Baking & Snack - May 2020 - 78

Automatic controls and
wider lines produce a
high volume of sweet
goods more efficiently.
AMF Bakery Systems

handling system, which in turn can create unnecessary
stops and gaps on the sheeting and makeup line."
Abruptly slowing down the line, he added, can create a
backup at the mixer that creates unusable dough or inconsistent weights in sheeting and makeup. Moreover, operating too slowly or too quickly can also cause unnecessary
wear and tear by overworking gearboxes and motors.
Nick Magistrelli, vice president of sales, Rademaker
USA, identified several ways to maximize efficiency to reduce waste. With ingredients, use them according to the
specifications and remove the variables that will lead to
waste and lower efficiency. When it comes to process parameters, he noted, ensure consistency and maintain temperature control for efficient output and less waste. That's
especially crucial during lamination, such as for croissants
and Danish, where maintaining a cool temperature prevents the dough from prematurely rising.
Additionally, he said, make sure to have proper equipment. Laminated sweet goods, for example, need a robust
fat pump in the beginning of the line to handle a variety of
butters and shortening to guarantee efficiency.
"When the final dough sheet is prepared, the makeup
table needs to have proper tooling to produce highquality goods in a repeatable manner while having the
flexibility to keep the changeover time to a minimum,"
Mr. Magistrelli said.
Such controls during dough formation remain vital to
heightening yield and lowering reject rates.
"Being able to adjust your dough sheet to provide the
proper size for each product at the makeup section will
keep your trim percentage low and your quality high,"
Mr. Giacoio said. "As the size and shape of products
change throughout your day, the size of the dough sheet
needs to change to reduce trim. Limiting the time for
changeovers allows you to optimize production."
Mr. Nikkels suggested that easily exchangeable tools
condense changeover time.
"The stability of the product in relation to critical trans-

78 Baking & Snack May 2020 / www.bakingbusiness.com

BY SLOWING DOWN A BIT,
EVERYTHING RUNS A LOT
BETTER IN THE END.
fers to the next process influences the number of damaged
products," he said. "Rondo provides sheeting solutions
for sweet goods like making donuts shaped out of a continuous dough band. The shape of the product is directly
related to the amount of waste. Clever shapes reduce the
waste and maximize efficiency."
Mr. Besems noted that AMF uses the line's greatest
capacity to define the waste and scrap percentages and
streamline the process as much as possible.
"Efficiency is not only determined by the makeup system," he said. "For maximum efficiency, you would need
to take a closer look at the complete process, including the
proofer, oven, cooler and packaging systems."

Put it on cruise control
Integrated technology plays a key role in ensuring highvolume production of a large swath of sweet goods. For
instance, Mr. McCally pointed out that the Auto-Bake
Serpentine System delivers less than 1% in process losses
by operating without stopping or changing speeds from
panning through baking and cooling to depanning.
"Each pan is on a perfect pitch and runs single file
through the entire system without touching, transferring
or leaving at any point," he said. "This ensures excellent
product-to-pan target interface and the most consistent
finished product quality in the industrial market."
Additionally, he said, it takes only one operator to call
up the recipe before the entire line pivots to preset parameters for each part of the process.
At many bakeries, the greatest amount of waste occurs after initially firing up the line following scheduled


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Baking & Snack - May 2020

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