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baking+biscuit
international
ISSUE 04 2012
+
IBA 2012
Innovation fireworks
+
INTERVIEW
Bernard Zorn, Mecatherm
+
SCIENCE
Optimized baking
+
PALM OIL
Sustainability
WWW BAKINGBISCUIT.COM
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A6.410
EDITORIAL
Knowledge & efficiency
Knowledge is power, although that power has an ever
shorter half-life. One would really think that for a
thousand-year-old art everything has already been experienced, researched and known. In reality it is exactly
the opposite. Scientists are providing ever more in-depth
knowledge about the processes taking place in dough,
right down to the molecular forces that play such a decisive part. Nowadays the various process technologies
have a decisive influence on the detailed results of baking.
It is no longer simply a question of baking bread, and as
much of it as possible. Instead it involves offering a differentiated variety, a variety definable by crust thickness,
crumb texture, flavor and shelf-life, among other things.
The business IT solution
for your entire enterprise
Success is a
matter of system
++ Hildegard Keil, Editor-in-Chief
Your commments or suggestions
are always appreciated:
fax: +49 40 39 90 12 29
In all our enthusiasm for baked goods, we must not forget
e-mail: [email protected]
the business management aspect. Different processes
create different cost structures, and sometimes it is precisely these small differences
that separate the competitive from the uncompetitive. Let’s not deceive ourselves,
there are no longer any competition-free areas, and in the long run no protected markets either. Knowledge and efficiency are the keys to success today.
But where can we find and assess all this new knowledge, and above all how can we
discover it in good time? The name of the key is communication, and nowadays anyone who neglects only one single communication pathway will fall behind in the
competition for the most up-to-date specialist knowledge just as they will fall behind
in the market. Don’t worry, I have no wish to take up cudgels for trade journals and/or
their websites here (although that would be fully justified). What I do want to recommend
to you is to visit trade fairs, seminars and congresses, to look around and to talk both
to the exhibitors and to the other visitors. These discussions are usually precisely the
ones that are the best and most informative. They won’t divulge any trade secrets, but
they will provide suggestions and provoke thought.
To exchange ideas with colleagues, especially those from other companies and other
countries, is not an admission of ignorance but a display of the ability to exchange
creatively for everyone’s benefit. Anyone who has ever been allowed to discuss freely
in a team will know that many more ideas and solutions are created on such occasions
than in a hierarchically organized conference led by a strict chairman. Nowadays the
creativity of spontaneous teams that give thought to a topic, develop ideas and sketch
out solution strategies is the source of development. Anyone who doesn’t grasp that
fact will be like a sulking child sitting in the corner while all the others play happily.
Furthermore, this creativity of spontaneous teams, even if playful, is in no sense limited
to the management level. Therefore when a company also gives the “lower ranks” an
opportunity to visit a trade fair or seminar, this is not just generosity but primarily a
proof of the quality of the management. The money spent is a good investment. It
strengthens the import of knowledge into the company while on the way promoting the
motivation of the employees, who feel they are important and are being taken seriously.
We look forward to seeing you in Munich
HACK AG
Hall A6
Booth A6.320
12
16-21 October 20
y
an
rm
Ge
,
in Munich
Faster.
More reliable.
More productive.
Across the globe, successful bread
and bakery companies choose the
CSB-System. HACK AG is one of
them: “What characterizes our
partnership with CSB-System AG
is the trust in a reliable IT partner
who supports us in implementing
our goals in the best possible way.“
Peter Hack, chairman of the board at
HACK AG
CSB-System AG
An Fürthenrode 9-15, 52511 Geilenkirchen
[email protected]
www.csb-system.com
CONTENT
82
© ILU
© GHM
76
++ F E A T U R E S
08 M A R K E T Hofer: Revolution in the Tirol
10 M A R K E T I N T E R V I E W Bernard Zorn: Decisions emerge from the product
12 N E W S WP-Kemper: Full-service provider for deep fried pastries
14 C O M P A N Y P O R T R A I T Almarai: Market leader through investment
18 I B A Rondo: Systematically redeveloped
24
I B A Kaak: From steel to technology
30
I B A Daub: Rolling Stones
32
I B A WP: Wide range
38
I B A König Maschinen: More freedom of choice
42
I B A Miwe: System solutions for all areas
46
I B A Exhibitors: Innovation fireworks
58
P R O D U C T I O N Premiere Moisson: Fully automated system
62
P R O D U C T I O N Mestemacher: Generating energy themselves
66
R A W M A T E R I A L S SchapfenMühle: Versatile raw material
70
P R O D U C T I O N Interview Gilbert Bundy: American pans for Europe
72
P A C K A G I N G Migration: Avoiding risks
76
S C I E N C E ILU/Wiesheu: Energy and quality optimized baking
82
R A W M A T E R I A L S Palm-oil: Sustainability as part of the product
For in-depth information about
the trade fair iba 2012 please visit:
www.bakingbiscuit.com
We’d be glad to meet you at
Hall A2 Stand 144
++ R E G U L A R S
03 E D I T O R I A L
05 N E W S
80 N E W S
© Book&Claim Ltd
18
10
10
© f2m
04
++ E D I T O R - I N - C H I E F
Hildegard M. Keil,
Behnstraße 61
22767 Hamburg, Germany
phone: +49 40 39 90 12 27
fax:
+49 40 39 90 12 29
++ E D I T O R I A L S T A F F
Bastian Borchfeld,
phone: +49 40 39 90 12 28
Barbara Zimny,
phone: +49 40 39 60 30 61
++ C O P Y E D I T O R
Ann Dixon,
phone: +44 18 25 89 12 21
++ A D V E R T I S I N G D E P T .
Behnstraße 61
22767 Hamburg, Germany
fax:
+49 40 39 90 12 29
International sales director
Dirk Dixon,
phone: +44 18 25 89 12 21
Advertisement administration
Wilfried Krause,
phone: +49 40 38 61 67 94
++ D I S T R I B U T I O N
Behnstraße 61, D-22767 Hamburg
phone: +49 40 39 90 12 27
fax:
+49 40 39 90 12 29
++ T Y P E S E T T I N G
David Sprinz · www.davidsprinz.de
Bertha-von-Suttner-Str. 39
21335 Lüneburg, Germany
++ P R I N T E D B Y
Leinebergland Druck GmbH & Co.KG
Industriestr. 2a,
31061 Alfeld (Leine), Germany
++ P U B L I S H I N G C O M P A N Y
f2m food multimedia gmbh
Behnstraße 61, 22767 Hamburg
++ B A K I N G + B I S C U I T I N T E R N A T I O N A L is published six times
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Currently valid advertising price list:
No. 8
BAKING+BISCUIT ISSUE 04 2012
title photos: © Burford
NEWS ++ NEWS ++ NEWS
ment also says that a further enlargement of the product range is currently
at the planning stage. Ulrich Ladurner,
founder and President of the group of
companies, sees the opening of the
new works as an important milestone
for the further development of Dr. Schär
on the American market. The business
and its 50 employees will in future ensure
the availability of gluten-free products
throughout the country in supermarkets
and in the catering area. +++
++ C O N A G R A F O O D S B U Y S
UNILEVER’S AMERICAN
CONVENIENCE FOOD DIVISION
According to a press release, ConAgra
Foods Inc., Omaha, plans to pay USD
265m (around EUR 217m) for the
Unilever Group’s convenience food division in the USA. The division, which
owns brands such as Bertolli’s and P.F.
Chang’s, among others, is said to have
had sales of around USD 300m (approx.
EUR 245m) in 2011. +++
++ D R . S C H Ä R O P E N S A
PRODUCTION FACILIT Y IN
THE USA
++ U S A : K R A F T F O O D S W I L L
BE SPLIT UP
According to the media, the US food
giant Kraft Foods, Northfield, Illinois,
will be split up after the close of business
on the New York stock exchange on 1st
October 2012. One day later, two companies will then be traded on the stock
exchange. One part of the business will
be continued as a North American food
company with the name Kraft. The plan
is for the other company to focus on
the international foodstuffs business
under the name Mondelez Internati.
The intention is for all the snacks and
confectioneries to be allocated to this
part. The Group’s CEO Irene Rosenfeld
thinks the two new parts of the firm
will be able to grow better in this way.
It is said that in the first place the split
will be very costly, and around 1,600
jobs in North America are at risk.
Europe’s market leader for gluten-free
foods, the Dr. Schär AG Company in
Burgstall, Italy, is continuing its expansion course, and in June this year
opened its first American production
facility in Swedesboro in the US state
of New Jersey. According to a press release, with Schär USA Inc. founded in
2007 and the commissioning of the
new works, the company is aiming for
market leadership in the United States.
Around USD 15m (around EUR 12.2m)
has been invested in the past few years
in the construction of the new production site. In addition to gluten-free ciabatta bread rolls, baguettes and frozen
breads, it will also produce bagels for
the entire American market on an area
of more than 15,000 m2. The announce-
++ Horst Buhr
© Wiesheu
© Wiesheu
++ P E R S O N A L D A T A
++ Christof Weiß
Horst Buhr joined the WIESHEU
GmbH, Affalterbach, Germany, as the
new Head of Service of the International Service Team on June 1st. Horst
is from the Osnabrück Region in Germany and studied Electrical Engineering in Osnabrück. After he graduated,
he worked in Telecommunications for
8 years, first as a Service Technician and
then later as Head of Service. Following that he was the Head of Customer
Service in a machinery and equipment
manufacturing company in the food
industry. Horst continued his international career as Technical Director
for South East Asia in Bangkok and
then as Customer Support Manager
for Central- and Eastern Europe.
Christof Weiß joined the WIESHEU
Team as Head of Logistics on July 1st.
Christof was born in Schorndorf in
1967 and grew up in Rudersberg, Germany. Following the completion of his
vocational training as an Industrial
Business Management Assistant in 1987,
Christof studied Business Studies at the
Academy for Business and Administration in Stuttgart. Christof worked in
Cost Accounting before moving on to
++ I N V A S I O N O F S W E E T
SNAILS IN NORTH AFRICA
There is still a dispute among the Libyan revolutionaries as to whether it’s
a case of cultural imperialism or a
peaceful invasion of the deliciously
sweet rolled-up yeast dough pastries
for which Cinnabon is famous. However, it is a fact that the American fastfood/café conglomerate Cinnabon,
which operates more than 900 shops
in over 51 countries, is setting out to
conquer North Africa. The first restaurant is already open in Tripoli, Libya, and as Mike Shattuck, President
of Cinnabon’s parent company announced recently, the plan is to conquer Algeria, Tunisia and Morocco as
well, peacefully of course. +++
++ S O N N E V E L D S T R E N G T H E N
ITS POSITION IN POLAND
At the beginning of July 2012, the Sonneveld Group B.V. (SG) from Papendrecht, The Netherlands, acquired Sonneveld Polska Sp. z o.o. and 80 % of
HOL-POL Sp. z o.o. to strengthen its
position in Poland. HOL-POL was established in 1992 as an independent
importer and distributor of bakery and
patisserie ingredients in Poland. Since
2006, the company based in Skalmierzyce, Poland, has had a joint venture
with SG and its Polish subsidiary Sonneveld Polska, respectively. +++
Materials Management. Following this
he gained further experience as a Head
of Procurement in the Manufacturing
industry. He then moved on to be Supply Chain Manager before being appointed Supply Chain Director in an
American company trading in consumer goods. Following this position he
worked as Head of Logistics in one of
the largest German window manufacturers in Thuringia where he focused on
the introduction of efficient shop floor
logistics and new load carriers. Prior
to joining the WIESHEU Team,
Christof was a Supply Chain Manager
at a large automotive supplier company
where he was responsible for logistics,
order management as well as the planning, building and commissioning of a
new distribution center. +++
05
CELEBRATING
50
YEARS OF INNOVATIVE DESIGN
AND MANUFACTURING EXPERTISE
We at Burford® are committed to the success
of the bakery business. From the small
bakery to international chains, designing
and manufacturing baking equipment is
our business. For 50 years we have been helping bakeries succeed
by providing efficient, expertly designed equipment with a support staff
committed to keeping your bakery up and running. Let us help your bakery
succeed! Contact your Burford® representative or call 001-405-867-4467.
www.burford.com
+DOO%6WDQG
Copyright © Burford Corp. All rights reserved. Burford Corp. is a registered trademark with the US Patent & Trademark Office.
PRACTICAL SOLUTIONS
THROUGH INNOVATIVE TECHNOLOGIES
MARKET
Hofer trials the revolution in the Tirol
A COUPLE OF WE E KS OF “I N-STOR E BAKI NG” IS HAPPE N I NG I N FOU R MARKETS OF TH E AUSTRIAN
H A R D D I S CO U N T E R H O F E R KG I N S AT T L E D T, W H I C H I S O W N E D BY A L D I S Ü D . D E P E N D I N G O N T H E
LOC ATION, TH E PRODUCT RANG E E XTE N DS F ROM 10 TO 30 PRODUCTS AN D WI LL B E BAKED AN D
OF F E R E D ON A S E LF-S E RVICE BA S I S TH ROUG HOUT TH E W HOLE DAY
++ figure 2
© f2m
++ figure 1
© f2m
08
++ figure 1
++ figure 2
The current flyer of Hofer presents its new “bakebox”
A well-filled cheese envelope, moist and baked to perfection with a tender flaky crust
Telfs, Innsbruck, Wörgl and Kufstein – four of Hofer’s
markets – four different concepts, four different oven
constructors, four different goods display systems – quite
obviously Hofer is currently running a large-scale experiment
on the real market in the Tirol. The aim seems to be to find
out which product ranges, which processes and which technology are optimally suitable for the discounter’s fresh baked
goods range under which conditions and at which location.
The whole system is called “Bakebox” and is being publicized
in newspaper adverts, on posters and on the walls of the
market buildings. The “Bakeboxes” are also distinctively
colored, and a leaflet at the market entrance has a flourthrowing baker with information about Hofer’s new service.
At all four locations the product range currently being baked
off comprises Austrian classics such as plain Kaiser rolls,
handmade rolls, pretzels, pretzel sticks, braided poppy-seed
rolls, cheese envelopes and two loaves weighing 500 and
750 g. The ranges of small baked goods and fine pastries and
bread are broader at the bigger locations, and also include
snack articles such as ham-and-cheese sticks. Individual
products are advertised as organic products.
A small reference publication, although for the time being
this can only be seen on the spot, provides information
about ingredients, nutritional values and suppliers without
using obscure pseudonyms. The full names and addresses of
Harry-Brot, Klemme, Fischer, Kuchenpeter, Hiestand Austria
etc. are mentioned.
The prices are distinctly higher than those of “off-the-shelf ”
goods, but also markedly lower than those of local store
chains. A Kaiser roll costs 15 cents, a handmade roll 49 cents,
a braided poppy-seed roll 49 cents, a knusperspitz 45 cents,
a pretzel 39 cents, an organic sunflower seed roll 69 cents, a
cheese envelope 99 cents, a 750 g sunflower seed loaf EUR 1.69,
a 750 g crusty loaf EUR 1.39 and a 500 g multigrain roll EUR 1.69.
+
All the branches have the same prices –
but not the same systems
1) In Telfs, where the product range is widest, customers will
see a row of display surfaces and chutes from which they can
remove the goods with tongs. The area is visually segregated
from the remainder of the shop by a wood frame on the wall
and by a different color on the floor. Behind the display surfaces can be seen a row of Werner & Pfleiderer Bakery Group
ovens from which the staff take the fully baked goods and
load them onto the display surfaces from the back.
2) Wörgl offers the smallest product range of approx. ten
items. Customers fish out the goods with a kind of hook and
push them into a flap or removal opening. In this case, they are
loaded from the front and are baked in a Dibas from Wiesheu
GmbH standing alongside the shelf. When the goods are ready,
staff slide the baking trays into a cooling trolley, then put
the products into boxes when required. Special equipment
allows several baking trays to be handled simultaneously.
3) Kufstein looks like an enlarged version of Wörgl, but here
there is no Dibas baking alongside the display boxes. Instead
there are four ovens from MIWE Michael Wenz GmbH in a
sideroom, although one can see into this from the shop. In
contrast to Wörgl and Telfs, due to this spatial separation,
there is no aroma of freshly baked goods in the shop.
4) In Innsbruck there are three automatic baking machines
side by side, which were specially built for Aldi and Hofer by
MARKET
RESORT
++ figure 3
HOME OF OUTSTANDING PERFORMANCES
© f2m
VISIT US AT
KOENIG RESORT
++ figure 3
A handmade roll, cut open with the final tuck still missing
HOME OF OUTSTANDING
PERFORMANCES
the Weiss Company. Between them the vending machines
offer 17 different products which appear in the dispensing
flap at the push of a button, the cheese envelopes on a
small cardboard tray. They are not always still warm at this
point, since they are obviously baked in small batches behind the scenes, and pushing the button simply controls
the dispenser. Here again there is no enticing aroma as an
encouragement to buy, and in contrast to the three variants
mentioned above, not all customers are aware of the new
offering. However, the vending machines require distinctly
fewer personnel: they only need to be loaded with a stock
of goods from time to time, and that takes place behind
the scenes.
On the first day it was not possible to find out how many
staff will be needed in the other branches on a permanent
basis to ensure the operation and permanent availability of
goods. It was quite obvious that Hofer had ensured that
the launch had a generous workforce budget. One or two
young women wearing smart clothing with the “Bakebox”
logo have been deployed at each location for a whole
month to encourage customers to taste the goods and to
pass on information about the new services. +++
HALL B2
BOOTH B2.470, B2.471
© f2m
++ figure 4
A 750 g sunflower seed loaf costs EUR 1.69
ADVERTISEMENT
++ figure 4
König Maschinen Gesellschaft m.b.H.
Statteggerstraße 80, 8045 Graz, AUSTRIA
[email protected],
B A K I Nwww.koenig-rex.com
G+BISCUIT ISSUE
04 2012
MARKET
Decisions emerge from the product
T H E I B A 2 0 1 2 S TA R T S I N A F E W D AY S . M A S S I V E S T R U C T U R A L C H A N G E S A R E C U R R E N T LY
A LT E R I N G T H E B A K I N G I N D U S T R Y W O R L D W I D E . B B I TA L K E D T O B E R N A R D Z O R N , P R E S I D E N T
OF TH E M EC ATH E RM GROUP I N BAR E MBACH, F RANCE, WHAT TH E FUTU R E OF TH E BAKI NG
MACHINERY CONSTRUCTION BUSINE SS MIGHT LOOK LIKE
bbi: Mr. Zorn, you are one of the doyens of the European bakery machine industry. Who, if not you, has an
instinctive feel for what we can expect at and from the iba?
Will this trade fair be anything more than a “big worldwide
school reunion”?
+ Zorn: After Europain, the iba is the second big industry
event this year, and in Munich we will again experience a
trend that was already apparent in Paris. Currently, there is
very heavy investment in new bakeries in the so-called
emerging and developing countries, and very often it is by
individuals, companies or groups for whom this is their first
entry into the baking industry. Personally I expect very many
of these “newcomers” at the iba. Alternatively the major
European businesses will also come to Munich, even though
their inclination to invest is somewhat restrained at present
due to the economic crisis. To this extent the trade fair will
also be a “big school reunion”.
+ bbi: What are these clients looking for at the iba if they
have only a limited desire to invest?
+ Zorn: That depends on the conditions. The big operators
come to Paris for the Europain because they are looking for
new product ideas, and they definitely find them there. They
come to the iba to look around for the production technology
needed for these products. They will definitely invest if the
project then turns out to be profitable. Nowadays all decisions
emerge from the product.
+
+ bbi: We are currently seeing structural changes in the baking
industry throughout the world. Will that have any influence
on the iba and on what will be displayed there?
+ Zorn: As far as structural change is concerned, we are experiencing throughout the world a trend towards more frozen
baked goods, and within this segment to more ready-baked
or almost ready-baked products. In Europe, one reason for
this is to be found in the entry by hard discounters into the
marketing of freshly baked goods. Their concepts could not
be implemented with white baked goods that are finishbaked for 15 min or more in the shop. Producing readybaked or almost ready-baked baguettes or bread rolls with
good, uniform quality requires the precision of industrial
fabrication lines. This process development will be one of the
big topics at this year’s iba.
+ bbi: If one considers Europe, one sees in the first place the
growing importance of frozen baked goods, albeit with a different weighting in the various countries, that is associated
with the growing influence of the food retail and of large fast
food and catering concepts on the marketing of baked goods.
© f2m
10
++ Bernard Zorn
President of the Mecatherm Group
In between there is a scrum of small to medium-sized suppliers
of “gourmet baked goods” that are sold as “manufactures”
embodying the spirit of our grandfathers’ generation. What
medium-term consequences in relation to baking will that
have for a continent that has always understood itself as the
home of hundreds of different speciality baked goods, if not
indeed as the absolute homeland of bread itself ?
+ Zorn: Europe’s small artisan businesses are disappearing
rapidly, and chain store operators are also having problems
in many places. My information tells me that even the bakeoff stations not operated by hard discounters were forced to
accept large sales losses in the first quarter of this year, and
by “large” I mean more than 20 %. The great strength of the
food retail and especially of the discounters demands a high
level of efficiency and performance from the baked goods
producers, which in turn leads to production operations
becoming ever larger. In that sense the emergence of the
manufactories is certainly not a real counterbalance, it is
more likely a niche market.
We are currently experiencing a situation in which the trend
is more towards baguettes and bread rolls that bring good,
authentic quality but do not pretend to be “sophisticated”, i.e.
have not undergone long resting and proofing times etc.
Consumers want quality but often no longer have the money
to buy expensive products, sometimes not even enough to
buy something to put on top of the roll or baguette. That’s
why it’s important that such a baguette tastes good and has
not been jazzed up with chemical treatments and large
amounts of yeast. An authentic baguette or bread roll with no
chemistry or pounds of yeast has a lot of flavor, and much
MARKET
know-how and great experience are needed both to manufacture a crust that is thin but crisp and to implement this in
industrial processes. As long as we in Europe develop the
processes and equipment needed for this, we will also remain
the “leading continent”.
European machine constructors at the iba, especially from
those countries where wages are low?
+ Zorn: Of course there is increasing competition from lowcost suppliers. But let me put it this way: “No-one would
think of buying a low-cost Airbus or a low-cost Boeing. It would
be too dangerous and too expensive.” Today we are already
seeing our plants being copied over and over again. However,
one can only copy what one can see, but not every detail and
not the perfection of the process or of the underlying knowhow. The quality of crisp varieties of bread, their texture and
their crust, are governed by so many parameters that a very
large amount of engineering is involved in improving a
pro cess of this kind.
The only question is which and with which planning horizon.
The industry is attractive and crisis-proof. Bread is a staple
food, but does nothing for funds that want to exit again after
three or four years with big profits. As you know, for a long
time Mecatherm has been owned by a French finance group
that sold the company six months ago to the French finance
group Wendel. The latter is backed by an industrial family in
the steel industry, and the average length of their shareholdings is 14 years. So we can look forward to at least a further
thirteen and a half years. But joking aside: merging in the
industry is expensive, as we have experienced personally.
When Mecatherm took over Gouet, it took us a year to get to
know one another and to understand the structures and
processes etc. Today, after nearly six years, all the participants
are happy with this step. We have made enormous development progress together and we are bringing in a good return.
You can’t achieve that with short-term thinking. However,
the pressure on prices at all levels, in the retail and among
the baked goods manufacturers and machine constructors,
will intensify the trend towards mergers.
+ bbi: Whoever offers the first baguettes on a new market need
+ bbi: Is merging absolutely essential, or can’t it also just be
+ bbi: Do you expect increased competition from non-
not necessarily supply top quality because there is neither
any opportunity for comparison nor any competition. Wouldn’t
it be possible for low-cost suppliers to compete with you in
such export markets?
+ Zorn: The first entrant would perhaps find the going easy,
but a second supplier will soon appear when the market picks
up, and will offer better quality as a competitive advantage.
Moreover, investment costs are not the decisive factor. Investors nowadays are more concerned with the direct unit
costs, the total cost of ownership and the technical and technological support they can expect from their suppliers.
+ bbi: Baked goods manufacturers are growing in size and
are often considerably bigger than their machine suppliers. It
wasn’t always like that. Is the bakery machine industry
changing?
+ Zorn: Baked goods manufacturers are becoming larger, but
they also often have customers that are significantly bigger
than they themselves, namely the food retail, which is in turn
growing rapidly. It is not always an entirely safe situation
when too much of one’s own turnover depends on a single
client. However, just as there are and will be mergers in the
baked goods industry, the same thing will also happen in
bakery machine construction. Probably we ourselves will, on
the one hand, then really be the junior partner, but on the
other hand the manufacturers need us as well.
+ bbi: We are currently seeing financial investors advancing
more deeply throughout the world both into the baking industry and into upstream supplier businesses. What mediumand long-term consequences will that have? Must we anticipate
the emergence of ever larger conglomerates that are controlled
mainly by their investors’ profit expectations?
+ Zorn: Merging is expensive, so it can be assumed that
more financial capital will appear in the industry sectors.
simple cooperation?
+ Zorn: In contrast to the past, when a baked goods producer
bought his oven here, his mixer there and the make-up from
a third supplier or perhaps had it done by hand, today the
market demands complete and if possible fully automated
lines. We still have a very large number of suppliers that
offer only parts of a line, which is why cooperations are sensible. Alternatively, the continuing development of complete
lines is more likely in the future to favor takeovers. So we
will probably have both in the industry, cooperations and
mergers.
+ bbi: Which route will Mecatherm/Gouet take?
+ Zorn: The Wendel Group attaches importance to focusing
its holdings on worldwide market leaders and then allowing
these to grow both organically and by purchased acquisitions. We have proved that we can generate organic growth
and can successfully manage purchased acquisitions. Much
still remains to be done in the bakery machine industry, and
we will be a part of it.
+ bbi: Looking again at the iba, which main points will
Mecatherm be emphasizing this year?
+ Zorn: One point of emphasis will be our Combibloc, a line
that can be used to produce both baguettes, bread rolls and
pan-baked loaves. The second focus will be a line for authentic baguettes of the type I have already described. We will
demonstrate this production at the iba, together with various
other products. One important element, in this respect, will
be an oven that must be able to bake very hot and quickly to
achieve a crust that is fine and thin but nevertheless crisp,
and must be able to do that at high hourly capacities.
+ bbi: Mr. Zorn, we thank you for the interview and wish you
a successful trade fair in Munich. +++
11
NEWS
Full-service provider for
deep fried pastries
W P - K E M P E R H A S TA K E N O V E R T H E D E E P F AT F R Y I N G D I V I S I O N O F Z E P P E L I N - R E I M E LT A N D
T H U S N O W O F F E R S A W I D E , R I C H LY V A R I E D P R O D U C T R A N G E F O R T H E M A N U F A C T U R E O F
DE E P F R I E D PA STR I E S
++ figure 2
© f2m
++ figure 1
© f2m
01 2
++ figure 1
++ figure 2
The donuts reach the first intermediate proofer for about 10 min and then, after the flat pressing station,
After leaving the pre-pressing station, where the donuts get
get for 10 min to the second intermediate proofer
its bulge, they reach the stamp and lose the hole inside
Deep fried pastries are one of the ranges of baked goods
that have gained considerable market importance in
the past few years. Whether in the Asian countries, where
products fried in fat have been an important component of
the diet from time immemorial, in Spanish-speaking countries, where the sweet variants have a firm place in the product
range of baked goods suppliers, or in the part of the world
under Anglo-American influence, which cannot do without
daily donuts or a donut ration – deep fat fried pastries have
the advantage of the ability to associate with familiar taste
experiences and to expand them, irrespective of whether in
sweet or salty variants. A good example of this is Central
Europe, where deep fried pastries manufactured mainly from
yeast dough originally represented seasonal offerings but are
now on sale throughout the year and are proving to be very
innovative, from donuts and quark balls to initial experiments
with savory variants.
Up to now the market for plant technology to manufacture
deep fried pastries has been served by suppliers who are small,
regional, and only partial even in the industrial area, and who
are proficient in only a single product variant, the ring donut.
The takeover of the deep fat frying plant business of ZeppelinReimelt, Rödermark, Germany, by WP-Kemper in Rietberg,
Germany, creates for the first time a supplier whose industrial plant engineering is fully proficient in all shapes, sizes
and variants of deep frying, whether it’s donuts, berliners,
bismarcks or little quark balls, filled or unfilled.
+
This is due mainly to the fact that Kemper shapes the baked
goods instead of just portioning them into the fat. As a result
Kemper has full command of every shape, because it originates from a ball of yeast dough. Analogous to bread roll
technology, the dough ball is produced via a dough dividing
and molding machine that divides and round molds accurately weighed dough pieces. Exactly as in a bread roll plant,
the dough then passes through a pre-proofing cabinet before it is finally molded and transferred to the final proofing
cabinet.
Few limits are imposed on the molding. The dough balls can
run through circular, be rolled into an elongated shape or be
turned into a ring donut. To create the donut shape, the
center of the dough ball is pressed in so only a thin skin of
dough remains, which is then punched out. The advantage
of this process is that the donut has a stable shape and there
is almost no formation of dough residue needing to be recycled. After proofing, it moves onward as before, into the
fat-frying pan developed by Reimelt, and to the filling,
decorating and depositing stations.
The technology from dough division to depositing the finished
product will be available in future from a single supplier,
and future development will also be concentrated in Rietberg,
Germany, where the plants will also be built. Around ten
employees will be transferred from Reimelt for this purpose,
including the customer advisers and technologists, bringing
with them many years of experience. +++
COMPANY PORTRAIT
Market leader through investment
ALMARAI IS ONE OF THE MARKET MAKERS IN FOOD PRODUCTION IN SAUDI ARABIA. IT HAS
I N V E S T E D H E A V I LY I N T H E B A K E R Y D I V I S I O N S I N C E 2 0 0 7 , A N D T H E M A R K E T L E A D E R P L A N S
FU RTH E R E XPAN S ION I N TH E FUTU R E
++ figure 1
© f2m
14
++ figure 1
A conti-mixer supplies the Fritsch plant with dough for puff pastry
The Almarai Bakeries with its two production sites in
Jeddah and Al-Kharj near Riyadh, the capital of Saudi
Arabia, is clearly one of the region’s market leaders. The
group’s parent company Almarai moved into baked goods
production by purchasing the Western Bakeries bakery in
2007. Around 160 t of flour every day is turned into toastbread loaves, hamburger buns, muffins, waffles, cakes and
croissants on various plants at the Jeddah site on the Red
Sea. Today Almarai Bakeries supplies baked goods to almost
70 % of all the shops and trading chains in Saudi Arabia.
This was made possible by building a new factory around
140 km south of Riyadh in 2009. The business invested approx.
EUR 55m at that time, e.g. to supply baked goods from there
to Riyadh’s population of around 4.1m. However, the company also wants to use the Al-Kharj site as a springboard for
new markets. Thus the export ratio is set to increase markedly
over the next few years. The planned figure is up to 30 %, with
the intended consumers coming, for example, from Oman,
Bahrain or Qatar. This would be difficult to achieve with
only one production site, and in any case Jeddah is around
+
1,000 km from Riyadh. However, the new site is also intended
to secure the bakery’s market leadership. This is why the
company is constantly investing in the site, which is in the
middle of the desert. The reason for the location is the easier
accessibility of groundwater. The company has consequently
also built a production facility to manufacture baby food
and milk powder at the same location.
State of the Art
Breads and croissants, buns, cakes, biscuits and ready-to-eat
baked goods are manufactured in the bakery itself. At the same
time the management attaches importance to the factories
living up to the claim of being “state of the art” whereby it
only invests in the most modern technology, mostly from
Europe and the USA. The employees exclusively produce
baked goods, fresh or packed in a protective atmos phere,
but no frozen products. One of the best selling items is a puff
pastry with a cheese filling which is eaten as a snack between
mealtimes. This individually packed pastry can be reheated
for a short time in a microwave if required, or can be eaten
15
COMPANY PORTRAIT
© f2m
++ figure 2
++ figure 2
The dough sheet is folded in
of the proofing time, the dough pieces weighing 120 g are
carried out of the proofing tunnel via two loaders and into a
single-deck continuous oven. Beforehand the dough pieces
are also sprayed with liquid egg, which ensures that the baked
products have the necessary gloss. After that the dough cases
move for 20 min on a steel belt through the oven, which is
from DFE Meincke, Skovlunde, Denmark. The total hourly
capacity of the Fritsch plant is 46,000 filled puff pastry. After
being baked, these are cooled down in a spiral cooler and afterwards individually packed in film.
Of course the dough cases can be filled with various
products, e.g. a date, apple or chocolate filling, but the cheese
snacks are the best sellers. The second production facility 왘
++ figure 3
© f2m
just as it is. The baked product is produced in Jeddah and
Al-Kharj. At the newer site the bakery relies on a plant supplied by the FRITSCH GmbH, Markt Einersheim, Germany.
The fine baked goods plant at this site is supplied by a conti
mixer from the Zeppelin Reimelt GmbH, Rödermark, Germany. After one mixing and one kneading phase, the wheat
dough enters the dough hopper via conveyor belts including
a short dough resting time. The dough sheet former with five
rollers produces a dough sheet that is afterwards processed
gently in the Fritsch Laminator 3000.
During processing a fat pump applies a sheet of fat to the
centre of the resulting dough sheet, and the dough is folded
in. This is followed by the first folding or lamination of the
dough, and the dough sheet is rolled out again. Next the
dough sheet is divided in half. One half will later become the
lower part of the baked product and the other half correspondingly the upper part. Each part-sheet is folded once
more, giving the whole plant an overall U-shape. After laminating the dough sheets, they are rolled out through several
stations in parallel to the required final thickness.
The lower dough sheet is now slightly moistened with water
and the filling is applied. The upper dough sheet formed in
parallel is passed through various stations and finally placed
on the lower dough sheet with the cheese filling. The dough
sheet is now cut lengthways by cutting rollers, forming a total
of 18 rows of dough. This is followed by the singling or
spreading apart of the dough strips, and crossways cutting
by a servo guillotine. The resulting dough pieces, each 156 mm
long and 56 mm wide, now move automatically for 60 min in
the belt proofing tunnel with a total of 12 decks. At the end
++ figure 3
Customers can buy the baked products in the supermarket, individually packed
and with different fillings. They can be eaten warm or cold
COMPANY PORTRAIT
in Jeddah will bring the bakery to a total hourly capacity of
120,000 items. The Danish pastries cost supermarket customers around EUR 0.20. At the same time, the Almarai
Bakeries staff of around 1,500 employees produces baked
goods under the L’usine and 7 Days brands. 7 Days is, in
turn, a brand belonging to the Chipita S.A., Athens, Greece,
with which there is a joint venture to open up new markets.
The bakery plans to further expand its total capa city in this
way. The plan includes, among other things, a new bread line
for which initial trials with rye flour have already started.
Through investments in a modern machinery base and the
development of new products, Almarai Bakeries intends to
be and remain No. 1 in Saudi Arabia and the market leader
when it comes to baked products quality. +++
++ figure 4
© f2m
Almarai – a success story
++ figure 4
Application of the filling is followed by “marriage”, i.e. placing the dough sheets,
one on top of another
© f2m
++ figure 5
++ figure 5
The individual filled strips of dough are spread apart, then cut, after which they go
into the tunnel proofing cabinet
++ figure 6
© f2m
16
++ figure 6
The dough cases leave the steel strip tunnel oven after 20 min
Almarai (Arabic for “pasture”) is a publicly listed food
producer with headquarters in Riyadh, Saudi Arabia.
Founded in 1977, the group’s aim was to adapt Arabia’s
traditional dairy industry to the needs of a rapidly
growing domestic market. Under the leadership of His
Highness Prince Sultan Bin Mohammed Bin Saud AlKabeer, numerous agricultural projects were established
to supply the population with, for example, fresh milk
and high quality milk products at an affordable price.
Almarai did this by building a central milk processing
plant and by combining a wide diversity of small dairy
cattle operations into large units. Various new farms
and giant “super farms” came into existence, together
with cheese-making plants.
The company has been listed on the stock exchange
since 2005 and is expanding steadily in the food production area. For example, the company bought
Western Bakeries in Jeddah, Saudi Arabia, in 2007.
Almarai also began the production of poultry and
eggs in 2009. Today the company also manufactures
baby food and a wide variety of fruit juices in addition to numerous milk products.
The company recently decided to invest around
EUR 3.35bn in the dairy, baked goods and poultry
business areas over the next five years. There is a
plan to develop new business fields, use available
resources efficiently and train employees. International
expansion will also be pushed forward further. For
example, Almarai took a share in the Fondomonte SA
in Argentina, which owns three farms in South America.
Almarai’s reason for doing this is to secure the supply
of animal feeding stuffs and other agricultural raw
materials.
In the first quarter (ending March 2012) Almarai reported a net profit of EUR 51.6m, an increase of 2.9 %
compared to the previous year.
Further information can be obtained at:
www.almarai.com +++
MODERN
BAKERY
MOSCOW
MODERN
BAKERY
MOSCOW
18
IBA
Systematically redeveloped
RO N D O S H O W E D I N I T I A L I D E A S F O R T H E H YG I E N I C D E S I G N O F B A K E RY M AC H I N E S AT A E U RO PA I N
T R A D E F A I R M O R E T H A N T H R E E Y E A R S A G O . S I N C E T H E N T H E S W I S S C O M P A N Y H A S S Y S T E M A T I C A L LY
R EDE SIG N ED ITS ENTI R E I N DUSTRIAL PRODUCT RANGE ACCORDI NG TO TH E SE RU LE S
++ figure 1
© Rondo
D 111
© Rondo
1 STAN
++ figure 1
++ figure 2
The flour dusters are moved away to clean the line
The belt is readily accessible from top and bottom, which makes it easy to clean
It was a far-reaching decision, and RONDO Burgdorf
AG were the first to take it and implement it. After
careful consideration, the machine builders from Burgdorf
in the Emmental region of Switzerland decided, more than
three years ago, not to be content with adapting the existing
designs, but to prepare a hygiene checklist on the basis of
which every existing plant and every machine must be redesigned and must also conform to every new development
(see table 1 on page 22).
There were several reasons for this radical rethink. On the one
hand, increasing numbers of companies coming from branches
of industry in which the applicable hygiene requirements are
distinctly higher were and are entering into the manufacture
of baked goods internationally. For example, meat producers
are now manufacturing filled pasties and ravioli. On the other
hand, developments in the USA show that the costs of poor
hygiene and product contaminations quickly end up in the tens
or even hundreds of millions region, either due to damages
compensation or closures of firms. The corresponding legal
position in the rest of the world is becoming more stringent,
and nowadays anyone who buys a plant that is intended to
produce for up to 15 years would do well to think ahead in
relation to hygiene if he doesn’t want to be forced sooner or
later into expensive retrofitting, or even into scrapping. On
top of that, as a result of a number of unhappy incidents, retail
auditors and certification authorities are now paying increasing
attention to breaches of hygiene. The public and consumers
no longer view them as a trivial offence.
At the iba in 2012, the Burgdorf company will present its entire
industrial product range, from laminating plants and make-up
stations, donut, pizza and bread lines to croissant plants, all
redesigned on hygiene-compliant principles. They will complete
the mammoth task in Munich with the new MIDOS dough
sheeter, which will replace the tried and tested OSCAR.
A number of the new generation plants are already in operation in various production facilities, and today the Swiss
company can not only predict by calculation, it can also
show by an actual example that the product and process are
+
++ figure 4
© Rondo
++ figure 3
© Rondo
HALL A
++ figure 2
++ figure 3
++ figure 4
The edge of the conveyor belt is welded for hygiene reasons
Only stainless steel and plastics approved for foodstuffs are used on ASTec lines
19
IBA
© Rondo
++ figure 6
© Rondo
++ figure 5
++ figure 5
++ figure 6
The cleaning processes on ASTec lines are documented in the controller
The cross-roller is easily accessible, thus it can be cleaned with no problems
still correct, but the cleaning effort has decreased markedly
and thus more production time is available. However, that’s
not all. The redesign has also increased flexibility because
retooling and cleaning have been comprehensively thought
through, and the risk that employees will inadvertently
use the wrong tool or make an incorrect setting has been
systematically reduced.
Anyone who operates or cleans the plant is guided meticulously through the program by the controller. The sequence
of steps is predetermined, together with the time needed for
them, and each step must be acknowledged, which also
includes recording the operator’s name.
Rondo intentionally implemented the new development of
the plant together with hygiene-aware clients. The outcome
is a twin-track solution. Depending on the area of use and
requirement, the investor can choose between ASTec wet and
ASTec dry. ASTec stands for advanced sanitary technology,
wet means a completely IP 65 cleanable in situ by water
pressure jet, and dry is a variant that must be cleaned dry or
with a damp cloth.
왘
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20
IBA
In both cases the fundamental design principles are unconditional accessibility to all points on the plant, the design of
the flour dusters and sugar shakers as mobile elements, the
easy interchangeability of all tools, the generous opening
possibilities of all safety flaps, the avoidance of cavities and
opportunities for flour dust to deposit, hygiene-friendly cabling
and a central lubrication system for each station on the line.
The construction of the controller and the touch panels used
is also identical.
The wet and dry variants differ in that different motors and
bearings are used. In addition, in contrast to the dry version,
the conveyor belt edges in the wet version are welded. Rondo
estimates the price difference between the two variants to be
around 10 %, and nowadays one plant in every five throughout the world is delivered as the wet version, mainly to the
USA and Great Britain. The trend is upwards. Incidentally,
drying after wet cleaning is carried out with compressed air,
and of course on request there are customized adaptations
or combinations between wet and dry.
In some respects the new design posed new challenges for the
machine builders. Primarily the search for suitable materials
and suppliers occasionally proved problematical, and a number
of components also needed to be initially redesigned. Chain
drives were largely prohibited, with direct drives or power
transmissions using toothed belts or racks being used instead.
Particular attention was devoted to the inputs and outputs
of the cabling, and also to the cable channels, which are
available at the client’s request either as open basket variants
or as closed stainless steel ducts.
A variety of cleaning programs as well as a maintenance timetable are stored in the controller. At the start of the maintenance
cycle the employee must identify him/herself and select the
required program. Next he/she is instructed in detail what
he/she must do in individual pre-defined steps, e.g. “Open
all safety flaps”. If one remains closed, it gives a signal and
nothing more can happen until the required state is reached.
All the information is recorded/reported as a cleaning history and is stored permanently for monitoring purposes.
Table 1: The RONDO hygiene checklist
Based on the principles of hygienic design, a checklist to verify the hygiene standards of new or planned systems was defined. It is used to identify
priorities for improvements to existing systems or to evaluate new machines.
ACTUAL
TARGET
Cleaning
Is the cleaning procedure carried out in line with GMP standards or other quality standards that can be verified by means of
115
active monitoring programmes?
Compatible materials
80
Are all equipment materials used compatible with the products, the environment and chemical cleaning agents?
Access
160
Are all system sections easily accessible for cleaning and hygiene, maintenance and inspection?
No material deposits
Is the system free of niches in which products or liquids can accumulate? Does self draining prevent the accumulation of
70
waste or liquids?
Sealed cavities
65
Are cavities avoided or are they permanently sealed?
No niches
185
Does the system have indentations, slits, corrosion, gaps, recesses or open seams? Are all the welding seams smooth?
Hygiene function
125
When under normal operating conditions, does the machine contribute to the propagation of bacteria?
Hygiene design for maintenance
35
Are the man-machine interfaces designed and constructed in such a way that neither products nor liquids can penetrate?
Hygiene compatibility with other systems
30
Is the machine design compatible with the bakery equipment and other systems such as power, steam, air and water systems?
Cleaning methods
70
Are the cleaning methods effective and efficient? Are they recorded? Are the chemicals used compatible?
Separate processes
25
Are different work processes separated to prevent cross contamination or to prevent products from being tampered with?
Equipment and personnel
40
Are equipment cleanliness standards and personnel hygiene requirements in compliance?
Total number of points
Evaluation
The purpose of the checklist is to evaluate a system and its
environment, to identify potential areas for improvement and
to support the continuous improvement process.
1,000
Evaluations
Requirements met to satisfactory degree
Requirements met in part
Requirements met to inadequate degree
Maximum number of points
Full number of points
Half the total number of points
No points
1,000 points
IBA
© Rondo
++ figure 7
++ figure 7
Clearances ensure that dirt cannot collect in corners and edges
For example, as the first step of a cleaning cycle on a laminating
plant, when a button is pressed all the roller nips on the running
plant open so the scrapers can transport out any remaining
dough residues. The machine then stops and all the scrapers
are released by quick-release fasteners and positioned on a
trolley. Each scraper carries a number that assigns it an unambiguous place in the plant, so no mix-ups can occur and
no-one needs to spend a long time wondering what belongs
where. The satellites are moved by pressing buttons so each
satellite roller can be cleaned. To avoid any injuries to the
cleaning staff in this process, the satellite head is accessible
from only one side, namely in the direction in which it rotates.
This makes it impossible for hands to be trapped. The belt
tension release operates via quick-release fasteners, and brackets
can be moved upright to give good access to the underside of
the belt as well.
There are many design details and the choice of new materials which, in conjunction with the hygiene-oriented controller design, intermesh not only enable more hygiene in the
production operation but also ensure its implementation by
gentle prompting. That then also helps with staff who know
nothing, don’t want to know and don’t …! +++
++ figure 8
All scrapers are clearly marked
ADVERTISEMENT
© Rondo
++ figure 8
DISCOVER THE WP
iba Live-Stream: www.wp-iba.com
TREASURES AT IBA
Haton
Kemper
Bakery Technologies
Industrial Bakery Technologies
24
IBA
From steel to technology
T H E K A A K G RO U P ’ S H I STO RY B E G A N W I T H B A K I N G T R AYS , PA N S A N D CO N V E YO R E N G I N E E R I N G
AFTER WHICH CONTROLLER EXPERTS, OVEN BUILDERS AND MAKE-UP SPECIALISTS JOINED
T H E G R O U P. A T T H E I B A I N M U N I C H T H E G R O U P W I L L S H O W T H A T A L L O F T H E S E E L E M E N T S
HAVE FUS ED TOG ETH E R SO THAT TODAY IT IS A TECH NOLOGY PROVI DE R
++ figure 1
D 430
© Kaak
1 STAN
© Kaak
HALL A
++ figure 2
++ figure 1
++ figure 2
Benier offers a wash-down Chorleywood mixer with complete dispensing
High-capacity round moulder with interchangeable heads by DrieM
New markets bring new ideas. It is mainly thanks to
the Asian market that Benier has developed a new
volume divider for sponge-doughs (very soft doughs with
fermented pre-dough) that officially weighs out dough weights
ranging from 30 to 300 g. In practice, it is also capable of
managing considerably smaller dough weights down to 15 g/
piece, and can do this 1,500 times per hour at a ratio of 80
parts water to 100 parts flour. Up to now, the dough divider,
which of course is also suitable for brioche doughs, works in
a single-row mode and yields four dough pieces per stroke,
but naturally it is also conceivable that it could work in a
multi-row operation.
Benier’s new long moulder is a further development of the
BM 600. It is used mainly with pre-fermented doughs and
promises to maintain the dough structure even if a prefermenting time of 60 minutes is allowed or sponge-doughs
are used.
Monitoring the width of the rolled-out dough and the controlled supply of dough are the essential features. All the
new long moulder’s settings are controlled via the choice of
recipe. This makes accidental incorrect adjustments by inattentive operators a thing of the past.
+
Chinese sponge-dough
Chinese doughs have a special recipe and method.
60 % of the flour together with yeast, water and improver are processed to yield a sponge that matures
for up to 4 hours. 20 % of the flour is separately scalded
with boiling water and salted. These two stages are
combined in the final dough with the remaining 20 %
of flour, sugar, butter, milk powder and the remainder
of the water. +++
Closure position control for bread plants
When a rolled-out piece of bread dough drops into an open
pan, it makes perfect sense for the dough piece to end up
resting on the closure so that the bread surface also emerges
closed and uniform after proofing and baking. To ensure
this, Benier has developed a closure position control for bread
plants that is usable not only on its own bread plants. Control
takes place via a camera and associated image recognition
system. 3,500 images/h are recorded and compared with a
standard. Put simply this means that for a given image, a cycle
time of around 1 second is available to compare the image,
detect irregularities on the upper half of the dough piece
surface and give the signal to continue turning the dough
piece until the closure is at the bottom, and only then to
open the flap that allows it to drop into the pan. Benier has
achieved this action of recognition and signalling within
10 ms and has patented it. According to Erik van Opstal,
Managing Director of the Kaak subsidiary, the next step will
be to use the technique on lines for hearth-baked loaves.
Another newcomer in the product range is a wash-down
Chorleywood mixer from Benier with dispensing. The market
for mixers working on the Chorleywood principle that can
knead doughs both under vacuum and at elevated pressure, 왘
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superior bread quality
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++ figure 4
© Kaak
++ figure 3
© Kaak
26
++ figure 3
++ figure 4
Beniers volume divider for very soft doughs with fermented pre-dough
Benier’s new long moulder is a further development of the BM 600
thus affecting the pore structure, became rather small after
the bankruptcy of one of the two English suppliers. This is
why Benier has now entered the market in cooperation with
the New Zealand supplier ECS Engineering. ECS, recently
renamed ADL, will in future look after engineering and research & development and will provide service in Australia
and New Zealand. However, all the mixers will be built at
the Benier plant in ’s-Hertogenbosch, the Netherlands, from
where marketing and service will operate throughout the
world apart from New Zealand and Australia.
However, the mixer that Benier will present at the iba is far
more than just a bowl in which dough is kneaded. Benier
together with ADL has turned it into a complete dough preparation unit, including solid and liquid components dispensing above the mixer and also incorporating a lifting tipper.
The flour hopper can pneumatically take up to three different
types of flour directly from the silos. Other dry ingredients
are also weighed out into the flour hopper, which stands on
three load cells. Raw materials are conveyed pneumatically
or mechanically, the required air passing through various filters
including odour filters. All the liquids are weighed out as a
percentage of the dry material weight. Of course two mixers
can also be fed from a single dispensing system.
Hygiene is of paramount importance for the new design and
therefore the enclosed frame structure is fully washable and
impervious to both oil and flour. A cleaning-in-place system
has also been incorporated for the mixing bowl; a spray head
ring is placed between bowl and closed lid and its nozzles
clean and rinse the whole of the interior. All the other parts
of the installation can also be washed down with water. The
water is collected in a tray and drains away. The mixer produces up to 350 kg of dough per batch, 12 times/h, thus
guaranteeing an hourly capacity of 4.2 t. If more is needed, a
twin plant with a shared lifting tipper is available.
In addition to the mixer’s glycol-cooled double jacket, which
directly affects the dough temperature, the mixer is enclosed
in a housing which is not only cooled but also fitted with antinoise protection. Both of these ensure that the environment
surrounding the mixer remains people-friendly in both the
literal and metaphorical sense.
In order to be able to offer this convenience, Benier considerably advanced the design of the drive main seal and ball
bearings. Power transmission is via Kevlar PolyChain toothed
belts; these avoid any slipping and slack and guarantee maximum power transfer. The new design also includes leakage
protection by way of double lip seals on both sides of the
bearing and “forced” drainage if one seal fails and liquid
penetrates. If leaks do occur, they become visible as soon as
the dough or liquids have passed the first seal but before they
have reached the bearing; this prevents the dough and liquids
from being ruined. However, as a preventative measure, it is
advisable to change the primary seal every two months,
which takes only a short amount of time thanks to the design.
This is an aspect that bears comparison with previous
Chorley wood mixers.
DrieM –High capacity dough piece-rounder
The limitation of just square-cut bread rolls from a dough
sheet has long been a thing of the past. The corners are
rounded by an additional dough piece-rounder which can
be installed on the line. DrieM has now even developed a
high-capacity round moulder with interchangeable heads
yielding up to 24,000 items/h, thus competing with classical
industrial bread roll lines. Piece weights from 40 to 120 g are
possible. A wide range of dough types can be processed by
the same machine, such as softer- and fruited doughs.
The various sizes of moulding cups plug in easily without
needing tools. Seven cups across the width and three rows in
the running direction are combined to form a system. A round
moulding station consists of two such systems. Two systems
are used because they mould in opposite directions and the
forces transferred to the belt and the whole plant by this
kind of movement largely cancel each other out.
When designing the rounding cups, DrieM took great care
to give enough room for the dough pieces to expand vertically
during round moulding.
27
IBA
© Kaak
++ figure 6
© Kaak
++ figure 5
++ figure 5
++ figure 6
A cold vapor proofing tower
The nozzles work with conventional pure tap water
The operator, who does not require any technical expertise,
gives the controlling system instructions corresponding to
the preselected recipe to define which moulding cups must
be plugged in and which exchange boxes need to be put on for
seeding etc. If the wrong one is installed, the line controller
reports the mistake.
DrieM controls weight accuracy via belt speed instead of via
the cut length. An automatic belt weighing system makes
the belt run faster or slower in order to slightly stretch or
compress the dough. In this way the cycle length and thus
the cut length stay the same, so equally sized pieces reach the
boards and the entire synchronisation of the board servicing
remains undisturbed and thus the capacity also stays constant.
Another new item in the DrieM product range is a roll-out
plant with a belt width ranging from 1,000 up to 1,400 mm
which is in demand to predominantly manufacture Swedish
thin bread and pizzas.
two-component nozzles. In contrast to ultrasonic humidifiers, these nozzles do not need reverse osmosis water or
demineralised water, but instead work with conventional
pure tap water. A lime filter should only be interposed if the
water hardness is very high. When using nozzles to generate
cold mist, the particle size is related directly to the air pressure,
water throughput and the nozzle technology used. Regulation
of the water throughput enables control of the amount of
water at each individual nozzle and, when combined with
the nozzle position, the exact amount of moisture at each
point in the room as well.
Cold vapour mist
Cold vapour mists are being used more and more often to
increase the air humidity in proofing and air-conditioning
plants. In contrast to water vapours generated by heat, the
considerably smaller water droplets have the advantage that
they easily become airborne and thus remain in the air for a
long time. In this way they enable a relative air humidity of
almost 100 % to be maintained. Also, because the mists are
cold, they condense less quickly on the cold surfaces of the
dough pieces in the thawing-out phase in the proofing interruption unit. In the experiments it was also discovered that
dough pieces proofed in cold vapour mist allow the surfaces
to become moist but not wet and smooth, and also not
sticky, and the uniform dampness in the whole dough piece
also enables a more uniform expansion of the baked product
in the baking phase.
The Kaak group in the Netherlands has now developed a
new way to generate cold vapour mists in proofing and conditioning rooms. It generates a microfine aerosol of water
particles with a droplet size of between 1–5 μm by using
Impingement oven from Ala
Heat transfer in an oven takes place via irradiation (Radiation),
hot air (Convection), conduction of heat from one material
to another (Conduction) or via steam (Condensation).
An impingement oven is the name given to a tunnel oven
that relies mainly on heat transfer by convection, i.e. the use
of hot air. Such ovens are needed primarily by the manufacturers of pizzas, rusks, cookies, crackers and pies, but are
also used for flaky pastry (puff pastry) or cakes and pies, i.e.
products that do not undergo any dough development due
to yeasts or enzymes during baking. The effect of the heat on
the product is rapid, and compared to bread ovens these ovens
are of simple construction and easy to maintain.
An innovation in the product range of the Italian oven
builder MCS since September 2011 has been an indirectly
fired impingement oven. The hot gases created by the burner
are passed into a heat exchanger. In contrast to the “Bakemaster” bread baking oven, this heat exchanger consists of
tubes instead of large panels. Powerful blowers pull in air
builds the oven in modules 2 m long so a decision can be
taken, depending on the application, as to how many energy
modules and simple transport modules there are between
the product inlet and outlet. The modular construction also
ensures fast installation on site. There are two variants of the
heat exchanger, one for oven widths of up to 2 m and a power
rating of 180 kW and one for oven widths of between 2–3 m 왘
IBA
© MCS
++ figure 7
++ figure 7
MCS impingement oven
with a power rating of 300 kW. Each energy module needs
its own flue connection. All belt types can be used in this
oven, although as a rule wire mesh belts or steel belts are
used, and sometimes stone slab belts as well. Large towers
simplify access to the oven’s interior for cleaning and maintenance. A brush cleans the belts at the end of the oven and
a “greasing unit” ensures the uniform application of the extremely thin film of fat required by the products, e.g. biscuits,
in order to release them easily from the belt. For biscuit and
cookie manufacturers there is also a cooling unit that cools
the belt down immediately after the oven exit to ensure the
products leave the belt with a stable shape.
The controls on this oven include baking time, temperature
(separately in each individual zone), air supply (separately
at top and bottom), the total amount of air circulated and the
amount of fresh air supplied to drive the moisture originating
from the products out of the oven.
Pizza plants
How do you make a perfect Italian pizza? If one’s family roots
go back to a genuine Italian family, one will know that there
is a need to improve the way pizzas are moulded industrially.
++ figure 9
++ figure 8 + 9
The pizza plants from MCS have an hourly capacity per rollout head of 1,000 pieces/h
There are three customary methods: a) cutting out from a
sheet of dough, b) using a stamp to press a round ball of
dough flat to the required thickness, and c) rolling out a ball
of dough lengthways and crossways. All three methods have
little similarity with what a pizza baker does by hand when
he wants to conjure a thin pizza base from a ball of dough.
Maurizio Tabarelli heads the Kaak subsidiary company MCS
in Ala, Italy, and the object lessons of his youth inspired him
to transfer the artisan technique of shaping dough and make
it suitable for industrial use.
The MCS pizza shaper operates in two stages and can process doughs that may have fermented for up to 6 h as well as
having been proofed for 45 min after dough division and
round moulding. In the first stage the dough ball is initially
pressed flat to a dough thickness of 12–15 mm without the
addition of any heat. At a second station a head in which six
rollers are arranged radially descends onto the dough pancake and spins at high speed. Photocells have previously arranged for the piece of dough to be positioned accurately
under the roller head. Three rollers are assigned to the
middle of the pizza base and three to the edge. Within 2 sec
the rollers gently push the dough outwards and the disk of
dough becomes thin and flat. The fact that the rollers effectively operate outwards from the centre simultaneously
creates the edge that is typical of the Italian pizza, thin but
with the ability to rise during baking. Since the dough does
not come into contact with any heat during shaping, the
surface is also not dry or already baked. Next the rolled out
dough is conveyed onwards to be treated with tomato and/
or other toppings.
The advantage of the new method is that a perfectly circular
pizza base is formed, and there is no longer any requirement
for manual corrections after shaping. The thickness of the
base and its edge as well as its diameter can be varied by
using different roll-out heads. The hourly capacity per rollout head is currently 1,000 pieces/h. MCS is collaborating
with its affiliated company Benier on a design concept for
complete pizza lines for output capacities of 1,000–8,000
pieces/h. +++
© Kaak
++ figure 8
© Kaak
28
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Visit us at IBA
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30
IBA
Rolling Stones
T H E H A M B U R G O V E N B U I L D E R D A U B , W H I C H B E L O N G S T O T H E K A A K G R O U P, W I L L S H O W A N E W
DEVE LOPM E NT AT TH E I BA 2012 THAT PROM ISE S MOR E HYGI E N E AN D LOWE R COSTS
++ figure 1
D 43
1 STAN
0
© Daub
HALL A
++ figures 1–3
The baking plates are picked up
by a paternoster system and
loaded with baked goods. After
positioning, a pusher slides the
plates into the oven and a baking
plate is pushed out at the oven
exit
Daub’s new pusher-type continuous oven
is called the “Stone-Motion”, and with a
baking area of 50 to 140 m2 it is intended
mainly for chain stores with artisan operations,
although it is also suitable for the manufacture
of part-baked goods. Stone is in no sense obligatory, and a mix of decks with stone or steel
plates is also conceivable.
The oven has a modular design but its construction is not modular, quite the opposite.
The plant is delivered as a complete block,
which reduces installation time to just a few
days. Baking takes place on stone slabs or
steel plates whose size ultimately determines
the oven’s format. The available selection of
slab/plate widths is 1,600, 2,000 or 2,500 mm,
and for the depth there is a choice between
800, 1,000 and 1,200 mm. Daub limits the
number of decks to seven.
All the baking plates consist of frames with
either stone slabs or steel plates set into them,
so they can weigh up to 100 kg. There are wheels
on each of the end faces, and engagement
+
holes on the transverse sides. The oven itself
contains heating panels through which thermooil flows, and above these there are L-shaped
profiles on each outer side of the hearth – no
chain, no motor, no tensioning device and no
drive shaft. The beauty of this is that the oven
itself, with a maximum length of 8 m, can be
completely cleaned with a vacuum cleaner
from both sides right down to the heating panel
without any problems, and maintenance work
on the hot oven interior is a thing of the past.
In addition the entire oven stands on support
legs 300 mm high, so there are no problems in
cleaning under it either. There is a paternoster
in front of the oven and another behind it,
each with four servomotors. The paternoster
in front holds a baking plate ready for loading, and lifts the full plate to the height of the
selected hearth. A pusher operating at the right
and left engages with the plate and pushes it
into the oven so that the rollers roll on the
L-shaped profile. With each next plate, the
previous one is pushed further through the
31
IBA
oven, the pusher braking before docking on the plates, to avoid
subjecting the baked goods to any vibration. An identical
paternoster undertakes the offloading and removal of the
baking plates after baking.
Daub has developed this simple, maintenance-friendly basic
principle further in the sense that baking plates removed
and unloaded at the other side of the oven are sent back to
the entry point in a heating channel below the hearths, being
heated up in the process, so that when the dough pieces are
loaded they land on hot hearth plates, which in turn benefits
the stability of the base and the oven spring.
Second plus point: the paternoster has two attachment
points for baking plates, so it is already in the process of
© Daub
++ figure 3
© Daub
++ figure 2
taking a second plate from the heating channel and bringing
it to be loaded just as the pusher accepts the previous one
and slides it into the oven. This reduces the loading cycle
time to less than 20 seconds.
The pushers and paternosters are driven by servomotors
positioned outside the oven and thus readily accessible for
maintenance and repair work.
The oven can be operated both in batch and in continuous
stepping mode. The plate is loaded either via a loading belt
or by feeding directly onto the hot plate. Alternatively the
baking plates can also transport bread pan clusters or trays
through the oven, which should please cake and stollen
bakers in particular. +++
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32
IBA
Wide range
TH E WP G ROUP W I LL PR E S E NT ITS E LF I N M U N ICH ON A L ARG E CO M B I N E D STAN D. I N ADDIT ION
TO TH E N EW DEVE LOPM E NTS BY TH E I N DIVI D UAL S U BS I DIARY CO M PAN I E S, TH E G ROUP W I LL
PRESENT JOINT PROGRAMS SUCH AS THE “CLEANTEC” HYGIENE LABEL AND NEW BUSINESS AREAS
++ figure 1
D 110
© WP
4 STAN
© WP
HALL B
++ figure 2
++ figures 1+2
Soft Star dough divider and moulder
WP-Kemper in Rietberg has redesigned its Soft Star
high-capacity dough dividing and molding machine
to focus mainly on more hygiene without sacrificing speed,
performance or weight accuracy. Like the predecessor model,
the new Soft Star with the “Kemper CleanTec” label consists
of a pre-portioner, weigher, dough processing zone for flour
dusting or air treatment, and finally the molding drum. It
divides at a maximum cycle rate of 60 cycles/min in dough
portions of 12 to 180 g. Instead of using hydraulic drives, the
new Soft Star is equipped with a series of servomotors that
are all collected together on one side of the machine and are
directly accessible for maintenance or exchange. Moreover,
the use of servomotors ensures gentler dough handling
when dividing. The piston that presses the dough into the
measuring compartment does not do so simply by brute
force, but at a speed that decreases with time and even nearly
stops altogether just before completing the stroke. The result
is as logical as it is pleasing: the gas bubbles in the dough
have distinctly improved chances of surviving the division
process. Collecting all the fastenings, bearings and suspensions
on one side of the machine housing is a part of the new Soft
+
Star’s construction principles. Consequently, the presentation
of the other side is open and accessible for cleaning. The entire machine is also fabricated from stainless steel or is made
of plastic like the pistons, so there is no need to take care
with sensitive materials during cleaning.
All the parts in contact with dough, such as the mouthpieces
in front of the division chamber, can be detached, folded
up etc. for cleaning, without needing to use a wrench. The
measuring drum body itself is made of plastic, is open on
the operator side, and with a diameter of more than 35 cm it
is readily accessible. It is also no longer necessary to dismantle the pistons, simply because there is no longer any
closed cavity behind them, only the open drum space. The
piston bars have also been redesigned in such a way that
here again there are no cavities remaining in which dough
or flour residues can accumulate.
The Rietberg engineers have even rethought “tiny details”
such as the intermediate belt. It now consists of single individually removable elements threaded onto an open rail.
Here again the applicable principle is that the drive is located
outside the production zone.
++ figure 3
++ figure 3
When developing the Selecta, particularly great importance was attached to the accessibility of the punching cup tools
33
IBA
++ figure 4
Matador store oven “history edition”
Moreover, for large and small products there are optional
presser rollers in two sizes where the plastic belt replaces the
felt belt and its associated hygiene problems; it is also removable, and is drawn onto a shoe-like component designed
as a hollow skeleton so that on the one hand it dries quickly
and on the other it processes the dough piece over a longer
length.
Less is more
Although the idea of dough development also plays a part in
a mixer carousel, as a rule the main aim is to supply a large
amount of dough continuously to a monoline while still
kneading batchwise. A new recruit in this area is the WP
subsidiary Kemper in Rietberg, Germany. Kemper’s mixer
carousel consists of at least three and a maximum of seven
stations with one or a maximum of three mixers in a circuit,
each together with a dispensing station and a station in
which a lifter-tipper takes the dough to the line.
The dough is manufactured using “Titan” series twin spiral
mixers that knead up to 400 kg of dough per batch, thus
attaining an hourly capacity of up to 3,200 kg per mixer,
depending on the dough. Log files document the entire
process including energy input and dough temperature, but
the dough data is not the only thing that is monitored. All
bearing points and motors are permanently monitored by
sensors, as are the pressure and temperature of the hydraulic
system, so warnings of malfunctions can be given in good
time. This allows maintenance and repairs to be planned.
All of the plant’s “intelligence” is housed in the mixer. The
construction of the mixer carousel itself is simple, open and
mechanically standardized. It consists practically of just a
center point from which radiate a corresponding number of
“arms” to accept the mixing bowls. Instead of a pincer-type
interlock, this uses a newly-developed quick-release fastener
into which the bowl only needs to latch in place. Once the
bowl is in it, a compressed air driven bolt secures the bowl
to prevent it exiting the position prematurely. Changing the
position of a bowl takes just 30 seconds.
Kemper has also based the design of this mixer carousel on
all the standards of the “CleanTec” program. The mixers
have CIP capability, the hood is fully encapsulated, and the
hood contains rotating water nozzles that can also clean the
mixer occasionally if required. A suction system ensures
that the water and cleaning agent disappear again as quickly
as they were input. All the supply pipes and inlet pipe work
have a roof-shaped profile to prevent dust being deposited
on them.
In-store baking ovens
The “little” brother of the richly traditional WP Matador is
called the Matador Store, which as a “history edition” brings
nostalgia into stores in the shape of the white enamel finish
from the Matador’s early years instead of stainless steel or
black facades. The oven is available as a classical four-deck
in-store baking oven for 60 x 40, 60 x 80 or 80 x 60 cm format
baking trays, and has a proofing cabinet below the oven.
Blue control – Remote-Service-Portal
At the iba 2012, WP promises the definitive end of differently structured controllers and their representations on
touchscreens. In future, irrespective of whether they are 왘
© WP
© WP
++ figure 4
IBA
++ figure 5
© WP
++ figure 5
WP-Haton V700 dough divider with an acid-resistant divider chamber
large production baking ovens, bread roll plants, refrigeration
systems or even in-store baking ovens, all the touchscreens
will use the same pictograms, colors and menu items to
guide the operators, without the need for long familiarization
times. At the same time all the machines, ovens and plants
will be equipped so that their controllers are connected via
the Internet to WP’s in-house service and can run a Remote
Service through it.
In the Front Baking area, the pictograms open up an additional
new way for bakers to address customers. The touchscreens
on the in-store baking ovens are twice as big as previously
and are also easily readable on the other side of the shop
counter. As a result the operator control panels are also suitable for point-of-sale advertising.
Hygiene on bread roll plants
In future the Selecta series of bread roll plants will rejoice in
a totally modular construction. Having decided for a basic
module – slit or molded bread rolls – there will be no problems
in expanding the plant at a later date to manufacture other
kinds of bread rolls.
The design of the Selecta Modular has also been made more
hygiene-friendly. Here, special emphasis was given to the
accessibility of the punching cup tools, which are inter-
changeable instead of being permanently installed. When
the hygiene program runs, the punching cups are released
one after another so they can be removed, following which,
the interior space with generous room for access can be
cleaned by vacuuming or brushing out.
The punching cups that have been removed can now be cleaned
outside the bread roll plant, either dry or wet. If they are
cleaned by brushing, the lower surface is also accessible.
However, due to the choice of new construction materials,
they can also be wet cleaned. This can be carried out by hand,
by wiping the punching cups with a damp cloth. Alternatively they can be put into a dishwasher-proof cleaning
container. The punching cups are transported by a transport
wagon from which the cleaning container is transferred into
a cover-type dishwashing machine where they are freed
from dough residues at 40°C. The dried punching cups are
afterwards replaced in the bread roll machine, and the plant
is ready for the next production run.
The interchangeable cutting machine represents another
step in the direction of hygiene. It can also be cleaned outside
the plant. This allows the cup unit to be opened even more
spaciously, and it is then accessible for cleaning. To complete hygiene in the punching area, the flour duster is also
removable. It is cleaned simply by emptying it by turning it
through 180°. When all the modules have been removed, there
is maximum accessibility to the cup unit. The entire plant
no longer contains any felt belts and instead modern plastic
belts are used. There are now hangers with interchangeable
inserts in the pre-proofing cabinet area. These hanger inserts
are changed in the plant. To do this the operator opens the
front wall cladding, removes the insert and installs a fresh
insert. The hanger inserts are available with various support
materials. Polyester felt will continue to be the standard, but
gauze is available as an alternative.
In Munich the WP subsidiary Haton in the Netherlands will
show classical bread lines and a V700 dough divider with an
acid-resistant divider chamber in a hygiene design.
The target groups for this are medium-sized and industrial
bakeries in which rye, rye mixture and wheat doughs are
manufactured. The controlled-pressure volumetric measuring
system of the V 700 is considered to handle the dough structure
particularly gently. Even though the hydraulic unit ensures
++ figure 6
© WP
34
++ figure 6
WP-IB Thermador oven, the indirectly heated tunnel oven with a new energy concept
IBA
++ figure 7
© WP
the freezing people.
++ figure 7
Together with hb-technik, Austria, WP-Ibis offering ist ZPM continuous mixer
in combination with raw materials dispensing
that the divider compartment is completely filled, the dough in it is not compressed too much. In this way the gas bubbles in the dough are not destroyed,
but nonetheless high weight accuracy is achieved. The dough resistance at which
the hydraulic system responds can be adjusted individually to the dough. The
V 700 was developed for use with wheat and wheat mix doughs, rye mix doughs
with a rye proportion of up to 70 %, doughs with a high dough yield and long
bowl fermentation, and doughs with special ingredients such as raisins, dried
tomatoes, seeds and grains. The V 700 adjusts to match each dough, not the other
way round. The divider unit for the new version is manufactured from a special
stainless steel alloy that is considerably harder and more wear-resistant than the
materials previously used. The material has a smooth surface that does not rust
and can be cleaned with water. All the parts that come into contact with dough
can be dismantled easily and washed with water. The machine also has a wagon
that can be used to move the entire discharge conveyor belts including the
collector trays out of the machine and into the washing section to be cleaned.
iba Munich
6 – 21, 2012
September 1
No. 270
hall A1 stand
sh Moscow
Agroprodma
2, 2012
October 08 –1
stand No. 20
pav. 2 hall 1
an
Polagra Pozn
1, 2012
October 07–1
No. 56
pav. 5 stand
lanca
Mafex Casab
2, 2012
Oct. 31 – Nov.
ADVERTISEMENT
Energy-saving designs for tunnel ovens
The Werner & Pfleiderer Group, Dinkelsbühl, Germany, industrial oven builders,
have relaunched their Thermador series of indirectly heated tunnel ovens and
issued a new energy concept at the same time. As a result of their modified construction, the rotors circulate larger volumes of air, so the energy employed is
better used. The circulation speed is variable and can be adjusted to different
baked goods, thus enabling the differing heat transfer rates to be tailored exactly
to the required baking profile, which depends, for example, on how much of a
wheat or rye note the dough has.
Technically a large energy input is needed to generate the steam needed in the
baking process. Therefore in the Thermador the amount of steam is automatically regulated to the product program that is set and optionally even via sensors
in the baking compartment.
The various temperature zones in the oven are controlled individually and are
monitored by the controller. When the temperature in a zone reaches the predetermined set-point value, this is automatically signalled to the burner, which
immediately reduces the energy supply.
The temperature profiles can be influenced via the positioning of the burner
zones, which improves energy efficiency. Due to the oven’s modular construction,
burners can be installed in exactly the zone in which most heat is needed by the
client’s main product. For example, if that product is wheat bread, it must first of
all form a large volume, during which it needs less heat. This is why the burners
were positioned only in the second or third zone. Nevertheless it would be possible
to bake rye bread as a secondary product, which needs a large amount of heat at
the very start of the process. A decreasing baking curve, i.e. the highest baking
compartment temperature at the start of the baking phase, can be guaranteed by
using the maximum revolution speed of the circulating blower.
왘
www.heinen.biz
IBA
The Thermador with “Smart Baking-Program” is available
in various models, depending on the product spectrum to be
baked. However, “Spectra” infra-red technology can also be
installed in all variants. This shifts the thermal radiation
into the infra-red region. The goods being baked reach the
required core temperature faster, which shortens the baking
time and saves energy. This again also has a beneficial effect
on product quality because it avoids unwanted surface
browning, the baked product retains higher moisture content
and has a better volume. The Thermador’s transport systems
are also variable: as a standard variant with a wire mesh belt
for all baked products, as stone (stone slab belt with double
belt heating) for emphatically crusty baked goods, and as a
grid (chain-guided carrier frames) optimized for pan breads.
The latest variant in the Thermador family is a toasting oven
for zwieback or skorpor (Swedish rusks).
Another entirely new Thermador is the Quatro, a variant that
comes close to being an impingement oven, but is also entirely
usable for baking in pan clusters. Up to now so-called duozones were installed in the continuous oven from Tamm that
was intended for this purpose, in which heat distribution
was ensured by two vertical air flows. The number of vertical
air streams has now been increased to four, which ensures
high air velocities and very rapid circulation of baking compartment air. At the start of the line, especially with pan
breads, this ensures that the dough rises well in the pans,
and the pan receives sufficient heat from below. A zone of
this kind can ensure additional browning at the end of the
line. This is why the Quatros are offered mainly for baking
pan breads, pizzas, pita breads and flatbreads.
WP IB will also show for the first time live in Munich all the
variations of proofing technology from belt proofing cabinets
++ figure 8
Kemper’s mixer carousel consists
to hanger, hollow and step proofing cabinets, so clients can
see the differences and touch them. Application examples
will also be presented by videos.
Something is also happening at WP IB in the conti-mixer
area: together with the hb-technik GmbH in Schwanenstadt,
Austria, the Tamm company is offering a combination of
raw materials dispensing and their ZPM continuous mixer
that regulate the entire dough manufacturing process via a
shared controller. This combination is usable mainly for
toast-bread, zwieback, soft rolls and long-life baked goods.
New business areas
+ Blue Value Service – a whole lifetime service program
consisting of checkups, remote monitoring and remote
maintenance, the alerting of service personnel and a service
manager to plan and organize cleaning and maintenance
work.
+ WP Green - The new “WP Green” business division deals
with these topics relating to the energy management of
bakeries. In practice that means, for example, the use of
stratified heat storage devices in combination with ovens
to make businesses measurably more energy-efficient. For
example, an intelligent multi-deck oven controller allows
the individual ovens to move to standby when there is a
pre-defined period of idling. The controller is designed so
that it is possible to say, manually or in the context of a
control network, when the oven should heat up again and
when it should then be available at the required operating
temperature.
The group will also present for the first time at the iba complete
solutions for baking stations at gas stations, in supermarkets
or in cafes under the new label WP Food. +++
++ figure 8
of at least three and a
maximum of seven stations and
has CIP-capability
© WP
36
Mixing at the highest level. Whether you mix powders, flakes, or granular materials
– the horizontal mixing process of the Bühler Sanimix is synonymous with an
unrivaled homogeneous product mix within extremely short mixing and discharge
times. Available in the form of a paddle- or chopper mixer, the Sanimix is optimally
equipped to handle both dry and specialty mixes. The unique geometry of the
mixing trough and tools ensures a consistent and repeatable mixing accuracy.
And needless to say that all this comes in the tried and true, rugged Bühler design
of sanitary stainless steel. Sanimix – mixing at the highest level.
www.buhlergroup.com/sanimix
Bühler AG, Grain Milling, CH-9240 Uzwil, Switzerland, T +41 71 955 11 11, F +41 71 955 66 11
[email protected], www.buhlergroup.com
IBA Munich 2012
Hall B5, Booth 480.
Sanimix MRMA.
Highest mixing
performance.
Outstanding homogeneity. The
perfect match between the mixing
trough and the mixing tools ensures
homogeneous mixing results.
Ultimate sanitation. Stainless steel
and an inner surface without gaps
satisfy the most rigorous sanitation
standards.
Tailor-made. Four machine sizes,
two surface finishes, and numerous
options allow an optimal adjustment
to individual requirements.
High throughput capacity. High
mixing capacity thanks to extremely
short mixing and fast discharge times.
Easy maintenance. Easy to operate,
easy to clean.
Innovations for a better world.
IBA
More freedom of choice
THE KÖNIG MASCHINEN GMBH, GRAZ, AUSTRIA, WILL EXHIBIT NEW PLANTS IN ALL FOUR KEY
SEGM E NTS OF ITS PRODUCT RANGE AT TH E I BA TH IS YEAR
++ figure 1
2 STAN
D 470
© König
HALL B
++ figure 1
3D picture of the Menes 600
making the weighing bars on the drum interchangeable with
each bar being designed for a specified weight range. The
drive for the punches, also interchangeable, that press the
dough into the recesses is attached to both sides and is also
provided with a new drive technology borrowed from automobile manufacturing which ensures guaranteed identical
pressure across all the rows.
Dividing the dough is followed by round moulding, and
here again the developers in Graz have had some new ideas.
The diameter of the individual shaping cups has been made
larger than in previous plants, so the dough ball travels
through a longer shaping distance before being transferred
At the iba three years ago the company from Graz presented a high-capacity dough dividing and moulding
machine, the Industrie Rex III Hyper, that is fully wet-cleanable. This year it is followed by another new development
for industrial bread roll lines in which on the one hand great
value is placed on high weight accuracy combined with gentle
dough handling, and on the other hand the hygiene and
maintenance friendliness achieved with the Industrie Rex
Hyper are largely retained. The Industrie Rex III AW (where
AW stands for “Accurate Weight”) achieves an hourly output
capacity of up 19,200 units in eight rows. Integrating additional
rows is not a problem. Precise weighing is achieved firstly by
+
++ figure 3
© König
++ figure 2
© König
38
++ figure 2
++ figure 3
The Menes dough sheet production system TEM
The dough sheet former of the Menes
39
IBA
© König
++ figure 5
© König
++ figure 4
++ figure 4
++ figure 5
The Industrie Rex-AW
The Combiline compact
into the pre-proofing cabinet. This allows the pressure on the
dough piece to be smaller, and the dough structure is therefore protected. The moulding eccentric is automatically
adjustable. The output spreader belt on the Industrie Rex III
AW is directly driven, which avoids belt slippage.
In the interests of hygiene friendliness, all the drive units of
the functional units that come into contact with dough are
systematically encapsulated. Large stainless steel operating
and maintenance doors that can be removed from their
hinges enable quick access for cleaning and servicing. The
drum with the weighing bars can be withdrawn completely
from the machine to take it to a washroom when necessary.
The transfer belt between the weighing and rounding drums
can be folded up from both ends to clear the way for cleaning
quickly and easily. The dough oiling unit is housed behind
smooth covers, and the entire divider-rounder machine is
mounted on legs 300 mm high, so it is also possible to clean
under the machine without any problems.
Also new in the product range is a modularly constructed dough
sheet plant in the Menes series with a working width of 왘
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» Engineering your success «
+
+
+
+
=
innovate
Clear solutions
Hall B4
Booth 350
The strict observation of stringent hygiene and safety regulations is essential for the
food industry. In order to fulfill all requirements, high quality systems are required.
Zeppelin Reimelt GmbH
Messenhäuser Str. 37 - 45
63322 Rödermark , Germany
[email protected]
www.zeppelin-systems.com
As the world-wide leading plant engineering company for the handling of high quality
bulk materials and liquids, we are in the forefront in this sensitive environment. Our
innovative system solutions set standards in the field of hygiene and safety for the
production of food.
IBA
++ figure 6
© König
40
++ figure 6
The rack oven Roto Passat
600 mm, targeted mainly at medium-sized and
larger artisan workshops. The plant processes
both soft and firm doughs to yield a dough
sheet. The novel feature of this variant is the
TEM dough sheet production system which
creates a dough sheet that is both uniform
and structurally homogeneous. The dough
funnel, which accepts the dough batch from
the lifting tipper or from the belt, operates
without oil. Its sidewalls consist of conveyor
belts that guide the dough gently and slowly
downwards onto the first conveyor belt. The
dough sheet formed there, still rudimentary,
is shaped as it passes onwards through two
further funnel systems with different roller
systems to yield a dough sheet that is both
stress-free and homogeneous in its weight,
before being carried forward to the satellite
roller unit.
The satellites in the Twin Sat 600 rotate at approximately the same peripheral speed in the
opposite direction to the planets so the dough
is neither stretched nor crushed and instead
the thickness of the dough sheet is reduced by
rapid tapping movements. The advantage of
this method lies in the fact that the dough is
spared stress of any kind, and after being
rolled out it can be cut, shaped and processed
without any further dough resting time.
Thanks to the modular construction, there
are no problems in extending the dough sheet
plant by adding moulding, cutting and seeding modules. A new feature is a special round
moulder unit developed from the classical cup
shaping plant which is able to operate at up
to 33 stroke/min. With five-row operation this
cor responds to an hourly output capacity of
9,900 round dough pieces for bread rolls.
Another new member of König’s product range
at this year’s iba is a compact machine for
small baked goods in many variants, called the
“Combiline Compact”. This bread roll plant,
with an hourly capacity of up to 9,000 items,
is extremely versatile and can deliver both
round, round-stamped, long-rolled-pressed
and long-rolled-cut products, and can do so
at optional working widths of 600 or 800 mm.
There is a choice between the Basic Rex, Classic
Rex or even a Classic Rex Futura as the dough
dividing and rounding machine. The dough
pieces are allowed a pre-proofing time of
8.5 min before being stamped, or 4 min if they
are to be long-rolled, which is done by a builtin long-rolling station. The long-rolled dough
pieces are given a further 4.5 min rest after
shaping, before they reach the stamping or
cutting station.
The stamping unit with reversible cups switches
at the push of a button from round bread rolls
to stamped or long-rolled, so a product change
takes virtually no time at all. The scrabbler at
the end of the machine can be supplemented
with a pull-out drawer to make work easier,
and of course there is also a bypass that brings
the dough balls directly from the dough dividing and rounding machine to the depositor device.
König has also redesigned the Roto-Passat
rack oven, paying great attention to hygiene
and maintenance-friendliness. The turntable
in the oven, normally a real “dirt trap”, can be
easily removed to allow cleaning underneath
it as well. The door seals are easy to change
without tools, and a “door-in-door” system
gives quick, easy access to the glazing and
lighting.
In addition to hygiene, the subject of energy
saving was also on the oven developers’ to-do
list. They have given the Roto Passat a new
battery of heaters, which according to König’s
CEO Richard Häusler, “will set new standards
for the energy efficiency of rack ovens.” +++
Cake/Pie production lines
Turn Key
Projects
Waffle production lines
TROMP GROUP
Pizza production lines
We proudly introduce to you the new Tromp Group. From now on Tromp
Bakery Equipment, Vanderpol Baking Systems and Den Boer Baking Systems
will join each other in one group as a joint venture.
CONCEPTS AROUND PRODUCTS
With our three company’s we bring years of knowledge and experience
together in order to give a wide range of total bakery solutions to you as our
customer.
Pastry production lines
STAND ALONE EQUIPMENT
Within the Tromp Group every company has his own speciality and stand
alone equipment, while together we offer turn key solutions.
UNIQUE POSITION
With this joint venture we are sure that we have created a unique position in the
bakery industry. A position which gives us possibilities to give an extra impulse to you as our customer and to the total market which we are working in.
Bread production lines
MORE INFO: WWW.TROMPGROUP.NL
IBA
System solutions for all areas
M I W E M I C H A E L W E N Z G M B H , A R N S T E I N , G E R M A N Y, I S S H O W I N G A W E A LT H O F I N N O V AT I O N S
AT TH E I BA U N DE R TH E MOTTO “BAK I NG CO M PE T E NCE HA S MANY FACE S”. I N ADDIT ION TO TH E
TO P I C O F E N E R G Y S AV I N G , H YG I E N E A L S O P L AYS A N I M P O RTA N T RO L E I N T H E N E W D E V E LO P M E N TS
++ figure 1
HALL A
2 STAN
D 511
© Miwe
42
++ figures 1+2
A self-regulating closure flap in
the rack oven’s flue gas pathway
ensures improved flow properties
The plant constructor Miwe will give a
systematic presentation of a variety of
baking worlds at the iba. For example, all the
baking stations will be presented on the stand
in the context of these worlds. The innovations in this product group include:
+ The new MIWE cleaning control 3.0 cleaning
system for the MIWE aero. According to
company information, the ecological cleaner
is easy to fill and guarantees good washing
results. The low consumption of electricity
and water ensures hygiene and energy saving,
with sustainable operation at the same time.
+ The proofing cabinets in all the baking stations are easy to clean due to an inner shell
– a so-called rounded softline.
+ The MIWE aero e+ is a baking station in which
optimized steaming equipment ensures an
even more uniform flow around the goods
being baked. This also improves the energy
yield. In addition there are new electrical
components and improved insulation.
+
In the rack ovens area, MIWE’s designers
have made further improvements in the MIWE
roll-in e+ to increase its energy efficiency.
The optimized model of the oven now has
even more cards up its sleeve. One example is
the MIWE eco:wing. This is a self-regulating,
purely mechanical and thus correspondingly
wear-free, maintenance-free closure flap in
the flue gas path. The company reports that
due to its special shaping and arrangement,
the flap has a beneficial effect on the flow
properties of the combustion gas flue. Heat
transfer in the heat exchanger is better, and
the overall efficiency of the system is improved
compared to the predecessor system. The new
MIWE eco:wing performs the function of a
conventional flue gas damper at the same
time and closes the flue gas duct when the
baking oven is not in operation, thus retaining
heat in the system. The developers have also
optimized the steaming equipment of the
MIWE roll-in e+. In the first version of the
IBA
++ figure 2
++ figure 3
++ figure 3
The new baking station with
MIWE roll-in e+ this had already been repositioned on the
rear wall of the oven system, directly behind the heating
register. In this way the heat from the flue gas is also used to
heat up the steaming equipment, which is reflected in distinctly lower flue gas temperatures and a correspondingly
© Miwe
© Miwe
optimized steaming equipment
higher degree of firing efficiency for the baking oven system.
The new roll-in e+a now uses steamer equipment made of
grey cast iron elements. This has a rougher surface and
therefore also a larger surface area for the same mass. This
ensures an improvement in heat transfer. Thus on the one 왘
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Meet us at the iba 2012
Hall A1, Booth no. A1.380
Our Strength: Rolls.
Rosendahl Maschinen GmbH, A-8212 Pischelsdorf, Schachen 57, phone: +43 3113 5100 160, www.back-tech.com
43
IBA
++ figure 4
© Miwe
44
++ figure 4
The multi-deck oven’s energy use
has been redesigned, and it now
utilizes energy better
hand energy is saved, and on the other it produces even softer, more saturated steam. The
company offers a special heat storage wall as
an option. This is designed to limit burner
load peaks, because the storage wall acts like a
heat buffer and has a balancing effect.
Energy aspects redesigned
Two decisive energy aspects of MIWE’s ideal
gas-fired multi-deck baking oven have been
redesigned. For example, in the new MIWE
ideal T e+ the developers have improved the
precision of the temperature control and have
increased the performance of the steaming
equipment. The purpose of this is to improve
its baking properties, and in addition the
oven now makes around 15 % better use of the
energy used. Its power consumption has been
decreased by 20 % while at the same time improving the steaming capacity. The new, more
precise burner control also allows operation
with much more flexible temperature profiles.
The topic of energy also plays a major role in
relation to the subject of energy. The MIWE
GVA fully automatic proofer has been further
improved, and the new universal climate
compartments are now called GVA e+. There
are technical improvements in the motors,
valves, lighting and controller which allow
further energy savings to be achieved. For
example, the energy input for the evaporator
blower is 43 % less and the energy required
for lighting is reduced by as much as 77 %,
while the performance coefficient of the refrigeration plant has risen by 13 % at the same
time. In addition the company will show a
fabrication concept in a single package, which
MIWE calls smart engineering. On the trade
fair stand they will also show application examples of how visitors can imagine successful
fabrication planning, e.g. of a bakery or production line. +++
+DOO%6WDQG
OUR PROMISE IS IN THE PROCESS.
When you partner with Reading Bakery Systems you’re
working with one of the world’s most experienced
manufacturers of process solutions. Our history of
innovation, reliability and problem-solving in unique
situations extends back over 118 years.
Our research-based solutions are driven by the needs
of our customers. And our brands – Thomas L. Green,
Reading Pretzel, Exact Mixing and Reading Thermal–
deliver efficient, sanitary and dependable equipment.
Additionally, our Science and Innovation Center
allows you to test new products, formulations,
equipment and processes, and the latest in food
science and market appeal. This unique facility is
a licensed food plant where you can confidentially
develop and test new product ideas – in a real
world environment.
So, for the critical support that guarantees success,
the answer is Reading.
(01) 610.693.5816 | READINGBAKERY.COM
IBA
Innovation fireworks
I N A F EW DAYS, I BA 2012 WI LL OPE N ITS DOO RS AT TH E MU N ICH FAI RG ROU N DS.
VISITORS SCHEDULE IS PRETTY TIGHT ALREADY
widest possible weight range. A patent application is currently
in progress for this special design. The divider pistons can
be changed and the weight range thus altered within a short
machine shutdown. In addition the ease of removal of the
piston units also guarantees that the inside of the divider
drum is easy to clean.
The portioned dough pieces from the divider drum are transferred directly into the drum molder unit, which has nine
honeycomb positions arranged around its circumference to
achieve a longer molding time. The novel arrangement of
the framework design ensures that the molding belt and
honeycomb drum can be changed quickly and easily.
A conventional frame design or machine frame has been
done away with completely on the divider-rounder machine.
The machine’s two side panels and the main chamber baseplate
take over these functions and also ensure complete separation
between the dough area and the drive area.
++ BackTech, ROSENDAHL Maschinen GmbH
Hall A1 Stand 380
The bakery machine builder BackTech, part of the Austrian
Rosenthal Group, will show for the first time at the iba the
prototype of a new industrial divider-rounder machine and
a bread roll plant with a built-in long roller.
The divider-rounder operates at 33 to 50 cycles/min and covers
a weight range of 10 to 350 g. The divider pistons in the divider
drums are correspondingly interchangeable. One focus of
the development was on weight accuracy and gentle dough
++ Backtech
++ Fortuna Maschinenbau Holding AG
handling. Both are achieved through a directly actuated cutter knife and by monitoring the force acting on the dough.
The dough is fed into the machine via a special plastic hopper
positioned over the divider drum. The hopper is designed to
pivot out easily for cleaning. The main compartment below
it, which accepts the dough into the divider piston for portioning, is bounded at the top by a moving cutter knife that
cuts off a new dough batch at every machine cycle.
This independently driven, servo-controlled knife cuts off a
quantity of dough that depends on the respective recipe settings and dough texture, thus forming the upper limit of the
main chamber, but to handle the dough gently it allows backflow of dough into the hopper. All the components of the
main chamber can be removed easily and quickly, allowing the
components and the empty main chamber to be cleaned easily.
The main piston is directly driven by a special variable-speed
motor with a special output gearbox. The filling pressure exerted on the dough by the main piston and by which the
dough is filled into the divider piston is thus adjustable via
the recipe and also controls itself automatically in relation
to dough replenishment, which guarantees a uniform filling
pressure and gentle dough handling.
Row blocking on the machine is arranged via rows that can
easily be switched off. The machine’s completely newly designed divider drum allows the plant operator the use of the
Hall A2 Stand 131
Fortuna Maschinenbau Holding AG, Bad Staffelstein, Germany, classifies its dough dividing and moulding machines
according to capacity classes and row numbers. The Primus
++ Fortuna
© Fortuna
© Backtech
46
Pro offers continuously adjustable weight ranges between
30 and 100 g/piece in four to six rows, with an additional
option for 30 to 130 g/piece, and hourly capacities from
5,300 to 8,000 pieces depending on the number of rows
There will in the future be new versions in the Magnus series
for capacities above 9,000 pieces/h.
The Primus Pro series in its four-, five- or six-row versions,
with an hourly capacity ranging from 5,300 to 8,000 units has
been entirely redesigned, with value placed on clearly distinguishable modules. This has achieved complete separation
between the drive and the dough areas. A large door clears
47
IBA
the way to the dough-handling area, which considerably improves accessibility. Individual modules can be dismantled
and taken away for wet cleaning, or just removed for maintenance. For example, design of the entire pre-divider allows
it to be swung out and removed, as can the associated flour
duster and pressure plungers, which are made of plastic and
are easy to dismantle and wash. The moulding speed is
electronically adjustable, and the deflection of the rounding
eccentric can be adjusted to match the required moulding.
Fortuna will be represented in future in the top capacity
class from 9,000 (6-row) through 24,000 (8-row) to 30,000
(10-row) units/hour with the Magnus Superior dough
dividing and moulding machine. This divider-rounder
machine has also been designed in accordance with the new
hygiene- and maintenance-friendly principles. The doughhandling area is completely separated from the drive. Here
again, two large doors simplify access for cleaning and
maintenance. The dough division chamber is quick and easy
to access by removing the washable hopper lid and removable plastic measuring piston. The chamber drum is also removable and washable. The moulding belt flour duster can
be dismantled easily, and the moulding belt can also be
changed quickly and without tools thanks to clamping levers
and quick-release fasteners. When the new moulding belt has
been put on, it is tensioned automatically, so that moulding
always takes place with the optimum belt tension.
The entire carriage with the spreader belts can be moved out
of the machine and taken for cleaning, so there is also easy
access from this side of the machine. An adjustable height
version of the spreader belt version can also be ordered if
required. Fortuna also supplies an optional pressure roller
on the spreader belt.
++ Ernst Böcker GmbH & Co. KG
Hall B 4 Stand 561
The Ernst Böcker GmbH & Co. KG, Minden, Germany, is
expanding its marketed range by adding solutions and concepts for gluten-free baking 2012. For the market launch, the
© Böcker
++ Böcker
company is offering four 500 g bread loaves: flaxseed bread,
golden linseed bread, multi-seed bread and potato bread.
There are also bread rolls. Cakes and fine pastries are at the
development stage. All the baked goods are manufactured
using gluten-free sourdoughs.
++ PS mako GmbH
Hall B1 Stand 371
The PS mako GmbH, Michelbach an der Bilz, Germany, will
present its manufacturing programs for the bread and baked
goods industry. In addition to semi- and fully-automatic
Clipfix closure machines, the company will also show fully
automatic bread packing machines. Three model series will
be shown for packing unsliced bread, sliced bread and toast
bread. Capacities are 35, 50 and 70 packs/minute, depending
on the model series. A fully automatic bread packing machine
with a front-mounted slicer will also be shown. This plant
can be expanded with various peripheral systems such as
conveyor belts, check-weighing machines, X-ray systems,
cluster packing etc.
++ Bizerba GmbH & Co. KG
Hall B3 Stand 524
The Bizerba GmbH & Co. KG, Balingen, Germany, is showing a new hygienic weighing machine at the trade fair. The
weighing machine is designed so that water cannot accumulate and can drain away easily. The base frame has many
curves, and consequently dirt cannot collect at joints, edges
++ REGO HERLITZIUS GmbH
© Bizerba
++ Bizerba
and corners. The weighing machine complies with the hygiene guidelines of the European Hygienic Engineering and
Design Group (EHEDG) and conforms to Protection Class
IP69k, i.e. it is protected against dust, powerful water jets
and aggressive cleaning agents.
Hall B5 Stand 321
The REGO HERLITZIUS GmbH, Haan, Germany, is showing
new bread slicers and continuous strip bread for the industry
and industrial bakeries. For industrial needs, the company
has two highlights on the trade fair stand: the Planet 3000
and SBA 3000 bread slicers. With up to 600 rpm and twolane use, the SBA 3000 has an output capacity of up to 90
bread packs in the sliced bread area. Thanks to optimized
oiling, which allows a product-dependent dosage quantity,
the plant can be specifically programmed for each product,
thus enabling minimum raw materials usage.
The machine builder is breaking completely new ground
with a new planetary drive for the circular knife. By decoupling the mechanism via an additional drive, this type of drive
offers the ability of preselecting an individual cutting speed
for each bread product. The new portioning device with 왘
IBA
servo-drives, for which a patent application has been filed,
allows almost uninterrupted pack portioning, and considerably higher production capacities can be achieved through
overlapping intelligent processes. This novel development is
rounded off with a very compact construction design with a
small footprint.
Rego has developed the Format Series 3000 strip bread
machines exclusively for industrial and major factories. They
are used for wheat, mixed and rye doughs with dough strands
of 2 x 1,450 mm or up to 3,000 mm of usable length, and can
shape up to 360 dough strands per hour. The special Teflonized
extrusion unit is fitted with a sliding closure for accurately
weighed dough division. The construction of the extruder is
pivotable and adaptable to enable optimum access for maintenance and cleaning. Screwed/bolted fastenings are largely
© IsernHäger
++ IsernHäger
technology, fermentation optimization, intelligent controllers,
time and cost saving and quality. On all of the days of the
trade fair, visitors can experience a program presented by
pre-dough experts with solutions in the areas of technology
and engineering for the industry, organized chain stores and
the artisan craft.
++ Rego
++ Boyens Backservice GmbH
Hall A3 Stand 110
The Boyens Backservice GmbH, Ibbenbüren, Germany, has
supplied the tried and tested KEG multi-path spray concept
for 17 years. It allows the client to apply release agents economically and without any mist. Boyens has now invested in
a new release agent filling plant to guarantee more hygiene,
quality, efficiency and time savings. The client profits from
the plant’s improved flexibility and efficiency, which in return
means consistently high product availability and short delivery times. The use of the new KEG spray-gun rounds off
the product range through flexibility and the latest nozzle
developments allow for even more economical consumption
of the release agents.
왘
++ Boyens Backservice
© Rego
avoided in the dough handling space, because residues can
accumulate on them. Load cells under the extruder control
the flow of dough to the preset nominal weight. The dough
is extruded gently by a degressive screw drive. Controller
technology synchronizes the extrusion speed to the speed of
the conveyor and downstream roller table. The integral
vacuum assistance avoids dough strand breaks. Separately
selectable top and bottom flour dusting can be switched on
when required.
++ IsernHäger GmbH & Co. KG
Hall A1 Stand 360
The IsernHäger GmbH & Co. KG, Isernhagen, Germany, is
presenting at the Innovations Forum on topics about pre-dough
© Boyens Backservice
48
1
2
3
4
MIWE makes baking simple.
iba, Munich.
Hall A2,
Stand 510/511.
Be our guest.
1
Plug‘n bake: convection and deck ovens for all kind of doughs even frozen pieces, for roasts, casseroles and much
more, 3 –18 trays. 2 Professional baking on a small footprint: Rack ovens with rotary table or resting on stone plates
– fired by oil /gas or heated electrically. For all products and processes and for all conventional baking tray sizes.
Baking area 1 to 52 m2. 3 The coolest way to protect your products: Fully automatic systems that produce quality
products. Flash freezing, cooling, proofing, proofing retardation and storage – from -42° C to +45° C. 4 Speed, Speed,
Speed: Fully automatic baking. In any size. With the highest level of flexibility and the greatest variety of products.
And all that 24 hours a day. Just visit www.miwe.com
MIWE Michael Wenz GmbH · D-97450 Arnstein · Phone +49-(0) 9363 - 680
IBA
From its tray-sealer product range, MULTIVAC is showing
the semi-automatic Traysealer T 250, which seals 16 to 20
trays/min. With its generously sized, variably divisible tray
drawer, the flexible T 260 is suitable for packing both confectionery articles and small portions.
The company is giving the market new impetus with the
MYLAR® BAKE concept. This involves deep-draw thermoformable films developed specifically for the preparation of
baked goods in ovens at up to 218 °C. The material, which
was developed by DuPont Teijin Films, is available in Europe,
Oceania and on the American continent exclusively from
MULTIVAC. MULTIVAC also supplies suitable packing
machine concepts.
++ DuPont de Nemours (Deutschland) GmbH
Hall A1 Stand 320
DuPont de Nemours (Deutschland) GmbH, Neu-Isenburg,
will present DuPont Industrial Bakery Solutions (DIBS) on
its stand. By means of a consistent, continuous quality assurance system, the aim of this initiative is to provide large
++ DuPont
++ Baker Perkins Ltd.
© DuPont
bakeries with a customized, high-quality non-stick sealing
system for baking pans under the Teflon® brand. The focus of
the DIBS initiative consists of special non-stick sealing systems
for baking trays and pans that are designed to guarantee
easy, reliable release of the baked products from the pan. The
company provides eight different Teflon® coating systems.
The initial focus is on bread, croissants and fine pastries.
These are divided into four groups: DIBS F: for flat trays or
trays with small depressions, e.g. for bread rolls or croissants,
DIBS D: for deep-drawn molds, e.g. for pan or sandwich
breads, DIBS P: for perforated, flat or corrugated trays, e.g.
for baguettes, and DIBS S: for special applications such as
pizzas or pretzel baking trays.
Hall A6 Stand 155
Baker Perkins will launch an upgraded and extended range
of Accurist dough dividers. The new Intelligent Dough Weight
Control system reduces the average dough piece scaling
weight by adjusting the divider in real time to compensate
for changes in dough density. The system reacts to the
gradual changes that occur over the life of a batch as well as
the sudden changes that occur when a new mix is dropped
into the divider. Working in conjunction with feedback from
++ Baker Perkins
++ MULTIVAC Sepp Haggenmüller GmbH & Co. KG
Hall B1 Stand 440
The MULTIVAC Sepp Haggenmüller GmbH & Co. KG,
Wolfertschwenden, Germany, is showing a variable deepdraw thermoform packing machine, the Model R 225, that is
designed for the medium capacity range and packs baked
goods under vacuum or in a protective gas atmosphere. Due
to its modular construction, the R 225 can easily be adapted
to customized requirements and applications. The machine
is also highly flexible with regard to the use of packing materials, cutting systems and formats. Both the outer surfaces
and the machine interior are hygiene-optimized and have a
fully wash-down capability. Easily removable side claddings
and generous cleaning spacings enable all areas of the machine
to be cleaned thoroughly. The R 225 can be integrated into
automated packing lines.
To label thermoform packs efficiently after the sealing process, the MULTIVAC subsidiary MULTIVAC Marking & Inspection is showing the Type MR625 OP cross-web labeling
machine. It labels directly onto the pack’s surface film, and
is designed for product markings that change frequently.
© Baker Perkins
50
the checkweigher, the system maintains dough piece weights
within tighter limits reducing giveaway and enabling the
target weight to be reduced. The dough divider also includes
a new oiling system with improved performance. An upgraded
filtration system keeps the circulating oil clean while a new
pumping and dosing arrangement ensures it is delivered
accurately and consistently. Improved oil pathways in the
ram provide reliable distribution enabling the divider to run
for extended periods. Maximum output has been raised
from 9,000 to 10,800 pieces/h.
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IBA
Organic”, which according to SternEnzym keeps the crumb
of packed baked goods such as sandwich toastbread soft for
longer. In Munich, Sternchemie will show a newly developed
sunflower seed lecithin that can replace soya lecithin, and
SternFlow, a liquid lecithin which at the client’s request can
be manufactured from sunflower seeds, rapeseed or soya.
Herza’s presentation will include micro-chocolate droplets,
and the youngest member of the Wywiol family, OlbrichtArom, will present its flavorings range for the first time.
++ Buhtz Food Tech GmbH & Co KG
Hall A3 Stand 590
The North German plant constructor will present for the
first time in Munich a conveyor belt plant for apricot glaze
and fondant so that baked goods can be decorated in a continuous process in a single procedure. The baked goods are
++ Buhtz Food Tech
++ Wachtel GmbH & Co
loaded by hand, sprayed with apricot glaze as a first step,
and then coated with fondant under a wave box. The wave
box can also be used for striped patterns by pulling out a
slide. The supply modules for the apricot glaze and fondant
can be decoupled from the belt unit. This considerably simplifies cleaning, and these modules can also be connected
separately to heat them up. In both cases the raw material is
circulated so that none is lost. Special equipment also allows
fat glaze and icing to be processed. A dry module is available
as an option. The plant, which has a working width of
400 mm as standard can be expanded at any time due to its
modular construction.
++ Stern Wywiol Group
Hall B5 Stand 461 and 424
The Stern Wywiol Group will present itself at the iba 2012 as
six of the eleven specialist companies, including Mühlenchemie, DeutscheBack, SternEnzym and Sternchemie, Herza
Schokolade and OlbrichtArom.
The current innovations from Mühlenchemie include the
EMCEbest WA series, enzyme-active ingredient compositions
that can be used as a substitute for guar flour in the production of bread and rolls. According to Mühlenchemie
they increase water absorption, improve stability during
dough preparation and increase the volume of the baked
goods. They are also available in a Clean Label specification.
At the iba, DeutscheBack will show a 50 % baking mix to
manufacture high protein content breads and a baking mix
with a high content of the soluble fiber beta-glucan. SternEnzym will bring along new enzymes for bread and small
baked goods manufacture that can be used as emulsifier
substitutes. The highlights will include “Sternzym Fresh
Hall B5 Stand 110
Wachtel will present the COLUMBUS 9-hearth multi-deck
oven with Triomat technology at the iba 2012. The oil-fired
or gas-heated oven bakes in three different temperature
zones. The baker has several application possibilities on a
baking area of approx. 44 m²: he can bake with three different temperatures in the oven, and each hearth group can be
the hottest. In mono operation with the Triomat technology,
the baker loads three hearths in sequence, and the baking
curve is governed by the hearth that is started first. The result is an almost identical baking profile for the entire hearth
group. After that the next hearth group is loaded and restarted with the program for the first hearth group or a different program. There is a matching automatic oven loader,
the “Comfortlift”.
The Hilden company will also exhibit in Munich the new
“Cult” in-store baking oven with a black design and goldcolored handles. The oven is fitted with a steam generator
from Wachtel’s Profi-Oven series, and as a module it fits the
Piccolo in-store baking ovens.
++ Wachtel
© Wachtel
© Buhtz Food Tech
52
The Piccolo, which will be shown in Munich, has a new
shutter frame from which the oven pane can be pulled out
without using tools, and pushed back in again after cleaning.
All the hearth controller columns also have a glass covering.
In 2009, the baking oven manufacturer had already exhibited
a rack oven heated with wood pellets, although it does not
produce wood-fired oven bread because the baked goods do
not come into contact with the fire or combustion compartment and consequently cannot develop any wood-fired 왘
© FRITSCH AD_BAGUETTE_GB01_01_09
The start of a good day
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the day. At the breakfast table, to be exact.
ly free of separating oils, and in every conceiv-
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able shape and size. Punched, rolled or cut. Long
your rolls, well, let’s face it: you are a master of
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IBA
modular belts in the Prolink line: e.g. the FullSeal Transilon
belt, which provides closed belt edges due to a special weave
structure without additional sealing, or the SmartSeal belt
edge sealing for textile conveyor belts. They will also show
elastic belts with homogeneous construction for small-format applications, e.g. spreader belts for divider-rounder
machines or for weighing and labeling plants. These are
used particularly in dough processing, where the available
take-up distances are only very small or non-existent. Frayfree Transilon belt types will also be on display where the
structural design reduces the fraying out of belt edges and
thus contamination of foodstuffs.
baking oven flavor. In the Wachtel oven, COMPACT F rack
ovens are now supplied in pairs from a single pellet heat exchanger. The first oven is heated by air heated by the exchanger, and the second oven by the hot exhaust gases
formed by the operation of the heat exchanger. According
to Wachtel, the patented system is said to achieve considerable energy savings in practice. The company itself says that
in this way it achieves an efficiency of 100 %.
++ Heinen Freezing GmbH & Co. KG
Hall A1 Stand 270
The Varel company will exhibit at the iba an arctic a6 spiral
system on which many applications and design variants can
be demonstrated. The selection of systems includes the compact, a spiral system pre-mounted on a frame for cooling
++ Heuft Thermo-Öl GmbH & Co KG
and freezing as a single tower, its versatile, flexible brother
the arctic, which is available in many sizes and design and
layout variants, and the acticool, a spiral system for precise,
hygienic, gentle active cooling under clean room conditions.
The proofline will also be there, a spiral system with a precise multi-zone climate for continuous proofing, with various
belt widths and deck spacings as well as different options for
medium to large capacities.
Heinen will also bring three new developments to the trade
fair. Hygienic cabling is an option in which all the cables from
the consumer equipment are brought out of the insulation
housing via the shortest route in the “single cable layering”
method and are laid outside of it in open stainless steel
channels with spacers in such a way as to enable easy, hygienic cleaning. The second innovation is a program to reduce
the energy consumption of chiller and freezer systems that
combines a series of individual improvements including
regulating the air velocity by using controlled frequency
blowers, or a self-optimized thawing/defrosting management
system for sequential thawing/defrosting. The third option
in Heinen’s bunch of innovations is an automatic state monitoring tool for the entire system.
++ Forbo Movement Systems (formerly Siegling)
Hall B6 Stand 360
At the iba in Munich, the company from Hanover will show
its product range of FDA-, EU- and USDA-compliant plastic
Hall B 6 Stand 451
On a stand area of 340 m², the baking oven builder from Bell
will show among other things a further development of the
biomass boiler. The focus in the oven product range is on
the topic of “baking on stone”. Various baking systems for
baking on stone will be displayed. For the VULKAN ThermoRoll® product range this starts with solutions for individual
plants and extends to the semi-automatic or fully automatic
loading of VULKAN Thermo-Roll® oven systems. In addition,
the Vulkan Thermo-Roll® will appear in a new visual outfit.
As an alternative to a large oven plant, Heuft will show the
VULKAN VATO multi-deck oven with 12 hearths and a
loading plant, and for in-store baking the Eifel oven builder
will present a retro-look VOE multi-deck oven model heated
by thermo-oil.
++ Heuft
© Heuft
++ Heinen Freezing
© Heinen Freezing
54
55
IBA
© Reading Bakery Systems
++ Reading Bakery Systems
++ Reading Bakery Systems
Hall B1 Stand 140
Reading Bakery Systems, located in Robesonia, Pennsylvania,
USA, presented in April this year a new continuous mixer to
manufacture doughs for snack articles.
A complete multi-crisps baked snack line that manufactures
between 250 and 1,000 kg of potato, wheat or corn flour
crisps depending on the number of oven zones involved, will
be presented at the iba. The line is able to process all three
raw materials, which is unusual. The “Multi-Crisp” process
starts with an Exact FX2 continuous mixer that manufactures dough from the respective flour. This dough is fed
into a 2-roll roller unit that turns it into a dough sheet which
moves onwards to a rotating cutter system. Optionally the
dough sheet can also run through a roller unit that gives the
surface its required structure.
After cutting to the required size and shape, the crisps move
into a Spectrum series convection oven. The special features
of this oven are the successive baking and drying zones;
these ensure that the moisture content and color of the end
product can be controlled perfectly. On request, molding
belts can also be installed in the oven to give the crisps a
defined shape during baking.
++ Bühler AG
Hall B5 Stand 480/481
The Swiss machine constructor Bühler AG has brought out
a new horizontal raw materials mixer, the Sanimix MRMA.
As a paddle mixer model it blends dry materials, while in
the ploughshare-like mixer, the tools and knives as in the
chopper mixer model also process fats and liquids. The latter
version is even able to incorporate whole blocks of fat into a
mix. The mixer is available with usable volumes of 500, 1,000,
2,000 or 4,000 l, and can be glass bead blasted or polished. If
required, Bühler also supplies the equipment with product
temperature monitoring, liquid injection, weighing machines,
recirculating air operation and upstream and downstream
containers. The seamless, self-emptying mixing chamber prevents product cross-contamination. It is also readily accessible
and easy to clean due to the large service door.
++ Ruitenberg Ingredients B.V.
Hall A5 Stand 470
“Flavors of the world” is the motto put into practice in fillings
by the Netherlands ingredients specialists Ruitenberg. Ethnic
fusions, authentic spice blends and exotic fruit flavors are
made for puff pastry, Danish pastry, bread, filo dough, quiches
and as a meal component. One of the most impressive aspects
of these fillings is the attractive appearance. Even after
freezing and/or baking the product, the filling keeps its
volume and stays stable inside the pastry. The spectrum of
trendy flavors range from Korean BBQ and the authentic
African Boboti blend to Jalapenos from South America, a
Mediterranean filling called Bella Italia and a tasty combination of quark and lime.
++ Rademaker BV
Hall A5 Stand 530
The highlight on the Netherlands company’s stand will be the
sneak preview of a new generation croissant machine. A
flexible and dough-friendly bread line is also being shown,
including the latest stress-free pre-sheeter and the new bread
rounder. The bread rounder lends itself to a wide range of
dough types and product weights ranging from 40 to 800 g.
Rademaker also presents its DoFlex make-up line, a flexible
semi-industrial line for ciabatta, free standing breads, tin and
toast breads, squares and buns, baguettes and pizzas and a
whole lot more. The Dutch company will also be demonstrating at the exhibition its high-speed cutter with a speed
of over 250 strokes/min. +++
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from 700 kg/to 3000 kg per hour
One SINGLE automatic line for:
• Soft and Crusty
• Tin bread or Baguette
• Petit pain soft or crusty from 50 g to 900 g
MECATHERM S.A. - F 67133 BAREMBACH (near Strasbourg) - Phone +33 (0)3 88 47 43 43 - Fax +33 (0)3 88 47 43 03 - [email protected] - www.mecatherm.fr
PRODUCTION
Fully automated system
TH E C ANADIAN BAKE RY CHAI N PR E M I E R E MOISSON I N TH E PROVI NCE OF QUEB EC AUTOMATED
TH E RAW MATE R IALS LO G I ST ICS AN D DOUG H PRODUCTION SYST E MS I N TH E CO M PANY ’S TWO
I N DUSTR IAL PRODUCTION LI N E S I N TH E PA ST YEAR
++ figure 2
© Esteve
++ figure 1
© Esteve
58
++ figure 1
++ figure 2
Bread line station with metering equipment
Automatic feeding of flour duster
The automation of the raw materials management and
dough production was carried out by the French silo
constructor ESTEVE from Rians, which belongs to the
Bretèche Group. The installation’s core is software developed
by Esteve, which communicates with PREMIERE MOISSON’S
ERP (Enter prise resource planning) system and develops
from it the quantity and time framework for the dough production operation. It also monitors the placing into storage
and removal of raw materials and the various stages of dough
manufacture, and documents all the data for traceability
purposes.
The system’s hardware comprises two 50 metric ton aluminum
free-standing outdoor skirt silos with a vibrating extractor
for emptying on a FIFO basis. The silos stand on load cells
to ensure real time monitoring of raw material stocks. Flour
transport is carried out by three pneumatic vacuum conveyers,
equipped with aligned magnetic filters and centrifugal sifters.
These three circuits serve both three filling stations of the
two lines as well as the automatic supply to the flour duster.
The Danish pastry line, which has a capacity up to 3,000 kg/h,
has a filling station with a removable container comprising a
flour receiving hopper with a dust removal system, a water
filler-mixer with automatic dough temperature monitoring and
a manual scale for adding and monitoring micro-ingredients.
The bread line’s first filling station with a removable container
is used for preparing the poolish. Fed by a pneumatic conveyer,
the station has a receiving hopper (for the flour) with a dust
removal system, a water filler-mixer and a mixing container
from VMI.
The station also has a reading/writing RFID detector to supply the RFID tag on each dough container with the unique
recipe number from which all the information about the
dough, the raw materials and the process steps can be derived.
Once the mix is finished, the container is moved to a resting
area, an automated system reads the time required for it to
rest and informs the operator when the dough is ready. With
this station, more than 900 kg/h of polish can be produced
to fill 22 containers on a permanent rotation system.
The second filling station of the bread line is used to prepare
the finished dough. The station is equipped with a feed hopper,
water filler-mixer, a dust removal system as well as a manual
scale, and the mixing bowls are also identified by RFID tags.
The dough is prepared in six successive stages: pouring the
poolish into the container, injecting complementary ingredients,
+
59
PRODUCTION
History
mixing, and then moving the container filled with the final
mix to the resting chamber. Once the dough is ready, the
container is taken to the elevator system where it is emptied
onto the line where it will move on to the dough divider.
The third filling station is used for the automatic feed to the
© Esteve
It was in 1992 that the Colpron-Fiset family founded
the Première Moisson bakery. In 2007, Première
Moisson became the first bakery to use natural wheat
flour exclusively produced with wheat grown in
Québec in all of its wheat breads. No bleaching is
used when producing the flour and no chemical
treatment is applied while using an exceptional mix
of wheat. At Première Moisson, approx. 150 employees work in the two factories, which are about 20
min away from each other, and over 1,000 employees
in the stores and headquarters. The company currently has 18 bakery outlets in the province of
Quebec, three take-away stores and some products
are on offer in the large supermarket networks of
Québec, Ontario and Maritimes as well as in the food
service (catering). +++
flour dusting system at the head of the bread line using a
pneumatic conveyer over a receiving hopper and the feeding
screws of the five flour dusters with level monitoring.
The Software runs on a Siemens automation system comprising a PLC as well as several operating terminals on each 왘
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w w w. a s h w o r t h . c o m
PRODUCTION
++ figure 4
line with touch screens. It communicates with the three
mixers to specify the time and duration of the mixing, and
uses the RFID tags on all the dough containers as a means of
communication. All the operators are themselves equipped
with an RFID tag in order to secure production by limiting
the access granted to each operation terminal. The bread
line is equipped with two LCD screens: one for the poolish
and another for the finished dough. With these screens, it is
© Esteve
++ figure 3
© Esteve
possible to follow the resting time status of each container in
real time. The entire automated system is subjected to computer supervision (SCADA) which makes it possible to work
with production timetables, production orders and recipes,
which allows for all ingredients and operators to be monitored.
The installation is also equipped with a backup computer
system as well as a modem connection for any necessary
remote maintenance. +++
++ figure 3
++ figure 5
Poolish dosage station
++ figure 4
Premiere Moisson 14
Pre-dough container
++ figure 5
RFID traceability
© Esteve
Es-Track®
Es-Track® software developed by ESTEVE is a recipe-based
metering and weighing system that simultaneously
monitors the process and documents it for traceability
purposes. Its objective is to fill the different raw materials
(powders and liquids) of a recipe into a weighting unit,
and then automatically empty them into a mixing bowl
giving mixing commands to the mixer.
It does the following:
+ Maintains products, ingredients and recipes and
other master data
+ Receives production orders from the ERP system and creates a production plan and timetable
+ Hosts the database and OPC client (open programmers connection) to communicate with the PLC of the silos,
weighting units and the mixer of Premiere Moisson
+ Monitors filling and traces production
+ The computer also makes it possible to save and visualize the different ingredient batches that are in place in the
silos, hoppers, etc., as well as tracing ingredients and production
+ The amount of data and files that can be stored is only limited by hard drive capacity. Current technology is
sufficient for industrial production +++
© Esteve
60
Rademaker stand:
A5 530 Hall 5
PRODUCTION
Generating energy themselves
T H E M E S T E M A C H E R G R O U P H A S C O M P L E T E LY C O N V E R T E D I T S E N E R G Y G E N E R A T I O N A T I T S
G Ü T E R S LO H S I T E TO A H I G H - E F F I C I E N C Y G A S E N G I N E M O D U L A R H E AT- A N D - P O W E R P L A N T.
TH I S HA S ALLOW E D TH E CO M PANY TO R E D U CE ITS AN N UAL CO2 E M I S S ION S BY 1,700 T
++ figure 1
© Matthias Gans/Neue Westfälische
62
++ figure 1
The project managers on the roof of the production building: Kim Folmeg (l.), Manager, Production, Engineering, Product Development and Quality Assurance,
Works Manager Maik Detmers and Prof. Dr. Ulrike Detmers, Co-partner and member of the management board of the Mestemacher Group
Things run very smoothly in the Mestemacher Group’s
bakeries, where more than 500 staff turn around 2,200 t
of cereals per month into baked products. That corresponds
to an average monthly quantity of 10m packs of bread. Their
bread specialties such as pumpernickel, wholegrain loaves,
pita or flatbreads, as well as wraps and many other baked
goods can be seen on supermarket shelves all over the world.
With an export ratio of 23 % of total sales (2011), the family
business is among the export world champions for deliciously
fresh breads with a long shelf life in an unopened state. The
Group earned a total turnover of EUR 118m in the 2011
financial year. This represents 5 % growth by the family
business, which celebrated its 140th company anniversary in
2011. In Euros that corresponds to 6m of additional sales in
2011 compared to 2010 (EUR 112m).
Investments of EUR 3.7m were carried out in the financial
year 2011. Even so, the plan for 2012 is EUR 4.6m. More
than ¼ of the majority of the sum invested goes into
technology to increase energy efficiency. The company’s in-
+
tention in doing this is firstly to considerably reduce CO2
emissions, and secondly to become less dependent on energy
price changes.
That’s why the Mestemacher Group’s top management decided
to invest in a block heat-and-power station at the company
headquarters in Gütersloh. Prof. Dr. Ulrike Detmers explains
that, “For us, utilizing the ecological advantages of combined
heat-and-power is a matter of simple logic. By changing the
energy supply to a high-efficiency gas engine block heatand-power station, the company can reduce its annual CO 2
emissions by 1,700 t.” At the same time, the company faced
big challenges installing the plant: on the one hand there
was very little space remaining on the site due to its position
in a residential and industrial area and on the other hand the
plant could not be too noisy and had to have as few emissions
as possible so as not to be a nuisance to the nearby residents.
The company found the solution by installing the power station
on the roof of the production building. Here, however, the
structural strength of the building needed to be taken into
63
PRODUCTION
© Mestemacher
++ figure 3
© Mestemacher
++ figure 2
++ figures 2+3
The power plant is housed in three containers. A crane hoists these onto the roof of the production building in Gütersloh
account, as the power station weighs nearly 100 t. The topic
of fire protection was another big challenge. For example, it
was necessary to clarify how the fire brigade could gain access to the plant in the event of an emergency.
The block heat-and-power station was delivered in three
containers. These were similar in size to standard shipping
Global market leader and more
The Mestemacher GmbH, Gütersloh, has focused on
producing pasteurized specialty breads. The family
business is considered to be the world market leader
in the area of long-life wholegrain breads and pumpernickel. However, there are also other baked goods
and cakes that leave the production sites. The breads
and baked goods can be found on the shelves of German and international food retail stores. The dynamic major bakery exports classical German wholegrain
breads and pumpernickel to more than 80 countries
worldwide.
The Group also owns the Aerzener Brot und Kuchen
GmbH, Aerzen, the Detmers Getreide-Vollwertkost
GmbH, Bielefeld, and the Modersohns Mühlen- und
Backbetrieb GmbH, Lippstadt. The portfolio of the
business is rounded off with the Group’s majority
shareholding in BENUS Spólka z o.o., Poznán, Poland. Mestemacher expects sales amounting to EUR
120m for 2012, an increase of 1.7% compared to 2011.
Since 1994 Mestemacher has promoted art on the
bread box and the equality of women and men in society. The corporate culture and ethics of the business are characterized by the integration of bread,
art and gender equality. For many years Mestemacher has played an active role in championing a multitude of social projects for gender equality in society
and the compatibility of profession and family on the
Scandinavian model. +++
containers, and a crane hoisted them onto the roof of the
building where they could be installed. The containers house
all the plant’s assemblies.
Function
The block heat-and-power station consists of a gas engine
and a boiler in which steam is generated, together with various
accessory and auxiliary assemblies. Natural gas is burnt in
the gas engine. It functions in a similar way to an automobile
engine. Mestemacher’s engine has a total of eight cylinders.
Its order of magnitude/size corresponds to that of a rather
small marine engine. The engine’s generator produces the
electricity. The engine’s cooling water is used to supply heat
to the heating users and a refrigerator. The hot exhaust gas
from the combustion in turn heats thermal oil and raises
steam in the boiler. This supplies steam, hot and cold water,
hot thermal oil and electricity to the entire production facility
in Gütersloh.
The changeover has yielded various benefits for Mestemacher.
Prof. Dr. Detmers explains that, “The combined generation
of heat and electricity is more efficient than steam generation
on its own and the purchase of electricity, and is thus more
economical when considered overall.”
왘
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KOENIG BACKMITTEL GMBH & CO. KG • Postfach 1453 • D-59444 Werl
Tel. 02922/9753-0 • Fax 02922/9753-99
E-Mail: [email protected] • Internet: www.koenig-backmittel.de
PRODUCTION
++ figure 4
© Mestemacher
64
++ figure 4
Fritz Detmers, Managing Partner of the Mestemacher Group; his wife Helma Detmers; Prof. Dr. Ulrike Detmers, Co-partner and member of the management board
of the Mestemacher Group, and Albert Detmers, Managing Partner of the Mestemacher Group
Economic benefits
1. The company uses comparatively more favorably priced
grid-bound natural gas, and is thus independent of the
rising price of oil
2. The company achieves a considerably higher level of
utilization through combined heat-and-power than with
the separate supply of electricity and heat
3. Mestemacher decouples itself almost completely from the
electricity market, and does not pay for electricity price
rises in the context of the Renewable Energies Act, which
increase the price of energy
4. The bakery receives subsidies and other funding grants,
because the installation of decentralized operating units
to generate electricity and heat is supported by the legislator in Germany through the Combined Heat and Power
Act (KWKG)
5. The electricity that we do not use ourselves is fed into the
public grid at the usual market prices. Mestemacher receives a CHP (combined heat-and-power) bonus for this
electricity
6. In relation to natural gas, further cost advantages result
because Mestemacher can apply for a retrospective tax
reduction based on the use of natural gas to generate
electricity and heat
Management of the interfaces during the installation of the
block heat-and-power station was the biggest challenge for
those responsible for the project, namely Kim Folmeg, Production, Engineering, Product Development and Quality
Assurance Manager, and Works Manager Maik Detmers.
Constant monitoring and coordination during the assembly
of the power station was necessary to avoid interference
with production. Today, even if the power station failed,
there would be no breakdown in production because double
security of supply is guaranteed at all times. In the event of
a failure, an uninterrupted supply of electricity from the
upstream grid is possible at all times, since the block heatand-power station runs in a parallel operation with the grid.
Folmeg explains that, “Due to the same voltage and frequency, this kind of changeover causes no problems.” According to Folmeg, “The steam storage vessel also holds a
stock of steam for times when the power station is not running.
If the breakdown exceeds the storage vessel’s capacity, we
will use the existing high-speed steam generators, which remain operational.” The heating also has a redundant design.
The Mestemacher management calculates that the total of
EUR 1.65m invested in the power station will pay for itself
after four years, and allow organic growth in the future as
well. +++
+DOO%6WDQG
RAW MATERIALS
Versatile raw material
BY I N V E ST I N G I N A N E W P L A N T, T H E C A R L K Ü N K E L E Z U R S C H A P F E N M Ü H L E G M B H & CO . KG ,
U L M / J U N G I N G E N , G E R M A N Y, C A N N O W P R O C E S S C E R E A L S P H Y S I C A L LY I N S U C H A W AY T H A T
T H E P U F F E D G R A I N S S W E L L Q U I C K LY I N D O U G H A N D A B S O R B L I Q U I D D I R E C T LY, W H I L E
R E TAI N I NG TH E I R N ATU RAL QUALIT Y CHARACTE R I ST ICS AT TH E SAM E T I M E
© Schapfenmühle
The history of the SchapfenMühle mill in Ulm dates
back to 1452. Today the business and its 170 employees
generate a total annual turnover of around EUR 60m. The
proportion exported has now grown to over 30 %. SchapfenMühle has devoted itself completely to grain, and has secured
its competence in mill technology by far-reaching innovative
investments, including a puffing plant.
+
In the plant, cereals are heated for a short time in a closed
tube (reactor) and exposed to steam pressure. This causes an
internal temperature rise of up to 185 °C and a pressure increase of up to 20 bar. The sudden opening of an outlet valve
then releases the contents into an expansion duct, with the
result that the abrupt pressure reduction causes the water
enclosed in the grain to evaporate. The energy thus released
++ figure 1
© Schapfenmühle
66
++ figure 1
The puffed cereal is able to absorb liquid directly, thus increasing its dough yield
67
RAW MATERIALS
++ figure 2
© Schapfenmühle
bursts the starch molecules apart, leading to almost complete
gelatinisation of the starch. Karl Schmitz, Managing Director
of SchapfenMühle’s bakery business, explains that this causes
the grain to undergo a large increase in volume. The increase
can be up to twelve times the original volume, depending on
the raw material.
CeralGran grains are designed specifically for the baking industry to offer bakers not only the practical advantages but
the final consumers can also enjoy the innovative, attractive
baked products.
Master bakers led by Karl Schmitz have examined and compared CeralGran products in SchapfenMühle’s experimental
bakery. Depending on the variety, the weight per litre of the
products is between 250 and 400 g/l, which means the puffed
cereals are among the lightweights. The products absorb a
large amount of liquid in a short time, and in practice they
are ready for use very quickly.
For example, puffed rye can already absorb approx. 55 % of
water after 15 min at a water temperature of 35 °C, and the
water absorption increases continuously thereafter (approx.
80 % after 45 min). As a comparison, with a scald (at 97 °C)
the water absorption of rye grains is approx. 45 % in a period
of 15 min, and rises only insignificantly with standing for a
longer time (approx. 52 % after 45 min).
If time is short in the bakery, up to 15 % of CeralGran grains can
be added to the dough preparation directly, even without 왘
++ figure 2
The company can process cereals physically with the new plant
ADVERTISEMENT
t the IBA
Visit us a
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RAW MATERIALS
++ figure 4
© Schapfenmühle
++ figure 3
© Schapfenmühle
++ figure 3
++ figure 4
The coating of CerelPAN
The control of the puffing
Recipe for wholegrain bread using
CeralGran durum
basic recipe: 10 kg total flour
75 % rye flour type 1150, 10 % wheat flour type 550
6.000 kg
2.400 kg
1.000 kg
0.240 kg
0.160 kg
0.130 kg
7.400 kg
rye flour type 1150
basic sourdough starter dough yield 160
(acid level 18)
CeralGran durum
pour the water over it and allow it to
swell for approx. 40 min
wheat flour type 550
salt
Schapfen RoggenPerfekt
yeast
approx. water
18.830 kg
approx. total dough
1.500 kg
Mixing time:
Dough temperature:
Dough resting time:
Dough piece weight:
Make-up:
Baking:
Baking temperature:
Baking time:
spiral mixer, slow for approx.
5–6 min. Do not mix to smeary
consistency
27–28 °C
30 min
1,200 g for a 1,000 g loaf.
White bread pan
24 cm x 10 cm x 10 cm.
weigh out dough pieces,
round mould, long roll in rye
flour without closure and place
into the pans.
load with full heat and steaming,
vent steam after 2 min
270 °C (20 °C above bread roll
baking temperature, decreasing
to approx. 40 °C below bread
roll baking temperature). Take
care to ensure good initial
bottom heat
approx. 65 min
a mash, scald or cold soak. At the same time the CeralGran
grains retain their full, clearly visible grain structure and are
not destroyed by the mixing process.
The results show that distinctly higher dough yields are also
achieved through the physically modified grains, and retrogradation is slowed down significantly.
However, not only is the retention of freshness in the bread
improved, the pore pattern also becomes more open and the
grains are distinctively and clearly visible in the crumb. According to Karl Schmitz: “There are also no specks in the bread
or hard grains in the baked goods.” In addition to the immediate
availability, faults in the manufacture of mashes, scalds or cold
soaks, such as non-uniform swelling, fermentation by foreign
organisms or scorching of the grains can be excluded.
It has been found in practice that in-house recipes need only
slight adjustment when using CeralGran products. It is absolutely essential that the addition of water is increased and the
amount of salt and dough acidification adjusted accordingly.
There is no need to declare CeralGran grains, because they have
only been hydrothermally processed. Karl Schmitz’s summary
is: “We invest and research constantly to give our clients access
to the mill technology benefits.” That’s how a multitude of
raw materials and product ideas are created. +++
++ figure 5
© f2m
68
++ figure 5
The fully baked bread slices with puffed cereals
THE DIFFERENCE BETWEEN
YUCKY & YUMMY:
DUPONT INDUSTRIAL BAKERY SOLUTIONS
» Increased baking productivity
» Longer-lasting nonstick coating systems
» Minimizes the use of oil & fat
» Quality assurance through audited licensing
12
IBA 20nd 320
1 | Sta
Hall A
The original nonstick coating system customized for your baking line!
Visit us at IBA or
www.dibs.dupont.com
Industrial Bakeware
Coatings
DIBS
DuPont Industrial Bakery Solutions
Copyright © 2012 DuPont. All rights reserved. The DuPont Oval logo, DuPont™, The miracles of science™ and Teflon®
are registered trademarks or trademarks of E.I. du Pont de Nemours and Company.
PRODUCTION
American pans for Europe
G I L B E R T B U N D Y , P R E S I D E N T O F A M E R I C A N PA N , A S U B S I D I A RY O F B U N DY B A K I N G S O LU T I O N S
F RO M U R BAN A, OH IO, U SA, TALKE D TO BAK I NG+B I SCU IT I NTE R N AT ION AL, ABOUT W HAT I S
N EW I N TH E WO RLD OF PAN S AN D ALSO W HAT K I N D OF N EW F E ATU R E S AN D S E RVICE S TH E
CO M PANY HA S FO R I NTE R N AT ION AL CLI E NTS
+ bbi: In your view, what are the biggest mistakes that are
made by baking businesses when handling and storing baking
trays and pans, and what processes damage the longevity of
the pans and coatings?
+ Bundy: A lot of damage to pans happens during the stacking
operation. Bakeries should maintain slow drop speeds, minimize drop height and angle when stacking pans and check
the adjustment of magnetic pick up on unstackers so as not
to apply any force to the pan. Stacking pans too high can
also cause damage since the bottom pan supports the entire
stack weight.
+ bbi: American Pan presented the first fluoro-polymer
© American Pan
70
++ Gilbert Bundy
President of American Pan
bbi: The baking industry worldwide is currently
undergoing a massive structural change towards fully
automatic industrial production lines. How does that affect
American Pan’s business?
+ Bundy: We are a custom pan manufacturer and engineering
pans to meet specific production needs is what we do. There
has definitely been an increased emphasis on precision and
larger pan sizes. To meet these demands, our engineering
department has significantly grown in size and we have added
new tooling and press capabilities.
+
+ bbi: Considering the various types of baking trays and
coatings, which systems and processes have, in your opinion,
become widely accepted, and are they the same throughout
the world or do they differ depending on countries and/or
on the products baked on them?
+ Bundy: The actual systems may vary somewhat around
the world but we are seeing a general trend toward larger pans
that produce a higher quantity of pieces per pan. Systems
such as Mecatherm and Autobake require pans that are precision manufactured to work with their equipment. We have
upgraded our manufacturing capabilities to meet this need.
Regarding coatings, it is often a matter of availability of high
quality options for both coating and recoating of the pan.
coating system without PFOA in 2008. How successful is
this process today throughout the world?
+ Bundy: It has been very successful! DuraShield is used in
over 70 countries worldwide on a wide variety of pans such
as bread pans, cake pans and screens. It has been certified to
meet or exceed the BRC standards for PFOA and continues
to outperform every other fluoro-polymer coating.
+ bbi: In 2007, you launched ePans onto the market, which
are made from a heavy-duty lightweight aluminium-steel alloy.
How has this innovation been accepted by the baking industry?
+ Bundy: The ePAN has been widely accepted. “e” technology
is definitely a growing trend and we have, in fact, developed
a whole “e” series of options. These options can produce a pan
that is up to 50 % lighter than traditional pans and cools
17–25 % faster. Bakers are very excited about the energy savings
and other benefits that this can bring to their operation.
+ bbi: Leaving the USA domestic market aside for a moment,
where are American Pan’s most important markets located in
the world today, and which baking products do they involve?
+ Bundy: We are seeing a lot of activity in Europe, the Middle
East and Africa right now. The products vary, but breads
and baguettes are the main products. We are also seeing the
South American market show some potential.
+ bbi: Does American Pan have any plans for new production
or coating factories outside the USA?
+ Bundy: We currently have a facility in LaCateau, France,
for recoating of DuraShield® (a joint venture with SASA) and
we are looking to add more service centers around the world.
However, there are no definite sites to announce at this time.
+ bbi: Many new bakeries are being set up in new markets,
the so-called emerging countries. Do the demands on American
PRODUCTION
© Am
n
Energy efficient e2PAN with DuraShield® coating
erica
n Pa
+ bbi: American Pan has been selling in Europe since the early 1990’s.
How has the business in Europe developed, and what are your plans for
the next few years?
+ Bundy: Our customer base in Europe has continued to grow since we
first started selling there in the early 1990’s and so much so that we
opened the DuraShield Europe plant with SASA in 2006 and, due to increased demand for our energy efficient pans, established an American
Pan sales office in Europe in 2010.
++ figure 1
© Am
+ bbi: Which coatings are being chosen, and how does the recoating
business operate, or do factories rely on the One-Dur-Pan?
+ Bundy: The choice of which coating to use is largely a geographical
question. If a bakery is located in close proximity to a glaze recoating
facility, such as in North America, it will tend to use a silicone glaze
coating. If recoating is not an option then bakeries will choose the coating with the longest release life, namely DuraShield®. However, for the
most demanding release applications such as baked goods with high
sugar content, DuraShield® is chosen by choice and the proximity to a
recoating facility has no significance.
erican
Pan
Pan as a supplier on the one hand and on the baking trays and pans on
the other hand differ there compared to the USA for example?
+ Bundy: The bakeries that we have been working with in the emerging
countries have been very high-tech and large in size. Demands have been
very similar to those that we experience in the USA and other established
markets.
++ figure 2
Stackable industrial baguette pan with DuraShield® coating
©A
me
rica
nP
an
+ bbi: What can your existing and future clients expect on your stand at
the iba?
+ Bundy: We will be showcasing our e-series of energy efficient baking
pans that we discussed previously but what we are most excited about is
the brand new technology that we will be introducing for baking screens
and baguettes. We have engineered a new design that allows for easy
and economical replacement of the screen that we think bakers will find
very appealing.
++ figure 3
+ bbi: Mr. Bundy, we thank you for the interview. +++
Custom bread pan design
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71
PACK AGI NG
Avoiding migration risks
J U ST A S W ITH I N KS AN D VAR N I S H E S FO R PR I NT I NG ON PACK AG I NG, ADH E S IVE S I N TH E FOO D
I N D U ST RY M U ST A L S O B E F R E E F RO M TOX I C S U B STA N C E S T H AT CO U L D M I G R AT E I N TO T H E F O O D
++ figure 1
© Henkel
72
++ figure 1
Adhesives for the food industry must be free from toxic substances
Dispersion adhesives play an important part in the
manufacture of packaging made from paper and board.
In the food industry, the possible migration of an adhesive’s
con stituents from glued folding boxes, bags or pouches represents a potential risk. This is why the conditions applying
to food packaging have become more stringent since 2011.
Among other things, they are subject to the European Plastics
Regulation, which specifies the maximum migration of constituents into packaged foods. This means that virtually no
constituents whatsoever from the adhesive can enter the food.
Adhesive manufacturers such as Henkel, Eukalin and BASF
have adapted to this and have optimized their formulations
and/or have developed new water-based adhesives.
+
Reducing contamination
The Henkel AG & Co. KGaA from Düsseldorf, Germany, now
offers, for the first time, a full range of water-based adhesive
products for low-migration consumer goods packaging as
Low Migration Adhesives under the Adhesin trademark.
Specific product variants are available for the various processing systems from roller to nozzle appli cation. Another
feature of the Adhesin Low Migration products is their ecoBAKING+BISCUIT ISSUE 04 2012
nomical consumption. Henkel completely avoids plasticizers
in this range. The use of other ingredients with a potential
migration risk, such as solvents, is also reduced to a minimum.
At the same time, amounts detectable in foods originate not
only directly from the packaging adhesive but also indirectly
from paper recycling: dispersion adhesives with plasticizers
contained in recycled packaging enter the paper recycling
loop and can accumulate in the paper fibres as a result. Paper
mills have no way of removing the plasticizers. Since the proportion of recycled fibres in board and paper manufacture is
constantly increasing, the proportion of entrained plasticizer
is also rising. Oliver Klewe, Henkel’s Marketing Manager for
paper converting in Europe, says, “The packaging industry
often ignores the migration risk due to adhesives. However,
for low migration packaging one needs a suitable combination
of paper, printing inks and adhesives.”
The new products comply with Recommendation XIV of the
German Federal Institute for Risk Assessment (BfR), Berlin,
Germany. The Recommendation applies to plastics dispersions in contact with food, and provides for a reduction in the
contamination of recycled paper by entrained plasticizers.
The plasticizer-free Henkel adhesives fulfil all the usual
PACK AGI NG
Epotal ECO can be used to glue all the usual biodegradable
materials. It is particularly suitable for the manufacture of
fully compostable packaging based on plastics such as polylactic acids (PLA) and NatureFlex or paper.
++ figure 2
Points scored for sustainability
The adhesives are processed by bead or dot application. The
latter is increasingly used for folding box gluing because it
can save adhesive. With its SpeedStar Diamond hot melt adhesive systems, the Robatech AG, headquartered in Muri, 왘
© Eukalin
ADVERTISEMENT
++ figure 2
The adhesive’s high initial tack and improved setting properties ensure a high
production rate with solid board boxes
industrial technical requirements for gluing folding boxes,
corrugated cardboard boxes, bags, pouches and other paper
packaging, including large-area lamination.
The problem of migration is also a priority topic for the Eukalin
GmbH, Eschweiler, Germany. Production rate limit ations
occur repeatedly in the solid board area due to resilience forces,
which are sometimes very large. Eukalin’s special adhesives
provide converters with products whose high initial adhesion
and improved setting properties enable high production
speeds. The inclusion of appropriate additives makes the adhesives detectable by a wide variety of glue detection devices.
This ensures reliable processing and monitoring in the production process.
Eukalin’s products are available in various viscosities, enabling
a suitable alternative to be offered for every application
method. All Eukalin adhesives are also free from plasticizers
containing phthalates, which has been a requirement in the
packaging industry for several years.
Compostable adhesive system
Since compostable packaging materials made from renewable
raw materials are increasingly coming onto the market, there
is a demand for corresponding adhesives that do not interfere
with these processes. BASF SE, Ludwigshafen, Germany,
offers an adhesive under the brand name Epotal ECO, which
is certified as compostable and has now received another
TÜV certificate (from DIN Certco). The new test seal relates
to the entire adhesive system consisting of Epotal ECO and
the associated crosslinking agent. It confirms that the products
satisfy the standard for compostable adhesives (EN 13432)
and are thus harmless to the composting process.
Epotal ECO is a dispersion adhesive that was the first to receive the compostable additives certificate awarded by DIN
Certco in 2010. Tests have shown that Epotal ECO is 90 %
degraded in only 70 days. It leaves no toxic residues after
degradation, and has no adverse effects on the environment.
Epotal ECO also offers all the advantages of water-based adhesives: high immediate strength and freedom from toxic
substances, which enables rapid further processing.
Natural sourdough
for best
fermentation flavour
Hall: B4
Booth: 561
Ernst Böcker GmbH & Co. KG
PO Box 2170
32378 Minden / GERMANY
Phone +49 571 83799-0
Fax
+49 571 83799-20
www.sauerteig.de
73
PACK AGI NG
++ figure 4
Robatech
++ figure 3
Robatech
74
++ figure 3
++ figure 4
SpeedStar Diamond series applicator heads set new standards for speed,
The new Concept Diamond adhesive melter in the Greenline series reduces energy
durability and precision
consumption
Switzerland, gives the industry sustained support in the
packing of various foods. The SpeedStar Diamond hot melt
application heads set new standards for speed, durability
and precision. As a global first, the SpeedStar application
heads can apply up to 800 adhesive dots per second. Thus
Robatech has succeeded in combining extremely fast switching
cycles with high wear resistance. In spite of temperatures up
to 185 °C and viscosities up to 5000 mPas (millipascal-seconds),
SpeedStar application heads achieve a much longer lifetime
than conventional heads.
Dot size and position are guaranteed over its lifetime without manual readjustment and therefore repeatability is high.
Another advantage is the adhesive consumption, which is
less due to reduced dot sizes or the stitching function. The
heat-resistant “Cool Touch” insulation markedly improves
energy efficiency and protects the operators from burns. Not
least, “Cool Touch” also prevents the melting of confectioneries
such as chocolate which heat up rapidly.
The new Concept Diamond adhesive melter in the Greenline series is another piece of equipment that scores points
when it comes to sustainability, because the insulation fitted
to the melting devices and the glue distributor lead to a distinct energy saving. This insulation also protects the operators
from burns. The equipment is equipped with the latest technologies such as network friendly ICS-Net electronics and
the user-friendly RobaVis touchscreen. The information and
operator’s display screen can also be installed in an external
housing. The Concept equipment can also be attached to a
RobaFeed automatic feeder system to guarantee a constant
amount of adhesive in the application device. The RobaFeed
fills the melt tank directly with granulates from a separate
container, so it no longer needs to be refilled by hand. This
increases personnel safety and also avoids contamination of
the tank. +++
Non-migrating printing inks
The public debate about mineral oil based printing inks
is a concern for the folding box industry. Food regulators
are constantly improving in their search to find the
tiniest amounts of unwanted migrating substances.
Their methods are so accurate that current detection
limits (10 ppb) will be overtaken in the future. Printing ink manufacturers have consequently adapted to
this, and now offer special low migration inks for the
area of foodstuffs. For example, the TempoNutripack
vegetable-based inks from the sheet fed offset series
offered by Siegwerk Druckfarben AG & Co. KGaA,
Siegburg, Germany, is eminently suitable for this
area. The modern TempoNutripack 2 offset series provides even greater security against the migration of
unwanted substances into foods. In addition, the
new series guarantees exceptional printability and
offset properties together with low mist formation,
even at high machine speeds. The vegetable components of the inks are free from genetically modified
organisms, and no component is of animal origin. The
pigmentation type is unchanged when compared to
the previous Tempo NutriPack inks and there is consequently no requirement for printers to alter their
ink formulas. +++
i Slicing
i Packaging
i Closing
i Combining
i Special solutions
Visit us:
Hall B1
Stand
B1.551
Packaging machine GBK 420
Products of success
with individual solutions and complete service.
GHD Georg Hartmann Maschinenbau GmbH
Schwalbenweg 24, D-33129 Delbrück, Germany
Tel: +49 (0)52 50.98 43-0, Fax: +49 (0)52 50.98 43-33
Web: www.ghd.net, eMail: [email protected]
SCIENCE
Energy and quality optimized baking
I LU AN D WI E SH E U HAVE DEVE LOPED A CONTROL SYSTE M TO BAKE I N A DI BA S HOT AI R I N-STO R E
BAK I NG OVE N THAT I NCLU DE S M E A S U RAB LE AN D CONTROLL AB LE PROCE S S PARAM E TE RS
AN D TH E R EFOR E TH E QUALITY OF TH E PRODUCTS COU LD BE OPTIM IZ ED WH I LE SAVI NG E N E RGY
AT TH E SAM E TIM E
In practice, as a rule, there is a single baking program for a
given product type, regardless of the actual amount being
loaded and the thermal state of the dough pieces existing at
the time. At best the user also provides an additional baking
program for a half load. However, in this case the user must
again make the choice himself, and the layout grids for half
and full loading are not optimally coordinated vis-à-vis
quality and energy. It would be beneficial to match the baking parameters automatically to the amount actually loaded
and to its thermal condition.
This was the starting point for a KF (industry/research agency
collaborative) project funded by ZIM (the German Central
Innovation Program for SMEs) between the cooperation
partners ILU e.V. in Nuthetal and the WIESHEU GmbH in
Affalterbach, both in Germany, in which a control system
was developed, not dependent on the state of the product, to
bake in a Dibas hot air in-store baking oven that includes
measurable and controllable process parameters to optimize
the quality of the products while saving energy at the same time.
The ILU’s task in this project was to determine the essential
factors influencing a baking process with regard to optimum
quality. These were determined for significant small wheat
baked products such as pretzels, croissants, Kaiser rolls and
folded-in bread rolls. Adaptation to the individually constantly changing product portfolios was thus easy to achieve
on this basis.
The main focus for WIESHEU was to take the baking process
parameters that ILU had found to be optimum and to integrate
them into the electromechanical and software engineering
systems of the currently existing Dibas product family in a
way that gave optimum results.
In addition to product quality, increasing attention is
being paid to energy consumption in the manufacturing process. This means, in particular, the baking process,
which accounts for almost ⅔rds of a bakery’s total energy
consumption (1–3).
The use of the energy from the exhaust gases is gaining everincreasing importance to improve the energy balance. When
baking in in-store baking ovens these options are either
non-existent or severely limited because the enthalpy
streams available for recovery are scarcely relevant from the
economic point of view. Thus for in-store baking it is important to use baking programs that are optimized from the
outset with regard to quality and energy consumption.
Due to the large number of variables: the baking parameters
themselves (temperature, time, amount of steam, damper
opening times etc.) as well as for the various products, different layouts in the oven and on the baking trays, and the
thermal state of the dough pieces prevailing at the relevant
time (including frozen or freshly proofed), it is possible to
implement energy-efficient baking programs only by using
measuring instruments to record the products.
+
++ figure 1
© ILU
76
++ figure 1
Test rig with experimental baking oven
Selected results to determine the factors affecting the
baking process
A precondition for the development of this system was the
determination of the factors affecting the baking process when
using standard baking programs to bake in hot air in-store
baking ovens. A large number of material and technological
variations were undertaken in the context of these studies:
+ Products (Kaiser rolls, folded-in bread rolls,
croissants, pretzels)
+ Heat-up temperature
+ Amount of water vapor during steaming
+ Exposure period and timing sequence of the steaming
+ Control of incoming and exhaust air
+ Dough piece weight and layout in the oven
+ Temperature of the dough pieces when loaded
+ Baking time
77
SCIENCE
Table 1: Standard baking program parameters for
folded-in bread rolls
++ figure 2
Resulting temperature profiles when
baking folded-in bread rolls (60 and 75 g)
250
Standard baking program parameters *
700
Exposure time [sec]
40
Baking temperature [°C]
180
Baking time [min]
18
150
100
50
* The entire baking program has even more intermediate steps, but
these will not be mentioned here.
The effect of the variations on the quality development of the
dough pieces and of the products as well as on the energy
consumption was determined.
The studies were carried out in a Dibas hot air in-store baking
oven made by WIESHEU (10 baking trays each measuring
60 x 40 cm) by varying the selected parameters in individual
test series and/or by using statistical experiment planning.
Figure 1 shows the test rig with the experimental baking
oven, printer and computer to record the temperatures during
baking.
The effect of the dough piece load when baking folded-in
bread rolls will be described as an example of the study results.
This experiment is important in the sense that inflexible
baking parameters take no account of the differing quantity,
thus there is reason to suspect an adverse effect on quality
and energy.
Figure 2 shows the temperature profiles in the oven and in the
crust and crumb of the dough pieces resulting from variations
in the dough piece weight (60 and 75 g respectively) when
baking folded-in bread rolls (same baking program in each
case!). The layout in the oven was 10 baking trays with a layout
0
T centre back [60]
T centre back [75]
crust [60]
crust [75]
crumb [60]
crumb [75]
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
baking time [min]
of 15 dough pieces on each tray. It can be seen from the
graph that the hearth temperatures rise more slowly after
loading 75 g dough pieces into the oven than for dough
pieces weighing 60 g. The temperature profile also causes
the temperatures in the crust and crumb to rise more slowly.
The reason for the changed temperature data is to be found
in the total dough mass, which is 2.25 kg larger for the 75 g
dough pieces than for the 60 g dough pieces. As might already
have been suspected, the results of the temperature profile
affect the quality of the products (including the baking loss
and crust browning). The standard system is unable to make
this distinction and is thus “blind” to varying amounts of
dough pieces, which can also certainly occur due to the
batch, i.e. as an error. An additional parameter variation visà-vis the total weight to be baked also occurs when producing smaller quantities.
The ideal situation would be for the temperature profiles for
crumb, crust and core to move identically irrespective of the
amount loaded and/or batch weight. That would ensure
constant quality and a more accurately targeted use of energy
(only what is actually needed).
왘
inform-werbeagentur.de
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source: ILU
Steaming [ml]
source: ILU
230
temperature [°C]
200
Preheat temperature [°C]
SCIENCE
++ figure 3
++ figure 4
Resulting baking loss of folded-in
bread rolls (60 g and 75 g respectively)
Comparison of folded-in bread rolls
from baking tray 1, 3, 6 and 9 in the
Wiesheu oven (from left to right)
21.7
1&2
60 g bread rolls
19.8
21.4
5&6
19.5
18,5
19
19,5
20
20,5
21
21,5
22
baking loss [%]
folded-in bread rolls [60g]
folded-in bread rolls [75g]
Figure 3 shows the baking losses of folded-in bread rolls
with different dough piece weights (from top to bottom in
the oven). It is evident that the baking losses in the upper
zone of the oven are always slightly higher than in the lower
zone of the oven. They differ by approx. 2.5 %. This difference due to the larger dough piece weight is approx. 10 %,
for which the standard baking parameters are to blame.
Thus it is apparent that a failure to distinguish between the
different dough piece weights when setting the baking
para meters also has an adverse effect on the baking loss.
Figure 4 shows the bread rolls on baking trays 1, 3, 6, and 9
(counting from the bottom). Firstly, it is apparent that
browning is more intense with a smaller weight, and secondly
that the surface pattern is defective at a higher weight, which
indicates an insufficient amount of steaming at the start of
the baking process. Both weights were baked using the same
standard baking program (see table 1). It is again evident that
an adjustment would already be necessary to the parameters
in the baking program in order to produce a constant quality
at different initial weights.
It must be concluded that appropriate control by scaling the
baking parameters to match the actually existing loading
state seems extremely sensible from the quality and energy
viewpoint. Table 2 summarizes the fundamentally different
magnitudes of effect on the quality characteristics and energy
source: ILU
18
19.3
75 g bread rolls
21.1
9 & 10
source: ILU
baking tray no. [–]
consumption of small wheat baked goods when using the
standard program (see table 1). The large number of possible parameter variations becomes visible when the variation
in weight (quantity loaded) and the thermal state are also taken
into consideration. Therefore the main parameters exerting
an effect must be found and must be scaled appropriately. In
this respect the most important influencing parameters are
baking temperature, baking time and the amount of water
vapour during steaming (a large beneficial effect is shown
by “+ + +” and a large adverse effect by “– – –”).
Development of the controller and integration of the
measured data and practical test
The essential outcome of the studies by ILU was the discovery
that an optimum baking process is decisively determined by
the climate prevailing in the baking compartment, irrespective
of the amount loaded. Thus the oven hardware and software
must provide this climate in such a way as to always generate
optimum quality with the smallest possible use of energy,
regardless of the temperature and quantity of the goods
loaded.
A circulating hot air oven was initially available to Matlab/
Simulink as a development environment for practical implementation. This was used to depict as a model the basic parameterisable functions of a circulating hot air oven. The
Table 2: Effects of technological parameters on baked goods quality
Baking loss/
crust properties
Parameter
Baking temperature (°C)
Baking time (min)
Amount of water evaporated (ml)
Steam exposure time (sec)
Size of effect on:
Gloss/
Surface
volume
pattern
Energy
consumption
230
+++
–
++
+++
200
––
+
–
––
18
+++
0
+
++
15
–––
0
–
––
750
+
+++
++
+
350
–
–––
––
–
20
0
––
–
0
40
0
++
+
0
source: ILU
78
79
SCIENCE
++ figure 5
E=8.4 [%]
4.0
energy [kWh]
3.0
1.2
E=4.3 [%]
Illustration of the energy consumption
relative to the course of a day
E=25.9 [%]
1.0
E=11.7 [%]
energy [kWh]
3.5
++ figure 6
Energy comparison of different control
managements when baking with a full load
2.5
2.0
1.5
E=39.1 [%]
E=45.3 [%]
bread rolls
pretzels
0.8
0.6
0.4
1.0
croissants
bread rolls
11.25 kg dough IAP
pretzels
11.25 kg dough Conv
aim was first of all to study the effectiveness in the model of
the adjustments that had been found, before undertaking
time-consuming CAD design and programming. At the same
time it must be said as a proviso that the models that were
generated cannot replace an evaluation model, but can be used
to set up a very effective signpost. The quality of the models
ultimately depends on the extent of knowledge of the boundary
conditions.
The next step consisted of developing a controller that can
scale the parameters to the quantity loaded and to the temperature prevailing at that time. To have this information
available appropriately at the start of baking, it was necessary
to set up a suitable measurement and control system and also
to integrate it into the controller. In addition the data obtained
by the ILU were incorporated into the baking process controller.
This controller was integrated into an existing Dibas 64L,
and for practical tests in a first step it was made available to
the project partner ILU for validation. As an example, we
show a comparison of the energies for a full load (10 baking
trays, 11.25 kg of dough) of the products “croissants”, “bread
rolls” and “pretzels”, firstly using the standard baking program
(see table 1) and secondly with the newly developed IAP (internal working title) control management (see figure 5). It can
be seen that smaller energy consumption is always achievable
with the newly developed control scheme than with the conventional programs. There is an energy saving of approx.
4–12 %, depending on the individual process for the different
products.
Figure 6 shows the energy comparison for the three products
“croissants”, “bread rolls” and “pretzels” when the oven is
loaded with only 2.25 kg of dough. This now reveals the consistently significantly lower energy expenditure of the newly
developed type of control (IAP) compared to standard programs (Conv). The difference in the quality of the products
formed is equally clearly apparent. Furthermore, in experiments
not reported in detail here, it was discovered that the energy
saving in the comparison between the “new” and the “conventional” type of control becomes even larger as the amount
of dough loaded [kg] is reduced. When interpolated, the resulting relationship for the energy saving as a function of
the amount of product loaded has a polynomial shape. In
source: Wiesheu
0
0
croissants
2.25 kg dough IAP
2.25 kg dough Conv
source: Wiesheu
0.2
0.5
other words, if value is placed on same-day fresh goods, and
therefore over the course of a day fewer goods are baked off
in accordance with the demand, the effect of the energy saving
then increases greatly, up to approx. 45 % (see figure 6).
After developing the controller, the prototype was subjected
to a practical test in a customer branch. This included determining data about energy consumption as a function of the
amount loaded and the temperature condition of the goods
loaded. The data for analysis were collected over a period of
four months.
In general, it was discovered that the oven was fully loaded
in only 16 % of all baking processes (see figure 7). Conversely this means an 84 % proportion of part-load operations in
which an unnecessarily large amount of energy is expended,
and this increased energy expenditure has an additional disadvantageous effect on the quality of the products. For example, this is detectable as an increased baking loss, excessive
intensity of browning and a volume that is too small.
왘
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TECHNOLOGY
++ figure 7
Illustration of the daily oven
occupancy in the branch tested
full
not full
Further data show that in one third of cases the baked goods
at the time of loading display large discrepancies relative to
the thermal preconditioning required at that time. This is a
situation that in theory cannot occur, but in practice always
creeps in due to overlapping work procedures. Here again
the system can provide support, if required, by detecting
this fact and adjusting the baking parameters accordingly. In
practice the implementation takes place in such a way as to
achieve a flexibility in handling the dough pieces that occurs
in practice without calling into question or trying to replace
the users’ actual know-how.
Summary and outlook
A product state dependent control system for baking in a Dibas
hot air in-store baking oven was developed and successfully
subjected to a practical test in the context of a KF (industry/
source: Wiesheu
research agency collaborative) project by the cooperation
partners ILU e.V. and the WIESHEU GmbH, funded by ZIM
(the German Central Innovation Program for SMEs).
During the development, attention was paid to finding a
simple, robust, practicable solution that fulfils a measurable
benefit gain. The development was able to achieve this. In
addition to optimum product quality, which is achieved irrespective of the oven loading, it was possible to reduce the
use of energy for baking by approx. 12%. Relative to the daily requirement of a branch, the measured saving for baking
was up to 45 %.
Another advantage of the novel control system is the direct
intervention of the operating personnel after the baking process
in the sense that it is possible, after assessing the quality of
the products, to exert a direct influence on individual quality
characteristics such as browning, baking loss or gloss.
The development of the novel oven with a product state
dependent controller gives the client a simpler to operate
technical solution for quality-assured, energy-saving baking.
The oven will be presented on WIESHEU’s booth at the iba
in Munich (Hall A3, Stand No. 530).
Literature
1. Hermann, Ch.: Baking rye mixed breads at low
temperatures (49 pages). Manual of Baked Goods
(Technology), 2003, B. Behr’s Verlag GmbH & Co.,
Hamburg, Publisher: W. Freund.
2. Nitz, M.: Heating without burning money.
DBZmagazin 94 (2007) 3, pp. 18-21.
3. wk.: Hot baking – ice-cold saving.
BäkoMagazin (2010) 10, pp. 56-67. +++
++ Horizontal mixing process
for raw materials
T
he Swiss manufacturer for plants and equipment Bühler
AG from Uzwil has brought out a new horizontal mixer
for raw materials, the Sanimix MRMA. As a paddle mixer,
the machine handles dry mixes; in the version as chopper
mixer, the mixing tools, which are similar to ploughshares,
and knives process even shortening and liquids. It is also
able to handle whole block fats. Horizontal mixing of the
product is completed quickly, thus speeding up the entire
process. The large outlet flap ensures fast, residue-free discharge. These features result in high throughput capacities.
The unit is available in four different sizes with volumes of
500, 1,000, 2,000 or 4,000 l. It can be optionally equipped with
a liquid injection system, product temperature monitoring,
wages, circulating air as well as a pre-chamber and a postchamber. Sanimix features a gap-free mixing chamber that
prevents cross-contamination. Compressed air purging of
bearing seals provides additional protection against product
carryover from one batch to the next.
www.buhlergroup.com/sanimix +++
© Bühler
80
Dough-how & more …
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RONDO Burgdorf AG, 3400 Burgdorf, Switzerland, Phone +41 34 420 81 11, Fax +41 34 420 81 99, [email protected]
RAW MATERIALS
Sustainability as part of the product
TH E E NVI RON M E NTAL I M PACT OF PALM-OI L I S B E I NG PI LLO R I E D B EC AU S E TH E AR E A S U S E D
F O R I T S C U LT I V AT I O N W E R E E N L A R G E D AT T H E E X P E N S E O F R A I N F O R E S T S . A S A M E M B E R
OF TH E ROU N D TAB LE FO R S U STAI N AB LE PALM OI L (RS PO), TH E CSM NV BA S E D I N DI E M E N,
T H E N E T H E R L A N D S , H A S P R O M O T E D E C O L O G I C A L A LT E R N A T I V E S S I N C E A S E A R LY A S 2 0 0 5
Growing demand has consequences
Consequently, the product from the palm tree has risen to
become the world’s most important vegetable oil with a market
share of 31%, ahead of even soya and rapeseed oil. It is no
wonder that according to a report by the World Wildlife
Fund (WWF), the oil palm’s cultivation acreage has doubled
to 12m ha since 1990. It also reports that the worldwide demand for palm oil is currently 50m t/year. About one tenth
of this goes to Europe, around 1.3m t ending up in Germany
– mainly in the food industry’s production plants.
However, the oil palm’s triumphal march has a clearly visible
dark side and is in the crossfire of criticism by environmental
protectionists. Enormous areas of tropical forests, chiefly in
Table 1: Palm oil and its derivates in functional margarines and fats
product
description
with palm
oil/derivates
without palm
oil/derivates
butter
oil
margarine for
puff pastry
applications
unhardened
hardened
/
margarine for
yeast dough
applications
unhardened
hardened
/
margarine
for baking
applications
unhardened
hardened
/
deep-frying fat
unhardened
hardened
/
shortening
unhardened
hardened
/
liquid fat
for baking
unhardened
hardened
/
liquid fat
for frying
unhardened
hardened
/
As the table illustrates, in a few applications there are no palm-free unhardened
functioning alternatives that can be offered when the use of hardened fats and
oils is not allowed. Hydrogenated rapeseed or sunflower oils and corresponding hydrogenated trans-esterifications can be used as alternatives.
source: CSM
”Trade means change” – this saying is also true for
baked goods manufacturers, whose ingredients are
subject to varying trends and changed market requirements.
Continuous change has taken place over the past few years,
especially in the area of margarines and fats. The industrywide reduction in trans fatty acids led not only to the outlawing of partially hardened oils and fats but it also banned
hardened oils and fats, with the result that today unhardened
fats and oils must fulfil the high demands applying to highperformance products.
To maintain functionality, palm fractions such as palm oil
or palm kernel stearines are used in the majority of cases.
This has made the oil palm one of the most important suppliers
of raw materials to manufacture multifunctional margarines
and fats. For special margarines such as margarines for puff
pastry, Danish dough, yeast dough and baking applications,
there are no palm-free alternatives – apart from the hardened
fats and oils condemned by consumer protectionists. Palm
oil also has many advantages: it has a wide variety of uses
and is very heat-resistant. Compared to rapeseed with a yield
of 0.6 t/ha, the oil palm is outstanding with an average of
4 t/ha of plantation.
+
CSM changes over to sustainable palm oil
This dilemma facing the main consumers of the coveted raw
material has led to a re-think – and to a solution for the
problem, namely a changeover to sustainably produced palm
oil as an ecological alternative. In 2004, following an initiative
by the WWF, this led to the foundation of the “Round Table
on Sustainable Palm Oil” (RSPO), to which more than 500
businesses in the palm oil supply chain now belong. CSM is
among the forerunners in the purchase of sustainable palm
oil: The company has been a member of the RSPO since 2005.
By 2015, in many small steps corresponding to the crop production capacities, CSM will completely change over its industrial framework conditions to sustainable palm oil with
an RSPO certificate.
The RSPO’s aim is to encourage the ecological, certified cultivation of oil palms, thus protecting the climate, wildlife
and mankind. All the members have voluntarily undertaken
special margarines
Katy Becks, a qualified confectioner and food technologist,
works at CSM in Bremen as
Market Manager Industry.
Before that she was employed
in product development at the
CSM site in Bingen, focusing on
fine baked goods. +++
the main producing countries of Indonesia and Malaysia,
are making way for raw materials suppliers. Other plant species
are being displaced and palm tree cultivation releases greenhouse gases. However, at a time of rising world population,
there is no visible way in which the future can be fashioned
without palm oil.
special fats
Author
© CSM
82
83
RAW MATERIALS
source: www.rspo.eu
Supply chain system:
“Book & Claim”
++ figure 1
At the “Book & Claim” certificate trading program, the supply chain for sustainable palm
oil is skipped. Instead, the sustainable palm oil producers sell GreenPalm certificates which
are for specified volume of sustainable palm oil. By buying and using the certificates, the
following claim can be said: “Increases the production of RSPO certified sustainable palm
oil”. Claimed volumes are matched.
++ figure 2
“Mass Balance”
source: www.rspo.eu
Information for entrepreneurs
Producers, traders, manufacturers and retailers will
find practical advice about how they can achieve the
various stages of certification and which conditions
they must fulfil to reach them at the Internet address
www.rspo.eu/market/howtobegin/index.html. With
the “Book & Claim” procedure, for example, entrepreneurs can obtain certificates from the onlinebased trading platform GreenPalm, which is committed to worldwide sustainable palm oil production.
One of these certificates corresponds to 1 t of palm
oil or its derivatives. Purchasers can use the corresponding labelling in their advertising. Membership
of the RSPO is not required, but members save the
GreenPalm fee amounting to USD 500 (approx.
EUR 406).
Alternatively, with the “Mass Balance” procedure,
only members of the Round Table can advertise using
sustainable palm oil. In this model, sustainable and
conventional palm oil can be mixed together in the
supply chain, and the proportion of ecologically
produced raw materials can be stated. The entire
added value chain must be audited and certified
regularly. The certification costs are comparable to
an ISO 9001 audit. The position is the same with the
“Segregation” procedure: in the latter model the two
kinds of oil are strictly segregated in the supply chain,
and the proportion of sustainable oil is labelled and
advertised with a corresponding claim. RSPO-certified
suppliers already ascertain the proportions of palm
oil and palm oil derivatives, and buy raw materials
accordingly on the basis of segregation criteria.
However, in contrast to pure palm oil, many derivatives such as palm stearin, palm oleins or palm
kernel derivatives cannot be purchased in “Segregation” quality, and so a complete changeover to exclusively sustainable palm oil or sustainable palm
oil products will take some further time. +++
++ figure 1
++ figure 2
At the “Mass Balance” certificate trading program, the sustainable palm oil from certified
plantation is allowed to be mixed with conventional oil throughout the supply chain, while
allowing specific sustainability claims. Up to final refinery, all transactions are reported to
and controlled from the UTZ Certified online monitoring system. Oil with this RSPO brand
can be labeled with the claim “mixed”.
++ figure 3
“Segregated”
source: www.rspo.eu
an obligation not to clear valuable forest areas for
plantations, to preserve the habitat of endangered
animal and plant species, and to respect property
rights and fair working conditions. The initiative’s
successes are plain to see: the first farmers brought
palm oil in conformity with the RSPO’s guidelines
onto the market in November 2008; the 5m t of certified oil in 2011 already accounted for one tenth of
world production.
At the same time, German retail, in particular, has
committed itself to promote the cultivation of
sustainable palm oil. In May 2010 the Rewe Group
and the consumer goods groups and Unilever together with the WWF and the German Society for
Inter national Cooperation (GIZ) set up a specific
forum with the aim of improving the RSPO criteria
and boosting demand in Germany, Austria and
Switzerland.
++ figure 3
Under the “Segregation” grading program, sustainably produced palm oil is kept separate
from the non-sustainably produced oil all through the value chain. Up to final refinery, all
transactions are reported to the UTZ Certified online monitoring system. Then the separated
production way is controlled by a independent certification authority. Producer can label
their products with “This product contains [only/...%] RSPOcertified sustainable palm oil”.
From silo to truck
Tur
Key Conc
t
ep
n
w w w.kaakgroup.com