Baking & Snack - May 2020 - 82

SWEET GOODS TECH

Top: Automated roller gap
adjustments and dough
tension monitoring
systems provide muchneeded consistency on
versatile lines.
Moline Machinery

Bottom: Laminated sweet
goods need a robust fat
pump to efficiently handle
a variety of butters
and shortenings.
Rademaker

"Usually, that's not the sheeting line," he said. "Usually,
it's going to be oven capacity and bake time. The ovens can
only go so fast because the products have to bake for a certain number of seconds."
Adding bite-sized sweet goods to a portfolio requires adjustments to the process and even retooling or investments
in equipment, such as more complex injection systems if
the new snack cakes require fillings.
"The only challenge is there are a lot more needles because the product is smaller so there are more rows across,
such as 24 across instead of 16 or 18," Mr. Peck said.
When turning out minis, bakers must account for
smaller needle sizes and the even distribution of crème to a
greater number of tiny treats.
"It's a little challenging, but we've done it enough times
where we have addressed the distribution issues and proper
needle size on a variety of crèmes," Mr. Peck said.
Viscous fillings such as peanut butter or caramel also

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

need preheating in jacketed vats and tanks from 100 to
130˚F to make them flow properly. To maintain those temperatures, all the piping as well as the injector's aluminum
manifold requires 150˚F hot water jacketing, especially if a
thermocouple indicates the filling's temperature has fallen
below its setpoint value.
Slowing down to work faster is also pertinent with
spot depositing.
"You want to make sure everything is synchronized perfectly," Mr. Moline said. "Otherwise, you will have a mess
on your hands. When you're dealing with eight lanes of
production instead of four, the complexity is just multiplied. You may not have more pounds-per-hour throughput, but you're dealing with a greater number of moving
parts and areas that you must pay attention to. That's where
slower, sometimes, does make it more manageable."
When starting up a new sweet goods line, Mr. Besems
advocates both classroom and hands-on training to deliver
the best results.
"First, you must explain what the process is, how to
properly operate the equipment on the line and then execute first runs of production on the line," he said. "Typically,
this takes at least a week to bring all operational teams up
to speed, especially when teaching multiple shift teams.
Unfortunately, a lot of companies don't take the time to
invest during this development phase. However, this will
ensure bakeries achieve maximum efficiency in the shortest
time on the line."
AMF Tromp also trains line operators on trial-anderror procedures.
"For example, what do you do when something goes
wrong on the line?" Mr. Besems asked. "We teach operators
what to do in these cases again both in class as well as in
real life on the line during the startup phase."
On makeup lines, he recommended allocating enough
space for future additions to make new products.
"Customers know what they make today but not necessarily what they will make tomorrow," Mr. Besems said.
"The biggest challenge with achieving maximum volume
is in the oven. When you make baked products, our Den
Boer tunnel ovens are of modular design so we can extend
them at a later stage."
Bottlenecks, like traffic jams, aren't necessarily bad.
They're often the sign of a bakery experiencing growing
pains, which is good news.
"When installing a new line, you tend to oversize the system," Mr. Moline said. "Today, you may need 10,000 lbs an
hour of production, and three to five years from now, it's
12,000 to 15,000 lbs an hour. It's obvious that you want to
size the system for 15,000 lbs an hour."
For successful bakers, planning ahead is one way to keep
traffic flowing smoothly, at least until they encounter the
next fork in the road.

*


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Baking & Snack - May 2020

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