Report Processing at Hudson Bread

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1 PROCESSING TECHNOLOGY FOR BAKING, BISCUITS AND SWEETS ISSN: Backtechnik Verlagsgesellschaft mbh, Luisenstr. 1a, Osnabrück, PVST 10 Report Processing at Hudson Bread 14 Bühler More than milling technology 18 Line production Dommitzsch dough plant 26 Plant construction Weighing, metering, kneading Volume 12 zkz58225 OFFICIAL ORGAN OF AIBI Edition Advertisement- ENGLISH Für deutsche Übersetzung bitte wenden!

2 ASTec lines: easy to clean easy to maintain easy to inspect Our Lines Your Safety RONDO is aware of the importance of food safety. Therefore our ASTec lines comply with international hygiene standards. You benefit from our pioneering hygiene concept: For example, during your next audit, with programmed hygiene protocols and documentation of the steps of the cleaning process. RONDO Burgdorf AG, 3400 Burgdorf, Switzerland, Tel. +41 (0) , Fax +41 (0) , AZ_Sicherheit_A4_E_QR-Code.indd :14

3 Editorial Advertisement Time factor As the last month of the year, December is often used to take stock - privately, professionally and financially. In terms of finances, it is the hard facts and figures that provide us with information about the past year. In our private and working lives, however, soft factors, which can often only be assessed with difficulty, are also significant. One of these factors is time (and that can measured) which is nearly always calculated too tightly. Planning a new production facility or the restructuring of existing systems generally makes this situation worse. Planning offices such as WD & Partner, who specialise in the project management and engineering of new builds, extensions and conversions, can create time. The planners, drawers and engineers do not release owners from their business responsibility, but they do prepare decision-making in a way that allows quick, sound and current solutions to be found. In industrial baking technology, the trend is towards automated solutions which not only increase product quality, but also reduce staff costs. Zeppelin Systems complied with this requirement in the construction of a production system for wheat-based biscuits and pastries and Photo: o: GBT The proofer with multi level conveyor belts is especially suitable for products which have been separated. where the system builder was not only responsible for his core business from raw material acceptance to dough delivery on the line but also for the building design. There is a completely different sense of time in the Hudson Bread production in North Bergen, America. Preliminary stages lasting several hours, long dough proving times and processing lines not run at full capacity characterise the image of this industrial company and its hand crafted products. We would like to wish you a similar relaxed approach to time for next year. However, take time to pore over Backtechnik Europe first. The major advantage: you can read it in your spare time or at work. We would like to wish all readers a wonderful Christmas and a happy New Year. Enjoy your read Your Editorial Team Pho to: Backt ech nik Over 21,000 visitors had four days to find out about the latest trends and systems at the IBIE in Las Vegas.

4 4 Backtechnik-europe Content 10 Report Processing at Hudson Bread Backtechnik Europe December Editorial 5 Background Information 8 IBIE 2013 Exhibitors and organizers look back on a successful show in Las Vegas. 10 Report: The Austrian company König delivered the complete processing equipment to Hudson Bread in North Bergen/America. 14 Company profile: Over its long company history, Bühler Group has developed into a global corporation specialising in several divisions. 18 Report: The Vandemoortele dough plant in Dommitzsch has been working successfully with the lines from Mecatherm. 14 Company profile Long tradition at Bühler 18 Report Dommitzsch dough plant 22 Company profile: The plant construction company GBT provides much knowledge in the fields of preparation, ovens and cooling systems. 26 Report: In addition to the system planning from raw material to dough acceptance, Zeppelin Systems was also involved in the building planning. 30 Interview with Bernd Jablonowski, director of Interpack and Save Food. 32 Special topic: How efficient, effective and futureproof consumer information has to be commucicated on food packaging? 36 Company profile: WD & Partner assume responsibility for the planning and project management of building projects and system expansions. 26 Report Complex system planning 36 Company profile Planning and project management

5 Backtechnik-europe Background Information 5 AGF is going to establish a scientific committee The executive board of the Arbeitsgemeinschaft Getreideforschung (AGF)(Cereal Research Study Group) has decided to establish a scientific committee. The objective of this committee is it to intensify activities in research and development at the location Ostwestfalen- Lippe. Its focus is on the conception, application and implementation of research projects, Dr. Götz Kröner explained on the occasion of the General Meeting in Detmold. Furthermore, it is planned to work closer with other institutes. tes. All members of the AGF or their authorized representatives from institutes or universities can become member of the scientific committee. e. The opening event of the fic committee will take place in Spring Until then, first project ideas could be sub- scientimitted. If you are interested in working in the committee as well as in case you have any further questions, please contact Tobias Schuhmacher, phone: , schuhmacher@agf-detmold.de. Photo: AGF Trade fairs 2014 January Sigep, Rimini, Italy ISM, Cologne, Germany February Gulfood, Dubai, VAE March Europain, Paris, France Internorga, Hamburg, Germany Bibac, Antwerpen, Belgium April Ibatech, Istanbul, Turkey Modern Bakery, Moscow, Russia May Interpack, Düsseldorf, Germany Bakery China, Shanghai, China Bakery Australia, Sydney, Australia June Bread, Kiew, Ukraine September Intercool, Düsseldorf, Germany Polagra, Posen, Poland October Südback, Stuttgart, Germany Sial, Paris, France Advertisement

6 6 Background Information Backtechnik-europe Flowers Food Pays Dividend The American bakery concern Flowers Foods is further going to distribute a quarterly dividend of US dollars per share to its shareholders. Recently, the concern reduced their dividend by nearly 30 percent to the current value in May The next payout of the quarterly dividend will be on 20 December The annual value for the shareholders will finally be 0.45 US dollars. This refers to a dividend yield of 2.02 percent with a current share price of US dollars (state: 24 November 2013). The concern with its headquarters in Thomasville in the US state of Georgia is one of the biggest manufacturers of baked goods in the USA. Flowers Foods is running 44 bakeries and also operates in trade and food services. Since the start of the year, the concern's share has been in minus with percent on Wall Street and has a current market capitalization of 4.65 billion US dollars. Bernhard Schmitt is leading WP Dinkelsbühl Bernhard Schmitt is the new manager of WP at the location Dinkelsbühl. Photo: WP Since 1 September 2013, Bernhard Schmitt has been the new managing director of WP at the location Dinkelsbühl. The experienced manager has worked in machine and plant building for more than 34 years. Bernhard Schmitt was the responsible technical manager for robot welding machines at the energy and automation concern ABB. Occupational stations as a business manager for machine and plant building at the manufacturer of building material Lafarge-Braas GmbH and as the executive board at the Josef Vögele AG, a well-known manufacturer of building machines, followed. Since 2004, Bernhard Schmitt has been the managing director of the Bystronic Lenhardt GmbH. Bystronic is a global supplier of complete machines for the glass production in the field of building and automotive industry and belongs to the Swiss Conzzeta AG. Advertisement TICKER Erweiterungsbau am Technologie- +++ Kamps in England. The Kamps Transfer-Zentrum GmbH in Schwalmtal opened (ttz) Bremerhaven its first "Kamps Bäckerei Café" in Tottenham Court Road, in London. The next location is planned to be opened already before Christmas in High Street Kensington. The brand Kamps has Mit more einem than Neubau 550 shops für das in Germany Institut and für Lebensmitteltechnologie had a und turnover Bioverfahrenstechnik of more than 240 wird million Bremer- euros Lotus Bakeries is going to celebrate about 20 openings next year. Last year, the company sees itself as well positioned.. haven The company als Standort Lotus der Bakeries Lebensmittelindustrie NV in Lembeke, weiter Belgium, told us that they expected a turnover gestärkt. for 2013 Der of Rohbau the same am height ttz Bremerhaven as they had earned ist Ende in In addition, Lotus made public that November inventions im in Rahmen production einer infrastructures Veranstaltung and von capacity Wirtschaftssenator the total Martin investment Günthner volume vorgestellt was 18 worden. million euros. With more than increase had taken place. For this purpose, 1200 employees, Dieser Lotus Neubau Bakeries wurde produces aufgrund and sells der biscuit vollen and Auftragsbücher turnover der of Forscher million notwendig. euros. +++ Das New ttz CEO Bremerha- at Güdel. After the re-brand- cake specialities. In 2012, the company had a ing of WVG Kainz ven to erweitert become Güdel sein Institut Intralogistics, für Lebensmitteltechnologie Güdel, und Bioverfahrenstechnik CEO of the Güdel Group. mit einem Mr. Baur Anbau leaves und the company by mutual Mr. Rupert Baur handed over the management to Mr. Rudolf agreement and modernisiert now going zudem to re-orientate den bereits himself bestehenden within this Gebäudekomplex. Director at So Wachtel. entstehen Since 500 October, Quadratmeter Oliver Frey, zusätz- Günter Wachtel's son-in- industry segment. +++ Frey new Managing law, has been at liche the head Technikumsfläche, of the manufacturer 100 Quadratmeter of baking ovens Bürofläche up und the medium-sized mehr Platz für traditional eine Versuchsbäckerei enterprise since sowie 1964 and will take over the and refrigeration technology. Wachtel has built chairmanship in eine Versuchsküche. +++ World of Neue Food Seminarräume Beijing.. The Koelnmesse bieten bald is expanding its worldwide trade fair programme bis zu 100 in Schulungsgästen the food segment. eine From anregende 26 to 28 Lernatmosphäre. will take place for the first time. The trade fair is the first comprehensive food November 2014, the World of Food Beijing exhibition based on the model of the Anuga in the North-East of China.

7 Backtechnik-europe Advertisement Changeover at Diosna Photo: Backtechnik The previous customer service manager Horst Holz (left) with his successor.jörg Ehrenbrink. The previous customer service manager, Mr. Horst Holz, will take his well-earned retirement after nearly 40 years of working in leading positions at Diosna. The new manager of the area of customer service and used machines at Diosna is Mr. Jörg Ehrenbrink who has already longterm experience in the after sales business. Investor participates in Back Werk The self-service chain Back Werk has been sold to the Swedish Private Equity Group EQT Partners AB. Non-disclosure was agreed on the sales price. The former owners and founders of the company, Dr. Hans-Christian Limmer and Dr. Dirk Schneider, remain minority shareholders and shall further be active in the operative business as CEOs. Dr. Hasso Kaempfe, who is the Industrial Advisor at the EQT will become the chairman of the supervisory board. This year, Back Werk from Essen which has now more than 300 franchise branches is expecting a turnover of approx. 173 million euros. Its increasing international presence pushes the company forward in Austria, Slovenia, Great Britain, as well as in the Netherlands. Back Werk which is currently present in Austria with 21 branches in total - from which just 11 are in Vienna, is going to open further shops in the Netherlands in Zaandam in the near future and in Nijmegen in the next year. In Manchester, the first Back Werk named Bake and Take opened at the end of November. Addition to the Technologie-Transfer- Zentrum (ttz) Bremerhaven With the new building for the Institut für Lebensmitteltechnologie und Bioverfahrenstechnik, Bremerhaven will be further strengthened as location of food industry. The building carcass on the ttz in Bremerhaven was represented by the economic senator, Martin Günthner, within the course of an event. This new building was required due to the researchers' full order books. The ttz Bremerhaven extends its Institute for Food Technology and Bioprocess Engineering with an addition and also modernizes the already existing building complex. Photo: ttz The Senator of Bremen for Economy, Labour and Harbours promotes the extension of the research and development at the ttz Institute for Food Technology and Bioprocess Engineering (BILB) with 2.7 million euros.

8 8 IBIE 2013 Backtechnik-europe Positive atmosphere in Las Vegas Exhibitors and organizers look back on a successful IBIE which could mainly convince by competent visitors. With a representive booth Rademaker was in Las Vegas. Photo: Backtechnik Rademaker Rademaker displayed the complete manufacturing range, from laminating technology via dosing systems to the Crusto-bread-roll line with gentle dough discharge system to the interested customers. In the first place, the team of the Dutch plant builder, who has an office in Hudson, Ohio, was convinced by the visitors competency and their good resonance on the first three fair days. Compared to the previous trade fair, the visitors were clearly better tempered, especially the fair visitors from America, so that, at this time, Rademaker expects a similar involvement in three years. Certainly, the good organization in the forefield and the satisfying physical distribution in the halls contributed to this decision. WP Photo: Backtechnik The discussions at WP were characterized by a positive moode. From the first minute on, the WP representatives were busy with answering the professional audience s questions concerning the displayed machines. They were mainly focussed on the preparation plant Pane which can produce round or square rolls and breads. Just as well, the head machine Softstar that is especially suitable for soft dough with long dough rest time was represented to the customers in America for the first time. The visitors were also very interested in the plants manufactured by the youngest subsidiary Riehle. Many conversations with old and new customers took place in a good atmosphere between the companies. This is the reason why the WP group wants to strengthen its presence in America in the next years. Diosna The team of the Managing Director, Dr. Wolfgang Eißer, from Diosna welcomed many visitors who were especially interested in kneader solutions for medium-sized businesses and the industry. More and more, the very compact trade fair establishes itself as a meeting place of the baking industry segment for the USA, South and Middle America. A bit longer Industry solutions were very much in demand. opening hours would help to improve the many and intensive contacts. All in all, the representatives of Diosna had a positive impression of the atmosphere among the American bakers. This was a reason for the plant builder also to exhibit together with Rondo to the same extent in three years. The Reiserbooth was always very busy. Photo: Backtechnik Vemag In the American market, Vemag is operating under the name of the parent company Reiser and here, it is successfully represented in different segments of the baking technology. Whether the classical dough divider for bread, pizza lines, cookies or cakes - the applications are very wide spread. In all conversation with customers about the lines, a clear trend towards automation occurred at the fair. Quality, quantity, traceability, and hygiene are increasingly catchwords in the American market which have to be implemented and satisfied by the baking companies.

9 Backtechnik-europe Advertisement Image processing is increasingly in demand in the packaging industry. Photo: Backtechnik A&B Verpackungsmaschinen Compared to the last trade fair, the Managing Director, Björn Brandt, was very satisfied with the course of the fair and the contacts at this year s IBIE. The existing customers were all very positive tempered and are planning investments in the field of packaging. In this context, the visitors were enthusiastic about the technology of the camera-aided counter. Especially in the field of image processing, enormous technical progress was achieved during the last years, which was utilized by the packaging industry. Besides the conversations with their existing customers, the A&B team also welcomed many new customers. In both groups, the Managing Director was convinced by the quality of the conversations which exceeded his expectations considerably. Rondo Jerry Murphy, Managing Director of Rondo, USA, observed a clear increase in the visitors competency and number compared with the preceding exhibits. He held many talks with decision makers who expressed their view on the current market situation in a cautiously optimistic way. In addition to the Astec lines which are designed to meet the requirements on hygiene and food safety, the laminating machines were in the visitors focus to achieve the reduction of personnel costs. Murphy felt positive about the duration of the IBIE while the labeling and the radio communication in the halls could be improved. Photo: Backtechnik Cost reduction through labor and cleaning costs were much discussed topics. Photo: Backtechnik Bühler Group saw an important trend in the automation of the lines. Bühler The first positive impression in the forefield of the fair due to good organization and smooth erection of the exhibition equipment also continued during the trade fair. IBIE upheld its reputation as the most important industrial fair for the American market of backed goods. The visitors specialist competence was accompanied by a clearly noticeable spirit of optimism. Bühler sees an important trend in the automation of the lines. The European market has already relied on complex systems for quite some time because high flexibility is required for the plants. In America, however, the focus lies on simple systems with very high performance. Now, a change of thinking is taking place which is strengthened by new trends with the products.

10 10 Report Backtechnik-europe Processing technology from one source The Austrian plant construction company König delivered the complete processing equipment for several lines and for different products to Hudson Bread in North Bergen/America. The baguettes are made-up using the Artisan SFI which gently produces a continuous dough string. New York, the mega city at the American East Coast, is not only the trend-setter in the fashion and music segments but it is also the forerunner in the culinary area. Among others, this is mirrored by various upscale restaurants, cafes, hotels and casinos. Exactly this target group is supplied with highquality baked goods by the Hudson Bread company from North Bergen. They are produced under industrial conditions but always considering handcraft production methods. We consider ourselves as modern, industrially oriented bakery which is very well technically equipped. However it is our objective to produce something special. We can only manage it, as we see it, when we produce in an artisan way and produce products that have a traditional character, Raymond Million, vice president of operations, explains the company philosophy. Hudson Bread has implemented this target very well since its foundation nearly 20 years ago. In the mean time, the company is working 24/7 to supply fresh goods to the large number of customers. Approximately kilos of dough are produced every day and processed to become bread and small baked goods. With this, Hudson Bread relies completely on the relationship between König, HB-Technik and Miwe, this includes all machines from processing, to the proofer and ovens. Mixer In the dough making line, Hudson Bread is working with four mixers. With this Ray Million uses three twintwist mixers. All machines are equip- Photo : Backtechnik

11 Backtechnik-europe Report 11 Photo : Backtechnik Photo : Backtechnik Photo : Backtechnik Left photo: Three helical kneaders and one spiral kneader with a dough capacity of up to 240 kilograms are used in the dough production department at Hudson Bread. Middle photo: Gradient angle and distance of the kneading spiral to the bowl wall are optimally adapted to each other. Right photo: Due to its accurately calculated geometry, the dough is intensively kneaded in the intake zone and relieved in the outlet zone of the tool. ped with movable mixing bowls which allow the fast processing of the dough and the batch can be emptied by a tilting hoist. The serial design with two mixing and two bowl rates guarantees optimum adaptation to the recipe. The company-own recipes can be saved in the freely programmable control via a touch panel. The mixer head rises and lowers hydraulically whereby it closes the bowl well when it is locked. In this way, no flour dust can get out. When the bowl is engaged, the kneader locks the hydraulic clamp lock and presses it against the friction wheel which drives the bowl. The tool of the spiral kneader has a large working radius and always reaches just to the wall of the bowl. During each rotation of the tool, mixing and kneading processes overlap in a controlled way. With the increasing speed of the tool and the bowl, kneading will be intensified and more energy will be introduced in the dough. In case of the twin-axis kneader, the two screw-shaped kneading tools are very well adapted to each other. In this process, the inner tool guides the dough continuously from the inside to the second tool to be actually kneaded. The tools which have special windings and are arranged to each other in an optimum angle bring the kneading energy gently into the dough while pulling and folding it. Compared to the spiral mixer, the kneading times are often shorter which results in a lower dough temperature and a shorter dough cycle. After kneading and resting, the dough is then transported to the plant. There, the bowls are moved into the bowl hoist Hercules. During the whole lifting and tipping process, the mixing bowls are safely locked in the fixing brackets. The wide tipping angle guarantees the complete emptying of the bowl. If the dough includes rye, or is soft and sticky, the scraping device is used to support the emptying process. Preparation The plant builder König delivers all machines to make-up all products at Hudson Bread, i.e. bread and small Photo : Backtechnik Photo : Backtechnik Photo : Backtechnik Left photo: The dough sheeting machine Artisan SFI is modularly designed and can be extended one after another with attachable units. Middle photo: Depending on the configuration, one or two satellite heads are used in the Artisan SFI. Right photo: To minimize the tension within the dough string and to achieve the required width, a transversal twin roll is used.

12 12 Report Backtechnik-europe Photo : Backtechnik Photo : Backtechnik Photo : Backtechnik Left photo: In the pull-off equipment, the baguettes are placed exactly on peel boards. Middle photo: The dough divider Ceres made by König is working in accordance with the patented gravity dough string principle. Right photo: The width of the dough string can be adjusted and varied between 60 and 150 millimetres. baked goods. To produce their bread, the American bakery is using the Ceres 2.1. It forms a defined dough string by means of gravity which is then portioned using a slicer. Mainly, the system consists of a cylindrical, non-stick coated stainless steel dough hopper of 300 litres capacity which is slightly tilted and it slowly rotates while it is placed on bearings in the top of the machine. The bottom of Photo : Backtechnik Facts Hudson Bread DBA Prestige Bread Co. Tonnelle Ave North Bergen, NJ The United States Tel.: info@hudsonbread.com Website: President: Mariusz Kolodziej Vice President of operations: Raymond Million Sales Manager: Ralph Bieluch Founded: 1994 Employees: approx 100 Production/day: Kilos/dough Businesses: 1 Product variety: 250 products Product percentages Bread: 40 percent Small baked goods: 60 percent the dough hopper is equipped with a bottom disc which can be slid in two directions and an internal taper in its centre, both made of food-grade plastics. If now the tilting hoist fills the dough in, a dough ring is formed in the lower part of the hopper around the taper and forms the first step of the dough string. After the plant has been switched on, bottom, taper and dough hopper start to rotate with the same speed while the two last mentioned parts are coated by means of a finely adjustable oiling unit. Now, the lateral moving function of the bottom disc will be started. In accordance with the desired dough weights, or the required optimum string width, the disc is displaced below the hopper and forms a more or less wide semilunar open section between the hopper edge and the bottom disc through which the dough can flow driven by gravity and with this, it forms the beginning of the dough string. Then, it falls directly on the floured transfer disc which turns with the same speed of the before mentioned machine components, so that the string cannot be pulled or pressed, i.e. it runs out steadily. A pick-up conveyor is installed at the height of the turning point of the transfer disc whose speed is synchronised with the speed of the other plant components, and it picks up the dough string and leads it to the electronic weighing unit with belt weigher. If the dough end has reached the selected weight, the electrical guillotine will be actuated and the dough piece is separated with gramaccuracy, whereby the computer control automatically calculates and compensates the belt speed during the weighing process. In addition, two laser sensors are continuously scanning the width of the dough string, so that, depending on the current dough consistency, always the optimum string thickness is ensured by automatic changing of the semilunar cutting opening. If, however, larger weight differences occur, perhaps at the beginning of a new dough batch, or when the last dough residue leaves the hopper, an acoustic signal will be triggered. Then, the dough pieces run over the height-adjustable discharge belt and are led to the manual or machine processing where rounding units, intermediate proofer and long roller are at the employees disposal in the production department. Hudson Bread also produces a large variety of products on the Artisan SFI machine which continuously and gently produces a dough string. At first, the dough sheet is levelled to achieve an equal height using several twin-rolls and stamp mechanisms. Depending on the configuration, one or two satellite roller heads are used in the plant supported by the transversal roller. Individually adjustable longitudinal slicers cut the dough sheet into even strips before the guillotine cuts the pieces

13 Backtechnik-europe Report 13 further. Attachable modules, e.g. rounding station, long rolling station, moistening and seeding unit and other easily changeable tools ensure the high variability of the plant. A pull-off unit pulls the products then onto the baking trays or other proofing goods carriers. Another line is designed for the manufacture of small baked goods. In this process, the dough is filled into the hopper of the Industrie Rex first. The dough dividing and rounding machine is the biggest representative of the Rexfamily and reaches an hourly capacity of 36,000 pieces. In this head machine, dividing and rounding are separated and are performed by two independently working areas. In this machinery, the rounding pressure and its intensity can be adjusted optimally depending on the recipe. Then, after the Industrie Rex, the Combi Line follows. Using this plant for small baked goods, a wide product range of the small baked goods can be covered. Stamping station, slicer and shaping station ensure the required variability which is required by Hudson Bread to implement their concept. Summary Starting with the dough making-up department to the conveying system for the products in the proofing room, Hudson Bread is using technology made by König. Using the machines and plants made by König, we can implement our concept of an industrial production with artisan character very well, Million explains their decision on this provider for the make-up line. In addition, he sees advantages for maintenance and service and for the training of the employees. Furthermore, he is convinced by the robustness of the plant which is in operation for twelve hours on each day of the week. Another reason for the durability of the machinery certainly is that it is not run at its capacity limits. We do not produce under full load. This does not only go easy on the machines but also the dough, and this is very important to us, Million completes. The success proves Hudson Breads right. The company is the leader in the supplier business for high-quality baked goods in the area around New York. We want to be the best ones in our field. Therefore, we always focus on our internal structures that we permanently adapt to our growth, Mariusz Kolodziej, the Managing Director, finishes our interview. Gregor Vogelpohl Advertisement

14 14 Company profile Backtechnik-europe Pho to: Bühler Bühler offers one-stop shop solutions for the acceptance, storage, dosing, weighing and provision of powder-form and liquid components. 150 years full of ideas Over its long company history, Bühler Group has developed into a global corporation specialising in grain technology, food processing and materials engineering. B ühler Group, based in Uzwil in Switzerland, is a specialist and technology partner for equipment, plant and services for processing basic foods and for manufacturing advanced materials. The group is a global market leader in the supply of flour production plants, animal feed manufacturing and also for pasta and chocolate production lines and aluminium die casting systems. The core technologies of the group are in the field of mechanical and thermal process engineering. With its expertise and over 150 years of experience, Bühler time and again rolls out unique and innovative solutions for its customers, helping them achieve success in the marketplace. Over the decades Bühler has come to be acknowledged as a reliable partner, due to its distinct commitment to quality and its global presence. Bühler Group operates in over 140 countries, employs over 10,000 people worldwide and generated sales revenues of almost EUR two billion in the 2012 financial year. In this company profile we describe several departments which are particularly important for industrial baking technology. Grain technology Twelve years after Bühler was founded in 1860, Adolf Bühler produced the first cast-iron rolls for roller mills in flour mills. These roller mills replaced those millstone techniques dating back centuries and paved the way for industrial flour mills. The underlying idea of the rolls has seen constant development over the last decades and as a result Bühler has now become the market leader in grain processing. This business unit offers stateof-the-art technologies and innovative engineering for the processing of wheat, durum wheat, corn, rye, oats, barley, millet/sorghum, buckwheat, soya, peas and beans to customers across the world. These consist of comprehensive overall solutions which range from grain acceptance

15 Backtechnik-europe Company profile 15 Pho to: Bühle hler Pho to o: Bü hler Pho to o: Bü hle r Left photo: The Sortex removes subtile defects and foreign material from a variety of products such as rice, grains, seeds, spices and dehydrated vegetables. Middle photo: The high-quality machine equipment of the Antares roller mill includes a compact roll pack with self-contained forces. Right photo: The Sirius Square Plansifter sifts and sorts coarsely ground, semolina-like and floury products and grades granular products or free-flowing granulates. through cleaning and milling to bagging and shipping, as well as the individual machines for each process step. Bühler s expertise also extends to ship unloading systems and grain storage. All Bühler plants guarantee the sensitive handling of valuable raw materials, achieve a very high product quality and yield and enable the optimisation of production and personnel costs and they have been doing this for more than 150 years. Bühler also offers solutions for the re-use of byproducts such as bran and shoots for healthy nutrition. The group s grain milling business unit operates across all continents bringing it close to its customers with 40 owned-subsidiaries and a presence in 140 countries. Bühler also offers training and development courses to its customers at its in-house training centre in Uzwil. One of the aspects covered by the training courses are the food processing sorting solutions from the Sortex program which recognises and eliminates products with colour, shape or size defects as any well as foreign bodies in food. Bühler also supports the Swiss School of Milling in St. Gallen, the internationally recognised training centre for grain milling technologists. Raw materials preparation Efficient raw materials handling processes in industrial baking technology companies have an impact on the profitability of baking production. In this regard Bühler uses its experiences of flour production as baking ingredient number one and incorporates it into this production process. Together with their customers project managers develop and create optimised solutions for every phase of the process which cover acceptance and storage through dosing, sieving and provision to the weighing of dry and liquid products. State-of the-art processing and automation technology is integrated into the precision-operating, reliable and hygienic plants. This starts with the raw materials acceptance. The simple geometry of the fully-welded silos enables hygienic storage on arrival whilst the discharger is designed to ensure a residue-free first-in/firstout emptying process. Well thoughtout solutions for sacking and big-bag discharge provide efficient, secure and ergonomic filling of small and medium component cells and dust-free filling of external and internal silo cells Pho to: Bühl hle r Ph ho to o: Bü hle r Left photo: Sieves in the receipt of goods used for quality assurance of incoming raw materials. Right photo: By making use of state-of-the-art technologies, Bühler has developed a wide range of different storage and weighing systems.

16 16 Company profile Backtechnik-europe Pho to: Bü hle r The portfolio also includes the storage and dosing of all available liquid components. This includes the automated fermentation of rye and wheat sourdough. is guaranteed. Integrated sampling and sifting also ensure maximum product safety. All components are transported in a pneumatic conveying line which ensures that small components are already mixed during transportation with the main components which enables clean transportation without any loss of small components. Components that need to be weighed manually are fully integrated into the plant automation which makes their handling safe and traceable. The portfolio also includes the processing of all the usual liquids which are used in the foodstuffs industry as well as Facts Bühler AG Gupfenstrasse Uzwil Switzerland Tel.: buhler.uzwil@buhlergroup.com Website: Chairman of the Board of Directors: Urs Bühler Managing Director: Calvin Grieder Revenue 2012: CHF 2409 million Employees: more than 10,000 solutions for starter dough and sour dough processing which come provided with fully-automatic CIP systems. The integrated plant management processes individual recipes and can be easily integrated into existing production systems via defined interfaces. All automated procedures and process commands are displayed graphically on the monitor and are clearly structured. The automatic operation optimises the process flows so that plant output can be increased and a consistently high product quality can be guaranteed. It is also possible at all times to switch to manual operation via the innovative touch screen. The assembly and smooth commissioning of the entire plant is monitored by Bühler with its team of machinery and electric plant specialists. Postcommissioning a worldwide service team is then available to support customers in the event of problems. Bakery Innovation Center As a flour service competence centre, the Bakery Innovation Center (BIC) provides solutions to optimise grain flours and develops new application concepts using state-of-the-art technologies. How can optimum and consistent flour quality be achieved and how can the company differentiate itself in the market with speciality flours and innovative product concepts? The experts at the BIC scrutinise these questions intensively. In-depth knowledge regarding the composition and quality of a flour is the starting point of the optimisation process. This information forms the basis for new recipe formulations for improving flour quality. Experts from the BIC and Bühler Cereal Analytics Laboratory work closely together to ensure optimum results. Together they are the experts to contact for the precise assessment of those raw materials and ingredients which increase flour quality. The baking test is used for the final assessment of a flour optimisation. To achieve true-to-life results, Bühler uses established baking technologies and well-informed experts. The detailed test analytics in the affiliated laboratory enable the finished products to be assessed both qualitatively and quantitatively. The BIC offers the full spectrum of cereals and flour analytics including dough rheology based on internationally standardised methods. Systematic evaluation and detailed reporting with good reproducibility are the final phases of the quality control. In addition to customised product and process solutions, the BIC also runs training courses which combine theory and practice. The BIC infrastructure consists of a modern auditorium with 32 seats which have a direct view into the test bakery and therefore provides a good platform for true-to-life, practically-oriented further training opportunities. The vocational training courses vary from needs-based customised courses to predefined BIC courses and additional milling training courses given by Bühler which cover baking-specific themes for the optimisation of added value and in which Bühler makes use of its knowledge network from global markets to meet local requirements in the best way possible. Gregor Vogelpohl

17 DISCOVER THE WP TREASURES Bakery Equipment that saves resources, ovens that guarantee perfect baking results or an intelligent diagnostic system the WP treasures are versatile. The high standards of quality we set for our machines, lines and concepts can be seen at a glance with our four quality labels: CleanTec // the WP hygiene concept GreenEnergy // minimal energy, maximal efficiency SmartControl // easy and standardized operation BakingQuality // baking with unique quality Discover our WP treasures: think process!

18 18 Report Backtechnik-europe A well-oiled team The Vandemoortele dough plant in Dommitzsch has been working successfully with the lines from Mecatherm, a machinery and industrial equipment manufacturer, for years. W hen the takeover took place in Dommitzsch in 1991 of what was once a combined oil and margarine company, no-one could have guessed how well the factory would do: neither the Vandemoortele Group, an investor, which can look back at over 20 years of success; nor the current Managing Director, Friedhelm Günther, who has been there from the outset loyally committing over 40 years of service and accompanying the change from a margarine factory into a modern dough plant. After the takeover in 1991, the new owner from Belgium resolutely invested in the area of deep frozen bakery products just one year later. One year on and the pretzel dough product line and first bread production line went into operation. Margarine production continued in parallel until the end of 1993 when it was finally relocated to the former Dresden margarine factory. Günther and his team met the challenge head-on, thus contributing significantly to this positive development. In fact, the original count of 58 employees has now risen to 190. The production volume is also impressive. A non-stop kneader supplies the two Bloc HP2 processing systems from Mecatherm. Photo: Back Technik Backtechnik chn k 04/

19 Backtechnik-europe Report 19 Photo: Back Technik Photo: Back Technik Photo: Back Technik Left photo: The dough divider is equipped with two hoppers, as dough items can be produced on two tracks in parallel. MIddle photo: Production is with 2,000 by 800 millimetre trays with 25 troughs; the dough pieces are positioned precisely within these. Right photo: Upstream of the proofing chamber, the trays from both processing systems are merged. 23,000 tonnes of finished products are currently produced a year, on five production lines. One of these is a Megaline II from the French machinery and industrial equipment manufacturer, Mecatherm. The system comprises the block for dividing and shaping the dough pieces, the final proofing tunnel, the automated cutting device, the oven, cooler and freezer, and all elements for conveying, handling and monitoring the tray cycle. Processing Dough preparation and processing in Dommitzsch takes place in its own designated hall. A non-stop kneader supplies two Bloc HP 2 processing systems with dough by means of conveyor belts. In the Bloc concept, Mecatherm has combined the functions of dough division, resting, shaping and the automated placing of the dough pieces. Every line has a dough divider equipped with two hoppers. The kneader dispensing belt goes left or right depending on which of the four hoppers has signalled a request. Another belt above the hoppers ensures that the dough is transferred correctly. The individual pieces of dough are then shaped on two tracks before merging back into one by the rolling mill. The dough pieces are then deposited on the 2,000 by 800 millimetre moulded trays which have 25 troughs. The line itself runs on a tray system, but can produce different items. The portfolio ranges from baguettes weighing around 300 gram to six rolls each weighing 40 grams, which can be placed in a trough. The filled trays then move to a switching point where both lines are merged. This is where the products are transferred to the proofing chamber. Proofing, baking and freezing The incorporated proofing chamber is designed for a total of 448 trays. The dough pieces rest for around two hours at a temperature of about 25 degrees Celsius and 80% humidity. The trays are guided vertically through the individual zones; this is typical of many Mecatherm applications, regardless of whether these concern climate control or oven technology. This allows them to be separated more easily; different settings, such as temperature, humidity, or steam, can be adjusted to the specific products. This also applies to the last zone of the proofing chamber, where drier and cooler air prevails. Stiffening the dough pieces has two major advantages; on the one hand, the cutting robot blades can process the products better and, on the other hand, it improves steam condensation on the product. A cutting pattern is stored in the cutting robot control system for every item. Following every cut, which may be diagonal, straight, overlapping or a combination of options, the blades move to a water basin. Here, they are cleaned and any residues are removed. To

20 20 Report Backtechnik-europe Photo: Back Technik Photo: Back Technik Photo: Back Technik Left photo: The trays stay in the proofing chamber for around two hours; this is designed for a capacity of 448 trays. Middle photo:the cutting robot is computer-controlled. The programs for the different items can be selected at the control desk. Right photo: The trays are moved upwards in the four oven baking chambers. achieve a satisfactory baking result Mecatherm recommends an oven with at least four baking chambers. All elements feature their own burners and steamers, which enables an individual profile to be created for every zone. When they Facts Dommitzsch dough plant Rudolf-Breitscheid-Str Dommitzsch Germany Tel.: info@vandemoortele.de Website: Founded: 1991 Managing Director: Friedhelm Günther Employees: 190 Production volume: 23,000 tons finished products/year Certifications: IFS 6, DIN 9001 enter the first baking chamber, the trays are immediately moved up a position vertically; a guided, heated air flow heats up the tray from underneath. After the next cycle in the second position, the air flow is reversed to allow for even heating of the tray. Like the trays, the steam is also directed from the bottom up in the first chamber. This is achieved by the vent at the top of the oven. The air velocity can be varied depending on the vent opening. In the last zone, the products finish baking before moving through the cooling and freezer zones. Both systems are designed for 144 trays and work, like the proofing chamber and oven, according to the paternoster principle. In addition to the components described, Mecatherm is also responsible for the conveyance, handling and monitoring of the tray circulation. As high standards demand, the products are not only counted prior to being packaged, but also quality controlled according to geometry or volumes. Summary Since the takeover of the combined company for oil and margarine in Dommitzsch in 1991, a lot of things have been done properly. One of the factors to success is indubitably continuity, which is evident in many areas. For example, HR policy is worth mentioning in this respect. Managing Director, Friedhelm Günther, and the Quality Officer, Inge Lingel, have worked in the factory for over 20 years; they exemplify the extremely high value in terms of lengths of staff service. Continuity is also represented by the flour suppliers. The main raw material has been supplied by the mills in Dresden and Alsleben for over 20 years. Both partners are well coordinated; this is reflected in the defined flour quality, which is optimally suited to the factory production lines. This is an essential criterion for good product quality and excellent system efficiency in the factory. Furthermore, continuity also applies to the selection of