Cover Story Shelf Life: Bringing the Best in "Best Before" - WorldBakers
←
→
Page content transcription
If your browser does not render page correctly, please read the page content below
ASIA PACIFIC
Summer 2020 | Issue 2 | Vol. 24
Supporting the international baking & biscuit industry
Profile
The Rise and Rise of Bakers Delight
Technology
Refrigeration Systems in Bakeries
Research
Performance in Process:
Enzymes
Cover Story
Shelf Life: Bringing
the Best in “Best Before”
visit the new www.worldbakers.com incorporating our digital magazine
2 Autumn - 2019
contents
Summer 2020 | Issue 2 | Vol. 24
04 Comment 22 Special Report
New Priorities COVID-19 Redefines Convenient
Consumption in the APAC
06 News
The Latest in Business Moves, 24 Profile
Market Trends, Events and Launches The Rise and Rise of Bakers Delight
08 Technology 28 Markets
Refrigeration Systems in Bakeries Major Changes Ahead in Australia’s
Bread Market
10 Cover Story
Shelf Life: Bringing the Best 30 Trade Fairs
in “Best Before” It’s a Go for Thaifex Anuga 2020,
the Hybrid Edition!
16 Process
Continuous Mixing Spells 32 Biscuits & Snacks
Efficient Workflow The Ultimate Comfort Snack
– Soft Biscuits
18 Research
Performance in Process:
Enzymes (by Campden BRI)
24
PROFILE
The Rise and Rise
of Bakers Delight
worldbakers.com 3
comment
New
Priorities
E
stablished trends building on our on-the-go lifestyles have //
ASIA PACIFIC
//
As consumers abruptly shifted at the beginning of the year and are beginning
to settle into what we anticipate to be a new normal. Breakfast
//
//
//
return to //
Supporting the international baking & biscuit industry
to-go has given way to at-home options, and the bakery industry // CATALINA MIHU - Editor in Chief
has already responded to the change in priorities. Convenience // email: catalina.mihu@trade.media
staples, product remains a valuable resource, but self-isolating consumers now start their
//
//
//
Tel: +40 756 141 442
//
development day preparing and consuming breakfast at home, which will significantly
broaden breakfast choices. This means the notion of convenience will
//
//
TUDOR VINTILOIU - Senior Editor
// email: tudor.vintiloiu@trade.media
has not paused take on new meanings, a report by GlobalData finds. Hot breakfast items
and baking mixes play a more prominent role over “portable” options like
//
//
//
Tel: +40 21 315 90 31
for a “basics breakfast biscuits, for example. The report emphasizes that convenience
//
//
//
CRISTINA NAE
Advertising Sales Director
only” strategy – //
is by no means obsolete, but rather it will manifest differently in this new
// email: cristina.nae@trade.media
self-isolating reality. A focus on ease and efficiency will still define lunch, // Tel: +32 499 73 11 14
//
on the contrary, but options will expand as homebound consumers enjoy access to a stove,
oven, and well-stocked fridge. Individual preferences will make way for
//
//
// ADRIAN CODREANU
it follows food options that will accommodate entire families, which also means //
//
//
Production Manager
email: adrian.codreanu@trade.media
single-serves are replaced by family sizes.
adjustments “The challenge for brands will be to reposition convenience-oriented
//
//
//
Mobile: +40 722 507 227
//
along with products to meet the needs of today’s more anxious, isolated and value-
conscious consumers,” the study points out. Important values calling
//
//
SIMONA DUMITRESCU
Circulation Manager
//
them. the shots in food choices include, more than ever, prioritizing health and //
//
//
email: simona.dumitrescu@trade.media
wellbeing. On the other hand, “Consumers want health, but ultimately //
taste is king and they will not be willing to compromise on taste even if the // RALUCA CANESCU
// Publisher
product has a health halo,” Novozymes’ Rashmi Uppal was telling me in a //
// raluca.canescu@trade.media
recent conversation (you can read more about it in this issue’s cover story). // Tel: +40 21 315 90 31
//
One product category that has mastered delivering both convenience //
//
and nutritionally-packed flavors is frozen bakery. The global frozen // NICOLETA MARASESCU
// General Manager
pizza market size could expand at a CAGR of 3.2% and reach a value of //
USD25.2bn by 2027, according to a new report by Grand View Research. // nicoleta.marasescu@trade.media
// Tel: +40 21 315 90 31
Ready to bake products are among the fastest-growing segments in //
//
this category, market data shows; and so is the demand for bread. As //
// Contributing writers
consumers return to staples, product development has not paused for // Campden BRI, Technavio,
//
a “basics only” strategy – on the contrary, it follows adjustments along // Euromonitor International, Sharmila Rajah,
//
with them. Premium bakeries in Australia, for example, now provide // Mintel, Markets & Markets, IBISWorld
//
bread subscription services, with a selection of bread every week, either //
// Editorial office:
delivered to their preferred location or customers get to pick up their bread //
// G-ral David Praporgescu Street, no.1,
in-store. New priorities are met with new solutions. // District 2, Bucharest, 020965, Romania
//
// Tel: +40 21 315 9031
// www.mediatrade.ro
Like our page and join our online community: Copyright © Trade Media Solutions. All rights reserved.
f www.facebook.com/worldbakers No part of this publication may be used, reproduced, stored in an information retrieval system or transmitted in any manner whatsoever without the express written permission of
Trade Media Solutions. The publication of the contributed articles contained herein does not necessarily imply that any opinions given are those of the publishers. The greatest care
has been taken to ensure accuracy but the publishers cannot accept responsibility for omissions or errors. European Baker is published six times a year by Trade Media Solutions.
Follow us on Twitter: http://twitter.com/worldbakers When you have finished with this magazine please RECYCLE IT!
t We will update regularly on our activities, upcoming
features and show attendance.
Annual subscription: one year £50/€60/US$77 and two years £90/€100/US$150.
Subscribe online: www.worldbakers.com/subscribe
Join our group on LinkedIn search for:
Email: subs@trade.media or Telephone: +40 21 315 90 31. Printed by:
l World Bakers News Visit our website: www.worldbakers.com Sothis
ISSN: 2537 - 2378
4 Summer - 2019
Perfect once.
Perfect a million times.
You can grow with GEA Bakery.
We share your passion to create perfection.
At GEA Bakery we combine the craftmanship
and knowhow of Comas and Imaforni with the
process expertise, innovation and global reach to
help you succeed.
Learn more at gea.com/bakery
news
Sigma And Spiromatic Create
Joint Venture
Sigma and Spiromatic recently announced
the creation of SCUDO, a joint venture with
over 100 years of combined expertise,
created to offer innovative dough-mixing
solutions for the bakery and industrial
pastry markets.
The Italian company Sigma, a
Food Industry Technology Show manufacturer of kneading machines
Korea 2020 Debuts and planetary mixers, and the Belgian
A new trade fair for international food technology Spiromatic, specialized in pre-food
is set to take place from November 25 to 28, 2020, processing, announced the birth of
at the Coex Center in Seoul (South Korea). DLG SCUDO, a joint venture created to
(Deutsche Landwirtschafts-Gesellschaft - German become a worldwide reference in are just some of these challenges.
Agricultural Society) will organize the Food Industry automated and customized dough mixing “We want to offer customized solutions
Technology Show Korea together with Korea’s solutions for industrial production. starting from the specific needs
leading trade fair company Coex. The premiere of the SCUDO, Specialized and CUstomized of our customers,” says Stefano
new platform for food technology, processing and DOugh-mixing solutions, supports its Salvadori, president of SCUDO. “This
packaging will focus on developments and offers customers facing the challenges of the approach allows us to design unique
international food technology its relevance for the market by taking care of the production dough-mixing solutions with cutting-
markets in Northern and Eastern Asia. Together with peculiarities of each context. The edge technologies. We manage the
the parallel Coex Food Week, the leading trade fair implementation of new technologies, the whole project: from manufacturing
for foods and beverages in the markets of North reduction of costs and waste of production and assembling to the integration of
and East Asia, the trade fair represents the entire process, the control and management of automated solutions and installation,
value-added chain. The deadline for registrations is increasingly complex production systems and up to after-sales services.”
September 29, 2020.
AMF Introduces First Emission-
Free Hydrogen Tunnel Oven
Led by a commitment to develop burners, also known as clean hydrogen,
environmentally sustainable solutions for a proven CO2-neutral fuel that is
automated food processing, AMF Bakery produced via a renewable source. Though
Systems has introduced the world’s first commercial ovens typically use natural
emission-free, hydrogen-fuelled tunnel gas as the resource for heating the oven,
oven. The Multibake® VITA Tunnel Oven this new patent-pending technology by
by AMF Den Boer offers industrial bakers AMF Den Boer will virtually eliminate CO2
AIB International Launches an effective solution to reduce carbon emissions from the oven while reducing
dioxide emissions by 99.9% within the the cost of utilities.
Pandemic Prepared Certification baking process. Final performance tests and customer
AIB International has launched the Pandemic Prepared AMF Den Boer has taken the application evaluations have been conducted at the
Certification, a standard created for the food and of hydrogen technology in baking from AMF Innovation Center in Gorinchem,
beverage supply chain that elevates critical planning concept to commercialization, thus the Netherlands. “Bakeries and food
for people, facilities and production inputs and delivers expanding AMF’s complete portfolio producers with a sustainability agenda,
significant social impacts, builds bottom line resiliency, of thermal technologies. The modular wanting to reduce the carbon footprint in
and unlocks insurance benefits. “We developed the Multibake® VITA their baking process, are invited to test
Pandemic Prepared Certification because the food and Tunnel Oven their products at our Innovation Center,”
beverage supply chain were ill-prepared for a global utilizes green said Remco Bijkerk, executive
pandemic and the associated disruption it created in hydrogen to product manager for AMF Den
nearly every aspect of business operations world-wide,” activate Boer. “We can even retrofit this
said Steve Robert, Global VP of Sales, Marketing and its technology into existing ovens
Innovation, AIB International. “The AIB International that are already in the field.
Pandemic Prepared Certification is a proactive measure to We are confident many food
help companies across the supply chain prepare for the producers will make the upgrade as
future with the only best-in-class protocol benchmark.” we see growing urgency for sustainability
measures in baking,” Bijkerk concluded.
6 Summer - 2020
Jeremy Better World Naturals Earns Clean-label
Xu Joins Project Certification
Ingredion Plant-based ingredient manufacturer Better World Naturals announced it has become the first ingredient
manufacturer to earn Clean-Label Project Certification. Clean Label Project is a recognized non-profit
Ingredion announced that Jeremy organization that uses data and science to bring transparency to consumer product labeling, awarded
Xu has been named senior vice the certification after subjecting the company to its rigorous assessment process.
president, and chief innovation officer, Better World Naturals told us that their rosemary extract comes in the form of a deodorized water-
effective October 1. In this capacity, soluble, oil-soluble liquid as well as powder form, to ease their use in various applications. “For bakery
Xu will be responsible for advancing goods, the product keeps their functionality up to 180-210°C, while the impact of the rosemary extract
the company’s focus on specialty on flavor is minimal, given the very small
growth platforms, identifying new dosage needed to get the AOX effect,” said an
growth opportunities and overseeing exclusive statement.
the Ingredion Idea Labs® innovation “Tests and certifications are an important
centers. Xu will report to Jim Zallie, guarantee of quality for our customers and
president and chief executive officer. consumers. Nevertheless, we believe testing
Xu will succeed Tony DeLio who will alone cannot guarantee quality in the long term.
be retiring in February 2021 after Rather, at Better World Naturals we complement
14 years of service. Xu joins the testing with traceability, working with farmers
company from Royal DSM, where in the field to ensure consistent standards while
he spent four years leading a global shortening supply chains to improve quality
business unit in the nutritional control. The model benefits all stakeholders,
ingredients space. Before that role, with farmers getting guaranteed revenues
he spent 16 years at DuPont serving and brands receiving consistently high-quality
in a variety of leadership roles across ingredients,” Laurent Zheng, founder and
Asia and the U.S. general manager of Better World Naturals, said.
technology
Keeping Cool in the APAC
Considering the inherent high ambient temperatures often
found in bakeries, any refrigeration system designed to operate
in this environment must meet very strict specifications in
terms of temperature variation, insulation, food safety and
maintenance requirements.
T
By Tudor Vintiloiu
emperature variations have a outside remote condensing units that
negative impact on the dough have no impact on the laboratory room
or the baking mixtures, because temperature. All the parameters of our
the yeast action becomes hard machines can be always monitored and
to control and obtaining the right set, accordingly with end-user needs. The
proving process is all but impossible. dough final step in the retarder prover gives
The demand for blast chillers and retarder the possibility to program and manage the
provers is continuously increasing because production flow, obtaining the best result
these two essential appliances can and the best product quality," says Camilla
significantly optimize the production flow of Lucato, Castel Mac APAC sales manager.
any bakery. Chilling and freezing cycles are The electrolyte steamer their equipment
more and more often used to chill down the uses allows bakers to obtain a very
dough for its correct conservation, before precise humidity regulation and to reach
its proving that will be completed in the a homogeneous production, according to
retarder proving chamber. Lucato. The cycle includes four phases, as
These processes favor important time- well as the final 'sleeper' step, that conserves
saving and waste-reduction benefits the products inside the chamber until the
by allowing bakers to have consistent, optimal moment to bake it.
homogeneous results over time.
Asia Pacific Baker & Biscuit approached COST-EFFICIENT PRODUCTION
refrigeration specialists from Castel "One of the most important features that
Mac and SKOPE to learn about the all Tecnomac appliances have in common
particulars of the APAC market demand is the user-friendliness. Extremely easy
for refrigeration solutions and the specific management allows maintenance cost
challenges in the region. reduction and quick training courses
for the whole staff. These machines are
FROM MIXTURE TO DOUGH designed to increase the production, and
Tecnomac water chillers, for example, help for this reason, they represent a significant
the production flow by providing cooled water return on the initial investment: increased
at a constant temperature to maintain the productivity, fewer staff costs, standard
right mixture temperature. work shifts, waste reduction, consistent
The correct dough cooling is very important product results," Locato points out.
to avoid any immediate fermentation, while The chilling and freezing processes slow
its optimal conservation with controlled or stop the bacteria activity, and the
temperature and humidity preserves all its quicker the cycle, the better the product
organoleptic characteristics. will be conserved. The preparation method,
"Our equipment includes some patented repeated over time, will reduce waste by
features, developed thanks to the optimizing the production time in order to
experience in bakeries and professional obtain a homogeneous and reliable product.
refrigeration sector with a wide choice of "Tecnomac blast chillers include a patented
functions. The biggest blast chillers are algorithm, useful to automatically control
projected and developed respecting the the temperature inside the chamber so to
installation specifications and creating avoid ice formation on the product surface.
8 Summer - 2020
In Tecnomac retarder provers, besides the Our baking customers know that
temperature control, we additionally allow
control over humidity, so that bakers can if you want to be productive, you
reach the results they desire.
need equipment that is not just
DESIGN AND BRAND REPUTATION reliable but also easy to maintain.
Raha Hadjarpour, SKOPE regional export
director for Europe, Middle East, Africa &
Asia, says that temperature stability and to recalibrate the cabinet, adds Hadjarpour.
consistency are of paramount importance "SKOPE-connect is also a great asset for
because it's what customers expect and bakers because it will clearly and simply
what their brand reputation is built on. show them the temperature hold by
"Starting with unit design and testing, every presenting them with up to five months of Raha Hadjarpour,
one of our back of house equipment is data at their fingertips. This temperature SKOPE regional
M1-rated at Climate Class 5 at our purpose- data can then be easily exported for HACCP export director for
built commercial refrigeration testing center compliance, meaning bakers spend less Europe, Middle East,
in New Zealand. This facility accurately time on administrative tasks and more time Africa & Asia
replicates the harshest heat environments baking," he illustrates.
seen in different parts of the world, which
is important because it means the baking APAC MARKET & DEMAND
sector across APAC can have complete Both producers are reporting a surge in
confidence that their SKOPE equipment has, demand for refrigeration solutions, which
for example, been ambient tested at +40°C," can be attributed to current trends and
Hadjarpour underlines. changing consumer tastes, but also to
SKOPE considers that operating, the COVID-19 pandemic, which has put
maintenance, and productivity costs all go notable pressure on upholding food safety
hand-in-hand. Neglecting or compromising standards around the globe. "Demand is
one will directly impact the others. Well- going up for high-performance refrigeration.
maintained refrigeration also means lower Before COVID-19, we were finding that
operational costs because it supports consumer demand for more local, fresh
long-term consistent performance. "Our food was driving this in many parts of
baking customers know that if you want to the world, as well as non-traditional
be productive, you need equipment that is “fresh food” sectors like convenience.
not just reliable but also easy to maintain," This includes APAC, despite the prevailing
says Hadjarpour. forecast that the region was destined to
adopt a more Western, packaged-oriented
SMART FEATURES appetite. But since the beginning of the
One of the sought-after features of SKOPE pandemic, the demand has been amplified
equipment is SKOPE-connect, a software that by the increased requirement for food
allows bakers to pre-set, monitor, and control that can be delivered with watertight food
the fridge or freezer with a touch of their safety. Consumers in every country care
Camilla Lucato, smartphone – right down to changing the about their health like never before, which
Castel Mac APAC temperature range for different products in a means healthier, fresher ingredients, and
sales manager few moments. For a baker, that could mean also the preservation of taste, texture, and
avoiding a call to a service technician or even smell," Hadjarpour explains.
the need to buy new refrigeration solutions. Castel Mac's Locato says they have also
With a SKOPE ReFlex or Prospec food storage observed an increased demand for cooling
freezer, they just touch a button on their app technologies in the APAC, correlated with
a global surge. "People are understanding
that these appliances are essential
One of the most important features equipment to improve production and
that all Tecnomac appliances have
to reduce staff costs, and especially to
preserve the products and ensure food
in common is the user-friendliness. safety. The best product quality quest is
always the first target for every kitchen
Extremely easy management allows and bakery, in order to always offer the
maintenance cost reduction and quick same standard and reliable product, which
determines customers to always come
training courses for the whole staff. back," Locato concludes.
worldbakers.com 9
cover story
Time after Time
Products and processes helping with the shelf-life of bakery
items not only ensure sustainability, profitability, and minimize
waste, but must also deliver consistent characteristics, which
must be the same in day one as in any of the “best before” dates.
It’s a tall order with innovative solutions.
By Catalina Mihu
B
aking is one of the most important And that’s not all, as TC elaborates; enzymes
industries Novozymes serves; every also bring various benefits that help differentiate
two out of three breads consumed products and meet consumer demands for
worldwide are likely to have been specific claims and health & wellness trends.
processed with enzymes from the Enzymes can help deliver products meeting
company. Maintaining product freshness is these demands. For example, claims such
one of the tasks for which enzymes provide as high protein, low carb, low GI, whole
the answer: “In essence, an enzyme is a grain/multi-grain are becoming popular and
protein produced from microbial technology, Novozymes’ solutions enable the production of
where we have enzymes acting on the starch such products. Another area where enzymes
molecule of the flour, to prevent it from bring great benefits is that they help to reduce
retrogradation,” TC Tan (TC), Asia-Pacific acrylamide significantly in a wide range of
regional vice president for F&B Business, products including baked goods and snacks.
Novozymes, explained for us. Enzymes make “Consumers in China are very Internet-savvy,
starch crystals less prone to re-crystalization interested in low E-number products. They buy
(staling), in this case. This supports food products online in advance and store them. So
sustainability and minimizes food waste. bakers are finding that traditional channels are
being disrupted with a change in consumption
ENZYME PROFICIENCY patterns. This is where enzymes become an
Importantly, enzymes help to reduce food waste, innovation tool, enabling differentiation from
which is one of the biggest problems that a marketing point of view,” highlights TC.
humanity faces today, especially when close On the other hand, “Consumers want health
to one-third of all of the food produced in the but ultimately taste is king and they will not
world is wasted. “Some markets are wasting a be willing to compromise on taste even if the
lot more at different stages of the value chain: product has a health halo,” adds Uppal; enzymes
anywhere from 5 to 20% of the food is wasted will deliver on this too, leaving no mark on the
on the distribution channel itself in some cases, fresh taste and feel of the final foods.
not to mention waste during production and Taking bread as an example, we look for
food discarded by consumers themselves,” different things in it: softness, healthy
Rashmi Uppal, Asia-Pacific regional marketing ingredients, great taste, crisp crust, soft
manager, also said on behalf of Novozymes. In and moist crumb. “I want this experience
some of the mature markets, in general, half until my loaf is over, not just when I’ve just
of all the food is wasted in consumers’ homes returned from the store today. That’s where
for various reasons. Enzymes extend freshness, our enzyme for freshness technology comes
reduce wastage and help to reduce the impact in. Enzymes preserve the bread fresh,
on the environment, from this perspective. moist, keep it resilient and elastic until it is
10 Summer - 2020finished. We’ve done studies and found that bakery product and maintain moistness and
consumers throw away bread when it gets enzymes to preserve softness. Ensuring
dry or becomes brittle; this is what staling both eating quality and inhibiting microbial
is all about. We have a gold standard called growth are critical and have very different
Novamyl, used for over 25 years in many strategies when formulating and making
countries around the world, which prevents baked goods with extended shelf-life.
the starch in the bread from becoming hard, Eating quality is usually what people think
and it does this in a very unique way: it of first and involves using ingredients or
modifies the starch granules. This amylase packaging that affect organoleptic properties
does not affect the primary starch structure; - texture, flavor, aroma, etc. “Inhibiting
it leaves it intact. Instead, it generates a microbial growth consists of chemistry
simple sugar such as maltose, and prevents and microbiology to help with formulation,
or slows down starch retrogadation. So the processing and packaging to minimize
crumb continues to be soft, making the exposure to mold and yeast naturally
bread stay softer for longer,” explains Uppal. occurring in the environment, adjust pH,
Depending on the type of finished product, lower water activity and minimizing the
each has different freshness needs. The presence of oxygen,” Dawn Foods’ R&D
timeframe of ideal shelf-life can range from teams elaborated in an interview.
5-90 days or more, depending on what Moreover, the use of natural or artificial
the specific market prefers for the product preservatives is commonly used in
itself. Whether they have that product today extended shelf-life products to inhibit the
or one month later, consumers want to have growth of microorganisms. For example,
the same freshness experience, just as they a typical wrapped muffin with no shelf
would have in a café or a bakery chain. This life-extending technology last five days,
is visible in social media conversations, but by controlling water activity and using
where consumers document their food the correct ingredients and dosages, shelf
experiences. “No matter where the product life could be increased to 90 days, Dawn’s
is consumed, freshness remains very specialists illustrate.
relevant,” highlights Uppal. Dawn’s core categories are donuts,
Michael Pruss, head of business muffins, cakes and brownies. While there
development, Deutsche Back, shares the are similarities in approach, each type of
company’s expertise: “Depending on the product can have different challenges and
formulation of the baked product, the recommendations. Biscuits and cookies by
mostly enzymatic shelf-life enhancement their very nature have lower water activity
works differently. While it is easier for (e.g. free water in the product) so the
bread and low-fat and low-sugar products, approach to extending shelf life is simpler
enzymes do not work on the same level in than for a muffin, for example. Cookies
an environment of high fat and sugar. It is may only require an enzyme to maintain
necessary to review both the formulation softness, but for muffins, a mold inhibitor
and the type of packaging to achieve the and humectant would be required at a
most efficient shelf-life improvement.” minimum, along with controlling the water
Side-effects must be considered depending activity. For cakes, the level of sugars, fats
on the product, he adds. Parameters to be and eggs are usually high enough that they
checked are, for example, the anti-staling, already eat very well for several days –
the moisture of the product, or even the especially when decorated or finished with
crusty appearance of the crust. a rich icing. “For brownies, it is common to
add a humectant like corn syrup to improve
THE SCIENCE IN SHELF-LIFE eating quality over shelf life. For donuts,
There is a variety of ingredients available to we commonly see the use of emulsifiers or
extend and achieve the desired shelf life of hydrocolloids to improve the shelf life for a
bakery products. Some examples include few days, and enzymes are becoming more
using potassium sorbate to reduce mold commonly used by formulators to increase
growth, and humectant (e.g. vegetable shelf life from days to several weeks,”
glycerine) to control free water in your Dawn’s experts tell us.
worldbakers.com 11cover story
PACKAGING AND STORING consideration when establishing the
The conditions from the exit of the oven best-by date,” Dawn’s specialists add.
to sitting in a bakery for sale are critical Knowing the display temperature and
to maintaining a product's shelf life. “It’s humidity is key in determining shelf life.
essential to know how the end customer “Freezing baked goods essentially stops
will receive and display the product and most of the staling and microbial growth
which country it’s designed for before and would be the best way to extend
product development even starts. Having shelf life. Besides that, avoiding storage
the correct packaging (wrapping, carton between 32°F - 50°F will help avoid the
and pallet) from the start will also help to staling process that is accelerated in
maintain the quality during transportation these conditions. After freezing, 60°F –
and extend shelf life. A baked good’s 80°F will be the best temperature zone
“mode of failure” is also considered – when on display,” explains Dawn.
whether it is via mold, staling or another The packaging is a very important
Dawn Foods’ mechanism. Packaging materials can parameter that must be reviewed.
R&D teams be modified via oxygen and/or moisture “Most products that are designed for
transmission to assist in establishing and long shelf-life are packaged. Some
prolonging the shelf life. If baked goods of these products have either been
are kept ambient during distribution, pasteurized after production in the
gas flushing the packaging is another bakery or a gas exchange was the
last step to close the package. Good
Inhibiting microbial growth consists packaging is essential to guarantee the
claimed shelf-life,” Pruss adds.
of chemistry and microbiology
to help with formulation, UNBOXING PACKAGING
REQUIREMENTS
processing and packaging to Ensuring product properties throughout
minimize exposure to mold and
its expected shelf life is an all-rounded
process involving but not limited to
yeast naturally occurring in the packaging film, packaging machine
characteristics and packaging process.
environment, adjust pH, lower Alberto Peverali, Asia sales manager,
water activity and minimizing the and Marco Nese, Bakery MAP product
manager at IMA-ILAPAK, have helped
presence of oxygen. shed life into the packaging perspective:
12 Summer - 2020Consumers want health, but organoleptic characteristics do remain
unaltered, taste and texture may be
ultimately taste is king and affected due to packaging. A well-studied
mix of inert gases (N2 and CO2) is vital to
they will not be willing to retain initial product characteristics, we
compromise on taste even if the learn. IMA ILAPAK involvement with MAP
and its commitment to R&D over the years
product has a health halo. has led to the development of patented
technologies allowing for oxygen residual
to be kept to the very minimum possible
“Enemies of food quality are oxygen, through vacuuming of the product itself.
bacteria and mold. Without oxygen, the
proliferation of bacteria and mold is PRODUCT-CENTRIC APPROACH
Rashmi Uppal, blocked, fermentation and degenerative The shelf-life of a baked good can be
marketing manager, activities inhibited. The product recipe, defined as the period in which it 1) maintains
Novozymes process, and packing environment its taste; 2) maintains its initial texture,
combined undoubtedly play an important and 3) remains safe to eat. For these three
role in reducing product contamination, challenges, Puratos offers its knowledge.
thus helping in securing an extended shelf- Frank Devos, senior business development
life,” they explain. manager Sourdough and grains, and
Baked products in general, and bread in Anh Thai, senior global product manager
particular, with a close relation to oxygen Patisserie, explained how to treat each type
residual level, are subject to mold growth. of product to optimize its shelf-life.
“Reducing oxygen content in the pack To maintain the initial texture of the baked
is a must to achieve an extended shelf- goods, Puratos offers two types of products:
life. Packing films are to offer a barrier enzyme-based solutions (Acti Fresh for cakes IMA ILAPAK
to oxygen and packaging machines are and Soft’R Improvers or Intens modular specialists
to deliver hermetic seals. IMA ILAPAK improvers for breads) to maintain freshness
for years has embraced MAP (Modified as much as possible; and well-balanced
Atmosphere Packaging) technology; water-based fillings to limit water migration
product is flushed with inert gases during between the different components.
packaging phases, to reduce the amount of
oxygen residual in the pack,” the specialists
tell us. The more porous the baked product Reducing oxygen content in the
is, i.e.: bread, the higher the percentage of
oxygen being trapped. Typically, an oxygen pack is a must to achieve an
residual of 3-8% in the package could extended shelf-life. Packing films
double the product shelf-life. Besides,
combining MAP technology with vacuum are to offer a barrier to oxygen
on products can reduce oxygen residual
down to 0,5% and this could lead to four
and packaging machines are to
times longer shelf-life, they illustrate. While deliver hermetic seals.
worldbakers.com 13cover story
Hardness and cohesiveness measurement of a cake over time:
Source: Puratos
Depending on the formulation enzyme-based improvers often range
between 0.5 to 1.5% on the total batter for
of the baked product, the cakes and from 0.5 to 1% on flour for bread.
mostly enzymatic shelf-life Store temperature should also be
acknowledged; “In reality, the “best before”
enhancement works differently. date needs to be defined by testing and
[...] It is necessary to review both putting the products in real conditions as it
depends on many other parameters such
the formulation and the type of as the respect of the Good Manufacturing
Practices,” Puratos says.
packaging to achieve the most A checklist of factors that can maximize (or
efficient shelf-life improvement. hinder) shelf-life in the bakery aisle is
extensive and starts from the cleanliness
of the production process, to balancing Frank Devos, senior
“To keep the product safe to eat, it is the recipe by mastering the water activity, business development
important to understand the migration of then selecting the right packaging material manager Sourdough
water and measure the Aw (Water Activity),” and correctly modifying the atmosphere in and Grains, Puratos
Devos underlined. Another example in bread the packaging process, through to storage
Michael Pruss, is shown in the graphs with Soft’r Melting (a temperature. When thoroughly navigating
head of business bread improver dedicated for sweet bread). all factors, time is kept in check and leaves
development, Bread dough composition vastly differs bakery goods largely unaffected.
Deutsche Back from the cake batter composition in terms
of sugar, fat, leavening system and, most
importantly, water availability. “Therefore, To keep the product safe to eat,
Puratos selects the right type of enzymes
which can optimally work with these it is important to understand the
different systems and meet our customers’ migration of water and measure
needs,” the specialists say. The dosage
differs from different applications. Puratos the Aw (Water Activity).
Hardness of a cake filled with different type of fillings – low Aw 0.4 and Well balance Aw 0.73
Source: Puratos
14 Summer - 2020process
Continuous Workflow
in the Mix
The continuous stream of mixed dough is a balancing act between correctly
feeding and incorporating ingredients into the mixer; when properly set, it
eliminates any cycle inconsistency in the product and guarantees finished
goods will have the standard size and texture.
By Catalina Mihu
T
here are many and mixing energy data, which
advantages in continuous ensures stability to the production
mixing, as it can procedures and the proper tools to
effectively eliminate ensure consistency of mixing.
variables and ensure With the development of artisan
dough’s even hydration constantly products requiring rest and
– if done right. A wide range of fermentation times, VMI’s VERYMIX
products can benefit from this continuous kneader has been
process without real limitations, able to adapt to this process,
combining essential parameters in particular by separating the
according to each application, from continuous phases of premixing,
the shape of the tank, the design fermentation and kneading. “For
of the tool, premixing, temperature, example, VMI’s horizontal premixer
speed, atmosphere, energy, etc. allows a first homogenization
The continuous monitoring and phase, which can either be
control of the process is key to integrated directly in the continuous
ensuring consistency of production. mixer, or go into buffer tanks for a
For French technology specialist VMI, fermentation phase, while other tanks
the latest innovations in improving feed the mixer,” Claire Auffrédou,
this process relate to automation marketing & communication at VMI,
and the feedback of data allowing explained for us.
better control of the process. For In the same way, the VERYMIX
example, its continuous mixer continuous mixers make it possible
Verymix provides graphs and visual to automate the flow management
metering of motor intensity, dough towards resting phases or for a
temperature, glycol valve openings transfer to the line, while also
16 Summer - 2020reintegrating the dough scraps. According
to the mixing phase, VMI has worked
The control of all these
particularly on the shape of its tools and parameters introduces flexibility,
which was before considered as
tanks, specific to premixing, kneading or
fermentation steps. “Our latest addition
is a mobile CIP station, to operate with
great flexibility. Continuous mixing allows
in contradiction with continuous
24/7 production and automated washing mixing principles.
system and limits production downtime,”
Auffrédou added. and other baking ingredients are hydrated
Zeppelin Systems GmbH’s latest upgrades with water and immediately form a
to mixers for continuous mixing include homogeneous dough and the beginning of
an improved hygienic design and the IP66 a gluten network. A continuously metering
Protection standard, which certifies its and weighing device for all the ingredients, Claire Auffrédou,
complete protection for washing in place, including liquids, is an important condition marketing &
Thomas Ismar explained on behalf of the to ensure the repeatability of the doughs communication, VMI
company. The German specialist’s newest that are produced. “Because of the specific
automatization features are directed toward geometric design, the mixing bowl of the
energy infeed control. “Servo drives help Verymix optimizes the thermal exchange
control the necessary parameters of infeed, with the dough. The temperature of the
speed, temperatures and energy to ensure raw materials and dough is measured
constant output quality,” he explains. continuously during the entire process
Zeppelin highlights automatization steps,” VMI’s specialist says.
features perfecting continuous sponge & The premixer helps optimize hydration;
dough process: it is more efficient than a lot of products can be produced in one
batch production due to the complete stage. “Our Dymomix hydration system
incorporation of ingredients, reducing ensures a homogeneous blend of both the
waste, using lower-energy while also dry and liquid ingredient streams,” explains
achieving a higher control of the product’s Zeppelin’s Ismar.
quality, the specialist explains.
APAC REQUIREMENTS
CONTINUOUS FEEDING In VMI’s experience with the APAC markets,
The continuous feeding of ingredients – soft products are in great demand. “They
dry and liquid – is fully integrated; Zeppelin have the particularity of requiring a finer,
controls this process and can deliver dough softer crumb, without holes,” she points
with temperatures of 18°C and higher out. Another trend in the region is the
without ice or CO2, and lower than that ability, through the process, to reduce
with the addition of CO2. additives, fat and salt. “The ability to
The continuous mixing process implies an better regulate product aeration, or even
uninterrupted workflow, from the dosing to control the atmosphere with our latest
of the flour through to the output of the continuous mixer, the CONTINUUM, allows
mixing bowl. Achieving dough consistency for a more homogeneous distribution of the
starts with dosing (by weight) of all air in the dough, reducing the sticky effect
powders and liquids that are part of the of the dough and improve its elasticity,”
recipe being produced. “Such continuous says Auffrédou.
systems make very accurate dosing of raw Zeppelin also reports continuous
materials possible, according to production mixer requests come mostly from
needs and at high rates,” VMI’s specialist manufacturers making toast, buns, rolls,
points out. Continuous mixing provides hard and soft cookies.
a very efficient alternative to extended For future developments in this process, VMI
process batch time, kneading variations, or takes two important aspects into account:
uncontrolled bowl resting time. the ability to integrate it into a global process,
Pre-mixing is essential to produce a and the ability to provide smart and predictive
homogeneous and smooth dough, also information to improve the equipment
continuously measured and verified. A process, its use and its maintenance. The
continuous flow of dough is therefore company tells us they are also working on
ensured. A pre-mixer upstream of the improving preventive adjustment of the
continuous mixer is essential for the process, according to the use and the data
consistency of the results. Flour, sugar that can be collected and analyzed.
worldbakers.com 17research
Performance in Process:
Enzymes
Enzymes allow manufacturers to make bread, cakes and
biscuits that have the texture a consumer expects as well as the
desired shelf-life. However, the importance of enzymes is not
always appreciated and there is still some mystery attached to
what enzymes are and what they do, particularly as they are
not mentioned on the ingredient list.
By Sarab Sahi, Rheology & Texture Section Manager, Campden BRI
18 Summer - 20201/3
T
he wide occurrence of enzymes key enzymes including alpha-amylases,
is well known; in nature, animals proteases, lipases, and hemicellulases.
and plants can obtain and use Campden BRI uses two methods to of the
energy very quickly due to the measure the naturally occurring cereal
presence of these biological alpha-amylase activity in flour. One,
consumers
catalysts. In chemical terms, enzymes called the falling number test, relies on surveyed would
are proteins that have catalytic activity the marked reduction in the viscosity of be willing to
due to the correct arrangement of amino a flour/water slurry as the enzyme action pay more for
acids (protein building blocks) in space rapidly reduces the molecular size of the non-plastic
to ensure only a certain type of substrate starch chains. A more direct method is the or recycled
will fit and attach to form an enzyme/ Ceralpha assay method using a commercial
substrate complex. This lowers the kit containing a reagent with chemical
materials
energy of the reaction and speeds up the groups that are specifically hydrolyzed
rate of reactions, thus saving time and by alpha-amylase. The quantity of the
improving efficiency. Only a small amount chemical group is measured and directly
of an enzyme is needed to bring about relates to the level of alpha-amylase in the
the transformation of a large number sample analyzed. This method is applicable
of substrate molecules. This is because to ground wheat, white wheat flours,
the enzyme is released to repeat the malt flours, and fungal alpha-amylase
transformation when the by-products of the preparations.
reaction are generated. Hence, enzymes Several indirect methods indicate the
carry on working until their substrate is presence of enzymes in flour. For example,
exhausted or environmental conditions the physical change in the dough properties
become such that the enzymes are or those of a batter system can be
denatured, and the activity falls off rapidly. measured instrumentally using texture
Important factors that influence enzyme analyzers or viscometers. As the enzymes
activity include temperature, pH, ionic degrade the structure forming compounds,
concentration and substrate availability. The such as starches and proteins, the physical
inactive residues of the enzymes remain in properties will change. Similar instrumental
the final product and are harmless. techniques can be used to measure the
Enzymes occur naturally in most raw effect of an added enzyme to a dough, such
materials used in food production, such as as a protease or a hemicellulase.
cereals and legumes. Wheat is known to be
rich in endogenous enzymes, with several BAKING APPLICATIONS
playing important roles in traditional bread The baking industry faces several challenges
making processes. The concentration of in providing products that meet the needs of
these endogenous enzymes is usually low modern consumers. This is not easy for an
but can vary depending on the weather industry in which many of its products are
conditions close to the time of wheat grain indulgent because of their high levels of fat
maturation. There are also numerous and sugar. It’s true, however, that industry
commercially available enzymes, or does not use fat and sugar without good
exogenous enzymes, that can be added to reason. Both have several functional roles
recipes to boost the levels of endogenous during processing as well as contributing to
enzymes to achieve the desired effect within the final product’s eating texture and shelf-
the limits of the manufacturing process. life. In addressing these needs, one of the
These include alpha-amylases, proteases, solutions available to the baking sector is the
lipases, oxidases and hemicellulases to use of enzymes as processing aids.
name a few. Enzymes break down or modify
key food components such as starches,
proteins, fats and non-starch carbohydrates The concentration of these
such as hemicelluloses. endogenous enzymes is usually
MEASUREMENT OF ENZYMES low but can vary depending on
The measurement of enzyme activity in
raw materials, such as wheat flour, can the weather conditions close
be difficult as they are present at low
concentrations. In wheat flour, bakers
to the time of wheat grain
are typically interested in the activity of maturation.
worldbakers.com 19research
Fat has many properties that make it an
essential ingredient for baked goods,
including:
• stabilization of gas bubbles;
• retention of water, and
• softening of texture.
Therefore, despite it being desirable from a
health perspective, reducing the fat levels
in a recipe can lead to many problems.
Emulsifiers can be used to reduce the fat and
oil content because they can replace some
of the fat functionality. However, they appear
on the ingredients label with an E-number,
and, while the industry knows this means
they are a safe ingredient, consumers have formation of fermentable sugars helps the
a less tolerant policy. One solution is the use yeast work in a more controlled way. Slow
of lipase enzymes to generate emulsification generation of carbon dioxide prevents
materials in situ. They are used in bread and damage to the delicate network of gas
cake manufacture and can reduce the fat cells created by gluten in the dough. Too
required in a recipe. Enough of the specific much sugar could result in excess carbon
fat substrate must be present for the enzyme dioxide and over-inflation of gas cells, which
to work effectively, in addition to the could subsequently rupture. Amylases work
correct conditions of pH, temperature and slowly to maintain the balance of sugars
sufficient time. for fermentation until the yeast is killed at
Sugar also has an important role in baked around 55°C. Sugar generation continues
goods, conferring properties that include: for a few minutes after this until the
• providing sweetness, amylases themselves are inactivated by the
• stabilizing and controlling batter oven heat. Small quantities of sugar left in
viscosity, the dough contribute to crust browning and
• influencing the starch and protein setting provide some flavor.
temperatures, Also on the diet and health agenda is fiber.
• providing color through caramelization Fiber materials are beneficial to our health
and Maillard reactions, and efforts are made to include them into
• acting as a humectant (preservative), and bakery products. However, fibers such as
• softening the texture. wheat bran absorb a lot of water and do
However, sucrose has received bad press so more slowly than other components in
recently to the extent that, in many ways, dough. This causes processing issues with
it has taken over from fat as the primary tight dough that does not mold well but also
diet and health concern. Sugar created resists expansion by yeast action resulting
enzymatically in situ has significant in poor quality bread. An enzymic solution
advantages over added sugar, and not just with xylanases is available and is now
because it helps a product appear as a used in most industrial bread manufacture.
clean label. This is where amylase enzymes Xylanases cut some of the linkages of large
come into play in bread production. For fiber molecules to release low molecular
example, in bread dough, a gradual weight sugars and water. This helps soften
dough slowly so it can be processed with
fewer issues. The fiber materials are still
Sugar created enzymatically in available as a dietary benefit.
There are several other enzymes used in
situ has significant advantages the manufacture of bakery products that
over added sugar, and not just confer specific benefits. Glucose oxidases
and lipoxygenases both help with gluten
because it helps a product development through their oxidation
potential, and lipoxygenase has a further
appear as a clean label. This is benefit in that it makes bread crumb
where amylase enzymes come whiter. Proteases can soften dough through
breaking down the gluten networks, making
into play in bread production. it flow better, which is useful when the
20 Summer - 2020dough must fill a mold or flatten out as with ingredients such as wheat and soy flour. They
pizza bases. However, it is the amylases, have played a major role in traditional bakery
lipases and xylanases that find the greatest products such as sourdough and bread made
use in bakery product manufacture. using sponge or brew systems. Enzymes
will be destroyed by the high temperatures
THE FUTURE FOR ENZYMES involved in the baking process helping bakers
Looking to the near future, however, there to maintain a highly desirable clean label
are significant changes ahead in terms of the image for the product.
use of enzymes in food due to the changing Campden BRI has been active in the
legislative landscape. For the first time, there application of enzymes to baking for many
may be specific EU legislation on the use of years. It has the expertise and facilities to
enzymes in food. The EU is in the process of investigate and analyze enzyme blends and
compiling a long list of permitted enzymes that research their effects on dough and batter
can be placed on the market and used in food. during processing as well as testing finished
While it remains to be seen what the outcome baked goods to assess product quality. We
of European Union Regulation 1332/2008 can help manufacturers get the most out
will be, it is safe to say that it will have far- of enzyme systems by understanding the
reaching implications for the baking industry. needs of the enzymes so that processing
Regardless of changing regulatory conditions can be optimized.
requirements, enzymes as processing aids
in the baking industry are here to stay. Their
functional capabilities, clean label properties, As the enzymes degrade the
ability to create more efficient processes and
reduce costs mean they are a must-have structure forming compounds,
in a competitive marketplace. The huge
advantage of using enzymes is that many
such as starches and proteins, the
are naturally occurring components in bakery physical properties will change.
worldbakers.com 21special report
COVID-19 Redefines
Convenient Consumption
Convenience will take on new meaning at mealtimes as
cocooning consumers re-evaluate their priorities. The once-
appealing notion of breakfast on-the-go may be rendered
irrelevant as consumers make more conscious efforts to stay
home and slow down their hectic lifestyles.
Katrina Diamonon, consumer analyst, GlobalData, contributed to this article
W
eekday breakfasts
are particularly
characterized by
the desire to pick
something quick
yet nourishing before rushing to get
household members out the door.
However, self-isolating consumers
have had the time to prepare and
consume breakfast at home, which
will significantly broaden breakfast
choices, notes the research company’s
report, “COVID-19 Case Study: New
Mealtime Priorities”.
The demands of on-the-go lifestyles
are less applicable today, which will
diminish the appeal of items such as
breakfast biscuits, drinkable yogurt,
pouch packaging, and other products
geared towards portability. On the
other hand, we’re likely to see hot
breakfast ingredients, professional-
grade coffee machines and baking
mixes play a more prominent role in
the breakfast occasion.
BAKERY THRIVES
The Bakery & Cereals market segment
is estimated to dodge the adverse with homebodies and is poised for
effects of COVID-19 and post positive growth, as shown by the increase
growth in APAC in 2020. Year-on-year in ingredient sales. Since 33% of Convenience is no longer
sales for Bakery and Cereals in 2020 consumers (Australia 32%, China 43%,
is expected to grow by 9.6% in 2020 India 47%) intend to spend more time measured by how portable
in Asia and 7.2% in Australasia, which
exceeds pre-pandemic forecasts.
cooking/preparing food at home in the
foreseeable future, we’re likely to see
it is or how easily it can be
Baking proves to be a popular hobby growing interest in baking ingredients consumed at an office desk.
22 Summer - 2020and baking mixes. As more households and
families spend time at home, there will likely
be a greater need for meal solutions that cater
more important to them now as a result
of the COVID-19 pandemic.
65%
to the entire family, e.g. family-sized pastry GOING THROUGH CHANGES of Chinese
shells and pizza bases. New consumer trends towards bakery goods consumers
consumption are shaping, for the long-term, consider secure
CONVENIENCE REVISED indicating that homebody does not spell
packaging more
The report emphasizes that convenience is by unadventurous regarding taste experiences.
no means obsolete, but rather it will manifest About 60% of consumers (Australia 55%, important now
differently in this new self-isolating reality. For China 83%, India 70%) intend to experiment
example, a focus on ease and efficiency will with new cuisines and recipes, presenting
still define the lunch occasion, but meal options opportunities for manufacturers to challenge
will expand as homebound consumers enjoy consumers with new flavors, exotic
access to a stove, oven, and well-stocked ingredients, and DIY recipes. Consumer survey
fridge. Lunch choices will no longer be driven insight is taken from GlobalData’s COVID-19
by individual preferences, but rather what the Recovery Tracker Survey (Week 2).
entire household will eat. Accordingly, single- Premium bakery goods largely fell off
serve portions and chilled snack packs will shopping lists, while the pandemic has also
be replaced by family-size servings and even made consumers prioritize even more healthy
cooking kits that children can help with, as products. New strategies can correct course.
school closures and social distancing keep the Premium purchasing has declined during the
entire family at home all day. pandemic: 23% of consumers (Australia 28%,
Convenience is no longer measured by China 19%, India 22%) intend to buy bakery,
33%
how portable it is or how easily it can be cereals, morning goods at the lower end of the
consumed at an office desk. However, meal price range, 43% (Australia 42%, China 44%,
simplification and preparation and efficiency India 36%) in the middle of the price range,
will continue to be crucial. 11% (Australia 11%, China 16%, India 14%) at
On the other hand, 59% of consumers (Australia the premium or highest end of the price range.
of consumers
57%, China 57%, India 67%) say that their Functional health benefits (particularly those intend to
product choices in the current situation are associated with digestive and immunity health) spend more
influenced by “how well the product/service and natural, plant-based ingredients have time cooking
aligns with my time and money constraints” the potential to justify a premium price tag as at home in the
illustrating the enduring need for products and consumers make more health-driven choices. foreseeable
services to save consumers time. R&D has by no means stopped, and new
This brings new opportunities for product launches over the next period
future
manufacturers: have the potential to perform well, in the
• Meal components and home cooking following categories:
helpers: 63% of consumers (Australia • Products with medicinal or therapeutic
62%, China 79%, India 75%) will continue qualities such as ginger, hemp/CBD,
to cook more meals from home after the beetroot are to emerge.
pandemic. • Also, floral flavors that add a multi-sensory
• Products that replicate out-of-home element to consumption e.g.hibiscus,
dining experiences: 51% of consumers elderflower are worth considering.
(Australia 45%, China 55%, India 63%) • Breakfast products that draw from
will continue to dine at home instead of international cuisines, e.g. Rendang porridge.
restaurants after the pandemic. In reviewing long-term business strategies,
• Healthy and easy-to-prepare lunch bakeries look into possible scenarios. Brands
options for remote working consumers must remain sensitive to consumers’ enduring
who are accustomed to grab-and-go uncertainty and anxiety even after the
meals during their lunch break: 31% pandemic. A heightened awareness of health
62%
of consumers (Australia 23%, China 21%, and hygiene will influence product choices and
India 59%) will continue working from approaches to shopping.
home instead of going to an office after However, consumers are seeking an antidote
the pandemic. to lockdown-induced boredom and some form of Australian
• A heightened awareness of hygiene of escapism, and brands can address this
consumers say
will elevate the role of packaging: 53% through new, unconventional and challenging
of consumers (Australia 48%, China products that help consumers rediscover their they will cook
65%, India 69%) say that secure and kitchen creativity and create new ways to more after the
“tamper-proof” sealed packaging is experiment, and connect with loved ones. pandemic
worldbakers.com 23You can also read
