Embed Size (px)
Citation preview
0416
www.bakingbiscuit.com
ProductionThe new factory of Mantinga UAB
InterviewGEA expands into the bakery sector
Puffed cerealsInnovative bakery ingredients
Visit us during the IBIE 2016 and experience the bakery of the future!
www.kaakgroup.com
K a a k F P S | K a a k B a k e w a r e | B e n i e r | D r i e M | D a u b | M C S | L h o t e l l i e r R 2 A | M u l t i p a r t s
Interested in hearing about how intelligent baking leads to cost reduction?
Total control of the process: a fantasy? ... or reality?
BOOTH 4331OCTOBER 8-11, 2016
KAAK_bakeware_adv_baking_biscuit.indd 1 04-07-16 11:42
1 2 3
4 5 6
7 8
0
9
Alt SpcSpc
CSB-System AG An Fürthenrode 9-1552511 Geilenkirchen [email protected]
Modules for the Smart FOOD FactorySmart Business Processes.Smart Automation.Smart Vision.
The factory of the future will be intelligent and networked.We will show you how you can prepare your business today forthe production processes of tomorrow.
With our software, automation and image processing solutions,we will accompany you on your way to the Smart FOOD Factory.Step by step and module by module.
Start with us into the digital future!
CSB_bakingandbiscuit_4_2016-06.indd 2 18.07.2016 11:21:58
AD
VE
RT
ISE
ME
NT
Tell me which field you really come from
E D I T O R I A L
The European meat industry has known about it for some time: since 1 April 2015 all pig, poultry, sheep and goat meat must have supplementary information about the origin of the meat. This applies to both fresh and frozen products. As a rule, two pieces of informa-tion are necessary: the country in which the majority of the fattening and rearing took place, and the coun-try in which it was slaughtered. The intention is to improve the transparency of the origin of meat across the whole production chain in this way.
A requirement to state the place of origin of beef has already existed for some years. Consumer confidence suffered as a result of the BSE crisis, and the purpose of labelling beef with mandatory information about birth, fattening, slaughter and the license number of the slaughtering and butchering company is to ensure confidence. Origin is also de-clared in other sectors, e.g. for fresh fruit and vegetables. We have become accus-tomed to the fact that asparagus comes from Greece and strawberries from Israel. This information affects the customer’s purchase decision, for example local suppli-ers may be given preference.
The subject of origin is also a current topic in the baking sector. The subject of regionality – from the region for the region – is used as a marketing tool, and there are various official logos designed to ensure confidence. Of course not all raw mate-rials can be sourced from the region. It is still possible for flour, sugar, fats, yeast or dairy products, but certainly not for seeds, fruits, spices or coffee. The savvy consum-er will know this. If the customer doesn’t know it, he will certainly understand that cocoa is cultivated in the tropics and doesn’t grow at all in the local region. What is harder to explain is the fact that although his flour is milled in the region, the cereal may possibly come from the USA, the Ukraine or Australia. The customer may possibly imagine this, but the consumer does not necessarily know it. Very soon, however, it will in future be possible to provide scientific proof of the region of origin if he wants to know this precisely. A new technology that can put to the test the system of proof, transparency and labelling in the baking sector is in the starting blocks. Various laboratories are currently gathering samples in order to catalogue them, including for example cereals from particular regions. The aim is a compre-hensive raw materials data base for use as a reference. This can then act as a test of whether the raw material that has been supplied really does originate from the stated region. This transparency will not please the black sheep. Customers or even the retail will be interested in the correct labelling of origin. They will want to know whether the sunflower seed or linseed really originate from the stated region. There-fore the baking sector should also ensure that it does not end up by scaring customers away or even misleading them through false promises about “regionality”.
Certainly we can now moan that this means yet more effort, more bureaucracy and even more costs, but it will do no good. The baked products market is highly compet-itive, and the retail will certainly demand the new opportunities for declaration of origin for baked goods as well, and not just by a signature on the delivery note or a small mention on the packaging. It will insist on reliable scientific proofs. It’s also really good, because the baking sector cannot afford any scandals. On the contrary, the new methods can create trust and even a competitive advantage.
Best regards,
++ Bastian Borchfeld, Editor-in-Chief [email protected]
www.bakingbiscuit.com 04/2016
C O N T E N T I M P R I N T
© G
EA G
roup
© f
2m
12 6206
Interview06 GEA: The GEA group expands into the bakery sector16 Prof. Thomas Becker: “Connected Bakery” 54 Dr. Johannes M. Peil: Fuel for muscles and brain
Production10 Dübör: How release agents affect the result of baking12 Mantinga UAB: No. 3 is for artisan products only28 Vandemoortele’s Dommitzsch location: Steady growth32 Trade Factory Bakery: Steamed baked products from the Netherlands38 Center-filled cakes: There’s more than meets the eye42 Gelé group: Answers from Cesson
Research36 FLOURplus: One raw material – many opportunities
Trays and Pans46 Anneliese: New functions for pan clusters48 acs Coating Systems: Coating made from high-performance plastic
Raw materials 50 Global trade: The Times They Are A-Changin‘
Food law56 On shaky ground: Labelling unpacked goods
Quality assurance60 Unannounced IFS Food Audits: Preparing for practical application
Ingredients62 Puffed cereals: Innovative bakery ingredients
Consulting66 LOGICON Dr. Edert Consultancy: Expert reports and funding
Regulars03 Editorial05 News26 News58 Trade fair calendar 65 News
PUBLISHING COMPANYf2m food multimedia gmbh Ehrenbergstr. 33 22767 Hamburg, Germany +49 40 39 90 12 27 www.foodmultimedia.de
PUBLISHERHildegard M. Keil +49 40 380 94 82 [email protected]
EDITOR-IN-CHIEFBastian Borchfeld +49 40 39 90 12 28 [email protected]
EDITORIAL STAFFHelga Baumfalk +49 40 39 60 30 61 [email protected] Sadykova [email protected]
ADVERTISING DEPT.International sales director Dirk Dixon +44 14 35 87 20 09 [email protected] administration Wilfried Krause +49 40 38 61 67 94 [email protected]
DISTRIBUTION+49 40 39 90 12 27 [email protected]
TRANSLATIONSkript Fachübersetzungen Gerd Röser [email protected]
TYPESETTINGTanja Forster [email protected]
PRINTED BYLeinebergland Druck GmbH & Co. KG Industriestr. 2a, 31061 Alfeld (Leine), Germany
BAKING+BISCUIT INTERNATIONALis published six times a year. Single copies may be purchased for EUR 15.– per copy. Subscription rates are EUR 75.– for one year. Students (with valid certification of student status) will pay EUR 40.– (all rates including postage and handling, but without VAT).
Cancellation of subscription must be presented three month prior to the end of the subscription period in writing to the publishing company. Address subscriptions to the above stated distribution department.
No claims will be accepted for not received or lost copies due to reasons being outside the responsibility of the publishing company. This magazine, including all articles and illustrations, is copyright protected. Any utilization beyond the tight limit set by the copyright act is subject to the publisher’s approval.
Online dispute resolution in accor- dance with Article 14 Para. 1 of the ODR-VO (European Online Dispute Resolution Regulation): The Euro- pean Commission provides a plat- form for Online Dispute Resolution (OS), which you can find at http://ec.europa.eu/consumers/odr
Valid advertising price list: 2016
cover photo: Reading
© S
chap
fenm
ühle
04
I M P R I N T
++ American Pan Opens Coatings Service Facility in Barcelona and Bowman Named Vice PresidentGilbert Bundy, CEO Bundy Baking Solutions, and Jose Busquets, CEO Excellent Coatings, recently announced the opening of American Pan Southern Europe, S.L. in May of
2016. This facility will provide bakery operations in Europe and the Middle East with new pan sales support along with pan cleaning, straightening and recoating services for American Pan’s DuraShield and OptiShield non-stick coat-ings and Excoat from Excellent Coatings. The opening of the operation in Spain marks the twenty-second pan servic-ing operation for Bundy Baking Solutions. There are cur-
rently 13 facilities in the United States, 4 in Canada, and one each in Mexico, Colombia, Brazil and the UK. In addition, Senior Vice Presi-dent of Global Sales, William Bundy, announced the promotion of Jason Bowman to Vice President of Eu-rope. Mr. Bowman, based in the UK, will be responsible for the strategic management of European sales and will sit on the Board of Directors for
American Pan SE. American Pan is part of the Bundy Bak-ing Solutions group of companies which is headquartered in Urbana, OH U.S.A. Bundy Baking Solutions also includes American Pan custom industrial baking pans, Chicago Me-tallic stock baking pans, DuraShield and OptiShield non-stick coatings for baking pans, RTB pre-owned pans and bakery equipment and Shaffer mixers and processing equip-ment. +++
++ Reading Names Hassan Harakeh Sales Manager for Middle East & AfricaHassan Harakeh has been appointed Sales Manager for the
Middle East & Africa Region for Reading Bakery Systems (RBS). In his new role, he will be responsible for directing sales efforts of RBS equipment and systems across the region, and assisting with trade shows, advertising, technical confer-ences and other marketing opportu-nities. He will report to David Kui-pers, Vice President, Sales &
Marketing. Harakeh is originally from Lebanon and is a graduate of the American University of Beirut with a Bach-elor’s Degree in Agricultural Engineering, and a Master’s in Food Production and Agricultural Economics. He is fluent in French, Arabic, and English. Prior to his new position, Harakeh was with Reading Bakery System’s parent company, the Markel Food Group, and helped establish Markel’s office and regional presence in Dubai. He worked with the equip-ment and processes from AMF and Tromp, and also helped RBS in a part-time role. Before that he had held positions with the Malco Group in both Dubai and Lebanon. +++
++ Heuft expands export managementThe Heuft group of companies, headquartered in Bell/Eifel, Germany, has strengthened its export team. In future,
Simon Tabruyn, Jankees Geurts and Peter De Naeghel will represent the thermo-oil oven constructor worldwide. +++
++ Stefan Scheiber is Bühler’s new CEOAs announced just over a year ago, Stefan Scheiber takes over the position of CEO at Bühler on 1 July 2016. He suc-ceeds Calvin Grieder, who is concentrating on his position
as Chairman of the Board of Direc-tors. On the occasion of the hando-ver of office, Stefan Scheiber says “To continue Bühler’s success story, we want to seize the opportunities of accelerated change arising from megatrends such as digitization, food security and sustainability.” As a result of the change at the top of the group, there will be new ap-pointments to other management
positions in the Grains and Food business area. Stefan Scheiber (Swiss, aged 50) has worked for Bühler since 1988. In his 25-year career he has headed various sales and pro-duction organizations at all hierarchy levels in Kenya, South Africa, Germany and Switzerland. Calvin Grieder, who has been CEO since 2000 and has also held the post of Chair-man of Bühler’s Board of Directors since 2014, will focus on his mandate as Chairman of the Board of Directors. Jo-hannes Wick already took over the office of CEO, Grains & Food, as of 1 April 2016, and is thus also a member of the Group’s management. Johannes Wick entered the Group in 2014 as Head of Grain Milling. He had previously worked for more than 20 years in various managerial functions in the energy and infrastructure sector. +++
© A
mer
ican
Pan
SE
Inside the new plant in Barcelona prior to start-up
© A
mer
ican
Pan
SE
Jason Bowman
© R
eadi
ng B
aker
y Sy
stem
s
Hassan Harakeh
© B
ühle
r
Stefan Scheiber
N E W S + + N E W S + + N E W S 05
© H
euft
Simon Tabruyn, Jankees Geurts, Peter De Naeghel
www.bakingbiscuit.com 04/2016
www.bakingbiscuit.com 04/2016
06 I N T E R V I E W
GEA expands into the bakery sectorThe GEA Group Aktiengesellschaft is on a buying spree: in 2015 the company acquired Comas headquar-tered in Torrebelvicino near Venice, and GEA has now taken over another supplier of baking tunnel ovens and complete production lines for biscuits, crackers and snacks, Imaforni Int’l S.p.A., whose head-quarters are in Verona. What’s the plan behind this?
+ Borchfeld: Mr. Oleas, what is the strategy behind the takeovers, and in particular why in such a short period of
time?+ Oleas: GEA’s acquisition strategy is aimed especially at es-tablishing a leading position in sophisticated process technolo-gies for the food industry. Entry into the areas of bakery prod-ucts fits into that exactly. For this we constantly analyze possi-ble acquisition candidates. The acquisition of Imaforni was a logical next step after the successful takeover of Comas, since both companies have cooperated together for a long time, and complement one another exceptionally well in their products and services spectrum.+ Borchfeld: Does GEA have any experience with entry into a new product category and/or into new production fields?+ Oleas: GEA looks back over a long success story with re-gard to expanding its portfolio through acquisitions. Three to four acquisitions per year were for a long time not a rare occur-rence for the company. In the last two to three years we have focused our emphasis on the correct alignment of the Group for the future, while on the other hand we have faced a quite reluctant M&A market due to the state of the economy. But then, in 2015, we were again able to accomplish four acquisi-tions with a total annual sales volume of more than EUR 120m.
++ Jürg Oleas, CEO of GEA Group Aktiengesellschaft
© G
EA G
roup
+ Borchfeld: GEA, with GEA Refrigeration Technolo-gies, has been known in the baked product sector in the past more as a supplier of refrigeration and freezing solu-tions. It offers, among other products, spiral freezers. GEA appeared for the first time together with the Comas company at the iba 2015 trade fair. What was the feedback from customers after the takeover?+ Oleas: In particular, the combination of Comas as an estab-lished supplier in its industrial area, and GEA as an innovative group operating globally and with an exceptionally good reputa-tion in the whole of the food industry, was received as very promising. With Comas, GEA expands its expertise by adding further process steps, therefore in future it can provide even bet-ter support to customers in meeting specific individual challeng-es. Furthermore, GEA’s global presence will enable Comas to serve its customer base even better in the future.+ Borchfeld: Exactly how must a customer imagine the inte-gration of Comas and now of Imaforni into the GEA business to involve?+ Oleas: By acquiring Comas we have created an entirely new Application Center Bakery. In these Centers, which we also have in our new structure for frozen foods or coffee and tea for example, we focus our application-specific know-how so as to be able to satisfy the individual needs of our customer groups even quicker and in a more tailor-made way. Imaforni with its complex production lines, especially for cookies, bis-cuits and crackers, has further strengthened the Bakery APC.+ Borchfeld: On which partners do you rely in relation to turnkey projects, or are there fixed partners?+ Oleas: GEA is one of the biggest system suppliers for the food-processing industry. In this respect we concentrate on process technology and components for sophisticated pro-duction processes. We have great experience in executing turnkey projects, but our focus is clearly on the design, deliv-ery and installation of the components and process lines that are relevant for a production plant.+ Borchfeld: Are there any current examples of such entire plants in the baking sector?+ Oleas: We construct around 10 to 15 turnkey projects in the bakery area each year. These involve customers that are al-ready active in the industry but want to open up new product areas or output dimensions, as well as customers who have no previous experience in manufacturing bakery end-products. For example, we recently had an order from Eastern Europe for which we supplied a complete fabrication plant for prod-ucts such as profiteroles, mini-profiteroles, éclairs, Paris-Brest cakes and Italian soft amarettini. The customer had already produced a few of these products by hand, but wanted to fully automate the manufacture on a larger scale. He therefore
Artezen Srl, Via Lago di Tovel 14, 36015 Schio - Italy, +39 0445 577495, [email protected]
Fully Automatic Bun Divider Rounder
Visit our webpage: www.artezen.eu
Artezen’s efficient roll plant comes with a stress-free dividing system and double rounding device. This unique two-row setup offers you a larger weight range without the need to change drums or stamps. The required weight is simply set through the drive controller while the electronic processor automatically sets the optimal parameters for highest accuracy and optimal rounding results.
l Ideal for single person operationl Quick startup and minimal maintenancel Optional integrated compact moulder for rolls
A D V E R T I S E M E N T
I N T E R V I E W
© G
EA G
roup
++ GEA technicians assembling a cupcake production line
came to GEA with samples of the products he wanted to produce, and we developed a customized turnkey solution for him. On the other hand, a customer from North Africa, for ex-ample, without any experience in the baking industry, asked us to construct a complete production line for two-color and marbled cakes and cupcakes.GEA also provided technical support for the two turnkey projects, and sent a specialist food technologist to the cus-tomer’s production sites in each case, to adapt the existing recipes or to de-velop new ones on the spot. The tech-nical side also took care of the shelf life of the end products, which was differ-ent for the two customers, particularly due to the climatic conditions at the plant locations.+ Borchfeld: When customers come to you with product ideas, how can you support them?+ Oleas: At GEA we attempt as far as possible to cover en-tire processes and the relevant services, thus offering our customers a full expertise. Together with our customers, we very often develop customized solutions for their require-ments or product ideas on this basis.
+ Borchfeld: As well as biscuits/cookies, cakes, crackers and gateaux, is there also a plan to have solutions for swiss rolls and other new products soon. Can you tell our readers anything more about this?+ Oleas: In addition to solutions for the product areas men-tioned above, which of course we want to expand further, we also offer some specific applications for pizza, e.g. pizza ovens and high-performance production lines, or for bread as well,
I N T E R V I E W 07
www.bakingbiscuit.com 04/2016
www.bakingbiscuit.com 04/2016
08 I N T E R V I E W
e.g. rye bread extruding machines, filling devices for garlic baguettes and depositing machines for gluten-free bread. However, all the production lines are different to one another due to almost complete customer-specific production.+ Borchfeld: GEA offers a production control program in the shape of the OTAS® controller. Will this system soon exist in the new subsidiary companies as well?+ Oleas: We now offer integrated automation solutions for complete manufacturing lines for the bakery sector that man-age entire turnkey plants simply and efficiently and maximize output, while at the same time focusing on operational flexi-bility and end-product quality.+ Borchfeld: What kind of synergies does GEA hope for as a result of the takeovers?+ Oleas: Our acquisitions follow the desire to expand further our leading market position, especially in the food area. We close technological gaps by taking over smaller companies with particular process know-how, thus enlarging our product range of complete process solutions in attractive markets. By taking over Comas last year, we entered the market for machines and plant to manufacture baked products. The acquisition of Imaforni now already makes us one of the process technology market leaders in the area of the bakery products industry. We will promote this position fur-ther by focusing our engineering capacities in the Application Center Bakery.
++ Cupcake development in the Bakery Experience Center
© G
EA G
roup
© G
EA G
roup
+ Borchfeld: Comas is well known as a manufacturer of lines to produce sweet baked goods and fine pastry products, exactly like Imaforni. Are further takeo-vers of plant constructors planned? + Oleas: We will grow further through acquisitions, and have already identified other potential takeover targets. At the same time, we are initially directing our attention at expanding the spectrum of applications.+ Borchfeld: Is expansion into the bread and bread roll area also conceiv-able?+ Oleas: Further expansion into the bread and bread roll area is conceivable
provided it involves manufacturers of sophisticated solutions.+ Borchfeld: Is it now time for consolidation?+ Oleas: For a long time GEA has followed a strategy of acquiring companies that open up new markets for the group, or that supplement the product range in a targeted way in known markets. The purpose of this is to offer cus-tomers an ever wider range of products and services from a single supplier. Thus it’s more a question of when attractive opportunities offer themselves than of a general consolida-tion trend.+ Borchfeld: Is there a reason for the fact that GEA has bought only in Italy just now?+ Oleas: No. Our acquisitions involve technological excel-lence, not regional reinforcement. As a rule, we are interested in small to medium-sized businesses that cover an area as a leading supplier with particular technologies, and with which we can further round out and/or complement our portfolio.+ Borchfeld: GEA’s strategy is: market leadership and, among other things, technology leadership. How do you plan to achieve this?+ Oleas: Today we are already among the market and tech-nology leaders in our business areas. We want to expand this position further. For example, our new organization structure will help us here. Firstly, it gives additional benefit to our in-novative strength by focusing our engineering capacities. Sec-ondly, through the Group’s more uniform identity based on the new national organizations, we are significantly closer to local customers, with the result that we can understand and serve their needs and wishes even better and faster.+ Borchfeld: Where do you see further opportunities for growth and takeovers?+ Oleas: In addition to the entry into the bakery product area, our acquisition strategy concentrates on the following fields: expanding our leading position in milk and beverages, strengthening the personal care field, expanding the position in relation to animal proteins, enlarging complete solutions for the edible oils, starches and sugar areas, strengthening competences in the packing area, and expanding process intelligence and automation. + Borchfeld: Mr. Oleas, thank you very much for the inter-view. +++
++ GEA successfully concluded the acquisition of Imaforni in Verona, Italy
I N T E R V I E W
TORTILLA
INDUSTRIAL
VERTICAL SERVO TWIST TYER
www.burford.com
CALL US TODAY +44 1638 668563
THE TYING EXPERTS
F2M ad.indd 1 1/15/14 8:00 AM
Burford Bakery Solutions, Unit 4 Sam Alper Court, Depot Road, Newmarket, Suffolk CB8 0GS UK • +44 1638 668563 • [email protected] P.O. Box 748 • Maysville, OK 73057• Telephone (405) 867-4467 • Fax (405) 867-4219 • e-mail: [email protected]
Model 2000VTR shownwith optional stand and
brush assembly
Booth 3507
I N T E R V I E W
www.bakingbiscuit.com 04/2016
P R O D U C T I O N10
the wrong way, as well as being expensive. On the other hand, it is more economical to focus on cleanliness and the correct choice of separating agent, as well as on the right spray technology. Spray equipments for optimum greasing are available, and are designed for use in a wide variety of plant sizes: from a manual spray device to a cus-tomized spray installation. The Airmix process is one of the best-sellers in the company’s product range. Its char-acteristic features are a uniform spray pattern and low spray mist formation. +++
How release agents affect the result of bakingVarious different consumption habits and country-specific features in relation to baked products require a large number of separating agents, cutting oils and slip oils. DÜBÖR Groneweg GmbH & Co. KG, Bad Salzuflen/Germany, are specialists in this field and have been active in the market since 1961.
+ Visual requirements, e.g. the uniform surface tex-ture of the end products, are as important when us-
ing separating agents as economic efficiency with regard to production times and processes. The type of separating agent has a decisive effect on the visual appearance of the baked product: emulsions impart a pale-colored, coarsely porous appearance, while separating oils ensure a brown, finely porous surface. The ratio of wax, oil and optionally water also exerts an influence on the baking result. The proportions of protein and sugar in the recipe also im-pose differing requirements on the separating power of the separating agent used. Although separating agents with a large proportion of wax are as a rule more expensive, they can be dispensed more economically and simplify the clean-ing of trays and pans. DÜBÖR’s products are from vegetable sources, have a neutral flavor, are free from the need for dec-laration, are certified in accordance with RSPO Segregated [Roundtable on Sustainable Palm Oil - Segregated] (prod-ucts that contain palm oil) and are free from allergens. The minimum shelf life is 9 to 12 months, depending on the grade. A palm-oil-free alternative option is offered for every product.
It is important to dispense the separating agent as spar-ingly as possible, so as to obtain only small residues or none at all. “A lot helps a lot” when using release agents is
© D
ÜBÖ
R
++ Release agents for greasing pans and trays, bowls and belts, or to release baked products or sweet products from molds, are available in various pack sizes
++ The emphasis when using release agents is on visual requirements such as a uniform end product surface texture
© Fotolia
I N T E R V I E W
Tape Closure System
F2M TCS 400 ad.indd 1 1/14/14 5:39 PM
CALL US TODAY +44 1638 668563 THE TAPING EXPERTS
The Burford ® Tape Closure System closes your packages using a metal free closure. The TCS-400 works with a wide variety of packaging materials and can easily be added to your existing production lines. For optimal performance aminimum bag thickness of 1.25 Mil is required.
www.burford.comBurford Bakery Solutions, Unit 4 Sam Alper Court, Depot Road, Newmarket, Suffolk CB8 0GS UK • +44 1638 668563 • [email protected]
P.O. Box 748 • Maysville, OK 73057• Telephone (405) 867-4467 • Fax (405) 867-4219 • e-mail: [email protected]
Model TCS-400Rshown with optional
conveyor and printer
Booth 3507
Tape Closure System
F2M TCS 400 ad.indd 1 1/14/14 5:39 PM
CALL US TODAY +44 1638 668563 THE TAPING EXPERTS
The Burford ® Tape Closure System closes your packages using a metal free closure. The TCS-400 works with a wide variety of packaging materials and can easily be added to your existing production lines. For optimal performance aminimum bag thickness of 1.25 Mil is required.
www.burford.comBurford Bakery Solutions, Unit 4 Sam Alper Court, Depot Road, Newmarket, Suffolk CB8 0GS UK • +44 1638 668563 • [email protected]
P.O. Box 748 • Maysville, OK 73057• Telephone (405) 867-4467 • Fax (405) 867-4219 • e-mail: [email protected]
Model TCS-400Rshown with optional
conveyor and printer
P R O D U C T I O N
www.bakingbiscuit.com 04/2016
baguettes, molded breads (ovals) or pointed baguettes each weighing between 100 and 530 g at an output capacity of be-tween 2,500 and 10,000 pieces/hour. The plant’s special fea-ture is that both the molded and the cut products are depos-ited onto proofing boards in the correct position, i.e. in the scrabbling direction. This is achieved by transferring the molded products onto the proofing board loader via a curved belt and the cut products via a deposition point. The curved belt is moved into the deposition zone when needed. Scrap dough arising during the make-up of the baked products re-turns automatically and thus in uniform amounts to the dough sheeter via a feeder belt. Further degrees of freedom remain even after make-up. Large amounts go into the automatic proofer, while smaller batches are loaded onto rack trolleys and move via a bypass into a push-through proofer and can also undergo further manual finishing if necessary. All the products are baked on stone in thermo-oil heated multi-deck ovens. Produc-tion director Arturas Venslauskas is confident that the en-closed baking chambers of the deck ovens yield the best baking result.
P R O D U C T I O N12
No. 3 is for artisan products onlyMantinga UAB is the biggest manufacturer of frozen baked products in the Baltic States. The first line in the new factory, which specializes entirely on artisan products and fat-fried pastries, began operating in early May.
++ The unloader with pointed tongues that fold up and prevent smaller products falling off inadvertently
+ Marijampolė is strategically well situated. The dis-tances are just 30 km to the Polish border and 200 km
to Kaliningrad in Russia, while 270 km of motorway-like roads lead to the major Baltic seaport of Klaipėda. From there it’s only a stone’s throw to Scandinavian countries, Mantinga’s biggest export markets, or even to Germany. The new factory, whose first line went on stream in early May, is aimed not least at these markets. In future it will produce mainly part-baked, craftsmanlike (English: “arti-san”) products such as ciabatta, bread twists etc., as well as donuts and Berliners.
The newly constructed building has a ground floor area of 24,000 m2 and part of it will be given a second story, so around 37,000 m2 will finally be available. The first bread line to move in is a one-off that provides all the flexibility re-quired by the management team headed by Agentas. It starts by using various flours, sourdoughs and hot-soaked grains, and continues through the almost endlessly variable Fritsch make-up line. When necessary, it delivers cut baguettes (omega baguettes), ciabatta, split seeded bread rolls, molded
© f
2m
1 3R U B R I K
www.bakingbiscuit.com 04/2016
P R O D U C T I O N
The whole of the proofing, baking and cool-ing technology comes from the Czech ma-chine builder Kornfeil. In automatic operat-ing mode, the hearth-baked bread dough pieces are deposited in an 1800 x 850 format onto peelboards on which they move through the proofer, which consists of eight towers. The proofer is heated by energy re-covered from the ovens by the so-called Ekoblok. The necessary air humidity is en-sured by an ultrasonic nebulizer that gener-ates a cold aerosol, which enables proofing to take place at temperatures of 26°C. The layout of the proofer allows various proof-ing times from 40 to 120 minutes. At the end of the proofing time, the dough pieces are scrabbled (peeled) from the peelboard, optionally cut by knives and strewn with seeds and grains, and handed over to the oven loader. The peelboards return in the base of the proofer and are suction-cleaned in the process.
The oven installation consists of four ther-mo-oil heated stone ovens, each with seven decks, which together almost fully bake 3,200 pieces per hour of the main product, a 350 g ciabatta. Each deck measures 4,32 m2. Each pair of ovens is served by a loader/un-loader. In fully automatic mode all the dough pieces come from the automatic proofer, but if small batches arriving from the push-through proofers are to be produced, the loader collects them from a special loading station that has previously scrabbled them from the peelboards. Incidentally, the load-er/unloader has two special features: to guarantee that the deck is fully emptied even with small products without one of them possibly rolling back, the loader nose folds up slightly after accepting the products, thus securely driving the whole batch out of the oven. In addition, a vacuum cleaner runs alongside in the baking compartment at every loading and unloading process to pre-vent the burning of crumbs, seeds that have fallen off etc. After being deposited onto the removal conveyor belts, they run through a cooling spiral for 30 to 40 minutes and from there into the freezer. The current produc-tion program for the new line, which has started two-shift operation immediately and is to run in three shifts at the end of the year, is planned for 18 to 20 different products. At present the main product is a 350 g ciab-atta and the smallest is a small bread roll weighing 75 g.
++ A Fritsch dough sheeting line
© f
2m
P R O D U C T I O N 1 3
++ The ovens and loaders are from Kornfeil©
f2m
++ Smaller batches go via a bypass into push-through proofers
© f
2m
www.bakingbiscuit.com 04/2016
14 P R O D U C T I O N
Mantinga UAB, MarijampolėIt all began in 1998 with the importation of frozen dough pieces from France. But Klemencas Agentas, who originally trained as a veterinarian, soon laid the foundation stone for his own production unit in Marijampolė, Lithuania. The original factory, long since enlarged several times, has 11 lines producing frozen baked goods ranging from classical bread rolls, batons and frozen doughs for household use to sweet or salty filled laminated fine pastries, Berliners and donuts. Agentas responded to the rapid growth in the snack markets at home and abroad by building a second factory in Marijampolė. Everything produced there – soft-dough bread rolls, ready-filled sandwiches, soups and pizzas – goes under the name Mantinga Food into supermarkets, filling stations and convenience shops. The newly opened third factory is aimed at the growing market for artisan products. Until the mid-2000s, Mantinga concentrated mainly on the domestic market, but exports now account for 60 % of turnover. The majority of the exported products goes to the Scandinavian and Western European markets, but Russia, Belarus and the Ukraine are also well-developed sales markets. +++
The entire line from proofer to freezer is designed as a single unit from the control engineering point of view, and in addition it communicates with the upstream plants so the whole line can respond to changes and malfunctions when necessary. The heat for the maximum temperature of 300°C that can be used for baking in this case is supplied by two thermo-oil boilers on the upper floor, which together can provide 1,000 kW of heating power, which is more than the four ovens need and thus has some in reserve for more ovens. The Ekoblok heat recovery plant is also made by Kornfeil. It recovers surplus heat from the hot water plant and the refrigerator compressors and either reuses it directly to heat water or puts it into semi-intermediate storage in water tanks holding 24,000 liters. +++
++ Technologist Darius Anelauskas (left) and engineer Kestutis Košuba bring the new production unit into operation
++ The thermo-oil oven’s twin boiler system with a total power of 1,000 kW, on the left the Ekoblok energy recovery unit and on the right the emergency tank for the oil
© f
2m©
f2m
www.bakingbiscuit.com 04/2016
+ Professor Thomas Becker, Full Professor for Brewing and
Beverage Technology at the TU Mu-nich, used it at the Automation Con-ference in Weihenstephan on 7 April 2016 when he presented a research project that he has initiated. His de-clared aim is to develop a practicable concept for a fully virtually visualiz-able baked goods production facility. + bbi: What does the term “Con-nected Bakery” stand for?+ Prof. Becker: It involves a philos-ophy in which the intention is for a baked goods production process to operate in a way that is highly flexi-ble, decentrally controlled and auto-mated to a noticeable extent. In this respect, the plan is for the control processes to be s imulated in a cloud database solution that can also be locat-ed geographically separated from the production facility. Individual subprocesses can also be geographically sepa-rated. Therefore the fact that constant, unbroken data exchange in real time is possible between the controller cloud and the production plant has central importance. In this respect the product has the task of telling the re-spective plant component what is to happen to the product. This represents the core of the philosophy. The dough says: “Roll me out!”. The dough piece says: “Put me in the proof-er” etc.. However, since this involves a foodstuff, the infor- mation – e.g. in the form of a QR or RFID code – cannot originate from the product itself, but must be present on a carrier medium associated with the latter. That can be the dough bowl or baking tray. However, “Connected Bakery” is not just a philosophy, it’s an entirely concrete research project which the TU Munich – Weihenstephan will carry out within a consortium. + bbi: When is the actual implementation of the research project planned to start?+ Prof. Becker: We are currently in the phase in which the partners are being assembled and the project formu- lated in detail. Completion of this step is expected by the end of 2016. The plan is then for the implementation phase to begin from mid-2017 onwards.
+ bbi: So is the “Connected Bakery” to come into being as a real plant? + Prof. Becker: Yes, of course. We will set up a reference plant here in Weihenstephan. The premises al-ready exist in the Technology Center, and that’s where we will con-struct a baked goods production unit meeting the standards of a “Connected Bakery”. Natur- ally the plant will also produce very real baked goods. Its methodology will embody all the basic ideas, but the quantitative flows will need to be adapted appropriately. I imaging a dough volume of 50 to 100 kilograms as the daily output. Only when the project is re-ally operating will groups of visitors
be given access to the plant.
+ bbi: Which products are you going to produce in the reference plant?+ Prof. Becker: It will involve bread and bread rolls, that’s clear. We want to evaluate whether we can downscale to a batch size of one. The product range will also not be too extensive. It will certainly be about ten different products – bread and bread rolls. It would be inappropriate to already commit oneself to more precise information at this point. The project really is break-ing new ground in many areas.
+ bbi: Can you tell us the sources from which the project is being financed?+ Prof. Becker: As far as financing is concerned, the “Connected Bakery” is a rather tradition-al research project. The framework has not been defined yet, but co-financing from the industry is certainly necessary, because ultimately that’s what it is designed for. The inten-tion is for the first half to be contributed in the form of physical resources and know-how from the participating companies. We want to have the other half financed by public funds from the State of Bavaria, the German Federal Government or the EU. We are already in contact with the competent agencies for this purpose. In fact, the “Connected Bakery” fits very well into the German Federal Ministry of Economics’ “Future Project Industry 4.0”.
I N T E R V I E W16
++ Prof. Thomas Becker, TU Munich
© B
ecke
r
“Connected Bakery” – Real and virtual baked products are created The topic of digitally imaging and controlling manufacturing processes is also continuing to spread in the production of baked goods, under the slogan “Industry 4.0” and “Artisan 4.0”. A new concept that has emerged at the same time is called the “Connected Bakery”.
A D V E R T I S E M E N T
BVT Vacuum Cooling Parallelweg 13 5349 AD OSS The Netherlands Tel.: +31(0)412 69 90 08 Fax: +31(0)412 63 95 65 E: [email protected] I: www.bvtvc.com Member of BVT Bakery Services
BVT Vacuum Cooling manufactures continuous and batch vacuum cooling systems for medium and industrial sized bakeries. This revolutionary system can offer your pro-duction:
1. Rapid cooling of baked products: up to 3 minutes 2. Improvement of product quality and longer shelf life of the bakery products 3. Reduction of baking time by up to ±30%, less acrylamide in product (up to 70%)
Together with our parent company we offer ''Total dough handling'' solutions for a wide range of bread and pastry products. We are well known for our turn-key projects for major bakery groups around the world. All equipment is designed and manufactured at our modern factory located in the Netherlands. For a complete overview of the delivery program, please visit our website: www.bvtvc.com, or feel free to contact us!
I N T E R V I E W
+ bbi: Who is to collaborate in the project on behalf of the companies?+ Prof. Becker: Please excuse me for not yet being able to mention any actual names in the present phase. However, of course it’s also clear that we have already commenced dis-cussions with certain companies. We need components from various different areas to allow the project to run. We need the actual production technology from flour silo to oven. You can already see from the production quantities I have mentioned that the plants need not be very big. In addition we also need the control engineering and IT infrastructure on the spot. However, the more important component will be the virtual counterpart of the plant in the data cloud. To enable this central element to function, we need the appro-priate electronic data-processing hardware and software, and of course extensive know-how in this area.
+ bbi: So how is the plant on site to be controlled in concrete terms?+ Prof. Becker: The plant will be controlled by the prod-ucts that are produced in it. The re-spective product must al-ways be able to state the next thing that is to happen to it. It need not necessarily “know” this information, but must ob-tain it from the cloud and then make it available – e.g. via an RFID or QR code.
+ bbi: How do you plan to ensure a continuous flow of data inside the plant? For example will the Weihenstephan “WS Bake” standard plan a role in this?+ Prof. Becker: Up to now, “WS Bake”, which defines a standardized interface, is in fact intended more as a way of simplifying communication between plant components and higher level control systems and MES (Manufacturing Execution Systems). That doesn’t fit very ex-actly with the philosophy of the “Connected Bakery”, since in the latter the product is always supposed to bring the information with it, rather than the upstream plant component passing it on to the next one. But if it’s a question of interfaces and data points, then we can certainly also refer back to the results from the “WS Bake” project in the “Connected Bakery” project. In fact, however, one of the essential tasks will be to develop a consistent data and communications interface.
+ bbi: What role does the human factor play in the “Connected Bakery”?+ Prof. Becker: The plant need not be fully automatic. It’s not primarily a question of robotics, instead it involves the parallel operation of the production process in the real world and in a virtual world, and controlling the pro-cesses by the product itself. Basically it’s not so important
I N T E R V I E W 17
www.bakingbiscuit.com 04/2016
© F
rits
ch
whether a tray of dough pieces is shoved into the oven by a lift or by a human hand. The key point is that the product tells the operator – whether the latter is human or mechan-ical – what he/it must do to it. An employee can also use a
scanner to read in a QR-Code. This factor also makes the project attractive for smaller businesses. It’s quite obvious: the bigger the production capacity, the more important will be the part played by automation in this production line. However, it’s also a solution with a restrained use of automation technology and a clearly recognizable propor-tion of manual work. A pretzel-twisting robot is really only worthwhile above a certain number of pieces.
+ bbi: Which main problems do you see as things stand at present?+ Prof. Becker: One central point will be financial via- bility as a function of batch size. What quantity per pro-duct must be assembled to enable a manufacturing operation that at least covers its costs? That will only become apparent during the trial, and the practicability of the “Connected Bakery” will also depend decisively on this factor. There will be information technology and process technology issues needing to be solved, of that I am quite certain.
+ bbi: By when do you plan for initial results to be visible?+ Prof. Becker: The intention is for the prototype of the “Connected Bakery” to be in existence by the end of 2018, and that is also when the first products will be produced. On the one hand I am very keen to see what they will taste like and look like at that time. On the other hand, however, I am also very optimistic that the project will be a success.
+ bbi: Professor Becker, many thanks for the interview. +++
— Author: Roland Ried
I N T E R V I E W18
++ German consumers are highly networkedAnyone who wants to buy online must first of all be net-worked. Consumers in the Federal Republic of Germany
are among the most highly networked consumers world-wide. This is the outcome of the GfK(Consumer Research Association) Connected Consumer Index, which shows how strongly and with which equipment the consumers in 78 countries and 8 regions worldwide network with one another as well as with digital contents. Germany is in 5th position in this worldwide ranking. Kevin Walsh, Director of Trends and Forecasting at GfK, comments: "We see con-sumer networking growing in all countries. For big growth markets, especially in the Near East, Africa and the emerg-ing countries in the Asia-Pacific region, the predominant trend remains the spread of smartphones. This is the de-vice used most often by consumers – and often the first de-vice used – for digital access to data sources. In the devel-oped markets, mainly in Western Europe and North Amer-ica, the influencing factors have already arrived at the next stage of networking. In this case wearables are far ahead, together with the Connected Car. Both bring new benefits to consumers. Smart Home technology has similar impor-tance, but its acceptance by consumers is slower, albeit probably more continuous." +++
N E W S + + N E W S + + N E W S
Index of online networking by consumers
Rank2015
Rank2016
Index2015
Index2016
1 1 Hong Kong 1,430 1,486
2 2 North America 952 1,062
8 3 United Arab Emirates 829 995
3 4 Norway 939 988
4 5 Germany 873 940
6 6 Saudi Arabia 836 935
5 7 Great Britain 856 916
10 8 Switzerland 801 914
7 9 Denmark 835 906
9 10 Sweden 807 875
Sour
ce: G
fK
Packing soft cakes: a special tool ensures gentle product handlingThe chocolate and cookies manufacturer Şölen is one of Turkey’s fastest growing companies, with a 20% annual turnover increase. Şölen has cooperated with Gerhard Schubert GmbH since 2010, and now has 16 TLM machines in use. The latest is a picker line to pack chocolate-coated soft cakes, located in the Gaziantep factory in Southeast Anatolia, which was only inaugurated in September 2014.
+ Luppo Petit Pie soft cakes are particularly delicate, and can easily be damaged during automated pack-
ing. To avoid this, Schubert developed a special tool to put the products into clamshells (plastic trays with a lid that can be firmly sealed). The special tools pick up the cookies by suction and simultaneously grip them. Additional retainer tools attached to both sides of the F44 robot’s gripper arms provide further stability and contribute to the precise inser-tion of the cookies into the trays. A conveyor belt carries the “Luppo Petit Pies” from the up-stream machine and into the Schubert machine. First of all, transmitted light scanners check the shape and position of the cookies. Only “good” products are released to be picked up by the robots. In parallel with the product loading, clam-shells are taken from magazines and inserted with millimeter accuracy into two continuously moving chains. This guaran-tees that each tray is fully loaded, and no flawless products overflow at the end of the product belt. The F44 robots with the special tools now pick up the products from the belt, turn them upright and place them vertically into the clamshells. The newly-developed Schubert 3-D scanner is currently be-ing prepared for use to increase the quality level even
© G
erha
rd S
chub
ert G
mbH
further. This scanner will be mounted at the product inlet, thus monitoring the entire product flow at the start of the robot line. The 3-D scanner recognizes three-dimensional defects: cookies that are too thin or too high, cookies with a missing top or those that consist of a top only are detected and reported to all the downstream F44 stations to ensure they are not picked up. The volume and weight of the cookies can also be calculated. Nine transmitted light scanners and 18 robotic arms are currently used in the plant. Because space for the plant was limited, Schubert mounted both magazines on the same side of the machine, so there is no need for discharge or buffering belts. The products are packed immediately after they are delivered from the up-stream machine. The packing process is particularly hygienic and efficient because no manual intervention is necessary. The machine can be expanded at any time to handle other formats, programs and tools. The transport chain is adjust-able. Deep-drawing the clamshells, which up to now still takes place on another supplier’s machine, would in princi-ple also be feasible on the TLM machine, and is currently being contemplated. The line packs up to 900 products per minute and achieves 98% efficiency.
R O B O T I C S 19I N T E R V I E W
www.bakingbiscuit.com 04/2016
www.bakingbiscuit.com 04/2016
The candy manufacturer ŞölenŞölen was founded by five brothers and two sisters in 1989, and today it is Turkey’s biggest chocolate exporter with annual export sales of around USD 200m (around EUR 173.27m). As measured by growth in the last ten years, Şölen is one of Turkey’s fastest-growing companies and currently occupies 80th position in the domestic ranking list. Their aim is the billion mark by 2020. The intention is not to achieve the target growth exclusively organically. Şölen is on the lookout for confectionery manufacturers, and not just in the chocolate area. Joint partner Hasan Coban says: “We are interested in internationally established companies with good sales and distribution networks inside Europe and in America.”
The company currently employs around 2,000 staff. Şölen built a 110,000 m² factory in 2014 including a logistics center with storage spaces for 50,000 pallets in Gaziantep, Southeast Anatolia, which combined the four previously existing factories under one roof. The new production facility increased capacity by 10%. Together with its second works in Istanbul, Şölen now has a production area of more than 160,000 m². Its production capacity is 260,000 tons.
The portfolio comprises more than 200 types of chocolate. Şölen also offers filled and coated cookies in the Biscolata series, Winergy and Duomax chocolate-coated snacks, and the Mojee brand of candy. The company is certified in accordance with ISO 9001:2008 and the BRC and IFS Food Safety Management System Standards. +++
++ From the left: Dirk Andrich (Schubert’s Area Sales Manager), Erdem Bozduman (Şölen’s Production Manager), Ali Coban (a Şölen partner), Gerald Schubert (Schubert’s Managing Director), Hasan Coban (a Şölen partner), Erdogan Coban (a Şölen partner), Hannes Schubert (Schubert’s Project Manager), Adnan Akman (Schubert’s Sales Manager) and Caglar Dogru (Füme Makina)
© G
erha
rd S
chub
ert G
mbH
++ F44 robots pick up the products from the belt, turn them upright and insert them vertically in the clamshells. Special tools handle the cookie products particularly gently by simultaneous suction and gripping
© G
erha
rd S
chub
ert G
mbH
R O B O T I C S20
Furthermore, Şölen recently installed two new TLM lines with various technical innovations. The first is a special bar packer for chocolate cakes, with two Transmodule sections that together pack 1,400 products per minute. High speed is also the particular challenge when packing chocolate cakes in four different formats. The products need to be forward-ed on the Transmoduls in cartons that are open in the direc-tion of transport. To ensure that the products are not falling out, Schubert developed special automatically controlled sheet metal inserts that lock the boxes. This solution is particularly useful during Transmodul cceleration and deceleration whilst transporting the filled cartons. It allows Şölen to purchase the carton blanks at significantly more favorable prices. +++
For more information visitwww.haas.com
MORE IDEAS MORE VALUE MORE FLEXIBILITY
www.haas.com
ScoOper
Vigor
Salubrious
N sh
Haas_wafer_II_Anzeige_210x297_RZ.indd 1 29.02.16 14:33
R O B O T I C S
www.bakingbiscuit.com 04/2016
Fast Picker scores bread rolls
R O B O T I C S22
+ The Belgian plant constructor Dewilde has developed a compact robot cell to score breads,
baguettes or rolls. Its key component is the TP80 Fast Picker, a four-axis device from Stäubli that makes up to 220 cuts/minute. The overall concept includes 3-D detection of the positions of the dough pieces, an automatic knife-changing station, a cleaning station and of course the robot itself. The TP80 scores
incoming baked products according to pre-defined scor-ing parameters. It receives the exact position data of the dough pieces via the upstream laser scanner. The robot itself picks the correct blade from the change magazine for the respective batch. For applications in which 220 scores/minute are not enough, the company offers a cell with two TP80 fast pickers which then achieve a rate of 440 scores/minute. +++
++ Photo left: Robot cell to score baked products; photo center: the incoming dough pieces are scored according to pre-defined scoring parameters; photo right: automatic knife cleaning and wetting
++ ABB’s IRB 140 six-axis robot packs 19 different types of cookie at Inter-banket; switching to a new product takes 5 to 10 minutes
© G
Stä
ubli
Tec-
Syst
ems
Gm
bH
© A
BB
Packing many different cookies+ Interbanket B.V. headquartered in Montfoort
near Amsterdam, the Netherlands, has pro-duced cookies under a variety of labels since the nineteen-sixties. Around 85 to 90% of the products are exported. Manufacturing takes place on two lines, one producing various types of biscuits and the other exclusively the typical Dutch “Stroopwa-fels” (syrup-filled waffles). Wilco Roelse, the third owner of the family-run business, says “Packing was done by hand until now, which among other things sent personnel costs sky-high and forced us to find a different solution.” His biggest worry was produc-tion los-ses during the transition from manual to automated packing. Therefore he invested a lot of time in identifying all the risks and assigning them to each product group. Interbanket’s biggest chal-lenge lay in the large number of cookies: 19 prod-ucts, 30 different types, packing the products in the trays, including lying flat or at an angle of 45° or 90°. Ron Haaring, Sales Director at Tehama, the company that won the order for the solution, says “So the line needed to be highly flexible, and the only way to solve that was to use robots.” The pro-ject team finally decided to use seven of ABB’s IRB 140 six-axis robots. +++
www.bakingbiscuit.com 04/2016
P A C K A G I N G24
Packing biscuits on edgeVariety is the trend in the pastries market. That also applies to package sizes. The market requires small formats just as much as big family packs. So a packing machine should have format flexibility and should make switching over as easy as possible. Leon Arkesteijn, Product Manager at Bosch Packaging Technology, talks about this.
++ The tubular bag machine packs biscuits in different product forms and with different slug lengths
+ bbi: How important is the baked products industry for a packing machine manufacturer?
+ Leon Arkesteijn: Very important. An increasing level of automation has been a feature of the sector for years. Due to rising sales volumes and wages costs together with the demand for consistent high quality, most manufacturers are already investing in processing and packing machines. The manual feeding or simple input that was usual in the past is being superseded. Automation is no longer limited to com-panies with high-performance plants, because small and medium-sized businesses are doing it as well.+ bbi: What is your estimate of the global market for biscuits?+ Arkesteijn: It looks very promising. Global Industry Ana-lysts forecast that the turnover with biscuits in 2017 will be USD 447bn (around EUR 404.3bn). China and India are
emerging as one of the fastest growing markets in this respect. We also want to continue serving the dynamic Lat-in-American market in the future. + bbi: Where are the challenges when packing biscuits?+ Arkesteijn: Biscuits are often easily broken, which is why they need gentle handling with minimum force applied. Our solution for the medium performance range is the Pack 301 LS horizontal tubular bag machine. The biggest risks of product damage are generally at the transfer points from slug loader to the crossbar chain and from the crossbar chain to the infeed chain, and finally into the film tube. We coun-teract this with a full-servo model of the Smart Measuring Loader. It carries out the placement of the portioned biscuits. We also operate with pre-acceleration, which ensures syn-chronization with the infeed chain. This in turn prevents large forces acting on the product as it is transported from the crossbar chain to the tubular bag machine.+ bbi: How are the biscuits held in the on-edge position as they are inserted into the film tube?+ Arkesteijn: By a counter-holder that can be positioned by the operator via an adjustment wheel. Between the form-ing unit and the cross-sealing station, lateral belts or chains gently transport the slug, i.e. the portioned biscuits for one package unit, towards the cross-sealing station. The operator can replace the lateral belts with lateral chains and vice versa, depending on the properties of the product. All these func-tions ensure that the products are handled in a controlled way during packing. +++
++ Leon Arkesteijn, Product Manager at Bosch Packaging Technology
© B
osch
Pac
kagi
ng T
echn
olog
y
© B
osch
Pac
kagi
ng T
echn
olog
y
* High Quality
MECAFLOW make-up with
continuous low speed depositing
Mixers
Low pressure water scoring
device
Short cooling with buffer
Freezer ‘‘ cold trays ‘‘ with calm zone
at entry
New ‘‘ BBB ‘‘ oven with Bottom
Bake Booster
Short final proofing with
cold zone
High speed depanner
Premium quality on trays Extended shelf lifeSolid bottom baked on plain non perforated traysAuthentic open crumb structureThin & crusty crustReal hot bread flavor98% line efficiencyShort final heat up or ready to eatHigh labor savingVery low production costsBasic and smooth conveying
For 10.000 fully baked HQ* baguettes per hour60.000 HQ* petits pains per hour / 3,5 t Dough per hour
High Quality Artisanal Bread
Mega II
P A C K A G I N G
www.bakingbiscuit.com 04/2016
N E W S + + N E W S + + N E W S26
++ Bernard Valluis is the new President of the European Flour MillersBernard Valluis from France was elected as the new President of the European Flour Millers (EFM), the umbrella associa-tion of the European milling industry, at its Members’ Gener-al Assembly in Madrid (Spain) on 27 May 2016, according to information from the Association of German Mills. Valluis brings with him many years of experience in the milling in-dustry, including as Vice-president of the French Milling As-sociation, and is an acknowledged cereals expert. He takes over the position for the next two years and thus the succes-sor following Gary Sharkey from Great Britain, who has headed the Association during the past three years. +++
++ Baker Perkins names its new Manager for Strategic DevelopmentBaker Perkins Ltd. has named Geoff Hawley as its new Strate-gic Development Manager. Hawley has more than 30 years of experience in the food industry, including as International Sales Manager for the baking sector at Baker Perkins in Great Britain, and as Sales Manager of Baker Perkins Inc. in Grand Rapids in the US state of Michigan. His new role comprises extensive responsibilities, including Strategy and Product Development, Competence Development, and Personnel and Key Account Management. +++
++ König Machines celebrated the company’s 50th anniversaryKönig Maschinen GmbH organized two celebrations at the company’s headquarters in Graz-Andritz in honor of the com-pany’s 50th anniversary: a sales and dealer event on 17 June and a big family celebration on 18 June 2016. The sales and dealer event was attended by 60 invited guests comprising König sales partners, worldwide employees and the specialist press. Details of important developments were dealt with in König’s Customer Demonstration Center on this day, and ma-chines were demonstrated, for example the hygiene model of the DW 240-H mixer and the Industrie Rex AW dough divid-er-rounder for high weight accuracy and an increased output of 75 strokes/minute. More than 400 guests celebrated the company’s 50th anniversary at the family festival in a big mar-quee on 18th June. The Management Board welcomed mem-bers of the König family, including Elisabeth König, wife of the company’s founder, and their two daughters Elisabeth Friedl and Andrea Jöbstl-König with their families, as well as the siblings of the company’s founder. In addition to the König
family and the Advisory Council, the majority of the guests consisted of numerous König Group employees who took part in the celebration together with their families. +++
++ Rustic Bun: a new top of the range bunSolutions provider for industrial bakers worldwide, ME-CATHERM developed a new top of the range bun: the Rustic Bun. The Rustic Bun is a high quality, light and tasty artisan bread, which has a crispy crust combined with a soft crumb. A healthy product with no additives or colouring, the rustic
bun can, depending on the recipe, be made without sugar and/or fat. Baked for 8'30'' in a FDA double action oven (single deck tunnel Radiation and/or convection oven) on Teflon or silicone
coated trays with bun indentations, the Rustic Bun is 8 or 10 cm in diameter and 5 to 6 cm high. MECATHERM’s Rustic Bun is aimed primarily at the European and US restaurant market. +++
++ The new No. 1 in the NetherlandsInitial rumors that Parcom B.V., owner of the supplier bakery group Bakkersland, might have found a buyer for this subsid-iary in the shape of Bakkerij Borgesius, emerged in the Neth-erlands early this year. Astonishing, because Bakkersland weighs in with annual sales of more than EUR 400m, whereas Borgesius’ most recently reported turnover for 2014 was stat-ed as EUR 126m. Discussions came to an abrupt end a few weeks ago with the tight-lipped explanation that agreement could not be reached. That explanation was obviously not quite complete, since negotiations continued. According to the rumors, it had to do with securities and other financing is-sues. At any rate, the fact is that the purchase contract was signed last week, and the Borgesius family business, present on the market with six factories until then, has now gained an additional 14 from Bakkersland. All of these supply mainly fresh bread to the food retail, so at least there’s no urgent need for any change there either. The situation could become more problematic for the “Bake-Five” bakery cooperative, which is owned by Borgesius. Behind it are a total of 12 independent family businesses, also mainly producing fresh bread on an industrial scale for the retail. Bakkersland was their biggest competitor until now. +++
++ The food service market in PolandPoland, population around 38 million, is ninth among the EU’s most populous countries. The npd group’s market researchers looked at the food service market recently, and discovered that 70% of the out-of-house market consists of visits to so-called Quick Service restaurants, which also include the range of snacks offered by bakeries. 40% of purchases take place at midday and in the afternoon, and 45% of the visitors are young people aged be-tween 18 and 34. According to the market researchers, Poland is a country with growing opportunities in the food service market. They say the income of the Poles is rising, the “lifestyle” is also changing towards western consumption patterns, and there is great interest in new food service concepts. +++©
Kön
ig M
asch
inen
Gm
bH
© M
ECAT
HER
M
N E W S + + N E W S + + N E W S
Do you want to simplify your process, improve consistency and reduce costs? Continuous Mixing can help you do all this and more. And Exact Mixing has more Continuous Mixing expertise than anyone around. With over 150 installations to date, we’ve solved the most complex mixing challenges for everything from cookies and crackers to baked chips, buns, pretzels and pizza dough. Find out how the leaders in Continuous Mixing technology and innovation can miximize your process – and maximize your profits.
To find Continuous Mixing knowledge, solutions, videos and more, visit exactmixing.com.
Talk to the experts.
Is Continuous Mixing right for your process?
EXACT MIXINGBY READING BAKERY SYSTEMS
A Markel Food Group CompanyI N T E R V I E W
A Markel Food Group Company
Your simple, 120-year recipe for success.
For over 120 years, the Thomas L. Green brand has been supplying biscuit and cracker manufacturers with the industry’s most effi cient, reliable and sanitary production systems. As the world’s most trusted brand, we offer a full line of modern, high volume systems for laminated and sheeted products. The unmatched baking experience and advanced technology that goes into every Thomas L. Green system ensures that you consistently bake your best product, day in and day out.
Call us at (01) 610-693-5816 today or visit us at www.readingbakery.com
Thomas L. Green, your partner for better biscuit and cracker systems.
See us atBooth #5109
www.bakingbiscuit.com 04/2016
+The factory at Dommitzsch in Saxony has belonged to the Vandemoortele Group Germany/Austria since
1991. Under the leadership of Site Manager Markus Krause-witz and his team of around 200 employees, specialty baked goods are pre-baked or fully baked and then shock frozen on five production lines and an area of approx. 35,000 m2. Annual capacity is sufficient for up to 23,000 tons of baked products. The company has invested a total of approx. EUR 56m in the former margarine factory since 1991. Around 60% of the location to the north of the town is now built up. Krausewitz explains that production could be expanded still further. Moreover, Vandemoortele is one of the biggest local employers in the small town of Dommitzsch, popula-tion 2,500.
From silo to frozen food warehouseA total of nine flour silos, each with a capacity of 35 tons, are available to the production operation. According to site manager Markus Krausewitz, flour consumption is at least 300 tons/week. Yeast granulate is used for all the baked prod-ucts because it can be metered better both in the batch mix-ers and in the existing continuous mixers. For example a batch mixer from VMI supplies the lye pretzel line. A divid-er/rounder machine from the Austrian plant constructor König takes care of the dividing and molding. After the in-termediate proof, either lye pretzel sticks or lye bread rolls are produced, or the pretzel dough with a dough yield of 150 moves via a bypass to one of the six workplaces where pretzel loopers give the pastry its personal touch. Manual shaping
P R O D U C T I O N28
Steady growthAround 200 employees at Vandemoortele’s Dommitzsch location in Saxony produce breads, pret-zels and rolls/buns in a 24/7 operation. The works is the biggest Vandemoortele site in Germany, and undergoing continuous expansion.
and intermediate proofing are followed by cutting, the lye bath and freezing the dough pieces. The lye pretzel line can produce up to 5,500 no-time dough pieces per hour. Site Manager Markus Krausewitz explains that “Work at the Dommitzsch site takes place every day on five production lines – of which three are bread lines, one is for lye baked products and one is a stone oven line with sourdough prod-ucts – to manufacture a very wide variety of products.” The operation runs with up to four shifts, depending on the product and season. Alongside the line to produce lye baked goods stands the Megaline II from the French supplier Me-catherm. This plant contains dough division and molding (Bloc HP2) together with the automatic cutter device, the oven, cooling and freezing, as well as all the tray transport elements. Hourly capacity is around 6,000 pieces. The plant is supplied by a continuously operating VMI mixer. The dough enters one or other of the two Bloc HP2 plants. Dough division is followed by proofing, and the dough ribbons are deposited into indented trays (2,000 x 800 mm, 6 indenta-tions). There is only one tray format, but different products. For example, baguettes with an initial dough weight of 300 grams or six bread rolls weighing 40 each can be deposited in one indentation. A robotic cutter ensures an appropriate cut pattern when necessary. Options include oblique, straight or overlapping cuts. The downstream proofer operates using a paternoster system and holds a total of 448 trays. Temperature and air humidity can be individually controlled in each of
© f
2m
www.bakingbiscuit.com 04/2016
P R O D U C T I O N
++ After baking, a conveyor belt carries the baked products to cool down
++ Robots cut the dough pieces after proofing
© f
2m©
f2m
P R O D U C T I O N 29
the zones. For example, the conditions initially prevailing are a temperature of 25°C and a relative humidity of 80%, and at the end of proofing, i.e. in the proofer’s last zone, there is a rather dryer, cooler climate to promote firming of the dough pieces. Baking finally takes place in a Me-catherm oven, which also operates on the paternoster sys-tem and has several zones. Each of these is fitted with its own burner, and each oven zone is separately controllable. After baking, the baked products pass through a cooling section and finally enter the freezer, which is then fol-lowed by a further semiautomatic packing plant.
Baguettes and the stone oven lineThe factory also has two baguette lines, each with an hour-ly capacity of 2,500 dough pieces. These plants manufac-ture pre- and fully-baked products, which can also be strewn with various seeds and grains when required.
The company’s most recent investment was in a stone oven line using sourdough. This has a total of four more VMI spiral mixers available for dough preparation. There is also an automatic sourdough plant that ensures a homogene-ous wheat sourdough. These lines are housed on the floor above the Rademaker CRUSTO bread/bread roll plant that has been in operation since 2015. The plant has an hourly capacity of approx. 1,200 – 2,400 kg/h, depending on the products and the whole infrastructure. The dough sheeter and roll-out line are able to process soft doughs with long resting times. The make-up modules and various product tools allow the line to manufacture products such as ciab-atta breads and bread rolls, angular buns and rolls, pointed rolls and baguettes (pressed-out or long-molded). The line’s high flexibility enables up to 54 different baked goods to be manufactured on the Rademaker plant.In total, the staff in Dommitzsch manufacture more than 135 different products and the trend is rising. A process has also been developed in Dommitzsch to slice baked products horizontally after freezing.
© f
2m©
f2m
++ Photo left: A continuous mixer supplies the Megaline II; photo right: Pretzels can be looped at a total of six workplaces. However, the same line can also produce lye plaits or rolls and buns
++ After cutting and dipping in lye, the dough pieces go into the freezer
www.bakingbiscuit.com 04/2016
The Vandemoortele Group is growing
The Belgian Vandemoortele Group, Ghent, has been completely in family hands again since 31 May 2016. The family shareholders’ holding company, Safinico NV, bought back 58% of the company’s shares from the investment company Gimv 23. According to the company, “The shares were sold in 2009 to strengthen the company’s financial situation and thus to enable growth, especially in the growing frozen baked products market, as well as to maintain the strong position in the margarine, culinary oils and fats area at the same time.” It also says the Gimv shareholding enabled an extensive investment program to be implemented. Thus on the one hand it allowed a program of organic growth, and on the other it became possible to make important acquisitions.
Vandemoortele holds a leading position in the two core businesses, Bakery Products and Margarines, Culinary Oils & Fats. It employs around 5,200 staff in 12 European countries. The Vandemoortele Group achieved sales amounting to EUR 1.357m in 2015 (+7% com-pared to 2014). The company increased its REBITDA (= EBITDA excluding one-off elements) to EUR 123m (+12%) and the REBIT (Re-curring Earnings Before Interests and Taxes) to EUR 68m (+4%). The Bakery Products business division achieved organic growth of
3.3% and, if the acquisition of LAG SpA in Italy is included, sales growth of 14.4% compared to the pre-vious year. According to a company statement, the sector’s good operating result reflects continuous improvements in the entire added-value chain and the stronger focus on developing promising prod-ucts and sales channels. As the company says, the Mar-garine, Culinary Oils & Fats business division was able to exceed the 2014 results despite a low volume in a slightly declining market.
The Group invested EUR 86m in 2015, including in the Baked Products branch of the business. A new production facility, e.g. for baguettes, was commissioned in Lyon (France). Construction of a new factory was started in Kutno (Poland), scheduled to start operations in mid-2016. It is intended for the produc-tion of bread rolls/buns and baguettes.
Through the takeover of LAG, a leading company in frozen baked products in Italy, Vandemoortele fur-ther expanded its portfolio in this segment. The integration process is said to be very largely complete. Executive Board President Jean Vandemoortele explained that “Both sectors record good performance for 2015, and the extensive investment program confirms our ambitious target, namely to continue on
this growth course.” The sites manufacturing margarine and fats also underwent further rationalization and modernization. In Belgium, the Group invested EUR 18m in significant projects in Eeklo, Seneffe and Izegem. In total, the Vandemoortele Group has more than 34 production sites and 17 branches. +++
P R O D U C T I O N30
After being packed, the baked products go into the frozen food warehouse, which has 2,800 pallet storage bays. An addi-tional 400 m² of deep-freeze storage area is available for order-picking. Loading takes place via one of the three HGV ramps. Around 80 HGVs leave the works every week, each carrying 660 pallets with 40 cartons of finished products on every pallet. Around 68% of this goes to Germany, around 15% to the Benelux Countries, 4% to the Czech Republic, ap-prox. 10% to Poland and 2% to Italy.
ChallengesThe topics of sustainability and environ-mental protection play a big role in the works for Site Manager Markus Krause-witz. For example, it has been possible to reduce aqueous ef-fluent by 8% since 2005, and around 33% less waste has been produced. The company also offers new training places for mechatronics engineers and specialist food technology staff. A great deal has happened for the well-practiced team in Dommitzsch since 1993. 58 staff were employed in the
margarine production unit at that time. As a result of the conversion to a bakery, there are now around 200 employees with an average age of 48. 21% of the employees will retire in the next five years. The site has therefore developed a men-toring system to pass on know-how. This is intended to safe-guard steady, sustainable growth. +++
© f
2m
++ Fully baked bread rolls, which the user need only thaw out. After that, the baked product can be top- ped and eaten immediately
© V
ande
moo
rtel
e; f
2m
++ Vandemoortele manufactures up to 54 different baked products on the Rademaker plant
Actipan supports an active lifestyle and a balanced diet.
Wholegrain bread for active people
Source of carbohydrates and energy
High proportion of � bre and protein
Natural source of vitamins and minerals
STRIDES AHEAD
OF WHOLE GRAIN!WITH THE POWER
®
Actipan_210x297_E.indd 2 02.10.15 11:30
P R O D U C T I O N
www.bakingbiscuit.com 04/2016
32 P R O D U C T I O N
Steamed baked products from the NetherlandsThe Trade Factory Bakery in the Netherlands specializes in producing bapao. These filled, steamed bread rolls are popular with young consumers. The baked products can be bought in the food retail, either fresh in a chiller display or as a frozen product.
+ In Asia, the subject of steamed baked goods brings to mind jiaozi, baozi, gyōza or mandu. These filled,
steamed dumplings are very popular. In China there are said to be more than 40 jiaozi, also called Chinese dump-lings, differing in size, shape, filling, wrapping type and cooking methods. The dough for gyōza, Japanese dump-lings, is somewhat thinner compared to jiaozi/baozi. The crescent-shaped, baked dumplings are often served as a side-dish. However, there are also steamed and fried vari-ants. The version from Korea is called mandu. It involves a steamed product served with or without filling. These Asian dough foods resemble Eastern European pelmeni, which are also boiled or steamed. Dumplings are another European product that can also be steamed or boiled. In Germany, Austria, South Tyrol and the Czech Republic there are dumplings as a side-dish, main dish or even as dessert and for adding to soups.
There are also bigger variants of steamed baked goods, both in Asia and in Europe. Germknödel, for example, a way of preparing yeast dumplings, are very popular in Austrian and Bavarian cuisine. Here again there are different variants, e.g. with plum or blueberry filling (South Bohemia/regions in the Czech Republic). Butter is poured over the warm ger-mknödel, or they are served with a vanilla custard sauce. The dishes can also be sprinkled with ground poppy and icing sugar. In China, hom bao are described as steamed buns. These are sold filled with sweet red bean paste, for example, but savory fillings are also possible.
Bapao for the NetherlandsThe Trade Factory Bakery B.V., CX IJmuiden, the Nether-lands, has found a special niche: the company produces Bapao, a kind of steamed bun with various fillings. How-ever, there is no particularly large Asian community in the
++ Three Rheon plants put the various fillings into the dough©
f2m
Your customers demand the highest product quality, delivered every time, at the right price. At Rademaker we understand the challenges and pressures our customers face every day. We offer our bakery equipment solutions only one way – The Right Way.
Rademaker Is: Sanitary Wash-Down Design for Over 20 Years Industrial Designs for Longer More E Industrial Designs for Longer More Efficient Production Runs Highest Product Quality and Consistency Rademaker 24/7 after sales service and support has no equal
Visit us at www.rademaker.com
Consistent Quality. Consistent Efficiency.Consistent Profitability
A D V E R T I S E M E N T
www.bakingbiscuit.com 04/2016
33P R O D U C T I O NP R O D U C T I O N
Netherlands that would create a demand for such prod-ucts. The baked goods are bought especially by young consumers who want to eat a snack quickly and easily. Trade Factory manager Erwin Koopstra explains that this is why Bapao can be bought in many supermarkets as frozen products or as fresh goods.
The bakery began operation in 2006. The bakery’s parent compa-ny group, Seafood Parlevliet, orig-inates from the fishing industry. This is noticeable in the produc-tion planning and in the high hy-giene standards. Production Man-ager Roel Heida explains that this is why the plants and the entire hall are wet-cleaned every day. The whole bakery was planned by the Kortlever Technical Bureau B.V., DJ Meerkerk.
Production of bapao starts at 06:00 hrs. every working day in a spiral mixer made by the Diosna company. The main raw material, wheat flour, is metered into the mixing bowl automatically. This is followed by water, sugar, yeast, salt and fat. Bowl tippers transport the fully mixed dough
into a pre-portioner. Conveyor belts then take the yeast dough into one of the three Rheon Corncopia KN400
encrusting machines. The Rheon has two hoppers. The dough for the steamed buns goes into one, and the filling goes into the other. Manager Erwin Koopstra says “For example, this can be chicken, beef or even a vegetarian filling.” The respective filling is supplied to the Trade Facto-ry already prepared ready for use.
The KN400 encrusting plant now forms the filled dough pieces from the mix/filling and the dough. There is an almost unrestricted choice of shape, depending on the portioner attachment and cutter aperture (iris). Creativity is almost unlimited,
thanks to a large number of several hundred possible at-tachments that have now been developed for the encrust-ing machines. In this respect, fillings extending to a con-sistency comparable to that of mayonnaise can be pro-cessed without any problems, as well as lumpy fillings and a wide selection of doughs. According to Master Baker Michael Kretschmann from the Rheon Automatic Ma-chinery GmbH Company, Düsseldorf, Germany, “The
++ The finished product with a beef filling
© f
2m
www.bakingbiscuit.com 04/2016
fillings can be either fully coated or half-coated, so they are visible at the top.”
The steam ovenThe filled dough pieces now leave the Rheon plants and are aligned. A conveyor belt carries the dough pieces forward to the deposition station, where a station provides prepared trays covered with baking paper. A tray can accommodate thir-ty dough pieces each weighing 120 grams. The full trays now pass automatically into a rack trol-ley. One of the two production staff then pushes the fully filled racks into the final proof. This in-volves racks being input in pairs onto a transport system in front of the tunnel proofer. The proofer holds a total of four racks on two lines, so parallel operation can take place. After proofing for 60 minutes, most of the dough pieces together with the racks move automatically into the steam oven. Ex-plaining the project, Gery Kortlever, Sales Manager of the Kortlever Technical Bureau B.V., says “The bakery also has the option to use one of the three Wachtel rack ovens.” As well as steamed baked goods, this also allows the bak-ery to offer browned products like a kind of pita bread with filling. This increases flexibility. However, only around 10% of the products that are manufactured end up in the rack ovens.
Around 90% of the production volume finishes up in the steam oven. It is loaded with two racks at a time and, like the proofer, holds a total of four racks. After 20 minutes the fully steamed buns leave the oven. This is followed by cooling and, if necessary, freezing. The packing depart-ment then awaits the products.
Production Manager Roel Heida and Manager Erwin Koopstra are satisfied with the workload on the produc-tion unit. The employees manufacture around 60,000
steamed buns per shift. A further production increase is still possible. The distribution channels include the na-tional and international retail, and the food service mar-ket. Individually developed products can be manufac-tured under their own label if required. The pans and molds can be open, closed, circular or elongated, and weight ranges from 40 to 200 grams are possible.
The quickest way to prepare the steamed products is in a microwave. Simply put the fresh goods (packed under protective gas, minimum shelf life: 90 days) with the pack-ing into a 700 watt microwave to heat up for around 40 seconds. Steaming is also an option. If the customer wants a browner baked product, the consumer can also bake the product at home in an oven at 170°C for 14 minutes. The Trade Factory plans further expansion in the future, and there have already been enquiries, e.g. from Belgium and Germany. For example, the bakery could also produce steamed hamburger buns. +++
34 P R O D U C T I O N
++ The filled dough pieces are deposited onto trays. Input and removal take place automatically. The entire project was designed by the Kortlever company
++ Pairs of rack trolleys are driven automatically into the proofing room, where they remain for 60 minutes
© f
2m©
f2m
www.bakingbiscuit.com 04/2016
© F
otol
ia
+ Just imagine that your raw material can talk to you and you can understand it, can adjust your recipes and
processes accordingly and can manufacture baked products with the required characteristics. That, admittedly put sim-ply, is the objective of FLOURplus, a European research pro-ject that has now advanced to the point where practical tri-als have begun. The key component is a data base with up to 85 pieces of analysis data for each flour, obtained and cali-brated via defined analysis methods and instruments. Such data currently exists for 39 flours from 14 mills in seven Eu-ropean countries. It can be expanding at any time by adding mills and baking companies that either request such data from their suppliers or determine it themselves.
R E S E A R C H36
One raw material – many opportunitiesThe FLOURplus research project is an attempt to find a correlation between the individual
analysis data of consignments of flour that are delivered and a company’s own in-house require-ments profile. It has already reached the trial phase.
The ttz (Technology Transfer Center) Bremerhaven Re-search Institute and the UCC (University College Cork) in Cork, Ireland, have developed so-called forecasting algorithms via baking experiments and an assessment of the products resulting from them, together with sensory and acceptance analyses with consumers. These are intend-ed to enable predictions for the expected end product, e.g. about crust and crumb color, crispness, crust gloss, flavor profile etc. to be made based on flour analysis data and process parameters. Conversely, instructions for changes to recipes and process parameters can be derived from them.The first products for which such correlations were pre-
pared were wheat bread rolls and toast breads. In this respect, a standard recipe for wheat bread rolls consists of flour, wa-ter, salt, dried yeast and fat. Baking agents have not been included up to now, but can be added as soon as their modes of action can be mapped through the algorithms.In the standard version, flours are defined via their moisture content, ash value, gluten index, proportion of wet gluten, sedimentation value, falling num-ber, protein content and the value for the water absorption power of the flour. Further parameters can be added. The water temperature, mixing/kneading time, proofing time and proofing temper-ature, and the air relative humidity dur-ing the proofing process were included as the standard process data. Here again, expansion is possible at any time. In the test version, the researchers defined source: ttz Bremerhaven
The FLOURplus consortium1
www.bakingbiscuit.com 04/2016
R E S E A R C H
weight, specific volume, height, width, pore density, succu-lence and crispness as the quality characteristics for the test products, and incorporated them into their algorithms. The system provides an opportunity to create a data history at the same time, thus allowing developments to be recognized and experience retrieved.The attractiveness of the story is that all this data can be entered through a user interface in the bakery, and a forecast of the expected product can be issued “at the push
of a button” and an explanation obtained as to which pa-rameters should be changed to obtain the desired result. In the final version, the user interfaces are linked to the data base via the Internet. Tests are currently ongoing to deter-mine whether the algorithms fulfill their function in view of this admittedly still very easily understandable volume of data, and whether they define the relationships correct-ly and thus allow predictions.Once that has been done, the plan is for the system to
be enlarged so each factory can expand the system by adding its own specific analy-sis, recipe and process data. Baking experiments will then also be needed to establish the connection via algo-rithms. However, that is a once-only process that any-one can initiate based on his measurements. Ultimately, FLOURplus will then offer a cross-industry IT portal that is nevertheless individually usable and makes results available only to whoever supplied the data needed for them. The advantage is that the entire system can learn from the individual correla-tions nonetheless, without vi-olating the individual’s data protection. +++
Concept2
Raw materials ∙ Flour analysis∙ Constituents∙ Application simulation
Experimental data
Company data
ttz Bremerhaven/UCC Cork
from Quality Assurance and Production
Baked product ∙ Instrumentally measurable properties
Consumer∙ Sensory systems∙ Preferences∙ Acceptance
Process∙ Parameters, especially fermentation/ proofing
Correlation models∙ Prediction of baking results∙ Process control (adaptation of process parameters)∙ Support during product development
FLOURplus data base
Recipe∙ Baking agent
source: ttz Bremerhaven
37R E S E A R C H
Influence of process parameters3
source: ttz Bremerhaven
www.bakingbiscuit.com 04/2016
38 P R O D U C T I O N
+bbi: Mr. Baumann, what is it about the center-filled cakes produced on your plant that makes them different
to filled cakes available on the market?+ Michael Baumann: The size, for example. If one goes to Starbucks or into a bakery, and one would like just a small, sweet appetizer to go with the coffee, one then usually ends up – and I am talking about individually packed products – with a Yes-Torty, a croissant or a donut, with or without a hole. However, all of them weigh as much as 80 to 150 g. As far as I know, smaller, individually packed appetizers are not marketed on a large scale. That’s the first point. The other is the way we manufacture the cakes. Fillings are often injected, i.e. introduced afterwards. The baked prod-ucts then have a hole out of which the filling can escape if pressure is applied. Our manufacture follows a different principle. I would not want to assign exclusively the term cake to the end products.+ bbi: But instead?+ Baumann: We have carried out successful panel tests on filled baked products positioned in the savory area. Instead of giving the products a sweet flavor, we strongly spiced them and used bacon and cheese. So that goes entirely in another direction, but is equally feasible with the machine. There’s ‘unlimited’ room for improvement.+ bbi: What is your estimate of the market for filled pro- ducts?+ Baumann: I should like to give an example in answer to your question. A client in the USA commissioned the plant early this year, and the trial phase is already past. The company has already sold his entire annual capacity, and the product doesn’t actually exist yet. The calculated output for the initial period is 30 to 40 million pieces per year.+ bbi: Which company are you referring to?+ Baumann: I’m not allowed to reveal that, at least not before the initial products are available for purchase. All I can say is that it’s a US manufacturer who is involved with confec-tionery and desserts for the needs of commercial restaurants. The product will be positioned as a side-sale in coffee shops or in other franchise businesses in the fast food area, e.g. Pizza Hut or McCafé.+ bbi: So is your plant initially starting in the sweet di-rection?+ Baumann: We began marketing the plant for cakes. However, we won’t let go of the subject of “savory” with
which we had ongoing success in panels. We are confident that “savory” can open up whole new markets. Here we are talking about products that can sit on the shelf, e.g. in filling stations. Small bites, packed, for a whole new need, a salty appetizer.+ bbi: Whom do you see as the target group for a CFC (center-filled cake) oven?+ Baumann: Companies with existing access to the market. With a production volume of 10,000 pieces/hour, we assume one should start by aiming at sales of at least 20 million piec-es/year. Perhaps that sounds a lot, but when multiplied by a piece weight of around 30 g, it becomes manageable. We assume a pay-back period of about two years.+ bbi: Many manufacturers target filled cakes mainly at chil-dren. Whom do you see as the end consumer target group?+ Baumann: We are casting our net considerably wider. In principle it includes everyone who wants a snack. The ingredients determine who is being addressed.+ bbi: What is feasible with regard to ingredients?+ Baumann: Virtually everything. The limit is in the user’s powers of imagination. The plant can be used to manufacture almost anything that can be baked. For the Japanese market, one could use a red bean paste filling instead of a sweet or
Center-filled cakes: there’s more than meets the eyeAfter two years of development work, the Haas Group has brought onto the market a plant that is able to produce filled cakes at the rate of 11,000 pieces per hour. Their final weight can be 45 g, and the proportion of filling up to 30%. Two pastry colors are possible, as well as two fillings. The end products can be positioned in the cake segment – or generally in the confectionery segment – although that far from exhausts their potential.
++ Michael Baumann, Managing Director of the CFT Haas Convenience Food Equipment GmbH
© H
aas
www.bakingbiscuit.com 04/2016
39P R O D U C T I O NP R O D U C T I O N
fruity filling. If a company is in the savory market business, cheese could be blended into the dough. One could design the product in such a way that the end consumer puts it into a microwave before consumption so as to eat it warm. One can operate with egg, or even without it for products that are to be sold in hot countries. Recipes with wheat flour func-tion exactly the same, or with other flours, e.g. made from len-tils or peas. We have tested many raw materials in our Techni-cal Center and have developed sample recipes. Further- more, the baking process can be controlled so the products have a crust or no crust. The ideas are almost limitless.+ bbi: But there will be limits regarding dough and filling?+ Baumann: Of course there are framework conditions. The dough must be pumpable; the filling must be baking-stable, i.e. it must be able to withstand a temperature of about 100°C for approx. 60 seconds. That means most fat-based crèmes are unsuitable. And the dough and filling must have a similar water activity to avoid moisture transfer.+ bbi: What proportion of filling do you recommend?+ Baumann: We have had good experience with a content between 20 and 30%. Of course, customers will want to ensure no filling escapes. That also means the filling must be fully enclosed by dough, which also means there must be a sufficient amount of baked dough mix around it. That limits the proportion.+ bbi: What is the situation regarding variety of shapes?+ Baumann: Virtually all the shapes we already produce are conceivable: animals, fruits, gugelhopf, rehrücken etc. One must not forget that all the products are baked all round, and can thus be shaped in all directions. That’s a decisive USP (Unique Selling Proposition). The product can have all possi-ble lines and surfaces, just no reentrant angles. Positive angles are needed to allow the product to be demolded (depanned). Thus a vertical heart shape, for example, would be unfeasible. A horizontal one would work, of course.+ bbi: Is there a visible seam?+ Michael Baumann: Yes, as a rule, similar to a soft waffle. But the seam is comparatively small.+ bbi: What is the product size limit?+ Baumann: I think the upper limit is 50 g. If bigger cakes are produced, baking time is longer and the output rate is re-duced. Everything is technically practicable, but probably not very sensible from the business economic viewpoint. I would put the lower limit at 20 g. One should switch to a different process for smaller products.
+ bbi: Is a particular product thickness necessary?+ Baumann: Products that are too thin cannot be demold-ed. The plant is also unable to process products whose dough consistency is too fluffy or too soft.+ bbi: Can differently shaped baked products be manufac-tured on one line?+ Baumann: That is possible, since shaping takes place via the baking plates. Different plates can run on the machine simultaneously. All that is needed is for the products to have approximately the same weight, and an equal number of products should be baked per baking plate. Incidentally the plant, with the same concept and without major modifica-tions, can also be used to bake fresh waffles. So the user needs to limit himself to a particular product.+ bbi: What advantage comes from the fact that your plant fills both baking plate pairs with dough?+ Baumann: It ensures very good demolding. Moreover, a uniform color gradient is obtained immediately, and bak-ing proceeds more uniformly.+ bbi: Are the depositors cooled?+ Baumann: Beyond a certain temperature range, they are water-cooled. Incidentally, the depositors can also insert lumpy material.+ bbi: How do you support your customers during commis-sioning?+ Baumann: First of all, I should like to make clear that the machines are not off-the-shelf machines. They are adapted to every user’s needs. This is where I see our strength. We offer a toolkit from which the suitable components of the finished machine can be assembled. Support from our side is available in a variety of ways, including in relation to shaping, technology and even for the recipes, which are virtually supplied along with the machine. However, foodstuff manufacturers themselves give them their final polish. Many use our technical center to test recipes. Customers work in conjunction with our technologists and use the CFC oven, the laboratory and our experience. We can also produce initial samples on hand-tongs or small waffle iron.+ bbi: Has your US customer used the Technical Center?+ Baumann: Three times. He developed his product in conjunction with our technologists here on the spot in Leobendorf.+ bbi: Mr. Baumann, thank you very much for the inter- view. +++
© M
aria
Haa
s/©
Haa
s
Baking in the third dimension
40 P R O D U C T I O N
+The way the Haas plant works is similar to a soft waffle plant, and it can undertake the tasks of
premixing, intermediate storage, aeration, baking and cooling. The key player is the new CFC oven with 74 or even 126 baking plates. The baking plates run through the oven continuously, strung together on an end- less chain. To produce Center-Filled Cakes, the cake dough is automatically applied to unfolded pairs of baking plates that have been pre-heated to 150 to 200°C, and is applied to both plates. If a filling is required, further depositors place the filling onto the dough, always in one mold of the pair of baking plates. The baking plates close and pass through the oven to bake them, which takes three to four minutes depending on the size of the finished product and the proportion of filling. At the end of the baking process the baking plates, still folded shut, finish up at the front section of the oven again and unfold. An extractor device then uses needle or vacuum grippers to release
the products from their molds. The baked products move onto a conveyor belt, then continue into a spiral cooler, cool down to room temperature, and are finally trans-ported to a packing machine or some other downstream machine.The release agents are metered in automatically, exactly like the filling and dough. All the baking plates consist
of steel, which simplifies demolding and shortens the cleaning intervals. A cleaning system can
be combined as an optional extra. It uses solid CO2 to clean the baking plates, and completes it for 74 baking plates in less than four hours. The auto-matic CFC baking machine is directly heated (gas) and operates with an auto-
matically controlled, energy-efficient heating system, meaning that baking
temperatures can be controlled individually depending on the recipe. The plant is designed
for a capacity of 10,000 to 11,000 filled cakes/hour, and an increase to 20,000 pieces/hour is equally feasible through a higher speed and additional baking plates.+++
www.bakingbiscuit.com 04/2016
© H
aas
© H
aas
++ Photo left: the CFC oven can manufacture Center-Filled Cakes at the rate of 10,800 or up to 20,000 pieces/hour; photo right: baking plates and depositor
© H
aas
www.bakingbiscuit.com 04/2016
Francois Gelé
Company founder Francois Gelé (66) has worked in the baking industry for more than 30 years. His CV: 1975: Diploma in Electrical Engineering and Applied Mechanics1976 - 1978: JACQUET: Engineer, Technical support & Investment Assistant Manager 1978 - 1980 : SBK: Technical and Commercial Project Engineer1980 - 1981 : JACQUET:Plant Manager1981 - 1986 : SBK: CEO1986 - present: President of GELE2007 - present: President of CONCEPT CONVERGENCE
P R O D U C T I O N42
+ Consultancy, development, implementation – this triple jump is professional routine for the 35 staff
employed by the company (strictly speaking there are two, see box) that has set up its headquarters in the small town of Cesson, a good 50 km south of Paris. Whereas the business of the “Concept Convergence” company revolves around engineering and technology, the business of the four divisions appearing under the name Gelé involves machines - Gelé is the representative in France for famous-name mechanical engineers – special machine constructors, building planning and construction, and agri-cultural products, including among others the novel stevia raw materials.
According to the company’s founder Francois Gelé: “When bakeries call us into their business, they do so not with the aim of producing more cheaply, because if we raise their process efficiencies by only a few percentage points, the return is significantly larger, and as a rule the products are qualitatively better and less easy to copy. Our clients achieve line availabilities considerably up to 98%, cleaning and maintenance work included.”
When it’s a question of product development, normally the process starts with a definition of what the client wants and/or the product for which he believes he can find a market. This is followed by product development in the laboratories in Cesson until the final outcome is exactly what the client had in mind. Only after that does thought turn to tests of possible plants and consideration of the actual process setup. Gelé says: “Most of the clients have neither the time nor the opportunities to carry out such tedious development work
Answers from CessonTheir job is to define and develop raw materials, products, processes and entire process chains. Their orders come from the worldwide baking industry and from industrial cake and confectionery manufacturers.
The microwave oven developed by Gelé is now producing crustless bread in France in three shifts (cf. our article “Crustless Baking”. The QR Code takes you directly to the article.)
© G
elé
Gro
up
© G
elé
Gro
up
www.bakingbiscuit.com 04/2016
THE CONVEYOR BELT EXPERTS
Around the world, more food is
proofed, baked, cooked, cooled
and frozen on our
conveyor belts.
Ask for Ashworth.
www.ashworth.com
59mmX265mm_En.indd 1 2/26/2014 8:12:29 AM
AD
VE
RT
ISE
ME
NT
P R O D U C T I O N P R O D U C T I O N
undisturbed in their own organization. In that respect we are rather like our clients’ toolbox, and only when we have defined and decided, together with him, what is to be produced, do we install it on existing or new lines and train the personnel. The end result is the yardstick of success, regardless of whether it’s a premium product or mass-produced goods.”
Furthermore, the development team at Concept Convergence works on projects of its own. Four of the company’s own innovations have now reached market viability, including a special kind of gentle pasteurization that protects the product’s flavor and prolongs the shelf life of brioche, sliced bread, gluten-free products, madeleines or sweet bread to three months. The second innovation is called an FTO croissant, which goes directly from freezer to oven. The third project has resulted in numerous gluten- and lactose-free products, and finally the fourth developed into an ice cream in which two thirds of the sugar content is replaced by a new kind of stevia.
Shelf life without alcohol, gas or freezingAccording to technologist Jessica Cozema, increasing numbers of baked products manufacturers in this country and abroad now want to abandon the use of alcohol or gas to extend shelf life, and don’t want to be forced to rely on freezing either. Gentle pasteurizing is a process that controls the interplay of temperature and residence time in both the heating up and cooling down phases of the pasteurizing process in such a way that the characteristic flavors of the product are protected. The products are packed in PE or PA bags whose weld seams must be absolutely leak-tight to ensure no recontamination can occur. Cozema recommends pasteurizing in a spiral oven, especially where available space is limited, because it gives all-round external heating and offers the option to control the atmosphere in its interior, rather like a spiral proofer. The technologist says that as a rule the recipes and processes are also looked at so as to optimize the process. Flour qualities differ greatly in this respect, and sometimes the use of older cereal varieties already improves shelf life. That’s also why she and her colleagues constantly search worldwide for old and new cereal varieties that naturally bring with them special properties and characteristics.
The development of the so-called FTO (Freezer To Oven) croissant is also aimed at prod-ucts for the food retail and food service sectors. This croissant is supplied to the customer via space-saving transport as a raw frozen dough, and can be baked off with the input of steam but without any thawing-out phase. In fact, the baking phase lasts 22 minutes in-stead of the usual 15, and the leavening is activated only in the last few minutes. In return, according to Cozema, thawing out is eliminated, the shelf life of the dough pieces is
++ Delicate structures and creamy filling: gluten- and lactose-free millefeuille cream slices
© f
2m
www.bakingbiscuit.com 04/2016
extended to 6 months, and the doughs are considerably less sus-ceptible to damage than pre-proofed or even pre-baked prod-ucts. A baking agent developed by Concept Convergence and customized to every application guarantees freedom from E-numbers. Moreover, the recipes for the croissants, which have a maximum weight of 65 g, contains at least 24% fat.
Gluten-free doughs through the weigherRecipe development and raw materials are the specialist field of David Wesmaël, a patissier and ice cream confectioner who has been honored with the title “Un des Meilleurs Ouvriers de France” (One of the Best Craftsmen of France) for special achievements in his profession. As a Project Manager at Con-cept Convergence, he is responsible for the creation/technolo-gy interface. Wesmaël has developed a large number of glu-ten-free baked products such as brioche, muffins and brownies that are in no sense inferior to the gluten-containing originals either in taste or structure. He also accounts for the develop-ment of gluten-free bread and bread roll doughs that can be pre-portioned by a classical divider, i.e. they are neither sticky nor liquid when they reach it.
++ Gently pasteurized milk rolls (left); a gently pasteurized brioche (right)
++ Many variants of gluten- and lactose-free confectionery
++ Gluten-free hamburger buns and gluten-free pastries
© f
2m©
f2m
© f
2m
© f
2m
© G
elé
Gro
up
© G
elé
Gro
up
P R O D U C T I O N44
His gluten- and lactose-free variants of millefeuille cream slices, delicate leafy strips of puff pastry filled with various crèmes, macaroons, chocolate mousse cubes and similar culinary delights, are a real temptation for all cake and patis-serie enthusiasts. These gently pasteurized gluten- and lactose-free pastries and cake developments, suitable for the product ranges of baking stations and food service providers, are more a product of the commercial brain of this distinguished master of his craft.
Finally, an entirely different story being looked after jointly by David Wesmaël together with company boss Francois Gelé is the cultivation and processing of stevia on the island of Mauritius. The plant is harvested there on the company’s own fields, and is processed by a partner company. Accord-ing to Gelé, the clever aspect of this is that the sweetness is extracted not by using chemicals and alcohol but simply with water. The flavor is distinctly milder. Up to now, stevia is approved in Europe (in contrast to North America or Australia) only in milk products and beverages but not in baked products. Honi soit qui mal y pense. +++
++ Macarons with stevia
© G
elé
Gro
up
WWW.TROMPGROUP.NL
Turn Key projects for the Bakery
Industry
Cake & Pie LinesWaffl e Lines
Pastry LinesPizza Lines
Sheeted Bread Lines
Meet us at:• ICF 2016• IBIE 2016• GULFOOD 2016
32225.TRG140043.Baking Biscuit INT-14 July 2016-Adv Cake and Pie 184-265.indd 1 13-06-16 13:26
P R O D U C T I O N
www.bakingbiscuit.com 04/2016
46 T R A Y S A N D P A N S
New functions for pan clustersPan clusters are not purchased off the peg, the majority are individually designed to fit the product, the oven, the process and the budget. Anneliese Backtechnik is one of the leading manufacturers in the market, and has endowed its pan clusters with new functions. Executive Director Helmut Leuver explains what is now possible.
+bbi: Mr. Leuver, Anneliese Backtech-nik has repositioned itself under your
management in recent years. What has happened?+ Leuver: We have made many changes to enable us to supply high-quality pan clus-ters and baking trays, all ‘Made in Germany’, at attractive prices. Our business relationships extend as far as Russia and other Eastern Euro-pean countries, where wages costs are well-known to be considerably more economical. Nonetheless, we are able to offer our products at competitive market prices even in such low-wage countries.+ bbi: How do you achieve that?+ Leuver: We have further standardized and also automated the fabrication processes, and as a result we attain high pro-cess stability with reduced unit costs. However, the decisive factors are not just costs but also high quality and innovative strength, together with the appropriate solution for each indi-vidual case.+ bbi: What is decisive for a perfect pan cluster?+ Leuver: The shape, size, material, surface and coating of the pans, as well as machining the pans and assembling the clusters. Deep-drawn pans, for example, are efficient. They allow clean, seamless pans that are easier to clean and consid-erably more suitable for coatings than folded metal pans.+ bbi: But what’s really new here?+ Leuver: The innovations are often not really so earth-shat-tering, but they are effective. For example, we have developed a pan cluster in which the pans are riveted. The advantage is that customers can remove damaged pans from the pan cluster themselves on the spot, and can replace them with new ones. The aim is longer pan cluster lifetime through the user’s own on-site repair facilities. Without rivets, the whole pan cluster would need to be returned to the manufacturer just to replace a single pan. Thus the customer saves the costs of returning to the manufacturer, who would then also prefer to repair entire batches, which requires significantly more pan clusters in the circulating stock. Thus the result is longer lifetime with a smaller circulating stock and correspondingly lower overall costs for the same level of quality. One can go even further and raise the quality level of the pan cluster. Due to the interchangeability of the pans, the frame structure be-comes almost a multiple-use system for pans. So designs that are more robust or more elaborately designed for handling systems become affordable because they can be amortized over a longer period of time.
Thus the problem that classical pan clus-ter designs are destroyed by recoating with pyrolysis can be effectively eliminat-ed. The frames are no longer part of the recoating process and are reusable almost any number of times. The pans can be replaced individually, or recoated on request.+ bbi: What else did you consider?+ Leuver: Innovations can also be achieved through a new way of assem-bling the pan cluster frame. In fact, pans in frames are often comparatively poorly
protected, and we already see the conse-quences of this in relation to interchangeable pan clusters. Therefore we thought about whether we can also use the frames to protect the pans. This has resulted in a frame that is higher than the pan. The result: the coating at the pan edge can no longer be damaged during the manual depanning process – i.e. when removing the bread from the pan.+ bbi: How important are coatings in the case of pan clusters?+ Leuver: Fewer and fewer bakeries use uncoated pan clusters. We almost no longer find them at all in the in- dustrial environment. The benefits of a high-quality coating are just too convincing. It’s different with trays. In this case, considerably more users still operate without coating, although here again there is much to be said for coatings.+ bbi: What can be said in their favor?+ Leuver:Anyone who uses coatings is aiming to optimize his handling processes, save separating agent and cleaning costs, and to increase the quality of his products and/or safeguard it via process stability. The more industrial the production operation, the more benefit bakers can derive from coatings. But smaller bakers also resort to coatings because the bigger the problem, e.g. with decorating sugar, the more expensive it will be to overcome this problem when using uncoated trays.+ bbi: How does a customer find a baking tray or pan cluster that is right for him? Aren’t there countless parameters to which attention must be paid? The process, moisture, clean-ing, temperature rise – surely they all play a part, and are different for every baker.+ Leuver: Correct. Baking is a highly complex process with many factors influencing the coating. We focus on comprehensive service, e.g. by providing test kits. These allow the baker to test the various coatings himself on the spot. If none of the test kit coatings achieves the
++ Helmut Leuver, Executive Director of Anneliese Backtechnik
© A
nnel
iese
Bac
ktec
hnik
www.bakingbiscuit.com 04/2016
BVT Bakery Services manufactures production lines for medium and industrial bakeries. We offer ''Total dough handling'' solutions for almost all bread and pastry products in the following categories :
1. Dough forming lines and make-up lines. 2. Product handling systems. 3. Product conditioning: proofing, cooling and freezing systems.
We are well known for our turn-key projects for major bakery groups around the world. All equipment is designed and manufactured at our modern factory located in the Netherlands. For a complete overview of the delivery program, please visit our website: www.bvtbs.com, or contact us!
BVT Bakery Services BV Parallelweg 13 5349 AD OSS The Netherlands Tel.: +31(0)412 69 90 08 Fax: +31(0)412 63 95 65 E: [email protected] I: www.bvtbs.com
A D V E R T I S E M E N T
47T R A Y S A N D P A N ST R A Y S A N D P A N S
++ Photo left: with a frame that is higher than the pans themselves, the coating is no longer damaged so easily when depanning breads; photo right: on a pan cluster with riveted pans, the baker can replace damaged pans himself
objective satisfactorily – which does happen now and again, since there is a great diversity of processes that cannot all be covered by standard products – we also offer a process analysis on the basis of which it is possible to fabricate individually customized coatings. We even have some of these produced to order by our coating suppliers who specialize in such cases.+ bbi: Which coatings do you work with?+ Leuver: The spectrum ranges from 2- and 3-layer non-stick systems based on PTFE, PFA and FEP to non-stick coatings based on resin rubber or silicone rubber. We use a wide variety of materials and processes that we have
optimized in the past few years. That’s why we offer entirely new grades in different gradations, both for trays and for pan clusters.+ bbi: Can you give more details of the processes?+ Leuver: The coating processes must remain our com- pany secret. All I can say is that we constantly work to optimize the properties of our products by varying the mate-rials used and the coating. However, whether and how that succeeds should not make bakers dependent on our methods, and it is better that they should test the coatings themselves.+ bbi: Mr. Leuver, many thanks for the interview. +++
© A
nnel
iese
Bac
ktec
hnik
© A
nnel
iese
Bac
ktec
hnik
www.bakingbiscuit.com 04/2016
48 T R A Y S A N D P A N S
Coating made from high- performance plasticOriginally developed for the automobile industry, a coating made from the high-performance plastic polyaryletherketone is now also being used for baking trays and pans. According to company informa-tion, the recommended maximum application temperature is 300 ° C.
++ The DURAPEK® coating can be used up to 300 ° C, and according to the company it is alkali-resistant
+ The German company acs Coating Systems GmbH, Wilhelmshaven, originally developed the DURA-
PEK® (patented) coating for applications in the automo-bile industry. The coating has now also proved successful in applications in catering, and was most recently opti-mized for requirements in the baking industry. Major clients such as manufacturers of combination steamers or catering systems, who demand at least 20,000 cycles, as well as pan manufacturers are using DURAPEK® coat-ings, partly under their own brand names. The coatings are based on the high-performance plastic polyarylether-ketone, abbreviated to PAEK, which according to acs Coating Systems Managing Director Dr. Christoph Stecher is harder and more resistant than PTFE, PFA or silicone.DURAPEK® coatings differ from the usual coatings not only in their material composition, they are also manufac-tured in a different way. The usual process is to spray on wet lacquer coatings, followed by stoving. DURAPEK® coatings, on the other hand, are electrostatically pow-der-coated and are also stoved in a different way. Dr. Stecher explains that this technique also yields a uni-form distribution with perforated metal sheets, even on the edges of the holes and on their reverse side. This sys-tematically avoids spalling off originating from the holes.
ProductionApplication of the coating is entirely fully automated, with the components being merely loaded and removed
again by hand. The coating plants have a central control system in which each product has its own program with all the machine parameters from pistol guidance to oven temperature. This guarantees repeat accuracy. Pans and bread pan clusters can also be coated, as well as baking trays. +++
© a
cs C
oati
ng S
yste
ms
Gm
bH©
acs
Coa
ting
Sys
tem
s G
mbH
- READ THE WHOLE STORY ON -
BACKWELTBLOG.COM
VISIT: WWW.BACKWELTBLOG.COM/LOACKER-EXPANDS-ITS-EAST-TYROL-MANUFACTURING-LOCATION
LOACKER EXPANDS ITS EAST TYROL MANUFACTURING LOCATION
© m
eran
er-h
ause
r.co
m
T R A Y S A N D P A N S
Validate your kill step
The SCORPION® 2 LITE Data Logger with Temperature Interface and Product Probes simplifies the measurement of environment and internal product core temperatures. After gathering the data, the SCORPION® 2 Software (SV8) Food Safety Module makes it easy to calculate lethality and then generates a comprehensive report displaying cumulative log reduction. By combining this ease of measurement with robust data capture, the SCORPION® 2 System makes it simple to optimize your process while meeting food safety standards.
3 Easy Steps to FSMA Compliance
The SCORPION® Software (SV8) Food Safety Module is the newest addition to the SCORPION® 2 line of oven data logging equipment. This module enables SCORPION® users / bakers to easily comply with new Kill Step Validation required by the Food Safety Modernization Act (FSMA). To learn more visit readingthermal.com or call 610-678-5890.
See how it works at IAFP #834readingthermal.com or 610-678-5890
A Markel Food Group Company
Validate your kill step
The SCORPION® 2 LITE Data Logger with Temperature Interface and Product Probes simplifies the measurement of environment and internal product core temperatures. After collecting the data, the SCORPION® 2 Software (SV8) Food Safety Module makes it easy to calculate lethality and then generate a comprehensive report displaying cumulative log reduction. By combining this ease of measurement with robust data capture, the SCORPION® 2 System makes it simple to optimize your process while meeting food safety standards. To learn more visit readingthermal.com or call 610-678-5890.
3 Easy Steps to Prove Food Safety
See how it works at IAFP Booth #834
Food Safety Ad_B&I.indd 1 6/27/16 11:06 AM
I N T E R V I E W
A Markel Food Group Company
Your simple, 120-year recipe for success.
For over 120 years, the Thomas L. Green brand has been supplying biscuit and cracker manufacturers with the industry’s most effi cient, reliable and sanitary production systems. As the world’s most trusted brand, we offer a full line of modern, high volume systems for laminated and sheeted products. The unmatched baking experience and advanced technology that goes into every Thomas L. Green system ensures that you consistently bake your best product, day in and day out.
Call us at (01) 610-693-5816 today or visit us at www.readingbakery.com
Thomas L. Green, your partner for better biscuit and cracker systems.
See us atBooth #5109
www.bakingbiscuit.com 04/2016
50 R A W M A T E R I A L S
The Times They Are A-Changin‘Nothing is the same as it was. So we need to adapt to the new reality; also in agriculture. What is this new reality? And what will it be for European ingredients supply?
+ The Times They Are A-Changin‘ – Bob Dylan sang it already in 1964. Changes in European Common
Agricultural Policy away from crop specific subsidies towards general subsidies have led to a much more market oriented crop production. At the same time this created a lot more volatility (uncertainty) which attracted invest-ment funds/speculators onto agricultural commodities; especially in times of very cheap money. Do not get me wrong, we need these people as they provide the necessary liquidity that markets need; they do not create trends they only enhance trends.
Gone are the days when wheat prices were dictated only by wheat fundamentals. The market reforms stated above have made the farmer much more the businessman he needs to be; meaning that his planting decisions will depend on what the market is willing to pay for his pro-duce (profit optimization). This means that we have now on our hands what you could call “a fight for acreage” where different crops compete for the same amount of land; this also means that crop prices now seem to move much more in tandem irrespective of their own funda-mentals.
The big elephant in the glass cabinet was and still is China. The creation of a wealthy middle class had led to much higher protein (meat) consumption which as such has led to a much higher demand for feed grains. China has tried over the years to stay as independent as possible from outside influenc-es; hence they created an agricultural support plan which stimulated local production. As this was done at prices higher than world market levels, the market distortion
was born. “Cheaper” world feed grains like DDGs, barley, tapioca and milo (sorghum) found their way into China causing the prices of these feed grains to rise considerably in their origin countries. Result is that China is currently facing the daunting task to get rid of their reserve stocks. (Corn currently estimated at 250 Mt, to put it in perspec-tive this is 4 times the whole EU corn production.) This will have serious consequences for agriculture worldwide. The change away from backyard farming to industrial farming has led to much more demand for industrial feed; hence China has become the biggest importer of soybeans being responsible for some 65% of total world imports of the oilseed (please see graph 1). The ferocious demand of China for soybeans has led to a dramatic increase in soybean production in South America (production has quadrupled over the last 20 years). Graph 3 shows that global trade in oilseeds and cereals is expected to increase quite consid-erable in the next few years.
Reasons: + Population growth+ Considerable planted area reserves in South America, Sub-Saharan Africa and FSU+ Higher yields (biotechnology)
So clearly production of agricultural commodities is shifting away from subsidized production towards regions where it is just the most economical to produce them (South America, FSU, Sub-Saharan Africa).
The usual trend is that such countries start with exporting the raw material and later on try to develop a local process-
ing industry to capture more added value. Great examples are Malaysia and Indonesia who account for 85% of to-tal world palm oil production, 20 years ago they were exporting mainly crude palm oil, today it is mainly processed products (refined, fractionated, dress-ings, margarines, etc...). The same we see in Argentina, currently the worlds’ biggest supplier of soybean meal and soy-bean oil (not soybeans). This also means that less and less will be produced in the industrialized countries (too expensive) unless support measures are put in place to stimulate local production. Remember one of the principle laws of physics: “an unconstrained system will always evolve towards a situation in which
Global soybean imports (Million metric tons)
source: USDA
1
KOENIG BACKMITTEL GMBH & CO. KG • Postfach 1453 • D-59444 WerlTel. 02922/9753-0 • Fax 02922/9753-99
E-Mail: [email protected] • Internet: www.koenig-backmittel.de
The Nut specialists
Quality-brand and freshness with long tradition
Almond- Hazelnut- and Peanut-Products,roasted, sliced, diced and slivered.Hazelnutfilling and Multi-Crunch.Please ask for products meeting your specifications.
KOENIG Motiv4 NTS 91x53.qxd 12.02.2007 11:10 Uhr Seite 1A D V E R T I S E M E N T
www.bakingbiscuit.com 04/2016
51R A W M A T E R I A L SR A W M A T E R I A L S
its free energy is the lowest; only then will the system be in equilibrium”. This means that sooner or later an artificially build up system will fall apart; history has given us enough examples of this. Unfortunately the bulk of the increase we have seen in agricul-tural production the last 10–20 years has happened mainly in politically unstable regions; this poses a risk long term. So one should try not to become totally dependent on imports (food safety/security).
Global Warming is putting stress on the world climate as does the 3–7 year El Nino/La Nina cycle. Unpredictable weather patterns pose a clear risk to food safety worldwide. Short sighted politicians go for quick wins (protec-tionist measures) just to win votes for the next election; this potentially distorts the equilibri-um situation as discussed before.
Other examples are “Buy Local Origin”, e.g. in Austria there is currently a big pressure from the supermarkets to go for Austrian origin; by definition this excludes all the rest and artificially inflates prices.
How do we get to a price for a commodity?Investment funds mostly invest in a basket of commodities, not so much in single commodities. Best known Commodity Index is the Standard & Poor’s Goldman Sachs Commodity Index (please see table 1). Energy is by far the most impor-tant group of commodities in this index (63%), while agri-cultural commodities make up 16% of the index. It is exactly because of this reason that you need to watch especially crude oil behavior. We saw it in the aftermath of the Lehman Brothers disaster when crude oil broke from 150 USD/bl. to 30 USD/bl. All agricultural commodities halved in price as well as funds invested in such commodity indexes were
source: USDA
3 Global trade: Wheat, coarse grains, soybeans and soybean products (Million metric tons)
forced to sell their other positions just to continue “mirror-ing” the index despite supportive fundamentals. We experienced the same behavior in early 2016. These “combined” moves (either way up or down) can cause that the price of a certain commodity will get disconnected from
its own fundamentals and as such creates buying/selling opportunities. Another very important factor in the whole pricing mechanism is of course foreign exchange. FX can make or break your price vs. world market levels. Great example is the Russian Ruble (RUB) which went to historic lows vs US-Dollar (USD) early 2016 (USDRUB @ 83), no coincidence that this happened when crude oil was hitting 25 USD/bl. Now USDRUB is back @ 65; so examples like this show that currency move- ments often determine much more your competitiveness than anything else. Markets do not like uncertainty, look e.g. at what happened during the Crimea crisis.
Soybean Production Major Exporters
source: USDA
2
www.bakingbiscuit.com 04/2016
© O
p de
Bee
ck
Euronext Milling Wheat futures shot up as that region is one of the most important export regions for wheat.
Price levels are also very much influenced by what I would call residual/floating demand. What do I mean by that? Let us take the example of wheat in Europe. We have a fairly sta-ble demand for wheat in Europe for human con- sumption (stable population) but the demand from on the one hand the export sector and the other hand the animal feed sector will depend on the relative competitive-ness vs. other feed grains/origins. Looking at exports FX
52 R A W M A T E R I A L S
will play an important role to see if Europe can be competi-tive on world markets. For the feed sector, prices of other feed grains/proteins will play a very important role in the incorporation volume in the feed mix. This points once again to the interconnectivity with other commodities like corn, rye, barley and oilseed meals. Therefor major developments in such competing products have to be moni-tored as they play an important role in determining the price of in this case wheat.
What does this all mean for Europe?Within the EU a probable shift of production from Western European countries towards Southeastern European countries as we still can find enough arable land in countries like Hungary, Romania and Bulgaria. Planted area will continue to increase in Ukraine and the rest of FSU (lower production cost).
Excess supply in Europe should diminish as competitive- ness on the world market is expected to decrease (high labor costs, high land costs, strong currency, and stricter regula-tions). So European production should become much more geared towards internal consumption, like US we will become more the residual world supplier of agricultural commodities (meaning we will be able to supply to the world market if there is a problem somewhere else).
To remain competitive Europe should focus more on quality instead of quantity as the cost disadvantage carries much more weigh on “simple” commodities as it does on “more complicated” commodities. Example: EU will still be able to export high protein wheat to North Africa and the Middle East but the regular milling wheat will be sold by Black Sea countries as they enjoy a clear cost advantage.
As the globalization process continues, “fortress” Europe will crack (sorry France) sooner rather than later as it is no longer justified to spend 38% of the total EU budget on agriculture and rural development. +++
— Author: Ir. Erik Op de Beeck, Director Risk Management & Sourcing, GoodMills Group GmbH, Vienna/Austria
Table 1: S&P GSCI Reference Percentage Dollar Weights*
Commodity 2015 RPDW 2016 RPDW
Chicago Wheat 3.535% 3.531%
Kansas Wheat 0.859% 0.879%
Corn 4.206% 4.231%
Soybeans 2.939% 2.950%
Coffee 0.936% 0.938%
Sugar 1.600% 1.593%
Cocoa 0.436% 0.452%
Cotton 1.190% 1.186%
Live Cattle 4.890% 4.786%
Feeder Cattle 1.215% 1.550%
Lean Hogs 2.261% 2.300%
WTI Crude Oil 20.91% 23.04%
Brent Crude Oil 21.52% 20.43%
Gas Oil 6.829% 5.822%
Heating Oil 5.562% 5.207%
RBOB Gasoline 5.503% 5.307%
Natural Gas 3.232% 3.241%
Aluminium 2.838% 2.877%
LME Copper 3.814% 3.850%
Lead 0.588% 0.600%
Nickel 0.673% 0.697%
Zinc 0.873% 0.882 %
Gold 3.194 % 3.245 %
Silver 0.391 % 0.405 %
* The RPDW´s (Reference Percentage Dollar Weights) are determined by using the 2015 Average Contract Reference Price (ACRP) for each individual commodity within the S&P GSCI.
www.bakingbiscuit.com 04/2016
R A W M A T E R I A L S
Diane Industries
Diane Industries - More than just a tray ...
u r a n u s t r i +
A NEW GENERATION OF NON-STICK COATINGS
Three silicone elastomer layers
Three fl uoropolymer PTFE / PFA layers
with ceramic
TÜV certifi cation : FDA – LFGBTested parameters: Food
contact and metal migration
Discover our full range of products:
WWW.DIANE-INDUSTRIES.COMZI du Champ du Roy - 8, rue Voltaire 02000 LAON ( FRANCE )Phone : + 33 (0) 3 65 90 00 23 E-mail : [email protected]
We developed a special frame construction to ensure cleaning cycles without interruption.
Why more than just a tray ?
Industries
WELDING WITH 3 YEARS
WARRANTY
5 > 9 FEBRUARY 2016
Meet us on :
Stand 4 D 88
www.bakingbiscuit.com 04/2016
R U B R I K5454 I N T E R V I E W
Fuel for muscles and brainThe 2016 Olympic Games will be held in Rio de Janeiro from 5th to 21st August 2016. In this interview with Dr. med. Johannes M. Peil, Chairman of the German Institute for Sport Nutrition e.V., he explains how the athletes prepare for the competition and the role played by diet, specifically baked products, in this preparation.
+Borchfeld: Dr. Peil, how often and how much bread should people eat?
+ Dr. Peil: The general rule is that one should utilize the great variety of bread types in a targeted, situation-specific way. It is difficult to generalize as to how often and how much bread people should eat each day. This is due to each person’s individual carbohydrate requirement. We recommend approx. 350 g of bread per day as a basis for a man, and approx. 250 g for a woman. Bread is a versatile, nutrient-rich food that tastes good, con-tains carbohydrate and protein, and can be integrated into almost every mealtime with great variety and diversity. + Borchfeld: In this respect, do you differentiate for example between indi-viduals that are active and those that are not so active?+ Dr. Peil: Bread is an important source of macro- and micro-nutrients, for active persons just as much as for those who are less active. Thus a person who eats a lot of bread, especially wholegrain bread, creates the perfect basis on which to supply a diet rich in nutrients and roughage. Implementation of the above recommendation in the form of wholegrain breads like “Wir für Deutschland-Brot” would on its own be a significant contribution, e.g. to an adequate supply of dietary fiber. Here again, its variety and the opportunities to combine it with various toppings speak in favor of bread. While less active individuals can make a big contribution to their weight management by using thinner slices of bread and low-fat top-pings, active athletes are, depending on the situation, well served with thick slices combined with a sweet topping or protein-rich quark. Active people benefit from consuming a larger quantity, because they need more carbohydrates as sources of energy, and can make better use of them to restock their energy reserves after activity. They can exploit the steady supply of energy via bread to support sporting aims like muscle-building through the input of protein. How-ever, they profit just as much as less active individuals from the more health-related importance of roughage, vitamins and minerals.
+ Borchfeld: Are the recommendations for top-ranking and leisure time athletes different? + Dr. Peil: Hobby and leisure time athletes differ mainly with
respect to their energy requirement and also in their micro-nutrient supply recommendations. An increasing amount of training, longer training periods and higher training intensi-ty, together with more frequent participation in competitions, also increase the recommendations regarding the amounts of
carbohydrate to be consumed, the protein require-ment rises considerably and there is also
a greater need for vitamins and minerals. However, high-quality foods are ade-
quate to cover this bigger demand. For top-class athletes, the nutrient rela-tionships and amounts of food must be matched to the type, extent and intensity of sporting activities. It is generally recognized that with a pe-riod of at least five hours of sport per
week, a sport-specific pattern of eat-ing and drinking is advisable. Further-
more, top-class athlete mostly follow aims that are different to those of leisure
athletes. Whereas the former focus mainly on performance, what matters for more than 60% of
hobby athletes is often weight management and health as-pects. Their pattern of eating and drinking should be matched to this as well.
+ Borchfeld: How exactly can bread support the perfor-mance of top-class athletes when preparing for a competition?+ Dr. Peil: A sufficient amount of the “correct” fuel – carbo-hydrates – is needed to achieve peak performance. It’s no coincidence that carbohydrates are also called “muscle gas”. An adequate amount of high-quality protein is also needed for regeneration and for musclebuilding and maintenance. To ensure a largely constant blood sugar concentration and to avoid any performance-impairing reduction in blood glucose, it is advisable to eat small, more frequent meals containing carbohydrate, and to rely on foods with a low to medium Glycemic Index (GI) at main mealtimes. Bread is more suita-ble for this objective than almost any other food, since it has the ability to fulfill the widest possible diversity of differ-ent sporting and fit-ness-oriented aims though the options to combine it with a variety of toppings. An intake of carbohy-drate-rich foods designed for the individual person’s needs and with a carbohydrate spectrum having a nutritional-phys-iologically sensible composition is ir-replaceable as an energy source appropriate for an athlete, both as a basic diet, to re-plenish reserves before a competition, and also during pauses in sport and in the recovery phase. We are confident that the
55R U B R I K
www.bakingbiscuit.com 04/2016
R U B R I KI N T E R V I E W
++ Dr. med. Johannes M. Peil , Chairman of the German Institute for Sport Nutrition
© b
acka
ldri
n
recommended proportions of carbohydrate and protein suit-able for sport can be well fulfilled by an increased consump-tion of carbohydrate-rich and/or starch-rich foods with a low to medium GI, such as wholegrain bread, and that the neces-sary intake of micronutrients can be guaranteed more easily at the same time.
+ Borchfeld: Do you recommend particular types of bread such as wholegrain bread, or can it also be an occasional slice of toast-bread?+ Dr. Peil: With regard to eating bread, I recommend wholegrain bread in the great majority of situations. As well as energy from various different carbohydrates and high-qual-ity fats, it also provides protein together with valuable vita-mins and minerals. Wholegrain breads contain the vitamins, minerals and dietary fiber from the entire cereal grain and thus contribute to a high-quality supply of nutrients. Another characteristic feature of wholegrain bread is its medium GI. It ensures a long-term constant blood sugar level that has a positive effect on the availability of energy in the majority of situations. Toast-bread made from white flour and with a sweet spread is suitable as a superfast energy provider short-ly before or during a pause in a sport. Due to its high GI it provides energy very quickly, but this should then be used immediately for intense activities. Toast is a perfect energy boost at half-time or when changing sides, and can counteract the rapid physical and mental fatigue during sport. Then, however, in the evening after the game or competition it should again be whole-grain bread with its fantastically good spectrum of vitamins and minerals.
+ Borchfeld: The highest performances are achieved only by those who also train conscientiously. Now you say nutri-tion can give athletes good support. How important is the topic of “enjoyment” in this respect?+ Dr. Peil: Enjoyment is a part of the joy of living and of quality of life. Eating and drinking without enjoyment makes no contribution to supporting performance.
An athlete will eat the recommended foods with a clear conscience and integrate them into his or her daily sportive life only if they taste good and correspond to the dietary behavior that has been learned. Nutritional recommendations must therefore always be customized to individual personal inclinations and preferences, and must be compatible with the learned dietary behavior. Other than sleep, the time during meals is often the only time remaining during which top competitive athletes can relax and be distracted from hard daily training. It is precisely for this reason that athletes’ mealtimes must satisfy enjoyment aspects to a high degree.
+ Borchfeld: Is the advice that one should eat like a king in the morning, like an ordinary citizen at midday and like a beggar in the evening currently still valid?
+ Dr. Peil: This recommendation is too sweeping for an athlete’s daily life at present, and thus scarcely sustainable in that form. When and how one should eat a large amount de-pends on many individual personal factors, e.g. daily rhythm, training times and even tolerance. Anyone who trains in the evening should be well fortified when they start training, and should support their regeneration afterwards by the above-mentioned food combination containing carbohydrate and protein. That can’t be achieved with a very modest evening meal. And someone who has their first training unit scheduled for shortly after breakfast will do better with a rather small, light first breakfast together with a bigger second breakfast.
+ Borchfeld: Now there are vegans or vegetarians as well as the Slow Carb diet (paleo-nutrition). Do you also see a trend in nutrition among athletes?+ Dr. Peil: Yes, various dietary trends are on the increase in athlete nutrition as well. Low-Carb nutrition is very popu-lar – a reduced carbohydrate diet with the emphasis on pro-tein and fat. However, it has only limited suitability for perfor-mance-oriented athletes. There is still a strong trend in rela-tion to vegetarianism or veganism. Vegan-living athletes in particular have an increased risk of nutrient deficiencies re-garding certain vitamins and trace elements. Therefore anyone who follows a dietary trend should be fully informed and should have his or her blood parameters analyzed regularly. An unbalanced diet, irrespective of the nutritional orientation, should be avoided on principle.
+ Borchfeld: Dr. Peil, thank you very much for the interview. +++
I N T E R V I E W 55
» Enjoyment is a central component of every diet plan for athletes. «
www.bakingbiscuit.com 04/2016
56 F O O D L A W
On shaky ground: labelling unpacked goodsFrom the viewpoint of chain store bakers, food labelling was a secondary theme for many years: the German legislator only required additives to be mentioned on the price-tag, on a notice or in a notebook. That changed in 2014 with the EU Food Information to Consumers Regulation (FIC): now allergens also had to be “visible” in a baker’s counter display.
+This presented gigantic challenges for branches: it was necessary for all the ingredients and recipes to be exam-
ined for allergens, and an entirely new labelling regime had to be set up and perpetually updated. In addition to this purely practical problem, a legal one arose: there were no clear rules for the allergen labelling of unpacked goods in Germany. Al-though the national legislator had already declared an intention in 2011 to enact a statutory amendment to the FIC, no draft materialized, and uncertainty among chain store bakers grew as the application date of the FIC in late 2014 moved closer.
The first Draft Bill for the statutory amendment appeared in the summer of 2014, but it was so flawed that the German Fed-eral Government did not pursue it any further. Then, almost at the last minute, the Provisional Food Information Supplemen-tary Regulation (German: VorlLMIEV) was pulled out of the hat. However, it governed only parts of allergen labelling, and other adaptations of national law to EU law had to wait. Then, astonishingly, the FIC Implementing Regulation(German: LMIVDV) appeared in March 2016, with a more comprehen-sive set of allergen rules . However, if anyone thought the label-ling law for unpacked goods in Germany would be complete after this legislative Odyssey, they were disappointed. Although the LMIVDV has at least established rules fit for practical use in relation to allergens, what is missing is an adaptation of the old German labelling law for additives.
For chain-store bakers, this in turn means a host of new prob-lems. For a number of years, the statutory basis for additive la-belling in chain store bakeries in Germany has been Section 9 of the Additives Approval Regulation (German: ZZulV). This piece of legislation is quite unwieldy: it extends over nine paragraphs and numerous sub-paragraphs, and is notorious among practitioners for its susceptibility to misin-terpretations. Although the additives law has already been regulated at European level for many years, this appendix of German labelling law persists. There have been no changes in the material content of the law since 1998. It is therefore hardly surprising that it doesn’t match properly with current allergen labelling law.
This is highlighted by a comparison between the kind of label-ling demanded by the ZZulV on the one hand and the LMI-VDV on the other. The legislator is very easy-going in relation to allergens: practically any form of communication is allowed, whether it’s a notebook, notices, verbal information, a tablet computer or even the “intelligent checkout”, in which the aller-gens of all the baked goods are stored as a computer file. In a nutshell: almost anything goes with regard to allergens. In relation to additives, the situation is very different: the require-ment here is that the information must always be available in writing and – according to the wording of the law – must be “di-rectly accessible” for customers (Section 9, Para. 8 No. 3 of the
© f
2m
The world’s leading industrial baking pans are now easier than ever to bring to your bakery. With our new, dedicated facilities in the UK, you can revolutionize your baking operations:
• Give your current pans/tins new life with cleaning, straightening, and recoating services• Experience superior AMERICOAT® Plus and DuraShield® coatings • Get custom pans built to your exact specifi cations • Spend less, save time, bake more, and take quality to the next level
40 5050 5,000
Reduce costs by up to 40% by cleaning
and recoating
Increase pan life by 50%+
with life cycle management
Achieve up to 5,000+ releases with DuraShield®
coating
Decrease pan weight by up to 50% with ePan designs
Units 6-8 Seddon PlaceStanley Industrial EstateSkelmersdale WN8 8EBTel: 01695 50500www.americanpan.co.uk
American Pan UKMixers
Industry-leading innovation and complete customization for your exact product and facility needs.
World-Class Quality. European Presence. American Pan ®.
Visit Us at Booth #5130
F O O D L A W
www.bakingbiscuit.com 04/2016
its labelling rules are very liberal – as shown above. For addi-tives, the legislator presumes only an “increased interest in information” on the part of the consumer, but nevertheless continues to insist that it must be in writing. ConclusionOn the third attempt, the German legislator has created a usable standard for allergen labeling in the shape of the LMI-VDV. Unfortunately, he has missed the opportunity to adapt additives law to these rules. We are already paying for that now in practice: chain store bakers are compelled to carry on jug-gling with different standards and different labelling require-ments. The legislator is therefore called upon to reform the ZZulV, and at long last create rules that enable chain store bak-ers to establish a fully comprehensive labelling system. This is also, and not least, in the interests of customers and of the Foodstuffs Inspectorate, who must monitor such rules. +++
— Author: Alexander Meyer-Kretschmer, Managing Director of the German Plant Bakers Association e.V., Düsseldorf (Germany)
58 F O O D L A W
Trade fair calendarAugust 1 – 3, 2016 Tokyo/Japan Patisserie & Bakery Japan www.bakery-expo.com/2016/en/index.html
October 8 – 11, 2016 Las Vegas/USA, Nevada IBIE 2016 - International Baking Industry Exposition www.ibie2016.com
October 22 – 25, 2016 Stuttgart/Germany südback– Trade Fair for Bakery and Confectionery Trade in Germany www.messe-stuttgart.de/en/suedback
October 26 – 27, 2016 Shanghai/China Bakery China Autumn 2016 www.bakerychina.com/bcaen/index.jhtml
November 2 – 4, 2016 Almaty/Kazakhstan WorldFood Kazakhstan www.worldfood.kz/en
November 7 – 9, 2016 Dubai yummex Middle East 2016 & Gulfood Manufacturing www.yummex-me.com www.gulfoodmanufacturing.com
November 19 – 22, 2016 Rimini/Italy Gluten Free Expo 2016 www.glutenfreeexpo.eu
November 23 – 25, 2016 Tashkent/Uzbekistan Food Industry – UzProdExpo 2016 http://ieg.uz/archives/2816?lang=en
December 1 – 3, 2016 Hong Kong/China IBE 2016 www.hkbakeryexpo.com
December 6 – 9, 2016 Tehran/Iran IBEX 2016 www.ibex.ir/en
2017 January 21-15, 2017 Rimini/Italy SIGEP 2017 - International Exhibi-tion dedicated to Artisan Gelato, Pastry and Bakery Production, and the Coffee Sector www.www.sigep.it February 19-21, 2017 Madrid/Spain INTERSICOP 2017 - International Bakery, Pastry, Ice Cream and Coffee Show www.ifema.es/intersicop_06 May 10-13, 2017 Shanghai/China Bakery China 2017 www.bakerychina.com/bcaen/index.jhtml
NOV
10MAY
ZZulV). This difference in wording has very tangible effects in practice: the German Foodstuffs Inspectorate has judged check-out print-outs with additives and allergens to be inadequate on several occasions. The grounds: the additives information was deemed to be not “directly accessible” for customers, as they needed to ask the staff for a print-out.
This gap between allergen law and additives law is impeding technical development in German chain store bakeries. Check-out systems using centralized data processing have massive ad-vantages: they can be kept up-to-date continuously, quickly and for all branches. They supply information about all the baked products easy to grasp, comprehensively and readily available to the customer. An intelligent checkout or other IT-based information systems would be a quantum leap for comprehensive customer information. However, they are not practicable under the current statutory rules in Germany: An-yone who has laboriously set up his IT system can indeed use it for allergen information, but in addition he must still have the additive information available as well, in fully written-out form – with twice the expense and twice the susceptibility to errors. It is indeed doubtful that the legislator really wanted this “belt and braces” solution. Moreover, the “directly accessible”-requirement indicates a strange priority of risks on the part of the legislator: the pur-pose of allergen labelling is to protect health, but nevertheless ©
Mey
er-K
rets
chm
er
www.bakingbiscuit.com 04/2016
59F O O D L A WF O O D L A W
Baking
IngredientsPacka
ging
TechnologySolutions
Innovation
The entire world of baking comes together in Las Vegas, USA for four high-impact days to explore what’s new in the grain-based foods industry—all of the latest product trends, innovative equipment & technology, and effective business strategies to help you run a more profitable operation. IBIE is your trade show, your industry, your world—and it only comes around once every three years. Seize the opportunity and become more competitive in the evolving global marketplace.
Join IBIE’s International Buyer Program by contacting your local U.S. Embassy
or Consulate and receive a 50% savings on registration. Visit www.IBIE2016.com
for international visitor information, travel tips and a Visa application.
REGISTER NOW AT WWW.IBIE2016.COM
YOUR
WORLD OF OPPORTUNITY
www.bakingbiscuit.com 04/2016
From 1 October 2016 onwards there is now an option to arrange for an unannounced full IFS Food Audit to be carried out on a voluntary basis. Various retail companies have already informed their suppliers of this in writing, and have requested them to implement the new procedure. Com-panies that have up to now also arranged for IFS Food Checks to be carried out in addition to the regu-lar and unannounced IFS Audits have adjusted to the situation, and some of them have also made intensive organizational preparations for it. This has now been followed by the unannounced full IFS audit: which additional challenges now need to be managed?
The current situationDuring an unannounced IFS audit, a “Full Audit” takes place with the associated evaluation scheme and the correspond-ing assessment “passed at basic level”, “passed at higher level” or “not passed”. The audit takes place in an 18-week time window extending over a period of 16 weeks before and two weeks after the scheduled date of the audit (Due Date). The standard setter specifies the Due Date via the date of first certification. It is noted on the company’s currently valid IFS Certificate.
Preparation for an unannounced Full IFS Audit.What do you need to do?Anyone who has already experienced Food Checks in his business will by now be familiar with the unannounced appearance of the auditor. Since the company is not given any prior information as to the time when the unannounced audit will take place, the employees who are present must be able to give the auditor the answers to the questions that are asked and to provide the associated information at any time. The required documents and proofs, e.g. delivery papers, specifications and test lists, must be kept accessible, fully up-to-date and available at all times. This means that the auditor will work with all the documents un- announced.
60 Q U A L I T Y A S S U R A N C E
Unannounced IFS Food Audits – preparing for practical applicationThe quality and safety/security requirement applying to foods is growing steadily. As a result, the retail is also increasingly demanding from its suppliers that they provide not only high-quality products but also the highest possible level of safety and security in their manufacture. Producers, especially own brand manufacturers, meet this demand through various external control schemes such as the IFS Food Standard.
+During an IFS Food Audit, the processes in the company are scrutinized by independent auditors and their safety
and security are checked. The outcome of their assessment, in the shape of the IFS Food Certificate, is intended to guarantee the product purchaser’s trust in the retail vis-à-vis processes that are legally prescribed and thus safely and securely designed
How can the retail’s confidence in auditing be further strengthened?Until 30 September 2016 there is an option to carry out unan-nounced “Food Checks” in addition to the scheduled IFS Food Audits. These Food Checks are based on a checklist com-pressed to the core aspects of the IFS Food Standard. The em-phasis during Food Checks focuses on the areas of process safety/security, hygiene and pest monitoring. Intensive docu-ment inspection is omitted, therefore the Food Check can be also limited to one day of auditing time.
++ Consulting for the baking industry
© Q
uant
» The retail is increasingly requesting producers to allow unannounced IFS Food Audits to be carried out in order to strengthen the reputation of the testing systems «
www.bakingbiscuit.com 04/2016
Q U A L I T Y A S S U R A N C E
What does that mean for implementation and practi-cal application?The requirements arising from the Food Check that deal specifically with processes and hygiene can often be answered by the responsible production staff without any problems, and to some extent even without support by the Quality Manager. For the full audit, including all the documents such as labelling, specifications and risk assessments, the company will need its complete team of specialists from the individual departments. In this case, if someone is not in the premises at the time of the audit, the question now is: how do I access the knowledge, or who can give further help?
It can be inferred from the current IFS papers that an unan-nounced Full Audit will take place in a similar way to the Food Check, i.e. after a brief document check, the auditor will go into the factory. In the first step it is important to have already prepared all the suggested documents as in the Food Check:
Checklist of Food Check documents:+ Organization chart with deputizing rules+ Layout plan, with information about routes for personnel,
raw materials, semi-finished and finished goods+ The current production plan for the day/week+ Flow diagram of the processes, annotated with the CCPs (Critical Control Points), together with a list of the CPs (Control Points) and CCPs+ Pest/vermin monitoring documentation
For the unannounced Full Audit, however, further thought should be given to:+ Who is responsible for which topics in the IFS Audit, and who can also deputize in an emergency?+ Who can carry out/lead an audit?+ Who has access to the documents and an overview of them?+ What is the deputizing rule for the management?
+ What are the general deputizing rules?+ Is there an established crisis management system?+ Who can provide information about investment plan-
ning?+ Can the Engineering function always answer the Maintenance function’s questions?+ Are the product specifications and labelling fully up to date?+ Has a “Knowledge Team” been formed and trained for every area and each shift?+ Are authorizations for access to the IT system to dis-
play process contents and process proofs held in readiness in every shift?
In short: All the documents relevant to IFS must be kept in readiness and up-to-date.
Recommendations for application in practicePreparing for the unannounced Full Audit means you should concern yourself with the entire audit process and organiza-tion. How do you achieve mastery of the procedure, and have the knowledge at the correct point at the right time? Employee training sessions lead to confidence in handling the documentation and filing systems, as well as in accompanying the audit itself. As a result, the employees’ information relia-bility and thus self-confidence in the audit situation will be in-creased. Training for unannounced audits should be taken into account as part of the training program in the company. The unannounced audit situation can also be simulated and practiced in the annual internal IFS audit. The staff will there-by obtain the necessary certainty andknowledge about the re-quirements that are necessary in their area. This can reduce the risk of a lack of ability to provide information on the part of the company. A structured document filing system is a pre-condition for this. Through regular knowledge transfer to the employees, the company will ensure that every employee knows his/her obligations regarding the requirements of the IFS Food Standard, and can apply these and communicate them to auditors.
SummarySome producers currently still have a free choice as to whether to carry out an announced or an unannounced IFS Audit. In the short term, however, every food manufacturer must crit-ically tackle the preconditions for carrying out unannounced IFS audits, as well as their possible consequences. Early prepa-ration eases the decision and guarantees the required execution of unannounced audits. One thing is certain: the sooner the changes are grappled with and the processes designed with appropriate certainty, the greater is the probability of a success-ful, conflict-free transition into the new audit practice. +++
Q U A L I T Y A S S U R A N C E 61©
Qua
nt
— Authors: Jochen Brandt (left) and Norbert Daut, Quant Qualitätssicherung, Fulda-Munich/Germany Contact: [email protected]
» Every individual employee in the company must be able to be put in a position to explain his/her range of tasks and area of work fully and with process safety/security/reliability. This is the only way to successfully pass unannounced IFS Food Audits! «
You will find the following additional documents and information on the IFS home page: IFS Food Version 6 – Audit Protocol for Unannounced Audits at: https://www.ifs-certification.com/images/standards
www.bakingbiscuit.com 04/2016
62 I N G R E D I E N T S
Puffed cereals – innovative bakery ingredientsPuffing technology has been known for a long time, and it has a wide variety of applications. It has only recently also gained acceptance as a highly promising raw materials enhancement method for cereals and pseudo-cereals. A striking feature of puffed cereals is their swelling capacity, their stable shape and their naturally attractive texture, which is comparable to that of wholegrain. Thus they represent interesting, innovative ingredients in the manufacture of bread and baked products.
Historical developmentThe history of puffing technology goes back more than 110 years. Alexander Pierce Anderson is said to have been its creator. The son of a Swedish immigrant, he was born in Minnesota, USA, in 1862. After graduating and during his professional work, he carried out various studies in the area of starch analysis. He was convinced that he would find free water in the core of starch clusters. In an experiment in 1910, he heated rice starch grains in a sealed glass container. His theory was based on the assumption that the water in the grains would accumulate as steam under their outer layer, and that something would happen to the starch when he shattered the glass container. His ideas were proved correct. When smashed the container, there was an explosion and small fragments of inflated “puffed” starch were formed. At a trade fair in St. Louis only a few years later, he attracted at-tention from the food industry by filling some bronze cylin-ders, which looked like small cannons, with rice and heating them. When he released the locked lid, there was a bang and the rice grains expanded instantaneously, similar to what happens with the maize popcorn that is popular nowadays.
Development of the puffing technologyFrom the beginnings until around 1970, the main cereals processed by similar methods were rice and wheat. At that time the process lasted up to 30 minutes and achieved a
60 – 70% yield of puffed grains. Further studies were carried out in the USA around 1940. It was discovered that the treat-ment time could be shortened to 6 minutes by adding satu-rated steam. Further technological development in the early nineteen-seventies added a prior pre-heating stage, which again reduced the processing cycle to approx. 4 minutes. The thermodynamic efficiency of the process was elucidated in the years around 1990 with the aim of achieving higher yields and consistent quality. The latest knowledge and state-of-the-art technology have allowed the process to be re-duced to 90 seconds and the yield increased to 92 – 95%, depending on the type of cereal.
The puffing processUp to the present time, the technology used for puffing is based on hydrothermal treatment of the water in the grain. It is a physical process in which the only influence exerted is on the physical state of the water in the grain, and this has an enormous effect. Large amounts of energy are needed to treat and process the cereal grains. Saturated and superheated steam act as the heat carrier, and are fed into the raw material. Part of the steam is used to preheat the process air and/or cereal, and flows through tube bundles as a heat exchange medium. As a result, the air that is fed in is heated up to 170 – 180°C. The grains are pretreated in a closed loop in suspended form in a
© S
chap
fenm
ühle
+ Water content: 10 – 15%+ Starch content: 60 – 85%+ Protein content: max. 18 – 20%+ Fat content: max. 12 – 15%
Higher protein and fat contents have a rather negative effect in the end product. Therefore it is difficult to achieve expansion with pulses and legumes.
Grain types that can currently be puffed
Cereals Pseudo-Cereals
Corn (maize)RiceDurum (hard) wheatWheatSpeltEmmer wheatRyeBarleyOatsMilletTeff
BuckwheatQuinoaAmaranthQañiwa
Areas of usePuffed grains have been well-established in the breakfast cereals area since the beginning. At a relatively early date, these neutral-flavor cereals, e.g. from rice and durum wheat, were also coated with layers of sugar or honey and processed to yield muesli, muesli bars and chocolate products. Puffed grains, including in an improved form, are an indispensable ingredient nowadays in many sweet and spicy foods. Puffed pseudo-cereal varieties are offered especially in the retail. Puffed grains are only recently coming to prominence as in-novative cereals for use in the manufacture of baked products.
Use in the bakeryPuffed cereals and puffed pseudo-cereals are available to bak-ery businesses nowadays as single-variety mono-products, and are exceptionally suitable as ingredients in baked prod-ucts. They offer advantages that cannot be shown by cereals in the form of whole grain, groats or meal. The starch is opened up, and the porous structure extends right up to the marginal zones, which ensures good swelling ability and absorption of liquid. Moreover, due to their purely physical manufacturing process, puffed grains need only be labelled as the respective cereal or pseudo-cereal type in the ingredients list. Processing
I N G R E D I E N T S
© S
chap
fenm
ühle
cyclone. The granule water is slightly mobilized at the same time, and the addition of heat causes pre-gelatinization of the starch in the marginal zones, thus making them more stable. Protein components that would interfere with the subsequent expansion are also denatured. After preheating, the cereal is transferred into the so-called reactor, which is hermetically sealed. The application of supersaturated steam takes place here. The cereal grains are treated by automatic control, taking into account the parameters of time, temper-ature and pressure. A core temperature of approx. 115°C can be reached at this time, and the pressure is increased to 20 bar, depending on the intended purpose. After the specified time has elapsed, the reactor opens suddenly and releases the grains into the expansion duct within milliseconds. The abrupt pressure drop vaporizes the water in the grain, thus ensuring its expansion. The grains expand to 12 times their original size at the same time, and they attain their final “puffed-up” shape after almost one second. Starch chains consisting of amylose and amylopectin ensure the required framework stability. The grains achieve their porous struc-ture together with the volume increase. Their apparent bulk density in grams per liter (liter weight) provides information about the degree of expansion.
Product advantages+ physically enhanced cereals+ with all of the grain’s own constituents+ in wholegrain quality+ grain-like shape+ neutral, undistorted flavor+ “clean label”+ versatile uses+ good swelling property+ high level of water binding+ stable shape, even when kneaded
Suitable raw materialsAccording to experience up to the present time, only cereal grains and the so-called pseudo-cereals possess the physi-co-chemical basis for puffing treatment. The water content in the grain is primarily responsible for the energy transfer dur-ing puffing, and the starch content is responsible for the structure and stability. Organic quality raw materials are also coming into use to an increasing extent, as well as conventional ones. Experience shows that raw materials with the following values are especially suitable:
I N G R E D I E N T S 63
www.bakingbiscuit.com 04/2016
www.bakingbiscuit.com 04/2016
is also extremely easy and safe. Puffed products from the clas-sical cereal varieties such as durum wheat, rye and spelt, with a weight per liter between 250 and 400 g/l are preferred for bread and bread rolls. However, amaranth and quinoa in puffed form are also popular as ingredients in baked products or as decorations for baked goods.
Practical advantages+ always available+ added amount variable up to 50%+ only slight adjustment of own recipes+ replaces scald, soaked grain or hot-soak + no wild yeast fermentation due to long swell times+ soft, juicy grains in the bread+ delayed retrogradation
Use and processingPuffed cereals are treated like an ingredient in the manufac-ture of baked products. The amount added depends on the recipe and type of baked product. They are wetted with a portion of the added liquid and mixed well, and should swell for a short time.Longer wetting and/or swelling times have a beneficial effect on baked product quality with higher proportions of cereals. A swell time of approx. 30 minutes has proved adequate, es-pecially with a large proportion of wholegrain or coarse meal. Puffed grains incorporate more liquid and considera-bly increase the dough yield (TA). The dough preparation method remains unchanged, since the grains scarcely change their shape as a result of the kneading process. Dough man-ufacture can take place by the “direct (single-stage) method”, since the time-consuming scald or hot-soak stages are omit-ted. Anyone who wants to vary small amounts of baked products can also mix small amounts of puffed cereals into the finished dough – with a corresponding addition of salt. It should just be wetted well and allowed a short swelling time to prevent post-swelling. The company’s own recipes need only a small amount of adjustment.
Tried and tested bread varieties+ “Mouthwatering wholegrain bread” with
40% puffed rye and 20% recycled bread containing rye
+ “Crunchy rye mixed bread” with 15% puffed durum wheat
+ “Organic quinoa bread” with 20% puffed quinoa in the mixed bread area
Advantages in baked productsThe benefits offered by puffed grains are recognizable in the baked products, especially in bread varieties with a large pro-portion of coarse ingredients. The crumb of the bread is well
64 I N G R E D I E N T S
leavened, has an open pore structure and is noticeably more moist. The longer consumption freshness is also an advantage. Baked products do not stale so quickly, because starch retro-gradation is delayed. The bread is also highly attractive from a purely visual point of view. The puffed grains are easily recog-nizable in the bread crumb and their structure is largely re-tained but still soft, thus producing a pleasant chewing im-pression. Of course they are slightly drier in the crust due to the baking process, but far less hard than pre-swollen or scald-ed grains. Puffed cereals do not impair the flavor of bread.
Advantage in bread+ good volume – good visual appearance+ the crumb looks attractive+ recognizable grain structure+ juicy crumb with soft grains+ typical well-rounded bread flavor+ longer shelf life
SummaryPuffed cereal has proved its worth since its beginnings in the food industry and is found in many products. In principle the technology is unchanged and has been automated as the years have passed. Puffed cereal and pseudo-cereal types have only come into use in baked products in recent times, and offer novel opportunities to vary standard baked products. Due to its physical manufacturing process, this raw material scores points especially in a discussion of the declaration of ingredi-ents. Processing is extremely easy and allows baked goods to be enhanced with a rich selection of varieties: either as an in-gredient or as decoration.
Note: First published in German in “backwaren aktuell”, Issue 2/2016
Literature and source citation1. Anderson, A.P.: https://en.wikipedia.org/wiki/
Alexander_P._Anderson (accessed on 14.01.2016) 2. Bichsel, R.: Hydrothermal processes in cereal puffing Getreide, Mehl und Brot 57 (2003) 6, pp. 372-3773. Schmitz, K.: A profile of ancient cereal grains Brot und Backwaren 02/2015, p. 34 +++
— Authors: Karl Schmitz, Ulm/Germany and Gérard Journeault, Ulm/Germany
© S
chap
fenm
ühle
www.bakingbiscuit.com 04/2016
I N G R E D I E N T S N E W S + + N E W S + + N E W S 65
++ EUR 400m investment: Bridor intends strong growthThe organic bread market in the USA is growing. As the American Agriculture Ministry found in an assessment of Nielsen data (retail checkout data), its share of sales was 0.5% in 2004 and 1.3% in 2010. At the same time, however, one must remember that the price of organic bread in both 2004 and 2010 was around one third higher than the price of conventional types of bread. In volume terms, the proportion of organic bread in the USA in 2010 was 0.8%, and thus half a percentage point higher than in 2004. Such price differences are not unusual on
the other side of the Atlantic. Organic eggs cost 82% more than the conventional product. Growth in the or-ganic range has probably progressed further in the last five years, although no figures for it are available. Flowers Foods Inc. in Thomasville, Georgia, with a total of 46 bakeries and one of the USA’s biggest baked products suppliers, recently bought up two organic bread manu-facturers, and Bimbo Bakeries USA is increasingly expanding its Eureka organic range. +++
++ Organics percentage grows in the USAThe organic bread market in the USA is growing. As the American Agriculture Ministry found in an assessment of Nielsen data (retail checkout data), its share of sales was 0.5% in 2004 and 1.3% in 2010. At the same time, however, one must remember that the price of organic bread in both 2004 and 2010 was around one third higher than the price of conventional types of bread. In volume terms, the proportion of organic bread in the USA in 2010 was 0.8%, and thus half a percentage point higher than in 2004. Such price differences are not unusual on the other side of the Atlantic. Organic eggs cost 82% more than the conventional product. Growth in the or-ganic range has probably progressed further in the last five years, although no figures for it are available. Flowers Foods Inc. in Thomasville, Georgia, with a total of 46 bakeries and one of the USA’s biggest baked products suppliers, recently bought up two organic bread manu-facturers, and Bimbo Bakeries USA is increasingly ex-panding its Eureka organic range. +++
++ Goldman Sachs can take over Continental BakeriesThe European Commission has approved the takeover of the Dutch company Continental Bakeries B.V. by the US-American investment company Goldman Sachs. Ac-cording to the present owner, the Dutch company NPM Capital N.V., Continental Bakeries has a turnover said to be about EUR 310m. The bakery group operates 12 sites in Western Europe, and employs a total workforce of 1,550. Continental Bakeries’ production includes zwieback, pas-tries and confectionery, as well as bread-like products and canapés. The focus is on own brand goods. Baked prod-ucts are also sold under the Haust, Gille, Bussink, Brinky and Continental Bakeries brand names. Since 2010 the company has also owned the German business Grabower Süsswaren GmbH, which produces whipped waffles, pastries and crispbread, among other things. +++
++ Bread in the retail, ready-mix for the food serviceHovis is a well-known brand of bread in Great Britain and is owned by the manufacturer Premier Foods, which markets a classical toast-bread with a proportion of wholegrain in the retail under the name “Hovis Best of Both”. Since late May, food service operators who want to distinguish themselves from the rest of the market by baking their bread themselves have been able to buy a ready-mix for bread and bread rolls from Hovis under the same name. “Best of Both” contains wheat flour, wholegrain wheat flour, wheat-germ etc., and is supplied in a 3.5 kg pack. All that still needs doing is written on it loud and clear: “Just add water”. +++
++ backaldrin supports the “Angel Bakery” in NairobiKorogocho is the third biggest slum in Nairobi (Kenya). It is where the organization “Hope for Future” began various development projects, including two school projects, the Acakoro Football Academy, a social health center and the bakery project “Angel Bakery”. The ovens in this bakery, which is managed by Thomas Huber, a master baker from Ternitz (Austria), have been operating since December 2014. Huber says “We have now been able to open the 14th ‘Angel Bakery Shop’ in the slum. We bring 3,500 loaves of ‘white bread’, a mix-ture of toast bread and milk bread, to customers every week.” The Angel Bakery was equipped with help from backaldrin The Kornspitz Company, and its operation is also supported. The bakery project aims at offering future prospects to as many people as possible. On the one hand by training and a job. Thomas Huber reports a milestone for the project’s future. A contract has been secured with the “Barack Obama Founda-tion”. “That means we can produce 1,500 more breads every day, so we can offer a job to even more people.” They now already number 27, including two fully qualified bakers and ten trainee bakers. Baked products from the “Angel Bakery” are supplied to schools, and the residents in the slums can also buy them at the “Angel Bakery Shops”. Thomas Huber wants to open up new sales channels by using mobile selling, and is currently starting it with five “bicycle shops”. +++
© B
rido
r
The factory in Louverné (France)
www.bakingbiscuit.com 04/2016
66 C O N S U LT I N G
Expert reports and fundingThe LOGICON Dr. Edert Consultancy advises businesses in various areas of the food industry, including dairies, large bakeries, juice manufacturers and meat & sausage producers. Expert reports and fund-raising are the main focus of the company’s activities, in addition to business management projects.
+ Dr. Broder Edert started the independent business in 1996 with location optimization. The consultancy
undertook assignments such as:
+ Calculating alternative scenarios for both single- and multi-location variants,+ Presenting the scenarios to committees and banks,+ Monitoring their implementation,+ Success monitoring,+ Funding applications were submitted in parallel.
Preparing expert reportsAs a result of his publicly appointed and sworn status as an “ex-pert business administration consultant to the dairy and food industry” by the Lüneburg-Wolfsburg IHK (Chamber of In-dustry & Commerce) in 2004, his area of responsibility nowa-days also includes an increasing number of judicial expert opinions. Since then he has written judicial expert reports for various German regional and appeal courts to make transpar-ent to the courts the special problems arising in the food in-dustry and in the relevant markets. So-called private appraisal reports are also prepared for judicial disputes, although these are at the request of one of the parties to the dispute, to strengthen the argumentation of the party making the request. In the extrajudicial area, business management expertises and studies are prepared for banks, purchasers and vendors. The preparation of expert’s reports is one of the main focuses of the consultancy office’s portfolio at the present time.
Professional funding managementFundraising is another of the consultancy’s main areas of work. According to Dr. Edert, professional funding management is worthwhile. He says that up to now the consultancy bureau can look back on over 30 approved funding applications with a total investment volume of more than EUR 350m, including several applications for large bakeries. But why should a professional take on a task that can also be carried out in the company itself? In this regard, the consultancy bureau says: submitting and monitoring a funding application and bringing it to a successful conclusion requires competence, experience and time. If these conditions are satisfied, the company does not need any sup-port. Dr. Broder Edert says: “However, if the structures are lean and there is a lack of (funding) competence, experience and time, a professional should be commissioned.” He says that as a rule, professional funding management also means more fund-ing. “Another plus point are the personal contacts to the coun-terparts in many funding establishments that have developed over the years, resulting in the existence of a good, trust-based relationship from which clients also benefit.”
Change projectsA third emphasis involves working with projects that structurally change a company, e.g. takeovers, expansions, mergers or closures. Dr. Edert says: “The company’s own workforce is often unable to cope with such projects, since it is fully occupied in running the day-to-day business.” The consultancy bureau undertakes the preparation of scenarios in such cases, thus providing reliable planning figures to underpin possible decision paths and enabling deci-sion-making committees, and if necessary banks, to be convinced. Project management and/or project controlling can be undertaken when required.Dr. Edert believes that “Nothing is feasible without a good basis of trust. Discretion and loyalty vis-à-vis clients are the most valuable aspects. Nonetheless, we will gladly give references on request and after consultation.”
Contact:LOGICON Dr. Edert GmbH Consultancy Bureau Dr. Broder Edert, Am Alten Sportplatz 721407 Deutsch Evern/Lüneburg (Germany)Tel.: +49 (0) 4131-731585E-mail: [email protected] Website: www.edert.de +++
Dr. Broder Edert
Dr. Broder Edert is the Managing Partner of the LOGI-CON Dr. Edert GmbH consultancy bureau which he founded in April 1996 and which is headquartered in Deutsch Evern near Lüneburg. The qualified dairy spe-cialist gained his PhD after studying Agricultural Eco-nomics in the Institute for Business Administration in Food Processing at the German Institute for Dairy Re-search. This was followed by six years of practical ex-perience, including as Controller and Fresh Produce Service Manager.
© E
dert
Don’t get hung out to dry.Stay well-informed!Sample the e-paper now.
© b
uizi
nga
Free of charge and without obligation atwww.bakingbiscuit.com/epaper-sample.html
C O N S U LT I N G
K a a k F P S | K a a k B a k e w a r e | B e n i e r | D r i e M | D a u b | M C S | L h o t e l l i e r R 2 A | M u l t i p a r t s
powered by the
Conveyor systems:
Bakeware:
System control:
Silo Mixing Cooling Freezing PackagingDough handling Final proofi ng
Cratehandling
Panhandling
Decorating Baking
Artisan Bread Lines
From silo to truckWith our wide range of “silo to truck” production lines, we offer a solution to meet the needs of your specifi c products. These customised confi gurations are tailored from the highest standards of equipment delivered by Kaak Group companies.
For more details and information check: www.kaakgroup.com
153074 Kaak Advertentie processchema 210x297 Engels Df.indd 1 11-05-15 10:02
