Bakery
MARCH 2019 No. 3
Journal for bakery and confectionery professionals www.foodreview.co.za
Creating tomorrow’s bakery and confectionery heroes today Convenient, functional and healthy ingredients
Custom designed belts and equipment for bakery excellence
Initiative fills the bakery and confectionery skills gap
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
EDITORIAL Editor: Maryke Foulds +27 (0)11 715 8012 maryke.foulds@newmedia.co.za Layout & Design: David Kyslinger david.kyslinger@newmedia.co.za 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 Sales Executive: Gayle Kihn +27 82 457 0896 gayle.kihn@newmedia.co.za CIRCULATION Circulation Manager: Felicity Garbers +27 (0)21 701 1566 felicity.garbers@newmedia.co.za PUBLISHING TEAM General Manager: Dev Naidoo Publishing Manager: Natalie Da Silva +27 (0)11 877 6281 natalie.dasilva@newmedia.co.za
Bakery Journal for bakery and confectionery professionals MARCH 2019 No. 3
4 CJP Chemicals Mould free and safe 5 CJP Chemicals Baked goods with a calcium boost
8 Ipco High quality baking at a low cost 10 Bakerite Custom designed for bakery excellence
6 Roha Make reds pop with heat stable beets
12 MBake A collaborative success
7 Savannah Fine Chemicals Looking for more than just nutritional benefits?
14 Chipkins Puratos Creating tomorrow’s bakery heroes
E D ’ S N OTE
Production Controller: Mandy Ackerman Art Director: David Kyslinger
A passion for excellence
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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. Bakery Review is printed and bound by Tandym Print.
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his is the third edition of this dedicated supplement for industrial, craft and instore bakeries. Bakery Review aims to provide readers with the latest ingredient news and technologies available today. This edition features a host of interconnected topics including an update on how to offset moulds and bacteria in baked goods and solutions to increase mean calcium intake through the use of innovative ingredients. Sugar reduction is a hot topic in industry right now. Trials using
chicory root fibres are making waves as bakers can now cut the sugar, but not the taste using these ingredients. We also welcome news that a bakery school has opened in Tembisa, Gauteng bringing much needed skills to this impoverished area. Did you know that bakers are now listed as the fourth scarcest skill in the wholesale and retail sector? It is great news that industry is heeding the call to upskill our youth. Enjoy the read!
Maryke.Foulds@newmediapub.co.za
BAKERYREVIEW MARCH 2019 3
C JP Ch e m i c a l s
Mould free and safe High temperatures and humidity found in industrial bakeries provide the perfect environment for mould and bacteria to thrive.
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ould spores are killed during the baking process, but recontamination can occur, specifically with airborne Penicillium, Aspergillus and Cladosporium spores. Bacterial spores, usually from Bacillus species are heat resistant and can survive after baking. They can cause rope formation on baked goods - characterised by a brownish, sticky and wet crumb, which results in an unpleasant odour.
Portfolio for bakery preservation Probake CP (calcium propionate) is commonly used as a bread preservative. It is an effective growth inhibitor of most moulds and some bacteria and can be used in bread and other yeast-based bakery goods.
Calcium propionate is preferred in rolls and bread as it contributes to nutritional enrichment by supplying calcium. Calcium ions of calcium propionate can however interfere with chemical leavening agents. It is suggested that Probake SP (sodium propionate) is used for non-yeast chemically leavened bakery products such as cakes or tortillas. The suggested dosages for Probake CP or SP cannot be correlated precisely with shelf life extension. For standard bread recipes, a concentration of 0.2 to 0.5 per cent Probake CP or SP on flour weight is recommended. Both products are available in different grades. Apart from propionates, acetates can also preserve bakery products. These additives have the advantage
of being labelled as acidity regulators instead of preservatives. Niacet produces two types of acetates suitable for baked goods. Progusta CA (calcium acetate) and Progusta SD (sodium diacetate) prevent rope formation and extend shelf life. Progusta CA does not affect the fermentation process of yeast and final bread volume. Progusta SD is mainly preferred for rye bread recipes or when pH reduction is needed. All food products produced by Niacet comply with the FCC, EU legislation, JECFA and the Japanese Standards of Food Additives. Products are supplied locally through CJP Chemicals. • CJP Chemicals – www.cjpchemicals.co.za
PROBAKE® – leading products for bakery shelf life extension www.cjpchemicals.co.za / 0114946700 Contact Jonathan Sher: jonathans@cjpchemicals.co.za 4 BAKERYREVIEW MARCH 2019
C JP CH E M I C ALS
Baked goods with a calcium boost The mean calcium intake in South Africa is far below the recommended amount of 1 000mg per day.
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n target groups who need a higher daily dose, i.e. adolescents and women over the age of 50, or people that do not have access to dairy products, the consumption of fortified food helps to provide this crucial nutrient.
A perfect match for bakery products With a calcium content of 40 per cent, Omya Calcipur provides one of the highest concentrations among calcium salts. The company’s high purity sources fulfil even the strictest food specifications. Products are available in various particle sizes to accommodate every application. Tailored particle size offers more benefits to formulators, beyond just calcium fortification. While coarser grades like Omyabake 50KP represent a costeffective solution for fortification in the
With Omya Calcipur consumers can reach their daily calcium intake target
bread industry, finer grades like Calcipur 90KP or Calcipur 110KP brings additional functionalities. These include anti-caking agents or natural white pigments for use in hard and soft baked goods. Baked goods can be easily fortified with calcium by replacing the corresponding amount of flour. Swapping 600mg in a single 35g bread roll achieves a calcium dose of
240mg. Compared with other available technical solutions, up to five times less Calcipur is required to obtain the same calcium dose in a finished foodstuff, and related claims can be made on pack. Calcipur can also reduce the amount of icing sugar in a recipe by as much as 35 per cent, resulting in significantly fewer calories in the product. Used in baking powders, Calcipur can replace starch as a segregating agent in the formula and offer a second source of CO² for optimum leavening efficiency. There are multiple ways in which Omya Calcipur can help you formulate to achieve the daily recommended intake of calcium. For more information, contact the local representative in South Africa, CJP Chemicals. • CJP Chemicals – www.cjpchemicals.co.za
Omya Consumer Goods omya.com
Bakery goods, naturally improved Omya high-purity natural Calcium Carbonate in bakery final formulations provides bioavailable calcium, while improving final product characteristics.
nevilleb@cjpchemicals.co.za
Official Distributor for RSA
BAKERYREVIEW MARCH 2019 5
ROHA
Make reds pop with
heat stable beets Global interest in the use of natural food colours is impacting new product solutions and development across the food and beverage industry.
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he bakery industry is faced with challenges when using bright red colours across different product categories. A normal red beet product fades at high temperatures; anthocyanin is not pH stable and carmine is banned in many countries. Roha’s penchant for innovation, research, development and lab trials have led to the possibility of a new application using red beet. Natracol Cerise is suitable for bakery and confectionery, among other applications across the food industry spectrum. Cerise is a red beet concentrate extracted from fresh beetroot. It is
pasteurised by physical means to obtain an intense, standardised colour. Betanin is its colouring component. Due to the processes used, this innovative red beet product is stable at higher temperatures and suitable for bakery applications. It is available in water soluble form. It typically provides shades ranging from pink to dark red.
• Applications – bakery, dairy products, beverage, meat and confectionery • Product forms available – water soluble powder • Shades – pink to dark red
Beetroot Red is extracted from beetroot. Its main coloring component is Betanin, present in beetroot. This range provides colors from bright red to bluish red. With an improved stability to heat and light, the range can be used across a variety of applications - mainly bakery and dairy.
Contact Us: Roha Dyechem Ltd. Plot 476, Sunbeam Street, Icon Industrial Park, Sunderland Ridge Ext 18, Centurion 0157, South Africa. T: +27 12 653 4901/2/3 | F: +27 86 537 5032 | roha.southafrica@rohagroup.com | www.roha.com Follow us on
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“Cerise is a red beet concentrate extracted from fresh beetroot. It is pasteurised by physical means to obtain an intense, standardised colour” Roha’s range of red beet products has had recorded success across new and exciting applications. The company also recently introduced Futurals Pro Red Velvet, suitable for cooked meat applications. • Roha – www.roha.com
SAVA N N A H F IN E C H E M I C ALS
Looking for more than just nutritional benefits? Trials using Beneo’s inulin and oligofructose chicory root fibres show it is possible to reduce sugar in chocolate chip cookies by 30 per cent, writes Rudy Wouters, vice president Beneo technology centre.
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he biggest benefit is that the reduction has no noticeable effect on mouthfeel or sensory impact. Seven out of 10 European consumers are trying to cut sugar consumption, but up to 60 per cent don’t want to forego the feeling of sugar-like indulgence.1 These trials are an important step forward for food manufacturers and consumers.
Even with a 30 per cent reduction in sugar content, the cookie’s sensory profile indicates that its sweetness, taste and crunchiness remained the same as in the full sugar variant
Sugar reduction in indulgent bakery applications is linked to many technical challenges including maintaining sweetness, appearance, texture, crunch, colour, biscuit strength and dough handling properties. The team at Beneo’s Technology Centre who developed the 30 per cent sugar-reduced recipe also carried out texture analyses and sensorial evaluation of cookies. Results indicate that sweetness, taste and crunchiness were the same as the full sugar variant. These cookies were however higher in fibre and can be sold as clean label products. Depending on the Beneo ingredient used, the product could display EU health claims of “promotes digestive health” and
ABOUT BENEO: A specialist in functional ingredients derived from chicory roots, beet sugar, rice and wheat. These ingredients are ideally placed to improve a product’s nutritional and technological characteristics. Key nutritional benefits include less fat, sugar, calories, added fibre, gluten-free and dairy alternatives coupled to energy management, digestive, bone and dental health. Key technological benefits focus on taste and texture improvements. “reduced blood glucose response” on a pack. Beneo is supplied locally through Savannah Fine Ingredients. • 1
Source: Consumer research by Insites, 2015,
Savannah Fine Chemicals – www.savannah.co.za
BAKERYREVIEW MARCH 2019 7
IP CO
High quality baking at a low cost Ipco, previously known as Sandvik Process Systems, supplies steel bake oven belts to OEMs and end users around the world.
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he advantages of a steel bake oven belt lies in its physical form: no other material can compete when it comes to its baking qualities. These units can deliver a reliable function in applications where temperatures can reach as high as 400°C, while providing excellent thermal conductivity for good baking performance and consistent product quality. Available in solid or perforated form, steel belts are suitable for baking products as diverse as bread, biscuits, brownies, crackers, pastries, sponges, all-butter cookies and pizza bases. Steel belts can also be used in finishing operations such as cutting, creaming and chocolate enrobing.
investing in an entire new production line, it is often possible to upgrade a conveyor system while retaining existing ovens when working with an OEM.
Economical operation and low energy cost While initial investment costs might be higher than for a mesh belt, figures look different when lifetime costs are compared.
Changing markets drive demand The qualities of a steel belt are essential during production of a global favourite: Americanstyle cookies. An example of a wide bake oven belt As these products use real butter and often chocolate chips, they must be baked on a solid belt Steel belts are strong and stable and to eliminate the risk of melted product feature excellent resistance to stretching. dripping and causing a fire, or simply Units can deliver a working life of 20 years to avoid biscuits drying out. The use or more – half a century is not unheard of. of a solid steel belt also produces an Their hard, flat, smooth surface means they attractive crisp base. are easier to clean than wire mesh belts. To keep up with global trends, bakery This allows high standards of hygiene to operations are looking to capitalise be maintained while minimising water and on opportunities available. This often chemical/detergent costs. necessitates a switch from a wire mesh to In addition to a long working life and a solid steel system. While it could mean low maintenance requirements, the relative 8 BAKERYREVIEW MARCH 2019
lightness of a steel belt can result in lower operating costs. Marko Leber, global product manager for Ipco’s food business explains, ‘The heavier the belt, the more energy is required to heat it. Solid steel belts are lighter than wire mesh and perforated steel belts are lighter still. These can cost up to 30 per cent less to heat. Each time a belt exits the baking chamber, it begins to cool only to be heated up again. Savings are therefore continuous. As much as 25 per cent of an oven’s energy consumption is needed to heat the belt, so these savings can be considerable.’ The weight advantage also means less energy is needed to drive the belt through the oven.
Wide belts for maximum productivity Ipco’s steel belts have been used for bake oven conveyor lines since the early part of the last century and the company can produce belts in widths from 800mm to 3 500mm. This makes it possible to achieve significant improvements in productivity without having to invest in factory extensions or new facilities. An oven with a 1 500mm wide belt offers almost twice the productivity of one with an 800mm belt without any increase in the line length. Upgrade to an oven with a 3 200mm belt or larger and throughput is increased by a factor of four. • IPCO – www.ipco.com
Solid and perforated bake oven belts for reliable, versatile, and efficient continuous baking IPCO is a new name in bake oven belts but a business partner with whom many in the industrial bakery industry will already be familiar. Previously operating as Sandvik Process Systems, we are now an independent company within the Wallenberg group with 600+ employees, more than 35 sales and service offices and annual sales in excess of $200 million. We continue to manufacture low maintenance solid and perforated carbon steel belts that offer energy efficient baking and a consistently high quality end product, with the same people, skills and global sales and service support that customers around the world rely on, but now under a new name and brand. Visit us at Africa Food Manufacturing Cairo, Egypt ¡ April 7-9 ¡ Hall 2 ¡ Stand K40
ipco.com/bake
BA KE R I TE
Custom designed for bakery excellence Bakerite features a distribution footprint that stretches through much of the African continent. It specialises in custom-made industrial baking equipment for food, retail, wholesale, hospitality and related industries.
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ne of its highly regarded innovations is the Bakerite steel floor tile. The system was originally designed to protect bakery floors from excessive wear caused by trolley wheels. ‘We work closely with our clients to design long-lasting, practical and cost-efficient solutions. Our streamlined, one-stop service and high volume production capabilities mean that we are equipped to meet most requirements from concept to final product,’ notes Dirk Jordaan of Bakerite. The company is vetted for distribution in the SADC region and its far-reaching distribution network services the African and Indian Ocean island markets with ease. The company is focused on growing its export market even further this year.
Bakerite steel floor tiles Flooring is a key element of overall hygiene protocol in the food industry. Bakerite is the original and sole manufacturer of its bespoke range of steel floor tiles in South Africa. These items are a standard requirement in many bakeries. The floor offers heavy-duty protection for high traffic, high impact and high heat areas in most industries, preventing excessive wear and temperature fluctuations. Units are durable, versatile, moisture, allergen and bacteria resistant and virtually maintenance
WHY CHOOSE BAKERITE? In operation for 29 years, the company prides itself as a specialist metal fabricator for standard and customdesigned industrial bakeware. High volume production capabilities result in quick turnaround times, coupled to complete service design.
free. Different custom options are available to fit in with a specific visual look.
Bakeware pans and cake tins The industrial bakeware range is available in most used shapes and sizes. Product scope includes standard bread pans, lids, baking trays, confectionery tins, and fully radiused folded pans - designed to stand up against harsh bakery conditions. Products are made of high-quality steel. Bakerite also manufactures a variety of custom shapes and sizes to meet individual challenges and requirements. These products can be used in industrial plant bakeries with travelling ovens or smaller instore bakeries with rotary or deck ovens. The following custom made products are available: • Freestanding units • Bread and oven trolleys • Rural stands
Bakery tech for maximum safety and efficiency
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• Countertop bread stands • Wire stands (custom cladding).
Trolleys Choosing the best equipment can help in boosting the sales and efficiency of the business. From industrial bakeries to the food services and hospitality industries, a wide range of highly durable and customised trolleys can meet the varied requirements of each industry. The trolley product range includes: • Bakeware trolleys • Fold up upright trolleys • Goods trolleys • Hotel and catering trolleys • Security trolleys • Customised solutions. Bakerite – www.bakerite.co.za
Confectionery
Bread Panss
Bakerite Steel Floor Tiles
A Range of Trolleys
Bakeware that rises to any occasion From our durable steel floor tiles to our high-quality standard as well as custom-made bakeware solutions, BAKERITE has risen over the last 29 years to become a leading supplier of industrial bakeware. With our wide range and quick turnaround times our innovative bakeware solutions can now become part of your success story too!
I N D U S T R I A L B A K E WA R E BAKERITE is a member of the
www.bakerite.co.za
BAKERITE Industrial Bakeware
+27 31 700 5288/9
A level 2 B-BBEE company
group
+27 31 700 5287
dirk@bakerite.co.za
Display Stands
M BA KE
A collaborative success M-Bake was started as collaboration between some of the most experienced engineers in the South Africa baking industry.
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ach engineer specialises in a specialised sector offering practical, workable equipment and solutions at a reasonable pricing level. Equipment is designed and manufactured to be robust enough to withstand harsh operating conditions. ‘We have designed our equipment to be easy to maintain. Our units are designed for African conditions, but are of equal standard to that of our European counterparts,’ explains MBake’s Muhammed Lavangee. ‘M-Bake is not just about selling equipment. We are in interested in building long lasting relationships with our clients by offering the correct solution coupled to the right equipment. Many of our clients have ordered second and third plants from us. ‘We manufacture and supply indirect and forced air convection travelling ovens
and electric and fuel fired (oil, diesel, paraffin and gas) ovens. Other products in the portfolio in include automatic swing tray proofers, depanners, delidders, pan
coolers, conveyors and bread cooling systems,’ Lavangee concludes. • MBake – www.mbake.co.za
Creative Flavors International offers the National and International market with quality flavours and emulsions. The Creative Flavors team developed a range of bake-stable flavours that are ideal for all your baking and biscuit needs. We can assist you in re-balancing your formula to allow our flavours to excel in your baking application. All of our flavours are Kosher- and Halaal suitable and manufactured under strict hygienic conditions with the necessary Good Manufacturing Practices in place. We are also ISO 22000 certified.
Tel: +27 11 760 1830 • Fax:+27 11 760 1829 www.creativeflavors.co.za
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CH IPK INS PU R ATO S
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Creating tomorrow’s bakery and confectionery heroes
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Well known as a bakery, patisserie and chocolate industry innovator, Chipkins Puratos has launched a bakery school. The facility is situated within the Masisebenze Secondary School in Tembisa, Gauteng.
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ts aim is to help 25 learners graduate with a matric certificate and an industry recognised technical qualification (NQF level 2 in bread and flour confectionary). This will effectively prepare them for the next step in their careers. ‘Bakers are the fourth scarcest skill in in the wholesale and retail sector today,’ says Richard Kuppan, national training manager and spokesperson for the Bakery School South Africa, a non-profit company. As bigger retail groups consistently add new stores and as we notice steady growth in informal sectors of small bakeries, we cannot ignore the need for skills in this space.’ Participants accepted to attend the two-year course through the Bakery School South Africa will come away with more than practical baking experience. They will be skilled in business focus areas like finance and communication. ‘Our intentions are to take previously disadvantaged grade 11 learners into a training and upskilling environment. By exposing them to theoretical and practical lessons they will be equipped with real skills to access tangible employment opportunities. We
“Bakers are the fourth scarcest skill in in the wholesale and retail sector today” will also provide those who demonstrate an entrepreneurial spirit with the skills needed to begin their journey to self employment,’ Kuppan adds. Globally, Puratos has helped open three similar schools with great success. One school is situated in India, another in Brazil and a third in Mexico. The company is expecting similar results here. ‘Courses have been designed to take pupils beyond basic education, giving them the practical training needed to make a decent living,’ Kuppan notes. ‘Chipkins Puratos will
employ the top graduates at the close of the programme, depending on the needs of the organisation at that time. Generally, at least five of our students will be offered secure employment upon completion with the remaining learners becoming part of a pipeline for customers and partners of the company.’ He goes on to say projects of this kind are about so much more than employment. ‘We realise how important it is to support the up-and-coming bakers of tomorrow, but this programme has far reaching consequences when you consider the socioeconomic impact that can be realised.’ The Bakery School South Africa will also provide at least one permanent job opportunity to a member of the community who will assist the school by cleaning. It has also committed to providing training for local bakery businesses. ‘Most vitally, 25 students have been enrolled in 2019, in the two year programme, and, with the addition of 25 students in 2020, we will be transferring skills to 50 students at any given time. These pupils will be better prepared to pursue their passion while enhancing their lives and the lives of those in their communities than if they’d followed more traditional education routes,’ Kuppan concludes. • Chipkins Puratos – www.chipkinspuratos.co.za
Learners at the new Chipkins Puratos Bakery School
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It’s more than an ingredient... It’s the whole solution. Huletts has a sweetening solution for
The Huletts range is available in various
every manufacturer in the food, catering,
pack sizes (25kg; bulk and semi-bulk);
baking, confectionery, pharmaceutical
backed by active quality assurance
and beverage industries.
systems to deliver consistent quality
It is the only local manufacturer that offers a wide range of industrial speciality sugars: • White granulated, speciality and milled sugars for inner and outer perfection • Speciality brown sugars with distinctive flavours, textures and colours • Liquid sugars and liquid fructose
and meet the required food safety and customer requirements. Certifications include: • FSSC 22 000
•
•
•
Artificial sweeteners are also available at our Cape Sweeteners Division. www.hulettssugar.co.za
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