Baking & Snack - February 2021 - 72

BAGEL PROCESSING

shiny crust which is paradoxically both firm and supple, "
Mr. Kuperman said. " The boiling step also impacts final
product volume and crust thickness, so it is key to have
good control of the boiling process. "
Technology has evolved to give bagel producers several
methods to boil their bagels: steaming, waterfall boilers
and submersion boiling. Each one delivers different crust
characteristics.
" Waterfall boiling systems provide a thinner and crispier
crust, " Mr. Johnson explained. " Using a submersible boiling system gives a thicker crust, which also benefits from
a short amount of retarding to reduce belt impressions.
Baking can include steaming in the oven, which creates a
different crust and shine. "
The traditional method of boiling bagels is submersion.
A top conveyor holds the bagels in place as they are submerged in the boiler. While this ensures proper registra-

Ovens with
high-output ribbon
burners, high-flow
convection and the
latest PLC platforms
help bakers achieve a
consistent bake.
Babbco

tion, or positioning, throughout boiling, the top conveyor
can leave marks on the bagels if they aren't retarded properly. Optimized retarding to get that initial thin skin is so
critical to product quality.
" The skin that is formed during the retarding process
provides bagels with the required integrity to minimize top
marking, " Mr. Kuperman said.
The other challenge that can crop up involves improper
submerging during boiling. If bagels are not fully under
water, the registration is lost and products can kiss or stick

72 Baking & Snack February 2021 / www.bakingbusiness.com

BAGEL DOUGH MAY BE
SUSCEPTIBLE TO CHANGES
IN FLOUR CHARACTERISTICS
AS WELL AS TEMPERATURE
CHANGES AS IT IS WORKED.
together during baking, another undesirable outcome.
It's not just technique, however. The quality of the water
in the boiler will also impact finished product quality.
" Many of the challenges in the boiling equipment
stem from maintenance and maintainability of the unit, "
Mr. Barnes said. " Debris in the water stream must be filtered out to prevent caking on and failure of immersion
heating elements, clogged nozzles and inconsistent product
appearance. "
When debris hinders the boiler's function, it adversely
affects product quality. Water must be routinely cleaned.
" After so many hours of running, bakeries have to change
the kettle water because it gets contaminated by starch, "
Mr. Borowski explained. " Without cleaning properly and
often enough, you get a cloudy film on the exterior bagel,
which affects appearance and taste. "
Babbco uses a continuous filtration system and bottom
rake to move sediment and debris toward the kettle's drain.
The company recently added a steam-heating process that
makes cleaning the system easier.
" This new development improves ease of cleaning as
it eliminates the need for heating pipes inside the tank
and therefore improves the cleaning access, " Mr. Barnes
explained.
Waterfall boiling is a way to get around the challenges of
submersion altogether while still achieving the bagel's characteristic skin. According to Mr. Kuperman, not only does
it eliminate both marking and product registration issues, it
also uses less water.
Babbco addresses those challenges of marking, registration and water quality with a spray system in a clam-shell
frame. Dual path filtering and spray bars enable bakers to
increase uptime. The system also gives bakers a great deal
of control over the spray, providing consistent coverage of
the product.
" This level of control is more important than before
as many producers are opting out of the retarding step, "
Mr. Barnes said.

Setting the structure
Even after forming and boiling, the bagels aren't out of the
woods yet. The end products can still get tricky - or sticky
- in the oven.


http://www.bakingbusiness.com

Baking & Snack - February 2021

Table of Contents for the Digital Edition of Baking & Snack - February 2021

Baking & Snack - February 2021 - 1
Baking & Snack - February 2021 - 1
Baking & Snack - February 2021 - 2
Baking & Snack - February 2021 - 3
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