Baking & Snack - September 2023 - 48

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R&D product trials at RBS
In January 2020, Pasquale, Patrick and Adriano made the
eight-hour drive to the RBS Science & Innovation Center
to see how the Multi-Crisp System would handle their fi ve
fl atbread varieties. The pieces of the system were all available
for demonstration in smaller, pilot-sized equipment. The
Zappias wanted to be sure that the fi nal products would be
similar enough to what they were already producing that their
customers wouldn't notice any diff erence.
Topping dispensers distribute salt, seeds or herbs as each
recipe requires.
Production on this system peaked at about 100 kg per
hour, and it made growing the bakery a challenge. In 2015,
Patrick's wife, Rachel, began managing the business and
relieved much of the administrative pressure, but the
production pain points remained. The Zappias knew they
wanted to upgrade to a more automated, labor-saving
solution, they just didn't know how.
The family began reaching out to tunnel oven manufacturers
in 2019 to explore their options. Their eff orts included a trip
to the International Baking Industry Exposition (IBIE) in Las
Vegas, where they met more oven manufacturers and got system
quotes. Some of those OEMs didn't quite understand what the
Zappias needed, and others proposed oven systems that were
either too big, or too expensive. The family found the process
overwhelming, but luckily, found their way to the RBS booth.
Meeting RBS at IBIE
The Zappias were struck by how confi dent RBS was that they
could help Via Oliveto move from rack ovens to a tunnel oven
system. " We thought, how could this be so easy for them? "
recalls Patrick Zappia. " We thought it was going to be such
a challenge - but, RBS made it sound like the opposite. " The
family was impressed by the company's willingness to work
with such a small bakery. They also liked that RBS, unlike some
of their competitors, was proposing a one-stop-shop solution
that featured an integrated sheeting line and oven, and the
fl exibility to produce new products in the future.
Eager to take the next step, the Zappias invited RBS to Via
Oliveto to observe their production process and further assess
their requirements. After seeing the family's fl atbread line in
action, RBS technical sales reps proposed a confi guration of
the modular, fully automated Multi-Crisp Baked Snack System.
The Zappias were impressed with the RBS visit and proposal
but remained wary of making such a big move. To help allay
their concerns, RBS invited the Zappias to the company's
Science & Innovation Center for a fl atbread trial run.
Via Oliveto takes leap from racks to tunnel oven
Their concerns were addressed quickly. Although the
Innovation Center was booked for a two-day trial, they
successfully created all the fl atbread recipes on the fi rst day. In
fact, the Multi-Crisp System actually improved product quality.
By eliminating the hot and cold spots the family faced with
their rack ovens, the RBS system delivered a more even baking
process that gave the fl atbread a better mouthfeel.
After seeing the Multi-Crisp System up close and tasting the
results, the Zappias were convinced that going with RBS was the
right decision. Within a few months, Via Oliveto and RBS closed
the deal, even as COVID-19 quarantines were in full swing.
Complications during the pandemic
Despite the pandemic, Via Oliveto's orders remained steady as
RBS manufactured their production line. Meanwhile, Rachel
searched for both a larger facility to fi t the new line and
funding sources to pay for it all. She found an 18,000 square
foot facility in Barrie, Ontario that was still under construction
when the family committed to it in February 2021. In March
2021, she learned that Via Oliveto had secured a $500,000
repayable contribution from the Canadian government for
which she had applied months earlier.
Just as things appeared to be falling into place, construction
delays at the new facility in Barrie forced the Zappias to stay
in their old location longer than they wanted. The delays also
meant the new facility would not be ready for the scheduled
delivery date of the RBS Multi-Crisp System. RBS was able to
hold on to the system components for several more weeks, a
critical delay that gave the Zappias the extra time they needed
to fi nd a storage solution.
System installation and setup
RBS installed Via Oliveto's new Multi-Crisp System in
September 2021 as the family kept baking in their old facility.
The roughly three-week overlap was made easier by the RBS
project team responsible for installing the new system and
instructing the Zappias on its operation. " We needed a lot of
handholding, " Patrick recalls. " But the RBS project managers
were amazing and always available. "
The RBS system confi gured for Via Oliveto uses a non-RBS
mixing bowl, as the Zappias wanted to upgrade to a larger
model of the same mixing bowl they were already comfortable
with. The bowl mixes 200 kg batches of dough at a time, which

Baking & Snack - September 2023

Table of Contents for the Digital Edition of Baking & Snack - September 2023

Baking & Snack - September 2023 - Intro
Baking & Snack - September 2023 - 1
Baking & Snack - September 2023 - 2
Baking & Snack - September 2023 - 3
Baking & Snack - September 2023 - 4
Baking & Snack - September 2023 - 5
Baking & Snack - September 2023 - 6
Baking & Snack - September 2023 - 7
Baking & Snack - September 2023 - 8
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Baking & Snack - September 2023 - 11
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