· 2020. 12. 13. · and a pioneer of plant proteins, an-nounces the appointment of Pierre Courduroux as its new CEO, effective December 14, 2020. Pierre Courduroux is currently

www.bakingbiscuit.com

0620

Mixer technology Factors that make a difference

Production Changes in the pizza market

Raw materials Ingredient with character

http://www.bakingbiscuit.comhttp://www.aibi.eu

Continuous Mixing. Nonstop Perfection.Bake your best buns every time with Exact Mixing.Bread and bun production is challenging with variables like temperature, environment, recipe accuracy, flour quality, and operator training affecting the finished product. Exact Mixing’s advanced Continuous Mixing technology eliminates these variables and makes flawless buns at rates exceeding 15,000 pounds per hour.

Make perfect product all day, every day with Continuous Mixing.

Interested in improving your mixing process? Contact us today. Visit exactmixing.com or call (01) 610-693-5816.

A Markel Food Group Company

EXACT MIXINGBY READING BAKERY SYSTEMS

• Just in time dough means less waste from line stoppages• Less labor and energy usage vs. batch mixing• Eliminates variables due to batch process• Consistent bun size and color• Excellent dough temperature control• User-friendly, automated system operation and controls

https://www.exactmixing.com

At f2m, we pride ourselves on bringing you, the reader, researched, up-to-date and relevant information about innovations and new processes involved in our industry. Our editors are the ones that make this happen through hard work, dedication and research, all carried out with the ultimate journalistic integrity.

Our team of editors is what allows us the luxury of offering first-rate reporting within our industry, a tradition that we have upheld for many years. They travel all over the world to bring you the latest cutting-edge technology stories from their first-hand perspective.

It therefore gives me great pleasure and an enormous sense of pride in introducing you to the newest member of this vibrant team, Catalina Mihu.

Catalina has been involved with our industry for many years in an editorial capacity. With her technical knowledge and energetic, spirited approach, she creates for us the perfect synergy that will enable us to move our titles into the future with the passion and commitment that we together as a team thrive on. She will be an excellent addition to our already dynamic team.

Catalina studied and received her degree in Journalism and Communications from the University of Bucharest. She went on to complete her Master’s Degree in Communication Sciences and is presently one year away from completing her PhD. She believes passionately in balanced and ethical reporting and I have no doubt that this philosophy will hold us in good stead for many years to come.

I, along with the rest of the team, look forward to working together with her and I personally welcome her with warmth and the utmost respect into our ever-changing and evolving industry.

As I am optimistic about our future, so I am optimistic about our industry moving forward. I see a light at the end of the proverbial tunnel and look forward, as I am sure the rest of the world does, to saying goodbye to 2020. The New Year will be one of renewed hope, vigor and optimism that will allow us to embrace the new normal and move forward as we must, in a positive and pragmatic manner.

Happy Holidays to you and your families from all of us at f2m!

Warmest wishes, Dirk Dixon

Strengthening our teamE D I T O R I A L

Continuous Mixing. Nonstop Perfection.Bake your best buns every time with Exact Mixing.Bread and bun production is challenging with variables like temperature, environment, recipe accuracy, flour quality, and operator training affecting the finished product. Exact Mixing’s advanced Continuous Mixing technology eliminates these variables and makes flawless buns at rates exceeding 15,000 pounds per hour.

Make perfect product all day, every day with Continuous Mixing.

Interested in improving your mixing process? Contact us today. Visit exactmixing.com or call (01) 610-693-5816.

A Markel Food Group Company

EXACT MIXINGBY READING BAKERY SYSTEMS

• Just in time dough means less waste from line stoppages• Less labor and energy usage vs. batch mixing• Eliminates variables due to batch process• Consistent bun size and color• Excellent dough temperature control• User-friendly, automated system operation and controls

++ Dirk Dixon, Publisher Your commments or suggestions are always appreciated: phone: +49 4178 244 9797 e-mail: [email protected]

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0620

Mixer technology Factors that make a difference

Production Changes in the pizza market

Raw materials Ingredient with character


THE EUROPEAN BAKERY MARKET

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Production06 North America and Europe: Changes in the pizza market08 Kaak: ‘Step by Step’ to becoming a system provider14 König: ‘Easy Clean’ concept extended16 MIWE: Baking technology live18 Diosna: Factors that make a difference26 FRITSCH: Wide range of applications29 DEBAG: Two in one: Cooling and shock freezing30 Freitag: “Our greatest opportunities lie in export”

Raw materials12 SchapfenMühle: “Western Europe is a strong market for ancient grains”22 IREKS: Ingredient with character

Market34 Retail: Accelerating change36 GfK: Children drive growing household interest in sustainability37 Trends 2021: Top 1042 South Africa: Food Lover’s Bakery

Research38 ILU: Cabbage and Beets in the bakery

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Regulars03 Editorial05 News10 News20 Trade Fair Calendar28 News35 News41 News

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++ RBS Promotes Kyle Sensenig to Project ManagerReading Bakery Systems (RBS), one of the world’s leading manufacturers of snack production systems, has an-nounced the promotion of Kyle Sensenig to Project Manager. In his new role, he will work closely with customers to manage the successful delivery of projects, control project

scopes, budgets and schedules. Sensenig, who has worked for RBS since January 2017 as a Mechanical Designer, holds a Bachelor’s degree in Mechanical Engineering from Penn State University and is OSHA-10 General Industry and SOLIDWORKS CSWA certified. +++

++ Dr. Christian Lau heads manu-facturing in the MULTIVAC GroupAs Executive Vice President for Manufacturing, Dr. Christian Lau becomes responsible with immediate effect for manufacturing within the MULTIVAC Group. As part of this role, he also becomes Managing Director of the two subsidiaries, MULTIVAC Lechaschau and MULTIVAC Bulgaria

Production, as well as Chairman of the Board of MULTIVAC Taicang (China). Dr Lau has been at MULTIVAC since July 2010, and in his most recent role as Executive Vice President he has been responsible for the Thermoforming Packaging Machines Business Unit. He studied Business Administration and Engineering at the University of Karlsruhe, and he subsequently gained his doctorate in Production Technology at Munich's Technical University. +++

++ Roquette announces Pierre Courduroux as new CEORoquette, La Madeleine/France, a global leader in plant-based ingredi-ents and pharmaceutical excipients for food, nutrition and health markets, and a pioneer of plant proteins, an-nounces the appointment of Pierre Courduroux as its new CEO, effective December 14, 2020. Pierre Courduroux

is currently the Chief Financial Officer (CFO) of Roquette, a position he took in October 2020. He has an extensive international experience, and was most recently the CFO of Monsanto. +++

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Messe Düsseldorf GmbH

P.O. Box 10 10 06 _ 40001 Düsseldorf _ Germany

Tel. +49 211 4560 01 _ Fax +49 211 4560 668

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2020-11-02 interpack 2021_International_Let`s Go_102 x 297 + 3mm_baking + biscuit international_4c_9269.indd 12020-11-02 interpack 2021_International_Let`s Go_102 x 297 + 3mm_baking + biscuit international_4c_9269.indd 1 06.10.20 09:2206.10.20 09:22

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P R O D U C T I O N06

Changes in the pizza marketThe pizza market is growing geographically. At the same time, food trends and nutritional profiles are changing on the traditional markets in North America and Europe.

+ October is known as “National Pizza Month” in the USA. It began in 1984 and was created by Gerry Durnell, pizzeria owner and the publisher of Pizza Today magazine. He selected October because it was the month that the first issue of the magazine was published. And today that tradition continues with late autumn considered the time for product innovations and real marketing fireworks.

Statistically calculated, every American eats around 40 pizzas per year, which makes the country the world champion in this discipline per capita. The second largest market is Europe, where, according to statistics, the Norwegians take first place in pizza consumption, followed by the British. Third place belongs to Germany with 10 pizzas per capita per year. The Asian markets, particularly China, India, Bangladesh and the Philippines, are still in the process of being established. Using a dynamic approach, distribution channels through supermarkets and out-of-home markets are growing.

Both major sales markets – North America as well as Europe – show growing fragmentation on the supply side. In addition to the simple and inexpensive frozen pizzas from the

supermarket or discount store, there are numerous restaurant chains and delivery services that specialize in pizza. More and more supermarkets are also offering fresh pizzas on their refrigerated shelves, with or without toppings, which are often produced in their own kitchens or in store bakeries.

The out-of-home market is currently growing faster than sales in the supermarket. In Germany, for example, pizza sales in supermarkets in 2019 grew by 5.7% in volume compared to the previous year, and by 6.6% in the out-of-home market. However, the out-of-home market has not even reached 10% of the volume that is sold in retail freezers. The takeaway pizza market in Germany owes its stronger growth not least to the intensive market cultivation by Domino’s. The group only came to Germany ten years ago and, after taking over some competitors, is now the number 1 with more than 330 stores.

Frozen pizza has long been considered an ‘iconic dish’ for young people and those with low incomes because it offers a complete meal for very little money, is easy to prepare and can be stored for a long time. It has also been included in the menus across generations and income levels.

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With the expansion of the target groups, the demands on manufacturers/suppliers have also grown. Restaurants try to differentiate themselves from pure delivery services through changing or even customizable product offers and menu packages. Since pizza deliveries are now offered on all possible delivery platforms, pure pizza delivery companies have increasingly had to prove their competitiveness by fulfilling the wishes of customers faster and more conveniently.

Rising social standards, personnel and rental costs in the metropolitan areas ensure that chains that rely on the supply of decentralized bases with fresh dough from a central production facility promote the automation of production and logistics. Digitizing ordering and logistics and thus making them faster and cheaper is now also on the investment plan for all delivery services. For example, Domino’s began testing fully automated, unmanned delivery vehicles in the United States as early as 2017. The latest development, a robot with the imaginative name R2, can even change the side of the street without colliding with the flow of other road users. It also manages to navigate within apartment complexes to the door of the respective customer, clearly demonstrating a superiority over a drone.

The production of frozen pizzas for retail is largely automated, depending on the output quantities. Here, automation drivers are more storage and distribution, especially when, as is often the case in the USA, dough production and decoration are carried out by different companies, or copackers are used for new product developments during the test phase.

New nutritional styles – new pizzas The most important changes currently relate to the pizza itself and drivers for this are on the one hand the attempt by manufacturers to set themselves apart from the competition with specialties, and on the other hand the increasingly dif-ferentiated nutritional styles of consumers. The first category includes pizzas with a filled crust, which are primarily sold in the USA, but are considered to be a niche market there.

The development of frozen pizzas with dough that can still rise when baked in the oven was much more successful. But having started as a premium product, it is now a variant that barely achieves higher prices in the supermarkets. In the USA in particular, this variety is only of limited importance. Many US pizza fans love deep-pan pizzas, which are very doughy in comparison. These are better baked from frozen as this large amount of dough would simply rise too quickly and too strongly in the oven.

The new ‘premium’ is therefore defined by the consumer profile and this includes, amongst other things the desire for more craftsmanship, and regionality of the ingredients, etc. These requirements are met by supermarkets that offer refrigerated fresh, often seasonally filled pizzas in their own restaurants or bakeries. A good example of how this desire also initiates movement in the frozen pizza market is the success of Franko Fresco GmbH from Geretsried in Bavaria. Launched in 2016, it markets pizzas under the name Gustavo Gusto, “as if fresh from the pizzeria, spread out by hand and topped with lactose-free mozzarella”. There are six varieties on the market, available from food retailers in Austria, Swit-zerland and Germany, but also now from Amazon’s brands, Fresh and Prime. The new-comer is now considered a winner extraordinaire!

The second variant of the new premium term is aimed at the nutritional style of the consumer, whether vegetarian, vegan, paleo, keto, lactose-free, low-salt, gluten-free or other. It’s true that in the past, pizzas, which were aimed at such a sophisticated, discerning clientele, couldn’t get around a list of ingredients

++ Gustavo Gusto Pizza

++ Website Magioni

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+ Before the Dutch Kaak took over the Italian System and Oven manufacturer from Ala Italy in 2005, it was rarely a company contacted by pizza manufacturers. This takeover was the first step into a new market for Kaak. From this initial step, the company has grown to be a modern full-service provider for industry and semi- industry, and today builds systems for every form of pizza worldwide.

Kaak continues to supply swingtray proofers, pizza presses and tunnel ovens for industrial manufacturers as well as machines for the decoration of pizzas. The subsidiary in Nieuwkuijk, which has been part of Kaak for a long time and contributes alongside with the classical dough divider, rounder and pre-proofer, its wash-down capable two-shaft extruders and dough dividers that work without oil and control the size of the dough piece via the speed of the shafts.

For large quantities of dough, however, Kaak also offers the “Mechanical Dough Developer”, a high-speed mixer that was developed as part of the so-called ‘Chorleywood Bread

Process’. If necessary, the mixer can knead under vacuum or pressure and delivers up to 385 kg of dough within 4 to 5 minutes. The mixer, which is provided with a cooling jacket, can be combined with an automatic weighing and dosing system and offers a patented clean-in-place system.

that exploded with additives. However, a new trend emerged some time ago - the use of vegetables as raw materials for the dough. In the USA, the vegetable processor Green Giant, which belongs to B&G Foods, sells frozen pizza bases at Walmart, the flour content of which has been reduced in favor of cauliflower, spaghetti squash, zucchini or asparagus. Green Giant advertises, for example, that such a cauliflower pizza base consists of 80% cauliflower and that the calorie content is halved.

Similar pizza bases are also on the market in Europe. The Dutch supermarket chain Jumbo sells pizza bases from Magioni, a company from Amsterdam that promotes its pizzas as ‘guilt-free’ and therefore people eating them don’t have to have a guilty conscience. The range includes pizza bases made from cauliflower, zucchini (courgettes) and red peppers. The proportion is between 32 and 37%.

Unfortunately, the company is currently not processing any press inquiries, so it remains unclear whether Magioni is still a producer or whether this task is with a copacker. In Germany, it is said from usually well-informed circles, that similar products will come onto the market in the foreseeable future. This is because the pizza bases made from vegetables have a big advantage. The list of ingredients is short and easy to understand, and from vegetables to healthy food is a simple and short way for consumers.

The German company Lizza GmbH from Neu Isenburg near Frankfurt offers a slightly different version. Their pizza bases consist primarily of gold flaxseed flour, soy flour, water, psyllium husk powder and sea salt and can therefore be advertised as gluten-free, vegan, low-carb, keto and of organic quality on top of that. +++

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P R O D U C T I O N

Kaak lines are used both for dough balls, which can be stored chilled until they are shaped in production or in the store for some days, as well as for complete lines that either press dough portions to the base using the hot or cold process or from the ‘cut out’ of a dough sheet. The technology of dough sheet production has been part of Kaak`s scope since 2009. New innovations include the combination of the dough sheet technology with the proofing system technology. The dough band of 50 to 60 m in length is sent through the proofer for 30 to 40 minutes and only then ‘cut out’ and baked on a belt. The rework dough goes straight back into the dough production. The process allows hourly outputs of up to 6,000 kg/h and enables a quick and easy product change.

According to Kaak, over the past few years, they have designed and built many lines for Italian-style pizzas (thin dough sheets). Dough balls are pressed with heated pressing heads directly onto the belt to the desired shape and baked on a stone belt after the tomato sauce has been applied, following which they are transferred to the oven.

++ MDD - the high-speed mixer that delivers up to 385 kg of dough per batch in 4 to 5 minutes

++ Up to 60 m long strips of dough are proofed on the belt, from which the pizza is then punched

++ Pressing heads

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In addition to the sauce nozzles and classic waterfall systems for sprinkling, Kaak has recently invented a special system that garnishes the edge of pizzas, so that it develops a particularly strong aroma.

Kaak has also significantly expanded its range of spiral freezers for the pizza industry. They are designed with cleaning systems that fully automatically foam, wash and dry the entire freezer including the spiral – and, according to the company, in half the time that manual cleaning would require. All in all, the Kaak Group provides a full scope of bakery equipment for pizza manufacturing. From silo to truck, everything in one hand. +++

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++ Pizza sheeting line with inline proofer

introduced the motto, ‘Together, we can bake it’. It is a phrase that has supported companies and customers over the past few months. In accordance with this motto, solidarity is key and services are constantly being expanded. “In order for us to better support our customers in the dynamic world of baking, we are constantly expanding our digital services,” explains backaldrin Managing Director Harald Deller. +++

++ AMF welcomes Alexander Beuschlein as new Regional Account Manager

AMF Bakery Systems (AMF) welcomes Alexander Beuschlein as Midwest Re-gional Account Manager for the United States. Beuschlein will focus on fostering new customer relationships and strength-ening production line support for ex-isting bakery customers in specialty segments including artisan bread and rolls, pizza, flatbreads, cakes, pies, pastries, and croissants. “Beuschlein’s

goal is to help solidify AMF’s position as the baking partner of choice for commercial bakeries around the world,” mentioned Guillaume Joly, Director of Sales, U.S. and Canada for the specialty baked goods segments. “His in depth knowledge of sheeting, depositing and laminating applications will contribute to the Company’s success in delivering the most optimal production solutions for bakers producing artisan breads, pizzas, cakes and other specialty baked goods.” A graduate of Dietrich Bonhoeffer Gymnasium – Wertheim in Germany, Beuschlein is a native German with fluency in both English and French. Prior to his sales roles in commercial baking, Alex achieved success in a variety of customer service and sales leadership roles within the German banking industry as well. +++

++ erlenbacher has a new CEO Dr. Bertram Böckel (41) is the new chairman and managing director of the frozen bakery products manufacturer erlenbacher. On November 1, he suc-ceeded Matthias Casanova, who had taken over the company management on an interim basis in August. This means that the management team of erlenbacher backwaren gmbh is complete, the company announced. Dr. Böckel

will manage the business together with Fritz Kellermann, Wolfgang Thul and Harald Lochmann. Casanova will con-tinue his management function within the Froneri Group, as Country Manager for Brazil, Argentina and Puerto Rico/Caribbean. Dr. Böckel will report to Matthias Casanova. +++


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++ February 2021: new digital format for ibaThere is still some time to go until iba 2021 takes place from 24 to 28 October in Munich. Before the fair goes live, GHM Gesellschaft für Handwerksmessen mbH will be initiating a digital kick-off event in February 2021 due to the lack of live formats and new contacts: the iba.CONNECTING EXPERTS.

This new, purely virtual format will have its premiere from 1 to 3 February 2021 and will initially focus on process and packag-ing technology. The basic idea behind it: international networking and new contacts in February, personal consolidation of

business relations, and products to try out and experience in Munich in October. Exhibitors can register for the event until mid-December. iba Project Manager Cathleen Kabashi: “We are in constant contact with our customers and are aware of the strong need for exchange and the acute necessity for reliably successful discussion forums. Numerous innova-tions have come about to which the industry has adapted and, due to the situation, has discovered new concepts. The new format picks up the international industry experts in February and sets the course for customer contacts and leads, who can network at the first industry meeting point of the year and satisfy their pent-up demand digitally and securely”. Visitors can register free of charge at https://connecting.iba.de/de. +++

++ New digital services at backaldrin

Austrian baking ingredients manufacturer backaldrin is expanding its digital services. From now on, product presentations, training and other customer services will also be possible via video conferencing. No long journeys are required and customers can connect with backaldrin directly from their own bakeries. Training and seminars from the ‘backademie’ are now also possible online.The master bakers and confectioners of the international family business are available in the virtual bakery for world-wide enquiries. It doesn’t matter whether questions are related to production processes or the introduction of new products. At the beginning of the Corona crisis in March 2020, backaldrin

++ The master bakers and confectioners at backaldrin are available in the digital bakery for worldwide enquiries

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FRITSCH is part ofthe MULTIVAC group

Passion for DoughPassion for Dough

FRITSCH IMPRESSA pizza – for round, oval or rectangular pizzas, all cut or punched FRITSCH IMPRESSA pizza – for round, oval or rectangular pizzas, all cut or punched from a single dough sheet. Fritsch’s SoftProcessing technology ensures gentle sheeting and handling of soft doughs and doughs requiring long pre-proofing, so the individual

dough structure stays intact. From Pizza Americano to artisinal Pizza Italiano – always the real thing, always delicious. Find out more at www.fritsch-group.com

Pass ionPass ionPass ionPizza cal ls for real Pizza cal ls for real

FRITSCH is part ofthe MULTIVAC group

Passion for DoughPassion for Dough

FRITSCH IMPRESSA pizza – for round, oval or rectangular pizzas, all cut or punched FRITSCH IMPRESSA pizza – for round, oval or rectangular pizzas, all cut or punched from a single dough sheet. Fritsch’s SoftProcessing technology ensures gentle sheeting and handling of soft doughs and doughs requiring long pre-proofing, so the individual

dough structure stays intact. From Pizza Americano to artisinal Pizza Italiano – always the real thing, always delicious. Find out more at www.fritsch-group.com

Pass ionPass ionPass ionPizza cal ls for real Pizza cal ls for real

https://www.fritsch-group.com


R A W M A T E R I A L S 12

“Western Europe is a strong market for ancient grains”

What does the market for ancient grains look like? And what impact is the growing health awareness of consumers having on demand? An interview with Ralph Seibold, Managing Director of SchapfenMühle GmbH & Co KG.

+ Helga Baumfalk: Mr. Seibold, Schapfen Mühle is considered a specialist for baked goods made from old grain varie-ties, especially spelt. Is the baked goods segment “ancient grains", i.e. spelt, emmer, einkorn forest perennial rye etc., currently benefitting from the Corona-induced growing sense of healthy nutrition amongst consumers? And is this trend more notice-able in a particular grain variety? + Ralph Seibold: Spelt and the original cereal varieties emmer, einkorn and forest herbaceous rye have long been highly popular with consumers. I would therefore not like to place this development as a conse-quence of the Corona pandemic. The steadily increasing demand for food produced with flours or other cereal products from the so-called founder plants due to the underlying health consciousness of consumers is one of the most powerful megatrends. According to food trend researcher, Hanni Rützler, this health trend will change our eating and drinking behavior forever. With Corona, the trend has merely received an additional jolt. Spelt is the most popular of the original grain varieties and this is clearly reflected in our range of products for the baking industry. As a grain specialist, we support our customers with high- quality blends as well as mono-products. The development

of these incorporates the current zeitgeist and consumer wishes. The mill premix Schapfen

Dinkel Classico, which we introduced in the fall, is a perfect response to this prevailing trend towards spelt-baked goods. This gives bakers numerous opportunities to create individual products to match their overall concept and thus meet consumers'

wishes for healthy variety.

+ Baumfalk: Will demand continue to grow in your estimation and which grain types will profit

most from it?+ Seibold: The trend will continue. This is not only predicted by experts, but we have also noticed this in discussions with our customers. These repeatedly confirm that we took the right path decades ago when we relied on cooperation with contract farmers and invested in the cultivation of spelt. In addition to spelt, emmer is becoming increasingly popular and demand will certainly continue to develop positively in 2021.

+ Baumfalk: Are there strong regional differences in Germany? And what about the neighboring countries such as Austria, Switzerland, France, BENELUX, Poland and the Czech Republic? Where is the per capita consumption the highest?

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+ Seibold: In general, the whole of Western Europe is a very strong market for original cereals, although consumption varies from country to country. Italy was the first country outside the DACH region to intensively deal with the demand for original cereals, especially spelt. It should be clarified that in Italy the so-called Farro, i.e. emmer, has always been the focus of attention and there are many traditional pastries and dishes made with emmer. Italy is definitely a pioneer in Western Europe as a spelt user. In the German-speaking countries, Austria, Switzerland and parts of the Benelux countries, the consumption of original cereals, primarily spelt, is analogous to Germany, i.e. there is a very high per capita consumption. Directly after Western Europe, Scandinavia is another region for original grain. But even here it is spelt that is used, while emmer still plays a subordinate role in the northern regions. For three years now, we have also been observing a massive interest in spelt products from Spanish customers, and the quantities ordered are increasing signifi-cantly. Looking to Eastern Europe, the situation there is currently such that neither spelt nor other original grain varieties are on the agenda on a large scale and are therefore not in demand.

+ Baumfalk: Are spelt baked goods a topic for the food service and what is the situation with spelt baked goods in food retail?+ Seibold: Spelt pastries or other dishes prepared with spelt flour, such as spelt noodles, are playing an increasingly important role in the food service and food retail sectors. In communal catering in the areas of daycare centers, kinder-gartens and schools, parents particularly want their children to be able to choose from healthy dishes. Our product 'spelt like rice'* is showing continuous growth in the foodservice sector. And if you take a close look at the bread shelves in the food retail trade, you will recognize spelt toast as an absolute

About SchapfenMühle SchapfenMühle GmbH & Co KG employs more than 200 people at its two locations in Ulm-Jungingen and Dornstadt (both in Germany) and processes more than 100,000 tons of grain per year. The company operates on the global market and offers flours, cereal flakes, mill mixes, seeds and kernels.

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++ Spelt bread and spelt bread-rolls

made with the mill premix Schapfen

Dinkel Classico. The finished baked

goods are character-ized by significantly improved freshness,

short bite and a juicy crumb

bestseller. The sales volumes of spelt toast and other new spelt products have certainly contributed significantly to the shortage of spelt.

+ Baumfalk: What is the 2020 harvest looking like for spelt, emmer and einkorn? Will it cover the demand until next autumn? If not, which countries will need imports?+ Seibold: We assume that there will be shortages and rising prices for spelt in 2021 due to the aforementioned unchecked demand. However, our good and long-standing partnership with our contract farmers will stand us in good stead, so that the SchapfenMühle will be able to supply spelt until the harvest in the current grain year 2020/2021. Nevertheless, it would certainly make sense for some of our customers with an increased demand for spelt to contact us at an early stage to discuss spelt contracts. The same advice applies to emmer. Customers planning a product launch of emmer bread or small baked goods should contact us in good time with a quantity specification. We are not yet expe-riencing a high demand for einkorn

+ Baumfalk: Mr. Seibold, many thanks for our conversation. +++

* “Spelt like rice” can be prepared like rice. The spelt grains are hulled and ground.


P R O D U C T I O N 14

‘Easy Clean’ concept extendedAt iba 2018, Koenig presented the Combiline plus in Easy Clean Design. Now the bakery machine manufacturer is extending the concept to the Combiline roll line.

+ “We see great demand for lines that are easy to clean and easy to use. The topics cleaning and maintenance are very important for many bakeries, which is why we will continue to expand the ‘Easy Clean’ series. Since autumn 2020, we have been presenting the globally proven Combiline roll line in the ‘Easy Clean’ design,” Koenig CEO Wolfgang Staufer explains.

In addition to the great versatility for various rolls, the Combiline EC offers easier cleaning, maintenance and access to all modules. The ‘Easy Clean’ concept enables significantly reduced cleaning time and downtimes.

The line can be combined with various dough dividing and rounding machines and offers an hourly output of approx. 7,500 pieces in 600mm working width or 9,000 pieces in 800mm working width.

With this line, bakeries can produce, amongst others, cut rolls, Kaiser rolls, hamburgers, hot dogs, housky (plaited rolls) etc.

The Combiline EC’s ‘Easy Clean Design’ at a glance:+ The ‘Easy Clean’ design features a new type of frame con-

struction and thus ensures optimized hygiene and acces-sibility. With beveled surfaces at a 45° angle, neither flour nor dough residues can build up.

+ The line offers generous ground clearance of at least 300mm and there are no machine feet directly next to each other.

+ When designing the line, welded constructions were largely preferred to screw connections.

+ The line is robustly made of Nirosta stainless steel and plastic parts for long-lasting operation and is completely rustproof.

+ Stamping station, proofer and forming station are in an open design for easy access; the forming tools are easy to remove and can be stored on a separate trolley for clean and protected storage.

+ The cable lines were laid as individual lines for easier cleaning.

+ The line is also equipped with UVC tubes for disinfecting the proofing swings. This serves to disinfect the surfaces and inhibits mold formation. +++

++ Stamping station in open design, the forming tools are easily removable

++ Koenig has extended the ‘Easy Clean’ concept to the Combiline roll line

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Baking technology liveMany things can be mapped digitally. But not everything! Nothing quite beats the real thing and exchanges between people. After its online trade fair in the summer, the bakery systems manufac-turer MIWE therefore decided to organize a “Live Expo” at its headquarters.

‘Experience baking technology live’ – this once would have been taken for granted but sounds strange in the extraordinary times we are now experiencing. Demand was there. And the in-house exhibition – it was also the first for MIWE – was well received. With a limited number of participants and under strict hygiene conditions, the event took place on four dates in the MIWE live baking center (LBC), the company's demonstration bakery at its headquarters in Arnstein/Germany.

In the 1,600 m2 LBC, MIWE demonstrated the entire pro-duction processes of various baked goods. In order to cover all areas from dough making and processing to bakery refrigeration and in-store baking, the expertise of partner companies was introduced, including Diosna, Rheon and IREKS.

How do the baking properties of the MIWE heating gas circulator positively affect the baking results when compared to those of the MIWE thermo-express thermal oil-heated deck oven, for example? Amongst other things, the visitors

The MIWE live baking center (LBC)

The MIWE live baking center (LBC) is the figurehead of the company. Here you can find almost everything that MIWE Michael Wenz GmbH has to offer in baking technology* (see below). In addition to the bakery itself, it also includes an analysis room and six seminar and meeting rooms. All are equipped with the latest media technology and digitally networked. "Bring your own device" is possible and there are large monitors, up to 98", some with touch screen, which facilitate visualization and discussion when it comes to new product developments, process comparisons or bakery planning.

Since its opening – the LBC was launched at iba 2018 – it has hosted visitors from over 60 countries, including Italy, Sweden and the USA as well as Israel, China, Hong Kong, Egypt and the Commonwealth of Independent States (CIS).

What can bakers use the LBC for?+ Test runs: What product character can be achieved

particularly well with thermal oil? What are the conse-quences for recipes and processing? What are the processes when using vacuum conditioning? Bakers can

clarify these and other questions by carrying out test runs on-site and can also bring their own raw materials.

+ Product and process development: It’s not usual for anyone working on a new product or new process to go into series production immediately. It’s normal to optimize it using small batches. In the LBC, alternatives can be tested.

+ Workshops and further education: MIWE conducts advanced training and workshops periodically. According to the company, the “MIWE roll-in intensive seminar”, which focuses on the numerous possibilities for fine

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P R O D U C T I O N

could make a direct comparison using the example of rye mixed bread, which was baked in both ovens at the same time.

Those who wanted to could switch from the live demonstra-tions to the accompanying lectures. Karl Heinz Hustings, Head of the Bakery at LBC, delivered a report on the long time dough method, which was greeted with great interest. In this he explained and demonstrated, giving concrete examples, on how night work can be shifted to day with the quality of the baked goods being enhanced at the same time. A factory tour of the oven production in Arnstein rounded off the in-house exhibition. As well as Arnstein, MIWE has a second production site in Germany.

AI at the preparation place When it comes to the topic of “digitization in store manage-ment”, the company is currently working on an intelligent solution for the preparation area. It is an “assistance system with AI” which instructs employees step by step to place the right product on the baking trays and to position the prod-ucts correctly. If the employee does something incorrectly, the system indicates the error in real time with unmistakable images and symbols on a screen. This system is intended to make work easier, especially for unskilled workers. The assistance system with artificial intelligence (AI) is a logical extension of the MIWE shop baking suite (sbs). This manage-ment software is used to administer all systems and processes in the store environment. +++

adjustment of the rack oven – including ‘atmospheric baking’ – is particularly popular.

The equipment: In the field of bakery refrigeration technology:+ Fully automated proofing unit MIWE GVA e+ (as well as

the small version in cabinet form MIWE GVA-S)+ Flash freezer MIWE SF-V+ Sucking flash freezer MIWE SF-D+ MIWE TLK dough preservation system+ Climate chamber MIWE KR+ Vacuum conditioning MIWE VCAll are operated with CO2 as refrigerant.

In the energy sector:+ Energy recovery system MIWE eco:nova+ MIWE eco:control energy monitoring system+ Buffer storage

In the area of production ovens:+ MIWE ideal deck oven (heating gas circulator, heated

with oil or gas)+ Electrically heated deck oven MIWE electro + Thermal oil heated deck oven MIWE thermo-express

(including central heating boiler in the technical room)All three are connected to the MIWE sherpa loading system.

+ Thermal oil heated MIWE thermo-static wagon oven (with central heating boiler in the technical room)

+ Rack ovens: MIWE roll-in and MIWE orbit

In the area of in-store baking:+ MIWE condo deck oven (in various designs, also with

integrated loader)+ Wenz 1919 deck oven (MIWE condo with cast-iron oven

door) + Convection ovens MIWE aero and MIWE econo+ Combi system MIWE backcombi (combination of convec-

tion and deck oven)+ Modular FreshFoodSystem MIWE cube + Convection ovens with gastronomic applications: MIWE

gusto and MIWE gusto:snack+ Convection oven with loading trolley for food retailing:

MIWE FBC

In the field of digital solutions:+ MIWE shop baking suite+ All systems are networked

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* with the exception of tunnel ovens and special systems such as the MIWE TKL deep-freeze hatch systems

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Mixer technologySpiral mixer Spiral mixer SP 240 E Wendel mixer

TA s m l s m l s m l

Wheat doughs

Dough for frozen applicationsbrezle, pizza, flat bread,… 150 2 2 2 2 2 2 3 1 1

Yeast – wheat based doughs

buns and rolls 154-156 1 1 1 1 1 1 3 1 1

baguette 165-168 1 1 1 1 1 1 3 1 1

ciabatta 180-185 1 1 1 2 2 2 3* 1* 1*

sandwich bread 154-156 2 2 2 2 2 2 3 1 1

tin bread 156 3 3 3 3 3 3 3 1 1

flat bread 152-162 1 1 2 1 1 2 3 1 1

pizza 150-152 2 2 2 2 2 2 3 1 1

wheat / white bread 154-156 1 1 2 1 1 2 3 1 1

Puff pasteriesrapid puff pastry 156 3 3 3 2 2 3 3 1 1

puff pastry 156 3 3 3 2 2 3 3 1 1

Mixed bread

Wheat mixed bread rye < 50% 165-168 1 1 1 1 2 3 3 1 1

Rye mixed bread 50%



P R O D U C T I O N

however, are very suitable for these dough groups, especially if they are equipped with a frequency converter and, if necessary, special tools.

According to practitioners, the advantages of kneading systems also depend on the stickiness of the respective dough. This can be clearly seen in the category of mixed breads with a rye content of more than 60% and a TA of 180. For medium and large batches, experts recommend the wendel mixer, while for small doughs the spiral mixer is more suitable, namely specifically the one without center discharge. If the dough sticks, dough residues remain stuck during emptying and manual reworking is required.

Further factors for kneader selectionFilling quantity or batch size of the dough: Wendel mixers should have approx. 30-50 % of the maximum filling quantity per batch in order to achieve a good kneading result. Less than 10% of the filling quantity is sufficient to achieve a proper result in a spiral mixer.

Pouring temperature of the water: It must be increased in the wendel mixer to reach the same dough temperature as in the spiral mixer. The efficiency of the two kneading systems in this respect is very different. While a Diosna spiral mixer without a center test bar adds approx. 1.5-2.5 °C/min to the dough heating during the high-speed kneading process, the special technical features of the wendel mixer allows only 0.5-1.5 °C/min to be achieved. In addition, it is advisable to knead the wheat doughs a little longer, since the gluten in the wendel mixer draws more strongly. For most doughs, a higher water absorption of 2-5% must be considered, at least when using European flours.

The viscoelastic properties of a dough are largely based on the hydration of the gluten. The protein fraction Gliadin contained in wheat ensures viscosity and flowability and the Glutenin provides elasticity. Their interplay or linkage during dough formation defines the elasticity and thus the gas retention capacity of the dough and is therefore decisive for the size and porosity of the pastry.

The Kieffer Rig test allows statements about the strength and elasticity of a dough. In trials, kneader manufacturer Disona has investigated the effects of spiral mixer and wendel mixer tools on different water/flour ratios under otherwise stand-ardized conditions and uniform flour quality.

The graph shows that a dough in the wendel mixer with a TA of 163 has the same strength as a dough with a TA of 160 from the spiral mixer. The wendel mixer binds more water and thus has the capacity to produce a larger volume of dough. The same dough with TA 163 from a spiral mixer would tend to be too soft to retain structure.

The wendel mixer offers better kneading, higher water absorption and less dough heating in a shorter time than a spiral mixer. Heat and energy input are higher with the spiral mixer than with the wendel mixer, not least because both the mixing phase and kneading phase of the spiral mixer takes up considerably more time.

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++ Diosna Premium Wendel Mixer

++ Kieffer Rig dough analysis for different mixing tools

Dispersion areas from the Kieffer Rig analysis DIOSNA standard with the same dough composition and kneading times. The kneading was parameterized with the Farinogram (application practice).

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++ Warming of the dough: spiral vs. wendel mixer tool

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Anyone believing they can make a qualified decision based on technical or technological differences alone could be mistaken, as it is not only the individual kneader type that counts, but the interaction with the entire process chain. Capacities of the individual process steps should be coordi-nated with each other as well as with the product range to be produced on this line.

For example, does it make sense to produce large batches that may not be processed quickly enough, so that the dough quality changes dur-ing this process step? This requires either an ongoing adaptation of the control system of downstream equipment, which is hardly feasible, or the acceptance of fluctuating qualities of the end product. The problem can be limited with several, but smaller batches. However, if the same hourly output is to be ensured, more kneaders may be required. This is where the conflict between technology and economic efficiency may arise.

Dough resting times, proofing times, and interruptions in proofing, in turn, are reflected in the entire duration of the process and thus influence the batch size together with the

selection of the subsequent process steps. The final temperature of the kneaded dough can also be of importance if the end product is not a ready-baked, but an unbaked frozen pastry. A low final temperature of the dough saves cooling energy.

Which kneading system is ultimately technologically and economically ad-vantageous is not only dependent on selecting the right kneading tool, but needs to be assessed in conjunction with all the individual factors of the respective production system.

When selecting a kneader, the raw materials as well as the recipe, the end product including desired properties and the overall process must be considered. +++

B. Sc. Ing Florian Paschen, Head of Technology Bakery at DIOSNA, Osnabrück/Germany.

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++ Diosna Wendel Mixer

++ Diosna Premium Spiral Mixer

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Digital February 1-3, 2021 (digital)iba.CONNECTING EXPERTS https://connecting.iba.de

February 20-23, 2021Madrid/SpainInterSICOPwww.ifema.es/en/intersicop

March 15-17, 2021 (physical show) Rimini/Italy SIGEP Exp. – International Trade Show of Artisan Gelato, Pastry, Bakery and the Coffee Worldhttps://en.sigep.it

Digital March 18-19, 2021SIGEP https://en.sigep.it

March 23-26Cologne/Germany Anuga FoodTecwww.anugafoodtec.com

March 23-26Moscow/RussiaModern Bakery Moscow 2021https://modern-bakery-moscow.ru. messefrankfurt.com/moscow/en.html

April 13-15, 2020Nanjing/China International Bake & Shop Expowww.bakeandshopexpo.com

October 24-28, 2021Munich/Germanyiba 2021 www.iba.de/en

Trade fair calendar 2021 (Physical & Digital)

P R O D U C T I O N

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+ Green spelt is well known by lovers of vegetarian and vegan dishes as a raw material for salads, soups or fried foods. With its slightly nutty to hearty-smoky aroma, unripe spelt grain is also suitable as an ingredient for baked goods – just as long as its special baking technology features are taken into account.

Increased water absorption and adapted kneading parametersPure green spelt flour is harvested early and since ingredients such as starch or gluten are not yet fully developed, it is not suitable for baking. Water absorption is high and so with 100% water in relation to flour, dry and firm doughs are

++ Left: Bread with 100 % spelt flour T630; on the right, bread with 100 % green spelt flour

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Ingredient with characterSpelt has been a hot topic for years among nutrition-conscious consumers. The trend towards plant-based food has recently seen a comeback for a special type of spelt – green spelt.


produced. The dough is inelastic and crumbly making it difficult to process. This results in the finished breads having only a very small amount of volume after baking. In addition, there is insufficient loosening and due to the high amount of water in the baked goods, it means the dough cannot be completely bound, so that grinding stripes are formed.

“In order to be able to produce stable baked goods with green spelt content, balanced mixtures with bakeable flours such as spelt flour must be developed,” says Dr. Thomas Kunte, Head of Research and Development at IREKS. “Especially with spelt, the right choice of variety is crucial for the quality of the baked goods, and, as a result, an agreement should be reached with the farmer beforehand as to which variety is to be grown”.

Baking tests have shown that the water absorption capacity of the doughs increases with an increasing proportion of green spelt flour, but the extensibility and stability decreases significantly. The latter must be taken into account above all when setting the kneading parameters. Dr. Kunte: “As with spelt doughs, the doughs should therefore not be over-kneaded. Too long an intensive kneading will destroy the spelt gluten framework and thus result in moist and diminishing doughs.”

The changes in dough properties due to adjustments in flour composition (spelt flour T630/green spelt flour) can also be traced using farinogram and extensogram measurements.



What is green spelt?Green spelt is semi-ripe harvested spelt, which is threshed two to three weeks before the regular harvest. At this stage of ripeness the seeds have an olive-green color and have already reached their full size. The water content is 40-50 %, which is quite high. Harvested grains are then dried in kilns using beechwood smoke to preserve them. This process gives the products their slightly nutty, but also hearty-smoky flavour.

++ Green spelt after the harvest

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Franconian origin The “home of green spelt” is a region in southern Ger-many. The “Franconian Green Spelt” produced here has been a protected designation of origin through-out Europe since April 8, 2015.1 The old spelt variety “Bauländer Spelz” is generally used for the produc-tion of “Fränkischer Grünkern”.2 Sources: 1 Wikipedia, 2 Working group for nutrition researchg

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Changes in dough properties due to adjustments in flour composition

Percentage of green spelt flour [%]

Water absorption at 500 (farinogram units) a [%]

Stabilitya[min]

Energyb[cm2]

Elasticityb[mm]

0 55.5 4.4 112 137

5 57.5 4.1 106 124

10 59.4 3.9 89 112

20 63.2 3.8 57 88aFarinogram | bExtensogram after 135 min. rest period

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With an increasing portion of green spelt flour, the breads become clearly smaller. The crumb becomes firmer and loses its bread-typical elastic properties. However, one way to counteract this is to add green spelt sourdough. “We have been producing a sourdough based on wholemeal green spelt flour since 2019,” reports Dr. Thomas Kunte, and continues: “In this process, sourdough is produced from selected wholemeal green spelt flour by a three-stage fermen-

tation process under controlled conditions. This gives the sourdough enough time to develop its typical aroma”. The finished sourdough is dried for stabilization without losing its grassy-fermented aroma. The product shows a mild acidity of about 35 degrees.

Juicy crumb and the slightly smoky taste of green speltThe development work at IREKS has resulted in the premix IREKS-DINKEL-GRÜNKERN. It consists of the two ingre-dients, spelt flour and green spelt in the form of wholemeal green spelt meal, the dried wholemeal green spelt sourdough and wholemeal green spelt flour. With this flour, rustic small-baked goods, soft croissants or crusty breads can be produced. The finished baked goods are characterized by a juicy soft crumb structure, a high degree of freshness and the slightly smoky taste of the green spelt. +++

++ Spelt breads with increasing amounts of green spelt flour from left to right: 0 %, 5 %, 10 %, 20 %

++ Spelt green spelt pumpkin seed crust and rye spelt green spelt bread

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R A W M A T E R I A L S R U B R I K

TECNOPOOL SPA – San Giorgio In Bosco (Padova) ItalyPhone +39 049 9453111 – [email protected] – www.tecnopool.it

https://www.tecnopool.it



Wide range of applicationsThe bakery plant manufacturer FRITSCH has redesigned the LAMINATOR 300. The sheeting line is even more flexible and gentle in dough treatment.

+ The demands on dough processing are growing. Systems are in demand that can be used flexibly and treat the dough as gently as possible. When forming a dough sheet, it is crucial to preserve the already developed dough structure, even when processing large quantities and demanding doughs.

The LAMINATOR 300 is a dough sheeter for automated production, which ensures an even and continuous dough sheet. This has now been further redesigned by FRITSCH in the area of dough feed and control. The system is now even more flexible and gentle in the treatment of dough.

From puff pastry, croissant, short and Danish dough types to soft dough types required for rustic baked goods such as baguettes and Ciabatta: The LAMINATOR 300 processes a wide range of different dough types. The system is constructed in three sections, which can be combined as desired. De-pending on the system configuration, the LAMINATOR 300 can be used as a block machine or as a continuous line for dough sheet production.

The universal version (Section 3) handle the soft the dough types. This system produces a continuous dough sheet with a capacity of 200 to 1,000 kg, which is then further processed to the respective end product.

Alternatively, the line can be used to produce dough blocks with a capacity of up to 1,500 kg of dough per hour. These blocks can then be cooled for a certain period of time before being formed into precise shapes and products on a FRITSCH MULTILINE (‘sheeting line’) and a ‘make-up line’. Both pos-sibilities can also be combined in one line.

Dough sheet processor now available for section 1Now and in the future, the dough can be discharged via the dough sheet former DS (3 roller former). It is also possible to combine the LAMINATOR 300 in section 1 with the low-stress dough sheet processor TBP in combination with a satellite head. Using five rollers TBP, all doughs are gently rolled and formed into an even, continuous dough sheet. The TBP is

Technical Data Laminator 300 Table width: 700 mmNet dough sheet width: max. 600 mm, infinitely adjustableBelt speed: 0.6 - 6 m/min on exit belt section 3Dough capacity: 300 - 1,200 kg/h (incl. fat and scrap dough)Dough block production: up to 1,500 kg/hLayers: 16 - 144 fat layers

++ Discharge nozzle: A new fat pump improves the flow properties of the fat – especially with butter

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P R O D U C T I O N

suitable for doughs with a dough yield of 145 to 175, making the entire process even gentler (‘soft processing’). According to information from FRITSCH, it has therefore been possible to dispense with the cost-intensive intermediate cooling at the appropriate room temperature in various projects.

Shaping of the butter sheet: improved flow propertiesOnce the dough sheet has been formed, adding the fat is another crucial step. A fat pump is used to convey drawing margarine or butter and apply it to the dough sheet in an even layer. The company's new fat pump improves the flow properties of the fat – especially in the case of butter – and thus produces an improved butter sheet. A water separator can be installed as an optional extra. By means of the sandwich folding system, an even dough-fat sandwich is produced.

Even after the sandwich folding, the company continues its SoftProcessing principle. This technology is mainly based on the satellite head developed by FRITSCH. This allows the dough to be exposed to minimal stress. The careful rolling of the dough sheet ensures that the structures built up in the dough survive these important steps without damage.

The dough is then folded. The folding channels are coated to repel the dough. Output and folding width are electronically controlled so that the dough sheet is deposited in evenly folded layers. The dough sheet is thus laid in four to twelve layers.

Cascading controlIn addition to the gentle processing of the dough, the company places great value on high system availability and ease of op-eration. An automatic, permanent cascade control system now makes operation even easier. The tedious calculation of

++ The LAMINATOR 300 can now be combined in section 1 with the TBP dough sheet processor with a satellite head. This makes the entire process gentler

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individual percentage values is no longer necessary. Due to factor chaining, manual input is no longer required for indi-vidual drives. With the LAMINATOR 300 control system, setting the output and number of layers is all that is needed. All subsequent adjustments to the folding width or number of layers are calculated automatically.

For example, if the operator wants to reduce or increase the number of pieces at short notice, there is no need for manual changeover. The control system calculates the values directly through factor chaining. This avoids errors and saves time.

According to FRITSCH, the new control system also has a lot to offer optically. Thanks to its modular design, the various views of the plant have been redesigned in 3D format. In addition, the new control system allows all users to be created individually, with specific rights. +++

++ Control system: Detailed views are displayed in 3D©

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++ UK: Hovis has a new ownerHovis with its headquarters in High Wycombe/

UK has a new owner – UK-based private equity investor Endless LLP. Previously, the 134-year-old British bread brand was owned by Premier Foods and US investment company the Gores Group. Hovis employs approx. 2,700 people and operates eight bakery sites and a flourmill with a distribution network covering Great Britain and Northern Ireland. The Endless LLP portfolio includes cake producer Bright Blue Foods Limited (BBF). The company is reportedly the largest private label cake producer in the UK with a turnover of over £160 m. BBF operates four bakeries in the UK and one in Poland and employs more than 2,000 people. +++

++ USA: Dunkin Brands has a new ownerNearly 13,000 Dunkin' Donuts bars worldwide

and 8,000 Baskin Robbins, previously part of Dunkin' Brands, will report to a new owner. Dunkin Brands head-quarters is located in Canton, Massachusetts/USA. The new owner goes by the name of ‘Inspire Brands’ and is a listed company that operates around 11,000 restaurants worldwide with names such as Arby's, Buffalo Wild Wings, Sonic and Jimmy John's. Inspire itself is owned by the private equity group Roark Capital Group. The Group also has a number of bakery and fast food companies in its portfolio, such as Cinnabon, Corner Bakery Cafe, Schlotzsky's Bakery Cafe, Auntie Anne's, The Cheesecake Factory, the smoothie chain Jamba, the barbecue specialist Jim 'N Nick's Bar-B-Q and McAlister's Deli. Some of the formats are grouped together under the umbrella brand Focus Brands. The Roark's brand has a wide variety of business types ranging from dental and furniture to waxing studios. +++

++ USA: Panera labels ‘Cool Food Meal’Panera Bread will label its ‘climate-friendly’

dishes as ‘Cool Food Meals’ in its bakery cafes in future, in-cluding dishes with a lower carbon footprint. The company is working together with the World Resources Institute (WRI). The aim is to give customers the opportunity of reducing the impact on climate change through the food they eat in the bakery cafes. According to the company, 55% of meals at Panera are ‘Cool Food Meals’, including salads, soups and sandwiches. Panera Bread currently operates 2,118 bakery cafes in 48 states in the US and in Ontario, Canada. They operate under the names Panera Bread® and Saint Louis Bread Co. +++

++ Italians like ‘free-from’ products‘Free-from’ products are gaining popularity in

Italy. The country’s large-scale retail trade now stocks more than 13,000 ‘free-from’ SKUs, the combined sales of which are worth 6.8bn euros.According to a survey from Osservatorio Immagino, products that are seeing the most annual growth within this category include those that claim to be 'antibiotic-free' (+62%), ‘yeast-free’ (+2%) and ‘palm oil free’ (+1.6%). Products that are

tailored to those with specific dietary intolerances continue to be the majority of items, with 9,431 SKUs labelled as ‘gluten-free’ or ‘lactose-free’. ‘Lactose-free’ products saw 3.6% annual growth, while ‘no-sugar’ products posted a 9% year-on-year increase and ‘low-sugar’” products were up 7.6%. +++

++ Denmark: More sales of organic foodAccording to Statistics Denmark, sales of organ-

ic food in Denmark in 2019 will increase by 9% year-on-year to DKK 14.1 billion (EUR 1.89 billion). This corresponds to 12 % of total sales. Organic products such as milk, grain, flour and vegetables were at the top of Danish consumers' shopping lists, although demand for other product catego-ries has also increased significantly.Danish customers' desire for more organic products is also reflected in the constant growth in sales of organic food over the past five years. The study lists the five organic products that showed the fastest growth in 2019: Spirits (+34%), wine (+19%), cookies and crackers (+28%), rye bread (+23%) and frozen vegetables and potato products (+45%). +++

++ Online shopping on the rise in EuropeAt the end of 2020, e-commerce sales in Europe are

expected to reach EUR 717 million. This would be an increase of 12.7 % compared to the previous year. Growth is thus somewhat weaker than in 2019, when European e-commerce grew by 14.2 %. According to a study by RetailX, Western Europe is still the most developed e-commerce market. This region accounts for 70 % of the e-commerce value in Europe as a whole. Western Europe also has the largest share of online buyers (83 %). However, the highest growth rates can be observed in Eastern Europe. The e-commerce markets in Romania and Bulgaria each experienced a growth rate of 30% last year, the highest in Europe. +++

++ Schenck Process to acquire Baker PerkinsThe Schenck Process Group (SPG), Darmstadt/Germany, is taking over Baker Perkins. The machines and systems from Baker Perkins, which is headquartered in Peterborough/UK and has a US site in Grand Rapids/Michigan, are used in the production of bakery products, pizzas, biscuits, crackers, confectionery, cereals, pet food, etc. With this acquisition, SPG intends to expand its portfolio for the food industry. In a press release, SPG states that the acquisition will sig-nificantly strengthen its European food processing and equipment capabilities, expand its product offering in North and South America and create growth opportunities throughout the Asia-Pacific region. Baker Perkins' existing Peterborough and Grand Rapids sites will be retained. Baker Perkins, as part of SPG's regional business structure, will continue to be managed by the existing Managing Directors. Managing Director of Baker Perkins UK is Dan Bassett; Dan Smith is responsible for Baker Perkins US. The acqui-sition is expected to be completed in the 4th quarter of 2020. +++



N E W S

A D V E R T I S E M E N T

Two in one: Cooling and shock freezing

+ DEBAG’s blast freezer works according to the suction principle. The air flows over each individual tray, thus ensuring that the products are cooled in a uniform way. The blast freezer works in a temperature range from - 30 to + 5 °C and is suitable for cooling and freezing of products hot from the oven as well as unripe and fully proofed dough pieces. The easy-to-use control unit is located on the front of the cell as standard. In combination systems, however, it can also be placed in a control cockpit above the cell door. The

temperature control can be based on either the room or the core temperature. The high-performance evaporator is suspended, which ensures that the base of the unit can be cleaned easily.In addition to the continuous operating mode (manual), it is also possible to control the cooling process automatically over a specified time or a defined final temperature (automatic). To prevent heavy icing on the evaporator, a defrosting process can be started manually with the door open. +++

baked goodsconditioning plant

work/packing area

blast freezer

blast freezer

blast freezer

automatic dough retarder++ Individually designed refrigeration system

++ DEBAG’s blast freezer for cooling and freezing. It is suitable for products hot from the oven as well as unripe and fully proofed dough pieces

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P R O D U C T I O N 30 P R O D U C T I O N

“Our greatest opportunities lie in export”When Hans Freitag opened his bakery and pastry shop 74 years ago, he had no idea that two generations later his company would develop into one of the largest producers of private label cookies in Europe.

++ Managing Director Anita Freitag-Meyer

++ Classics in the cookie segment: Fruit tartlets (left) and the Mozart sticks (middle) created by company founder Hans Freitag. Right: For black and white baked goods, Hans Freitag uses a 6-head Rheon system

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+ The production of cookie and wafer mixes is the business area in which the Verden cookie and wafer factory, Hans Freitag operates. The company is a trademark specialist and, when it comes to tonnage, is one of the big players in Germany and Europe with an annual production of 26,000 tons. It is all about the mixtures in the bags, which weigh 400 or 500 g as standard, contain six to eight types of cookies and are available on the market at prices sometimes below one EUR. It's a low-margin business; quantities count.

“Our driver is the suitability for mass production; the large batch sizes don’t chanage very much.” says Anita Freitag- Meyer, who has been managing the company, now in the 3rd family generation since 1991. “As a private label manufacturer, we pay attention to the mainstream. We are there for the classics in the cookie segment.” Classics such as the fruit tartlet (cookie filled with jam) or the Mozart stick (cream-filled hollow wafer, partly covered with chocolate), the latter developed by Anita’s grandfather and company founder Hans Freitag.

Growing tradeIn the 2019 financial year, the company generated sales of around EUR 55 million, 80% of which was generated with

“Our driver is the suitability for mass production.”

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private labels. The cookie manufacturer has grown with the retail trade. Early on, the company founder made contact with Edeka, and today Edeka still remains a very important customer. All the other large German retail groups and discounters are clients as well, including Hofer in Austria, Migros and Aldi in Switzerland and Mercadona in Spain. The export share is 30 %.

“We are very active in export,” reports the Managing Director. “This is where I see our greatest opportunities for growth. Today, we are represented in 50 countries world-wide and are strong in Italy, Austria, Switzerland and Scan-dinavia and even stronger in North America and Asia in terms of sales.” In Beijing today, there is barely a supermarket without Hans Freitag cookies. The company also has contacts in India: "Up to now, just as in China 20 years ago, India didn’t have packages with mixed cookies. We wanted to change that.” She explains that, "Pure veggie is important in India, and so whole egg powder cannot be used. Smaller units are also required, hence no 500-g bags. Large bags would overtax the neighborhood stores and the wallets of Indian customers. The previously strong Turkish business has broken away, although we now have a foothold in Brazil. A lot of business is also done abroad through our own brand ‘Hans Freitag’. Not every customer fits private label. That is why we have to bring our brand with us. Export is not easy, but worthwhile.”

With the online store, Hans Freitag has established a further sales channel. Money-wise, it plays a minor role, but it is important for other reasons. “We are very active on social media, seeking contact with end customers via Facebook and Instagram and we also have a Cookie Blog. When you

Verden cookie and wafer factory, Hans Freitag+ Specializing in cookie and wafer

blends + 35 types of molded, injection-

molded and cut cookies as well as wafer cookies

+ Sales 2019 (Verden plant): approx.: EUR 55 million

+ Share of private labels: 80 % + Export rate: 30 % (export to over 50 countries)+ 27,000 qm production area+ Max. daily production: 130 t cookies and wafers+ 330 employees, 300 in productionVerdener Keks- und Waffelfabrik was founded in 1946, originally as a bakery and confectionery by Master Baker Hans Freitag. In 1948 the company moved to its present location. Since 1949, the company has concentrated exclusively on the production of cookies and wafers.

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“Twin Sat” satellite head

Two satellite rollers positioned one above the other produce a virtually tension-free dough sheet. The Twin Sat module reduces high mechanical load to a minimum while gently forming the dough sheet.

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Second location A second cookie factory has been part of the

Hans Freitag Group since the summer of 2019. The factory is located about 50 km away and

operates under the name ‘Heidekeks’. It also produces private label baked goods. It has approx. 180 employees and has almost the same amount of machinery as the main headquarters. In addition to cookies and wafers, seasonal baked goods such as gin-gerbread and pepper nuts are also pro-

duced.


P R O D U C T I O N 32

communicate with the consumer, you have to provide a platform for the consumer where they can buy the products”.

Three shift operation, five days a week The production in Verden is divided into the bakery and the wafer department, with each section headed by a Master Baker. Everything is fully automated except for the dosing of small components such as flavors or salt. Approx. 300 em-ployees in production work in three shifts, five days a week. In addition to Haas and Hebenstreit automatic wafer baking machines, five Werner & Pfleiderer and Meincke steel band ovens are used to bake shaped and wire-cut cookies.

The company also uses Ishida and MULTIPOND multiheaded weighing systems, a 6-head Rheon line for black and white cookies and a ROVEMA Form Fill and Seal machine for packaging.

Trends and challengesThe baked goods market is continually looking for innova-tion. Even for a private label specialist, it is important to keep up with trend topics such as protein cookies, sugar reduc-tion, a better nutritional profile in general, the use of hemp, turmeric or chickpea flour, products to-go and new weight units. “We don’t have the time to explore new areas and so we have a collaboration with Dr. Quendt. One of the latest de-velopments is an organic hemp spelt cookie with chocolate chips”, reports Anita Freitag-Meyer.

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The Managing Director sees one of the biggest challenges in the cookie market as people's eating habits: “A cookie

is a cookie and cannot become an apple. It will always re-main a product of pleasure.” The fact that other market par-ticipants such as confectionery manufacturer Ferrero are pushing into the cookie market is also having an effect on the market. “The area we serve is not growing. That is why we have to keep working at it to ensure that the company is still sustainable in 10 years' time.”

Reducing film is a hot topicPackaging is the consumer’s touch-point and packaging material reduction is a big issue for the cookie manufacturer from Verden. Mainly, packaging is done in bags made of OPP (oriented polypropylene) foils from the roll, and also, to a lesser extent, in cans (cardboard core, coated with aluminium inside). Anita Freitag-Meyer: “The trade demands savings of up to 30%. But because we pack in bags, not in blisters, our starting points are limited. We see possibilities in reducing the repeat and making the bag shorter. Savings of 10 µm on our 58 µm thick film are also conceivable. All in all, we will definitely end up with over 20 % less plastic”. +++

Private Label in Europe: a permanent feature in the supermarket Private labels are an integral part of any supermarket range. According to a study conducted by Nielsen Market Research for the yearbook of the PLMA (Private Label Manufacturers Association), the market share of private labels in terms of volume is above the 30% mark in almost all of the 19 European countries considered. In Italy, it is "only" 22.3%. Switzerland has the highest share, 49.6%, which is mainly due to the dominance of the local Migros and Coop retail groups. Spain is not much lower, with a share of 49.5 %. The UK is in third place with 46.8 %, and Germany with 43.1 % and Austria with 42.2 % are mid table.

P R O D U C T I O N

Food2Multimedia GmbHSchoolkoppel 27 · 21449 Radbruch · Germany · [email protected] · www.foodmultimedia.de

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The European Bakery Market 2019

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M A R K E T 34

The Retail Report 2021 in German is available for 150 EUR

(incl. VAT) in the online shop of the Zukunftsinstitut. It compris-

es 128 pages and was pub-lished in August 2020 with the

ISBN: 978-3-945647-73-8.

© Zukunftsinstitut

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Accelerating changeNo matter how long and intense the corona crisis is: Business with consumers will never be quite the same again.

+ Theresa Schleicher is a renowned con-noisseur of the retail trade. In the current issue of her annual Retail Report, Schleicher has focused on the corona- induced acceleration of changes in the consumer goods market for the Zukunft-sinstitut. However, not everything that is currently changing can be attributed to the pandemic – for example, the trend towards cashless payments or the willingness to give up unprofitable locations. The crisis is merely a trend accelerator. Other things are being brought into focus, such as the value of personal contact and the willingness to strive for the wellbeing and sense of security of customers. Whereas in the past a long queue of customers in front of the shop was regarded as a sign of quality and demand; today it is more a sign of ignorance and the inability to reorganize shopping in the shop.

In her report, Schleicher deals with the retail trade in its entirety and dedicates chapters to the clothing sector, furniture and consumer electronics. Nevertheless, it is well worth reading for food suppliers, especially the parts that deal with the sensitivities of consumers.

According to Schleicher, there will be no return to ‘business as usual’. The crisis has

Documents

· 2020. 12. 13. · and a pioneer of plant proteins, an-nounces the appointment of Pierre Courduroux as its new CEO, effective December 14, 2020. Pierre Courduroux is currently