Baking & Snack - June 2024 - 66

PRETZEL PROCESSING
rolling out items like pretzel bagels to bring the category
to new eating occasions, noted Felix Pang, robotic solutions
specialist, ABI Ltd.
" Once perceived as a niche product, pretzels have transitioned
into a mainstream commodity within the snacking
and foodservice sectors over the years, " he said. " Consumers
have embraced pretzels as a healthier alternative to sugary
treats, prompting manufacturers to respond to the growing
demand by enhancing production capabilities. This has involved
the development of equipment capable of producing
high-quality pretzels on an industrial scale. "
Tech-driven innovation
As pretzels compete in other categories, the processes
have adapted to add versatility that's resulted in a panoply
of new items.
" Flexible pretzel production lines offer the capability
to bypass the lye bath stage, facilitating the production
Pretzel processing
equipment can be
adapted to make
appetizers and handheld
products filled with chili
or cheesesteak to cater
to consumers' regional
preferences.
Rheon
of more than 3% per year, " said Stefan Praller, senior director,
customer experience of Fritsch, a Multivac Group
company. " Healthier snack options drive the demand for
pretzels as they are perceived as healthier compared to
other options. Plus, snacking itself is a huge trend caused
by rising urbanization and busier lifestyles. Manufacturers
are constantly innovating to cater to different consumer
preferences. This includes the introduction of new flavors,
shapes and textures to appeal to different tastes. "
Pretzels are also competing in the grab-and-go market
with sticks, bites and nuggets. Some bakeries are
Comparing the OLD and
NEW worlds of pretzels
If soft pretzels competed in a culinary
Olympics this summer, the
heavyweight contenders would
involve the historic reigning champion
German team against upstart
Americans who have a style, flavor
and texture that's all their own.
The European soft pretzels are
typically more dense, chewier and
darker in color, noted John Giacoio,
Rheon USA. While the formulas
differ, the processes and technology
often have much in common.
" In Europe, they typically use a
pre-ferment that enhances the flavor
of the pretzel, " he explained. " A line
for making pretzel bread, pretzel rolls
66 Baking & Snack June 2024 / www.bakingbusiness.com
of both artisan and conventional bread, " Pang observed.
" Software advancements have enhanced production line
flexibility, enabling equipment to automatically adjust its
settings when transitioning between recipes. "
Companies looking to diversify their portfolios can
rely on a sheeted dough or even a cracker line to bake a
pretzel-like snack.
" This type of pretzel product is 'healthier' as the recipe
contains lower-fat items than traditional pretzels, "
said Paolo Betto, application manager, snacks, hardsweet
biscuits and crackers, GEA Bakery. " The process
requires a specially designed rotary cutting unit and a
or traditional pretzel strands would
be our stress-free V4 systems, which
lend themselves very well for making
both the European and American
styles of pretzels. This versatility is
built into the machine, so modifications
are not needed based on the
type of pretzel you're making. "
The biggest difference involves the
increased use of sugar, said Stefan
Praller, senior director customer experience
of Fritsch, a Multivac Group
company. Specifically, Americanstyle
soft pretzels contain a fair
amount of sugar.
He added Fritsch's MultiTwist, an
automatic pretzel dough twisting
system, can process sweet dough.
" The challenge is that these
doughs are stickier and need to
be slightly dried before twisting, "
Praller explained. " This is preferably
done with air because this results in
less contamination and cleaning effort.
As a general rule, this works up
to a fat content of 5% [flour weight
in the formula]. If the fat content is
higher, we use flour instead of air. "
Ken Johnson, president, Gemini
Bakery Equipment, pointed out
European twisted soft pretzels, notably
Bavarian varieties, have a wider
scored belly in the knot of the twist.
" They tend to be dryer than
American soft pretzels with the
exception of the 'belly,' which tends
to retain some moistness, " he
said. " Designed correctly, a pretzel
production plant can accommodate
both styles. "
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