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Bakery Products
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Bakery Products

Bakery products include a large variety of items such as: bread, cakes, croissants, biscuits, crackers, toasts, buns, pies etc. and nowadays are produced in large wholesale quantities in up-to-date industrial facilities. Quality and low cost are two vice-contesting factors which both play the major role in making the product successful in the market.

In Industrial Bakery we make systems for:

1. Dough cooling at mixers by chilled water 0oC

During mixing and leavening dough temperature control is vital in order to achieve proper development of the gluten proteins.

Heat is generated due to the mixer's friction and due to hydration effect which occurs as the flour absorbs water. This heat needs to be absorbed and dough temperature to be maintained at 25.5o-27.5oC For the best dough temperature control mixing water must be supplied at a temperature of 0-1oC This is a tough goal because water must absolutely stay liquid but can easily solidify in minor temperature drops. To achieve this use of an ice cooling open tank is the best solution. Ice cooling open tanks for dough cooling water have a different design compared to milk cooling tanks because their operation is constant and ceaseless.

2. Lamination rooms cooling at 16o / 18oC with humidity control

Pastry bakery products such as croissants, pies or crackers undergo the lamination process where low temperate air-conditioning (18oC) and humidity control (50%) is required. Temperature control helps keep spread butter at a solid state during lamination assuring best texture quality results. Lamination refrigeration systems have special requirements because those rooms contain large quantities of airborne flour and can easily block the cooling coils. Moreover air re-circulation can lead to serious contamination effects because airborne flour is perfect nourishment for microbes and germs which can re-produce in extreme rates. For these reasons the use of common air-conditioning units or duct systems is inappropriate.

3. Fermentation rooms special conditions

Proper fermentation requires temperature and relative humidity control. Bread products demand maintenance of temperature at 27oC and relative humidity 75% to control water evaporation from the sponge.

Pastry products need warmer conditions. A challenging issue in fermentation rooms is the implementation of equal conditions in the entire volume of the room. Many manufacturers put the sponges in an enclosed conditioned space to perform fermentation whereas others keep the sponge moving in a belt traveling inside an enclosed tunnel where the proper fermentation conditions are applied and maintained. In both methods the challenge is to achieve equal conditions in the entire volume of the enclosed area which is not an easy job.

4. Heat extraction from Baking Areas

Baking areas produce large quantities of heat.  Nowadays baking ovens are well insulated, yet there is always a great amount of heat loss from their surfaces. However, the greatest amount of heat load is generated by the product which exits the oven at a crust temperature of 230oC and the extracted heat is greatly diffused when ovens door opens  to extract the batch. This generated heat is dispersed in the whole volume of the factory leading to important air-conditioning needs. In many plants operating personnel opens plant doors and windows in order to allow for some ambient airstream in order to alleviate the intolerable conditions. Leaving doors open permits the penetration of dust, insects even birds and rats in the production area, leading to serious contamination risk. The solution to this so frequently encountered situation is proper mechanical ventilation. With clever designed mechanical ventilation the extracted heat can seriously be restrained and exhausted. Fresh filtered air supply can create a physical air curtain and block the generated heat from flowing to the rest production areas. Also this system can provide free cooling taking advantage of the ambient air conditions.

5. Special Bread cooling before slicing

Product needs to cool down at an appropriate temperature for slicing or further processing. Bread leaves the oven having a crust temperature of 230oC and a core temperature of 95oC. Same conditions, more or less, apply to other baking products. Some products need to cool down at a lower temperature than the production area temperature with atmospheric cooling. In those cases refrigeration is required. Temperature and relative humidity of the cooling air is very important because affects the loaf texture and can lead to crust shrivel or crack.

6. Plant ventilation with clean filtered air

Plant ventilation is essential in order to clean the air from the air-born food materials which are generated from the process and are nutritious for the air-born microbes, thus contributing to air contamination and unpleasant odors. Also having an effective ventilation system process dust, odors and generated heat can be deterred and extracted leading to more comfortable conditions in the plant and better operation of the production equipment. What is more it is necessary to supply with fresh-filtered air to replenish the air which process equipment exhausts from the plant and provide air equilibrium or even overpressure.

7. Packaging area comfort air-conditioning

Packaging area air-conditioning is frequently required in order to provide to the operating personnel pleasant conditions and therefor increase productivity. Specifically if the packaging area is in the same space with the baking area, packaging area air-conditioning is necessary. Air-conditioning systems which serve packing area air conditioning have a totally different design and operation from those used for commercial or building air-conditioning. The differences regard many aspects, but most importantly the design of the compressor system which can achieve starting of the internal units even at 50oC internal temperature. The internal units must be in compliance with HACCP for food industry, must have large fin pitch in order to avoid coil clogging, must provide easy maintenance and must have flat smooth structure deterring material accumulation in hidden spots.

8. Blast Freezers for dough or final product quick freezing

Many bread or pastry manufacturers freeze the product in order to deliver it to the market at a later date. Also dough products are commonly frozen and distributed frozen to stores where they are sold as frozen products or thawed and baked. To preserve best cell structure and final texture bread should be frozen down to its freezing point as fast as possible. This is materialized by spiral blast freezer.

9. Cold Rooms 0o / 4o and -20o / -18o for the needs of the plant

Refrigerated storage of baking ingredients helps prolong their shelf lives, maintains flavor and beats microbial growth as well as insect infestation. Ingredients which definitely require cooling at low temperatures: 1-3oC IS: fresh yeast and liquid egg products. Nevertheless many bread manufacturers use active dry or instant dry yeast which do not need refrigeration. What is more dried egg solids are frequently used which can be stored at ambient temperature  as well as shelf stable whole egg of which the 2/3 of water has been replaced by sugar allowing for no refrigeration demand. Other ingredients such us dried milk products, cocoa, spices etc. require dry storage at 21oC temperature. Some ingredients require heating such us shortenings or some form of sugars like corn syrups.

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