Baking & Snack - August 2018 - 98
To ensure accuracy, Mr. Toole recommended periodic
calibration of all the measuring devices by trained inhouse personnel. "Calibrating these devices will confirm
the weight of ingredients are exact and as precise as possible. This can help with calculating costs and find any
discrepancies between amounts delivered versus quantities used," he explained.
Mr. Toole added that calibration frequencies range
from monthly or quarterly to weekly or even daily, depending on the needs of the operation.
Not a lot of water
From an ingredient handling perspective, controlling
water usage and temperature - especially with temperamental doughs - safeguards critical process consistency from the get-go, according to Darren Adams, vicepresident of engineering, The Fred D. Pfening Co. Often
bakeries need to use ice or mechanical chilling to ensure
proper dough temperature.
"It's really a science to determine what the right temperature of ingredients should be," Mr. Adams said.
"Sometimes, the easiest way to achieve that end dough
temperature is to chill the mixing jacket itself. The
dough is making contact with that very cold surface.
More often, bakers just want to add as cold of water possible until they reach that dough temperature they need."
Pfening's Enviro-Blender incorporates up to three
temperatures of water such as cold, city tap and hot
water to reach a formula's optimum level. "When the
water is not cold enough, we'll make a brine solution,
assuming the dough accepts salt, and we can then provide really cold water," Mr. Adams explained.
The water-saving blender serves up to three mixers,
gives a flow rate of up to 300 lb a minute and offers 10
batch and temperature set-points with touchscreen controls. It also can be integrated into older equipment and in
newer software management systems.
Mr. Adams added that Pfening's metering system,
with flow rates up to 400 lb a minute, also handles oils,
corn syrup and a variety of other liquid ingredients.
A lot of questions
Bakers must delve into the details to determine how
their ingredient handling system supplements their
plants' food safety programs, cost-savings efforts and
continuous improvement initiatives. This will make sure
they're getting the validated and verified data they need.
"Operations leaders should ask themselves how they
can be sure the ingredients are being scaled correctly
with accurate lot code information and how they might
improve ingredient flow through the plant with smart use
of silos and holding bins," Mr. Cross observed. "Another
question is whether an additional layer of automation at
98 Baking & Snack August 2018 / www.bakingandsnack.com
Going from HFCS to sugar
Often at the request of foodservice
and retail customers, bakers are
switching from high-fructose corn
syrup (HFCS) to more natural-sounding sweeteners.
"Many bakers are now looking at
changing to a sugar liquefying system
to take advantage of existing HFCS delivery systems already installed in the
plant and piped to all points of use,"
said Joseph Cross, process manager,
Zeppelin Systems USA. "By creating
liquid sugar from water and granulated sugar fed from a big bag or silo
system, a plant can limit the expense
of new conveying systems and the
explosion protection systems typically
associated with them."
However, liquid sugar often requires additional sanitation measures
beyond those used in typical HFCS
systems. Jason Stricker, director of
sales and marketing, Shick Esteve,
pointed out that bakers may need to
add ultraviolet sterilization to prevent
microbial growth in an existing HFCS
system. "You'll also need more frequent inspections to ensure you don't
have any microbial growth," he said.
Darren Adams, vice-president of
engineering, The Fred D. Pfening Co.,
noted that installing a sugar liquification system is a viable option, especially if a bakery already receives
granular sugar. "You just transfer it
through our system to make liquid
sugar," he said. "You don't have to pay
to deliver the liquid part of it. You're
not paying to ship water, so there
is an incredibly fast return on your
Other sweeteners such as tapioca,
brown rice or invert syrups may require greater investments because of
their viscosity and challenges in automatically handling them. But there are
other concerns as well. "The challenge
with those is not only the sheer cost of
the ingredient but also the availability
of it," Mr. Adams said.