth Shogoe CEO: MEDIA24: Ishmet Davidson HEAD OFFICE 8th floor, Media24 Centre, 40 Heerengracht, Cape Town 8001 PO Box 440, Green Point, Cape Town 8051 Tel: +27 (0)21 406 2002 www.newmedia.co.za
Bakery Review is published by New Media Publishing (Pty) Ltd. Views expressed in this journal, other than where specifically stated, are not necessarily those of the publisher. The editor welcomes for publishing consideration news items, press releases, articles and photographs relating to developments in the food and beverage industries. No responsibility is accepted should contributions be lost. Readers are prohibited from using the contact details displayed in any advertisement or editorial within the pages of this publication to generate and/or distribute unsolicited bulk emails or other forms of mass marketing correspondence.
ED ’S N OTE
Fresh baked goodness As consumers search for healthier food and beverage options, the bakery industry have had to adapt their products to these changing needs. This has meant the creation of baked goods that are more nutritious, contain a lower sugar content and that include more functional ingredients. Fortunately, ingredient companies throughout the world are focusing on finding the right ingredients and tools to help the food and beverage manufacturing industry produce baked items that not only taste good, but that
also have an impact on the overall health of the consumer. We explore the latest and greatest ingredients and equipment in the bakery industry in this issue of Bakery Review. Plus, discover the most sustainable packaging options for your products. Read on to find the perfect sugar alternative solution or uncover the freshest ingredients available for your bakery needs. Happy Reading!
Tennille Aron
B A K ER YR E V IE W 2 0 2 2
3
N EWS
New gluten-free and keto-friendly flour blends Ardent Mills, the premier flour-
friendly blends and
milling and ingredient company,
gluten-free blends
announced the launch of its new
provide bakers with
certified gluten-free flour blends
uncompromised
and keto-friendly flour blends. A
formulations
major step for the industry, Ardent
for keto-friendly
Mills’ keto-friendly flour blends
or gluten-free
can be used as a replacement
applications.”
for conventional flour without
The new flour
compromising taste, texture or
blends will only
functionality, while their new gluten-
be available for
free flour blends offer ease of use for
purchase directly
a variety of formats.
through Ardent Mills
“Interest in keto-friendly and
Canada and bakery
gluten-free lifestyles continues to
and foodservice
grow as consumers seek solutions
distributors across
that match their personal health
Canada. “Today,
values and preferences. In fact, Keto
consumers expect
is the fastest growing ‘healthy claim’
food choices
appearing on menus, and 44% of
that align with their individual
thrilled that we can now offer
consumers eat gluten-free at least
diet preferences and these latest
bread and bakery manufacturers,
some of the time, according to Ardent
alternative offerings are a major step
retail and wholesale bakeries,
Mills proprietary research,” said
forward in making that a reality,”
and foodservice and pizza chain
Elaine O’Doherty, Canada marketing
said Buck Vanniejenhuis, Canada
operators a one-stop shop for all their
lead, Ardent Mills. “Our new keto-
general manager, Ardent Mills. “We’re
flour and alternative grain needs.”
New colouring made from organic safflower GNT has expanded its range of EU organic-certified Exberry Coloring Foods with new yellow and green shades made from organic safflower. Exberry Organics Fruit & Veg Yellow is made from organic safflower and organic apple, while Exberry Organics Veg Green is made from organic safflower and organic spirulina. Both are compliant with Organic Regulation (EU) 2018/848. They are also suitable for a wide variety of food and beverage applications including bakery. Based on the principle of colouring food with food, Exberry Organics are created from edible fruit, vegetables, and plants using traditional physical processing methods.
4 B A K ER YR E V IE W 2 0 2 2
1 READ STREET ♦ CNR HARRIS DRIVE ♦ OTTERY ♦ CAPE TOWN ♦ SOUTH AFRICA
Converters of flexible packaging materials and allied products • Polypropylene (BOPP) / Cellophane • Bio-degradable starch based film • 3 side sealed laminated pouches • Stand-up pouches, with or without zipper • Stand-up pouches, with or without spouts
Tel: (021) 704 1135/6/7 | Fax: (021) 704 1210 | Email: pracpak@iafrica.com | www.pracpak.com
N EWS
A naturally white colour solution With the new PearlEdge
rollout meets the evolving
proprietary white colour
needs of customers and
solutions, ADM have created
consumers, as brands look
a fantastic alternative to
for TiO2 replacements that
titanium dioxide (TiO2). The
not only provide a bright white
new line is derived from
shade, but also meet clean-label
natural ingredients, such
targets.”
Buyer’sguide The PearlEdge portfolio is
THE
as native corn starch, and
delivers brilliant, stable and
designed to address different
uniform white colouring for a
applications and performs
variety of food and beverage applications.
“Our team has been diligently working to perfect our
exceptionally well in confection and bakery icings and
fillings as well as sugar-free offerings. 2017/2018 PearlEdge also
new line of white colour solutions, assuring its ground-
delivers elevated sensory appeal as an opacifying base
breaking quality and performance,” said Hélène Moeller,
coat for vibrant colours, and it creates smoother texture in
vice president of global product marketing, ADM. “This
certain applications.
THE
Buyer’sguide
2021/2022 2020/2021
The directory for manufacturers of food, beverages, pharmaceuticals, cosmetics, toiletries, packaging and the printing industry
Available online: www.thebuyersguide.co.za Buyers Guide 2018.indd 1
6
B A K ER YR E V IE W 2 0 2 2
2018/05/07 3:09 PM
N EWS
Reducing food wastage in the bakery industry The need to reduce food waste has never been more
when a producer is looking
important than now especially in the bakery industry that
at the initial investment
accounts for a large amount of food wastage explains Jessica
in reformulation. But by
Cassity in the KerryDigest Blog.
adding just a day or two, you’re
“On average around the world, about a third of the food
significantly increasing the chance
that we produce goes to waste”, says Emma Cahill, managing
that the food will be able to feed people,
director for Food Protection & Preservation. ‘And that hasn’t
and stretching the reach of your supply chain to a new market.
changed over a number of years.
You’re also increasing the likelihood that products will leave the
“Globally, the bakery category has the greatest volume of
supermarket shelf and decreasing the number of costly returns”.
food waste, in terms of finished processed goods,” says Cahill.
But products can also be rejected much earlier in the
“Being able to extend bakery shelf-life could really impact and
supply chain, suggesting a focus on production processes is
reduce waste figures.” Stale bread, bread rolls and cookies
also essential for reducing food waste. For example, bakery
are said to account for a majority of bakery waste. One recent
dough that sticks to a mixing bowl or to a divider would
study from Sweden suggests that 80 000 tonnes of bread are
count as food loss. Also categorised as waste are misshapen
wasted per year in the country or about 8kg per person. Other
products that can’t be packaged for sale. Here, a combination
research suggests that in the U.S., 25% of bread goes to waste
of process changes and recipe updates can help. For example,
in the consumer’s home due to short shelf-life. In addition, in
one manufacturer of baked crackers was recently able to
bakeries and plants where processes aren’t optimised, a large
process updates and reformulate its recipe to include a new
percentage of output may never even make it to consumers.
enzyme solution, effectively cutting its food waste from 30%
One reason bread and bakery products contribute to so much waste is their naturally short shelf-life—the low cost,
of each batch to just 10%. Being able to make changes at scale for industrial production
too, makes it easy to discard some products after just one day
can help resources go further, something that is important in
due to freshness concerns. The addition of traditional food
places with food scarcity. As the definition of sustainability
protection and preservation options could be a solution, due to
continues to change, improving conditions for people as well as
their ability to extend palatability. “The impact of an increase in
the planet—such as through a greater availability of sustainable
shelf-life of a few days or a percentage may seem hard to quantify
nutrition—is a growing priority.
Distributors of Rondo equipment in South Africa
Polyline The Polyline is Rondo’s starting point for automatic pie production. In addition to pies you can produce folded, rolled, filled, decorated, cut and even stamped out products with the Polyline.
Tel: +27 11 462 3224/5 Fax: +27 11 462 3226 E-mail: foodequip@arbonia.co.za
Rondostar 4000 The Rondostar 4000 can produce dough bands and blocks easily and gently. It can also produce very thin dough bands and process the more difficult dough types like shortcrust pastry.
B A K ER YR E V IE W 2 0 2 2
7
AECI FO O D & B E VER AG E
The nobility of milk proteins in food processing If it is overall peace of mind that you are looking for when it comes to your baked goods, then look no further than the Arla Food Ingredients milk proteins. AECI Food & Beverage in partnership with Arla Food Ingredients, brings you the convenience of eggless baking with their range of milk protein egg replacers.
T
he purpose at AECI Food & Beverage is
consumers who still regard eggs as a natural and
to supply to their customers with a range
desirable ingredient.
of technology driven and consumer-led
Just like egg, Arla milk proteins contain all
additives and ingredients that are cost
the essential amino acids that are beneficial for
effective without compromising the nutritional and
human health, and that add to the nutritional
organoleptic values of the final product. With this
value of the end product. Furthermore, they come
range of milk proteins, that is exactly what they
with the benefit of being cholesterol free, low
can give to their clients.
in fat and are easy to handle and store before
Why choose Arla milk proteins for baking?
manufacturing because they do not require
Eggs are such a traditional ingredient in many cake recipes that it can be hard to imagine baking without them. However, a long history of fluctuating prices and, more recently, a series of supply problems is increasingly making eggs a target for replacement. The challenge for bakers is how to control the cost and quality of their cake products, while pleasing the many
controlled temperatures (refrigeration). They are easy to use in applications and there is a costsaving benefit because you only need a small dosage in your recipe to achieve your goal. As an egg replacement for baked products, the milk proteins stabilise the cake batter and strengthen the cake structure resulting in improved volume of the final cake. The improved structure makes slicing much easier and there is also reduced production waste. The water binding effect of the protein results in an improved moistness and freshness perception of the final cake, without compromising on the cake quality. These milk proteins also work well for gluten-free baking. The Arla milk proteins will not only provide you with consistent product quality, but they will also make your processing/baking efficient and keep your customers begging for more.
BR
AECI Food & Beverage - www.aeciworld.com 8
B A K ER YR E V IE W 2 0 2 2
SY N ER CO R E
Solutions to your bakery supply chain challenges The Baking Ingredient Division of African Food Industries (AFI) supplies functional food ingredients to the milling and baking industries within Sub-Saharan Africa. With a combined experience of over 135 years within the industry, this AFI team’s skill set stretches from industrial bakery optimisation to artisanal craft demonstrations.
D
uring the Covid-19 pandemic, many
replacement products DR1000 and DR2000 have
imported ingredients were, and still are,
been the most successful at replacing DATEM,
in short supply. The international freight
which has shown to be the ingredient with the
backlog and rise in fuel prices have resulted in
largest supply shortage. AFI further developed a
the inflation of ingredient prices. It is due to this
yeast-lowering functional ingredient called YR1000
challenge that AFI’s research and development
that enhances the activity
team developed cost-effective, functional enzyme-
of yeast through
based replacements for many imported materials.
improved yeast
The team have developed alternatives for a number
food and nutrient
of emulsifiers and dough conditioners that have
availability
proven to be very successful as 1:1 replacement
during
for DATEM, SSL, monoglycerides and various
proving. The
combinations of conditioners. The emulsifier
boost in yeast
10 B A K ER YR E V IE W 2 0 2 2
SY N ER CO R E
activity has resulted in 25% lower yeast usage, while increasing the control of oven spring. AFI now also designs and supplies productspecific improvers and enzyme blends to match the expectations of individual customers. Enzymes can modify different components of dough, starch,
“AFI’s research and development team developed cost-effective, functional enzyme-based replacements for many imported materials.”
proteins or lipids, and can be used to improve crumb texture, dough stability, loaf volume, tolerance, taste and flavour. These enzyme blends
Additional chemical leavening systems, like
can optimise ingredient activity or create synergies
baking powders, are available to suit product needs
between a multitude of functional ingredients. At
ranging from doughnuts to flapjacks, flatbreads
AFI, enzymes are selected after extensive trials and
and cakes. Each baking powder is activated by
are sourced from many global enzyme specialist
varying reactions to moisture, time, temperature
suppliers. Enzyme formulations are developed
and physical activity. AFI specialists are available to
according to the individual needs of bakeries
assist customers in evaluating the ideal leavening
and mills, and are only finalised once the blend
product for optimal results.
of enzymes performs optimally according to the customer’s expectation in application. Tortilla improvers are another example of AFI’S
AFI’s flavour team also supplies a range of colour and flavour options to clients and bakery research and development. With both sweet and
product-specific offering. The tortilla improvers
savoury options, and dozens of flavours available,
contain high-performance ingredient selections
their range is often used in the development of
for extensibility, conditioning, leavening and
cake, sponge and muffin mixes. One of their latest
preservation. Combinations of these technologies
offerings is the bun spice, which makes for the
can be made to suit the plant or product required.
perfect Easter bun glaze.
BR
Synercore - www.synercore.co.za 12 B A K ER YR E V IE W 2 0 2 2
Achieve Professional Results with
SUPREME Flour! We provide a comprehensive range of professional products to suit your bakery’s needs. Some of our offerings include: 1.
SUPREME Cake Wheat Flour is unfortified, highly refined flour which is purified to reduce bran and mineral content, making it ideal for baked products that require exceptionally white flour. SUPREME Cake Wheat Flour is a high-performance product which is finer in texture for better baking. It’s often used in puff pastry applications and other bakery goods which require consistently reliable and delicious results.
2. SUPREME Bread Wheat Flour is available in two variants: SUPREME White Bread Wheat Flour, which is your ideal choice for producing baked products with lighter colours, are strong in proteins and have robust volume; and SUPREME Brown Bread Wheat Flour, which has a higher bran content than our White Bread Flour and is great for baking products with a warmer colour and higher bran content.
3. SUPREME Turbo 5% Bread Concentrate has been uniquely developed from the highest quality raw materials. Bread baked with Turbo 5% Concentrate exhibits superior shelf life, guaranteed consistency and excellent water absorption, resulting in decreased cost-per-loaf. For best results, use in conjunction with SUPREME White and Brown Bread Wheat Flour, specifically, to produce white and brown tin bread. 4. SUPREME Multi-Pro is specifically created for multiple uses in professional and high-end artisanal baking. This high protein flour contains higher levels of gluten, which delivers increased water absorption rates and greater yields, as well as improved dough strength, stability, and baked volume. This makes it best suited for the manufacturing of bread, pizza bases, artisan bread, bagels and frozen products that are not baked in pans.
If you are interested in enquiring about any of our SUPREME Flours or Prepared Mixes, visit or contact us on our SUPREME website.
D I OS NA
Reaching your goal
more safely with hygiene Today more than ever, hygiene measures play an almost overriding role in both private and professional contexts. In the area of food production, large companies and operations must look beyond personnel hygiene to production hygiene to manufacture safe products. Comprehensive hygiene management is essential in this regard. In this context, a shortage of skilled personnel, higher demands on productivity and efficiency, and short time working also present the bakery industry with special challenges.
C
ompanies like Diosna Dierks & Soehne have
In the context of the above-mentioned focal
broadened their scope to be able to provide
points, consulting in the area of hygiene
an extended service portfolio in addition to
management, including HACCP testing also
their well-known machines and systems for pre-
supports Diosna customers in drawing up
dough, kneading and mixes. In addition to food
cleaning plans and using the right cleaning
technology and analysis services, this portfolio
agents. Environmental and swab samples as
also offers advice on hygiene management issues.
well as air sampling can also be carried out and
Diosna roughly divides hygiene management
a hygiene concept drawn up based on this. In
into the three sub-areas of personnel hygiene,
addition, Diosna offers consulting services to
operational hygiene and process hygiene.
ensure that hygiene regulations, such as EU Regulation 852/2004 and the German Food Hygiene Regulation, are implemented safely in the plants. The comprehensive range of services is complemented by the latest developments in the field of hygienic design plant engineering.
Hygiene in production - What does hygienic design mean? The challenges in the context of hygiene management are not only faced by food-producing companies. Machine and plant manufacturers must Diosna Wendel Mixer of the Hygienic Design Line (WH series)
14 B A K ER YR E V IE W 2 0 2 2
D I OS NA
also upgrade to remain the first point of contact
are many hygiene-critical points that require
in the future. Therefore, they too have to deal with
attention in quality-controlled installations. These
the current hygiene regulations of their customers
include internal angles and edges, welded joints or
by means of specialised personnel and create
a hygienic cable feed-through.
solutions. Various standards and guidelines, such
Diosna designs machines taking into account
as DIN 10516, help to provide orientation and to
the cleaning-friendly design of parts, components
implement them.
and surfaces. In cooperation between Diosna
Ideally, it is already questioned during the design
designers, technologists, hygiene specialists
phase whether the planned surfaces, especially
and customers, proven and new products are
the product-contacting parts, comply with the
constantly optimised.
recommendations and standards. Thus, in addition
Mobile tanks are the standard, solutions for
to the material, the material properties, such as the
complete draining of cleaning liquids, center
roughness of the surfaces, also play a role.
draining, pincer locking on mixers and elevator
Furthermore, it must be checked whether screw
tippers, sufficient floor clearance and the use
connections and pipe joints are hygienically
of easily removable covers are good solutions
designed and easy to clean. It is also important to
for the general range of machines. The use
avoid ‘dead spaces’ in which liquids can accumulate
of suitable materials and raw materials, e.g.,
or to ensure that they drain off unhindered. There
lubricants, air is essential.
Diosna Hygienic Design Line
B A K ER YR E V IE W 2 0 2 2
15
D I OS NA
Hygienic Design line - The Wendel mixer with special hygienic profile The latest development in the field of Hygienic Design is the Diosna Wendel Mixer of the Hygienic Design Line (WH series). The design is based on the guidelines of the European Hygienic Engineering & Design Group. The aim of this special design is to provide even more support to manufacturers in the baking, dough and snack industries to avoid microbial and particulate contamination of the end product, also on a plant basis. The Wendel Mixer is designed as an open construction and round stainless-steel profile. These features guarantee a short and optimised
type); with other kneading systems, the kneading time ranges between 12 and 20 minutes. For smaller dough quantities, the Diosna Wendel
cleaning process and a reduction of deposits.
mixer WH 240 E has a performance in wheat dough of
Surfaces are hygienically optimised to prevent
240 kg and a yield of 156.
microbial and particulate contamination of the baked product. This mixing system is suitable for all kinds
Reaching your goal more safely with hygiene
of dough due to the gentle mixing process and
Increased requirements and good hygiene
the low dough heating. At the end of the mixing
management pose a number of challenges for
process, the dough is either discharged through the
manufacturers in the food and mechanical
electrically controlled bowl opening of the under-
engineering sectors.
bowl discharge system (WHE-series) or transferable via the moveable bowl (WHA-series).
Benefits from Wendel mixers in hygienic design
Diosna offers companies comprehensive advice as well as conceptual and practical recommendations on this topic. This includes plant assessment and training of selected personnel on the following themes: personnel hygiene, plant hygiene and
Manufacturers get cooler doughs, shorter kneading
production hygiene. Machines suitable for cleaning
times, higher dough yield, higher water absorption
and the systems of the new Hygienic Design Line,
and improved measurable dough structures. The
together with the comprehensive service portfolio,
dough is not only compressed and pulled during the
represent a holistic offer. In this way, Diosna aims to
kneading process, but also folded. In this process,
continue to secure its position as the first point of
90% of the energy is used for dough production and
contact for quality-leading pre-dough and kneading
only about 10% is lost as rising temperature, i.e.,
machines, organic and pre-dough technology, and
0.5 °C – 1.5 °C temperature rise per minute at high
hygiene management in order to meet current and
speed, depending on dough viscosity. In addition, a
future challenges with its customers.
BR
kneading capacity of up to 3 000 kg/hour per mixer can be achieved. The total kneading time varies between 6 and 8 minutes (depending on the dough
16 B A K ER YR E V IE W 2 0 2 2
Diosna Dierks & Soehne GmbH - www.diosna.com
IP CO
Getting the best from your
steel bake oven belt IPCO is the world’s largest supplier of steel bake oven belts and has nearly 100 years’ experience of working with the bakery industry. This gives the company an understanding of production issues that goes beyond belts themselves, as IPCO global product manager Marko Leber explains.
T
IPCO Global Product Manager: Marko Leber
he primary role of an IPCO steel bake oven belt is to convey goods through a continuously operating oven. The high
thermal conductivity of this type of belt, whether solid or perforated, concentrates heat onto the product to achieve the desired crisp base, and the smooth, flat surface ensures a clean discharge at the end of the line with minimal risk of damage to fragile products. A high-quality bake oven belt will have key mechanical properties – flatness, straightness – ‘engineered in’ at the production stage to ensure that it runs through the oven as it should. Consistency of colour is important too; dark areas absorb heat
the productivity, quality and profitability of the
while light, shiny areas reflect it, so uneven belt
overall bake oven line.
colour could result in an uneven bake. This has to be engineered into the belt too. In short, the quality of the manufacturing
A steel belt that has been manufactured to the highest standards is an highly efficient tool, one that with the right maintenance will
process – the transformation of a length of
deliver reliable service for longer than any other
cold rolled carbon steel band into a high
conveying medium; a belt life of 20 or more
precision component – determines the long-
years is not unusual, some can last two or even
term reliability of a bake oven belt and, in turn,
three times that long.
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17
IP CO
Maintenance procedures Maintenance requirements are relatively low compared with other belt materials. Solid and
life. It also helps to maintain a regular belt colour for an even bake. The easiest way to apply a lubricant is via
perforated steel belts are by their very nature
graphite skid bars, which deliver a gradual
highly durable and resistant to stretching and this
deposit of graphite to the inside of the belt. IPCO
alone keeps downtime to a minimum. A premium
graphite skid bars are available for all standard
quality belt will also display good tension and
belt widths.
tracking characteristics, which is key to reliable, trouble-free operation. So, what maintenance does a steel belt need?
If, for any reason, a skid bar cannot be used, graphite should generally be applied to the inside of the belt once a month for the first three months
Aside from regular checks, more of which in a
after installation, then every three to six months.
moment, lubrication and cleaning are the two
If graphite is not permitted, specially selected oils
most important maintenance tasks.
can be used instead.
Lubricant is essential as well as reducing
Cleaning is usually carried out using rotating
friction. It helps eliminate risk of rust caused
brushes, with the application of scrapers as
by condensation, it reduces wear, prevents belt
necessary. The brushes should be adjusted to
distortion and, ultimately, leads to a longer belt
apply gentle cleaning of the belt surface. Ineffective cleaning will result in a build-up
“The primary role of an IPCO steel bake oven belt is to convey goods through a continuously operating oven.”
18 B A K ER YR E V IE W 2 0 2 2
of carbon deposits on the baking side of the belt, leading to less than perfect products and, ultimately, a risk to health due to the presence of hazardous acrylamide. A range of factors including belt type, end product, oven type and personal preference
IP CO
will determine the most effective approach to
a whole. For our service teams, analysis of belt
the removal of carbon deposits and will usually
condition can paint a clear picture of how that
involve the application of chemicals, dry ice or
system is performing.
detergents and great deal of manual input. It’s
It’s almost always the case that any issue
a task that cannot be ignored if an oven is to
with belt condition is the symptom of another
produce high quality goods.
problem, not one in its own right. Once the cause
Of course, some issues go beyond what could
has been identified and rectified, we can return
be termed ‘everyday’ maintenance and this is
our attention to the belt itself and take whatever
where our service support operation comes in.
remedial action may be necessary to make sure
IPCO service support One of the unique strengths of IPCO is our
that it’s in a condition to perform reliably for years to come. For example, if side wandering is occurring, this
ability to offer maintenance support that looks
can often cause the belt to come into contact with
beyond the belt. For some customers, belt
the structure or another rigid object, resulting
supply is all that’s needed, but for others we
in burrs. Wavy belt edges could be another
support the OEM or end user with a full range
indication of side wandering, or of uneven
of conveyor components, from drums, sheaves
temperature in the oven. It can also indicate
and shafts to tracking systems, break points
uneven pressure from the belt cleaner or scraper,
and graphite stations.
or a belt scraper that is wider than the belt itself.
We understand how a belt interacts with the other components that make up the system as
We look for deformations in the belt, which could suggest problems with drums, belt
B A K ER YR E V IE W 2 0 2 2
19
IP CO
supports or other parts
better than cure. By offering
coming into contact with
Preventative Maintenance
the belt. Remedial actions
Agreements (PMAs), we aim
include cleaning the drums,
to identify risks of failure
cleaning or replacing belt
before they have chance to
supports, and checking
disrupt production.
scrapers, rollers and
Inspection work will cover
belt tensioning.
all major system components.
We also inspect the
We check that terminal
underside of the belt, as
drums, rollers and skid bars
any scratches could indicate
are aligned horizontally and
worn or damaged belt
at right angles to the center
supports or safety scrapers.
line of the longitudinal axis of
In one recent case, a
the oven line. We check that
customer asked us to look
terminal drums and rollers are
at belt tracking problems
rotating freely and that tension
they were experiencing.
and tracking devices are
They believed they’d
operating as they should be.
probably need a new belt
As a company we have
but wanted us to identify the root cause of the
fully trained and equipped service teams
problem first.
on the ground in all key markets, including
As it turned out, the condition of the belt
Africa. This means we can provide a quick
itself was not a concern but it was clear to
response to any service or repair needs, and
our engineers that certain components were
that work is carried out by qualified people
incapable of providing the reliability and
with a real understanding of customers’ needs
performance that could be expected of modern
and values.
conveyor equipment. The surfaces of the drums,
Local teams can call on the support of IPCO’s
for example, were no longer suitable for effective
Special Engineering team, experts who can be
belt tracking.
sent anywhere in the world to troubleshoot issues
We were able to retrofit a range of new components including inlet and outlet drums,
and provide specialist support. We also support customers in the form
tracking devices, a graphite station and a cleaning
of technician training, either on-site or at
brush and scrapers, and retain the existing belt.
our regional headquarters in Johannesburg.
The customer ended up with a state-of-the-art
Subjects can be tailored to requirements, but
conveyor system capable of delivering significantly
will typically focus on best practices in belt
improved productivity, at a cost 25% less than it
maintenance, repair techniques and use of the
would have been for a new belt.
QuickTools range, all specially designed to make
Preventative Maintenance Agreements While trouble-shooting is a great way of supporting customers, prevention is obviously
20 B A K ER YR E V IE W 2 0 2 2
repair work as efficient as possible.
IPCO - www.ipco.com/bake
BR
Bake more, bake better with IPCO steel belt technology Our solid and perforated steel belts have helped bakeries produce premium quality products for almost 100 years. Flat, straight, durable and easy to clean, they provide a baking surface that’s ideal for everything from rich, chewy all butter cookies to traditional biscuits and crackers. The other reason for choosing IPCO is our global service capability, providing the reassurance of premium productivity too. • • • • •
High productivity wide belts up to 3500 mm. Maximum versatility – bake more on an IPCO steel belt. Energy efficient – lighter belt means lower carbon footprint. Belt only or full range of conveyor components. Installations, upgrades (mesh replacement), repair, maintenance and spare parts. See us at IBIE Las Vegas · 18-21 Sept · Booth 2971
ipco.com/bake
CAMA
Adapting to the changing needs of the bakery industry Paola Fraschini marketing manager at Cama spoke to Tennille Aron about the ever-changing needs of the bakery industry when it comes to packaging. Q: What bakery categories do you see growing the fastest? The largest growth in bakery has been the ‘free
Q: What role does packaging equipment have in helping meet the need for longer shelf-life for bakery products?
from’ sector with ‘no-gluten’ being a reason for
Cama’s range of equipment is around paper-based
new market entrants and start-up producers
packaging, which is less about barrier properties
looking to gain share in the bakery sector. In
and more about the structural side for sleeves,
general, the bakery industry is promoting healthy
cartons and cases that are designed to protect the
products with low-sugar and low-fat content.
product in transit so that it arrives at the consumer
Q: What is the most challenging request that you have received from a bakery customer to help them package their bakery products?
in good condition. This is a pre-requisite even before shelf-life concerns are addressed. Cama’s solutions are helping manufacturers to achieve plastic reduction targets and make efficiency gains. In addition, the wide range of shelf-ready
We receive many requests to automate innovative
packaging covered by the Cama machine is able to
packaging designs, which are normally hand-
provide all the solutions for a shelf-ready pack.
packed first. In every project, Cama supported the
Furthermore, the capability of Cama to have
customer with their knowledge and experience.
developed their own robotic system allows them
Targets can be different, and we can summarise
to cover the requirements coming from the bakery
them into different macro categories, namely:
industry, which now requires a flexible production
• Handle a high number of products per minutes
able to supply different packing configurations
• Deliver a custom and innovative packing
or flavours in a short time. With their fast and
solution developed by the customer’s marketing
automatic change over systems, Cama machines
departments
can easily meet these requests.
• Fit the packaging machine in an existing
of the projects
Q5: What has been the contributing factor to the continued success of the Cama Group?
For all these needs, Cama is able to support
Through the years, the Cama Group staff has
building with limited space • Support the customer in the engineering phase
their customers and deliver the best solution.
22 B A K ER YR E V IE W 2 0 2 2
grown up to 350 employees, including highly-
CAMA
To access video, check out the Bakery Review Digimag.
skilled engineers and technicians, sales
division) and robotic loading units (robotic
consultants, sales engineers, and their own
division), allows Cama to propose complete
packaging consulting department. With
lines starting from the handling of primary
more than 40 years’ experience in the design
packages, such as flow-wraps, bags,
and testing of packaging paperboard and
and trays, to the supply of final carton/
cardboard, the Cama packaging department
corrugated packaging ready for palletising.
is available to help customers achieve high efficiency, improve sustainability and
To find out more about Cama’s bakery
reduce material costs. In addition, the group
solutions, request your free bakery brochure by
annually invests 5% of sales to research and
emailing marketing@camagroup.com
development, to be able to offer its’ customers innovative packaging solutions. The company’s outstanding packaging knowledge, combined with a unique machine range (packaging
CAMA – www.cama.com USS Pactech – www.usspactech.co.za
THERE IS PERFECT SYNERGY AMONG OUR MACHINES. AS BETWEEN YOU AND YOUR FAVORITE COOKIES. Cama Group is a leading supplier of advanced secondary packaging systems in the bakery industry, continuously investing in innovative solutions. www. camagroup.com - sales@camagroup.com
smartpackaginghub.com
B A K ER YR E V IE W 2 0 2 2
23
SAVAN NAH
Savannah has the solutions to all your bakery needs. Explore some of their top ingredients below: BREADS, CAKES AND BISCUITS Carabuta NH The Carabuta NH is a milk fat replacer with flavour precursors
FROSTINGS, FILLINGS, AERATED CREAM AND TOPPING OF BAKERY GOODS Icing Short 400
creating butter notes
The Icing Short 400 has excellent creaming
during baking similar
power with high mechanical tolerance. It is
to dairy butter. It
suitable for large production volume of buns
gives the natural
and cakes. It gives smooth and light texture
buttery flavour
to filling creams and improves meltdown
to baked goods
sensation. It is able to incorporate a higher
providing economy
quantity of air, giving larger volume of fillings,
in replacing milk fat.
therefore, saving you money. The Icing Short
The flavour will be
400 comes with clean label options.
developed once the heat is induced and it is stable. Being low in trans-fats and free from cholesterol, it is also easier to store compared to dairy fat.
SPONGE AND EMULSIFIED CAKES Durkex 140 The high stability oil Durkex 140 is specially designed to substitute liquid shortening widely used in emulsified cake applications. It decreases the crumb hardening over time by retarding the staling rate of the cake. It also finds good texture and taste for chocolate bakery products like brownies and devil’s food cake. It is non-GMO, non-hydrogenated and nonlauric, providing good economy and functionality benefit to the end product.
24 B A K ER YR E V IE W 2 0 2 2
SAVAN NAH
Durkex 103 Durkex 103 is the most premium product, delivering maximum indulgence and heat resilience. It also has a high stability with nuts like peanuts, hazelnuts, almonds and pistachios in warm climates.
Durkex 105 Durkex 105 contains an
FOR SPREADS
emulsifier to further improve
Durkex is a range of spreads designed to avoid de-
the heat resistance without
oiling at higher storage temperatures or at higher nut
affecting the
(oil) content levels. These give maximum indulgence
mouthfeel
thanks to combination of pasty texture and rich
or flavour.
mouthfeel, delivering a very pleasant overall experience. Spreadability is a key feature, even out of the refrigerator.
C
M
Y
CM
MY
CY
CMY
K
+27 21 830 5306
B A K ER YR E V IE W 2 0 2 2
25
SAVAN NAH
Savannah Fine Chemicals are also the local distributers of Barry Callebaut’s Bensdorp range of cocoa powders and ingredients, which are the perfect ingredients to help manufacturers adapt to the ever-changing needs of the chocolate industry. These are just a few of the ingredients that they have on offer: Dark Chocolate Powder
Defatted Cocoa Powder
Bensdorp’s Dark Chocolate powder
The Defatted Cocoa Powder contains
is made with no addition of dairy.
less than 1% of fat and has a reduced
However, it allows you to claim
risk of fat blooming because it has a
chocolate on the pack and show
very low cocoa butter content. This
real pieces of chocolate on the
powder is ideal for aerated bakery
packaging. These powders have
applications. It provides increased
a round chocolate flavour with
volumes of batter (~+20%) and has
caramel and milky notes.
better baking stability. This powder has a classic balanced cocoa and dark chocolate flavour with a brown colour.
Ebony Black Cocoa Powder This cocoa powder is a fat-reduced highly dutched cocoa powder with distinctive intense black colour. It is one of the blackest cocoa powders on the market and has a strong roasted cocoa flavour with a slightly bitter after-taste.
Croquoa Add Croquoa to your mixture for a delicious multitextured chewy stracciatella. These crunchy inclusions have a light, aerated texture and a delicious dark chocolate flavour. They show excellent behaviour at high temperatures (up to 200 °C). The best part is that they are made of cocoa and sugar only.
26 B A K ER YR E V IE W 2 0 2 2
SAVAN NAH
Callebaut 811 Take on any job with Callebaut 811, which has a full-bodied taste, solid cocoa body and fine, fruity notes. This master in balance pairs perfectly with a wide variety of ingredients and works in all applications ranging from confectionery to biscuits, sauces and drinks. For bakery it is best used for icing.
Callebaut Gold
Callebaut w2
Callebaut Gold is caramel
To create a delightful taste with
chocolate that has rich
pronounced milky, creamy, caramel
notes of toffee, butter,
and vanilla notes that are in perfect
cream and an exciting
balance, Callebaut W2 can be used.
dash of salt, which works
It is best used as icing.
well in almost all applications. For bakery applications it is best used in enrobing/icing.
Sicao hazelnut filling This is a soft filling with a delicious nutty flavour and a velvety sensation that can be added to rolls, croissants and pastries, and it easily resists temperatures up to 200 °C.
Savannah Fine Chemicals – www.savannah.co.za Barry Callebut Bensdorp - https://www.barry-callebaut.com/en-ZA/manufacturers/bensdorp B A K ER YR E V IE W 2 0 2 2
27
IN G R E TO
Evolving and adapting to South Africa’s baking needs
Choosing a reliable partner to help you produce the best baked goods for the South African market is crucial. Ingreto explains what to consider when choosing your supplier of baking ingredients.
T
he food industry has a long history of
innovative emulsifiers and baking enhancing
responding to the changing needs and
products have sprouted up and are abundantly
expectations of consumers. The challenges,
available on the market.
however, are the complex paradoxes surrounding
However, the genesis of all food is in its
product expectations. Consumers demand quality,
ingredients. To produce optimal quality and
but at their perception of a reasonable price; they
freshness at a competitive price, these additives
want to indulge, yet expect simultaneous nutrition;
must be carefully formulated, requiring
they have hope of a conventional product, but
consistency, stability, structure and texture. Which
believe it must be achieved with a longer shelf-life.
is why choosing a reliable supplier is imperative.
As with other food products, baked goods have also become more intricate over the years. With
Quality begins from the ground up. Ingreto (Pty) Ltd is a leading ingredient solutions
the high demand for common food products, such
supplier in South Africa. The company offers a wide
as breads, cakes, sauces, margarines and sweets,
range of products and raw materials that are required
28 B A K ER YR E V IE W 2 0 2 2
IN G R E TO
for baking, and it also offers specialist custom blending. With their sole distribution rights with Lasenor, an international specialist in the production, development and application of emulsifiers, Ingreto has brought a whole new dynamic to food emulsifying in South Africa. “Adding more complex products, such as innovative emulsifiers, will improve the yield, crumb, texture and colour of products, especially in cakes,” explains Sonia Kittle, director at Ingreto. Based in Gauteng, Ingreto offers the Lasenor BK101 emulsifier as well as other products such as Lecithin, whipping agents and PGPR, to name a few. The general commodities they supply include sugar, flour, starches, thickeners, and baking powder, to mention a few. “Our clients benefit from products that are competitively priced and approved by multi-national companies,” concludes Kittle.
BR
Ingreto - www.ingreto.co.za
“To produce optimal quality and freshness at a competitive price, bakery ingredients must be carefully formulated, requiring consistency, stability, structure and texture.”
Ingreto - https://www.ingreto.co.za/
B A K ER YR E V IE W 2 0 2 2
29
CH EM G R IT FO O D
Sugar alternatives – finding the sweet spot
The drive for healthier food with reduced sugar content continues to gain momentum and while there are now several sugar alternatives – both natural and synthetic – replacing sugar in baked goods and confectionery remains a bit of a challenge thanks to the fact that sugar does much more than just adding sweetness.
F
ood manufacturers continue to face mounting pressure to reduce the sugar content in food in order to curb the increased incidence
of obesity and diabetes. This includes the confectionery and bakery industry, which due to the nature of many of its products such as cakes, biscuits and other indulgent snacks, shoulders much of the criticism for the incidence of weightrelated health issues. The challenge for this, and other food producers, is that while consumers are conscious
preventing them from going stale as quickly as
of reducing sugar intake, they are not prepared to
baked goods made without sugar. Its moisture-
compromise the taste experience.
grabbing character also helps to delay gluten
When it comes to baked goods, however, sugar does more than just provide a sweet kick – sugar contributes not only to the taste of food items, but also to other factors including texture, bulk, mouthfeel, aroma and colour. It also helps to brown goods quickly and evenly
development and it helps with leavening of baked goods by providing a structure for gas expansion in the oven, promoting lift and rise in baked goods. Although there are several different sweetening options available, none taste or, more importantly, behave
because it caramelises
exactly like sugar.
when heated. It is
According to Margaret
hygroscopic and thus,
Carter Chemgrit, food
helps baked goods hold
product sales manager,
onto moisture, keeping
there are other issues to
them moist and tender,
30 B A K ER YR E V IE W 2 0 2 2
consider when looking at
CH EM G R IT FO O D
Chemgrit Food, a division of Chemgrit SA sugar alternatives. With sweeteners you have to consider whether they are nutritive or non-nutritive, their comparative sweetness to sugar, ease of use, heat stability, how the product is metabolised with other ingredients, after taste, compatibility with other sweeteners and laxative effect. Furthermore, because sugar does more than one
supplies the bakery and confectionary industry with a number of ingredients including a range of sugar and sugar alternatives. Chemgrit represents industry leaders and deals directly with manufacturers & suppliers both locally and internationally.
thing, it is impossible to replace it with just one thing. Multiple ingredients are needed to fulfil all
than sugar and has zero calories, is very easy to
the other roles it performs. This is not only because
use although it performs best in dairy products as
of the chemistry involved, but also due to physical
well as in beverages and candies.
quantities. Many of the sugar alternatives – be they
Saccharine, Sodium Cyclamate, Aspartame
artificial or natural – are significantly sweeter than
and Acesulfame K are also popular alternatives to
sugar, and are required in much lower quantities,
sugar and are used in many food products.
which affects the bulk of products.
Adding bulk
Smart consumers Consumers are also becoming smarter and savvier,
Bulking agents like
and are more specific
maltodextrin can be
about what goes into their
used, however, if
food. While most sugar
reducing calories is what
alternatives are recognised
manufacturers are after,
as being safe, there
then this is not ideal as
remains some resistance to
maltodextrin actually has a
synthetic sugar alternatives
similar number of calories
with a growing demand
to sugar. Conversely, other
for clean and sustainable
bulking agents that are
ingredients. This is driving
low in calories are more expensive than the
the demand for natural sweeteners such as monk
ingredients they are replacing, making them
fruit, stevia, agave nectar, date syrup and coconut
unattractive from a costing point of view.
palm sugar.
A combination of sweetening options and thickeners may need to be used in order to achieve
Taste still trumps
a palatable outcome. This is easier in sweet baked
“While the industry is making great strides in
goods and has been achieved in some instances,
reducing and replacing sugar in food products,
but has not been as successful in breads.
in particular confectionery and baked goods,
The sweet alternative
it seems that for the moment, taste and experience remain the most important issue
Sucralose has become a popular replacement
for consumers,” says Lucinda Cordia, Chemgrit
for sugar and is in greater demand. While price
Food general manager.
and availability has been an issue, it is now more readily available. Sucralose is 600 times sweeter
32 B A K ER YR E V IE W 2 0 2 2
BR
Chemgrit Food - www.chemgritsa.co.za
LET’S BREAK BREAD
TOGETHER
+27 011 474 2424
MANUFACTURERS OF SPECIALITY FLOURS OAT FLOUR OAT MEAL MALT FLOUR RICE FLOUR
+27 011 474 3141 sales@cerealandmalt.com cerealandmalt.com 6 Bunsen Street, Industria, Johannesburg
The newest name in the Bakery industry is 124 years old!! Say hello to AECI Food & Beverage!
We are a supplier into the Bakery industry and proud distributor of Budenheim phosphates and cocoa powder from JB Cocoa and milk proteins from Arla Food Ingredients. Included in our portfolio is a wide range of ingredients for bakery applications. 2 Galaxy Park, 17 Galaxy Avenue, Linbro Business Park, JHB 011 409 5000 99 Kasselsvlei Road, Bellville South, CPT 021 958 2180 Preshonthi Naidoo 064 750 2080 preshonthi.naidoo@aeciworld.com
