(http://biscuitpeople.

com/)

ARTICLES(HTTP://BISCUITPEOPLE.COM/ARTICLES/)
TECHNOLOGY(HTTP://BISCUITPEOPLE.COM/CATEGORY/TECHNOLOGY/)
COMPANIES(HTTP://BISCUITPEOPLE.COM/LISTINGS/)
(http://www.berndorfband.at/en/steelbelts/)

MYACCOUNT(HTTP://BISCUITPEOPLE.COM/MYACCOUNT/)
LOGIN(HTTP://BISCUITPEOPLE.COM/WPLOGIN.PHP) / REGISTER
(HTTP://BISCUITPEOPLE.COM/WPLOGIN.PHP?ACTION=REGISTER)
HOME(HTTP://BISCUITPEOPLE.COM) / ourexperts(http://biscuitpeople.com/category/ourexperts/)SETTINGUPABAKERY(3) /
SETTINGUPABAKERY(3)

ThisserieswillcoveravarioustopicsaroundsettingupaBakery,andinparticularan
industrialsizefactorymakingbakeryproducts.Asconsultantswhowereintheindustryas
manufacturerintherecentpastweknowonalmostalllevelsthechallengesofrunninga
business,andsettingupaneworexpandingbusiness.Fromourfiveexperiences(including
our400m2testbakery/lab)wewillshareourknowledgewithregardstothistopic.
Thefirstarticlecoveredthebasicsaroundchoosingproducts,markets,standardsandmakingafailsafebusinessplan.It
mightbewisetostressthefollowing:partofmakingabusinessplanisdoingyourmathshomeworkonyourcostingwill
be/canbe.Furthermorethearticleiswrittenforsettingupabakeryingeneral,Size,equipmentselectionwillbe
influencedonyourproductportfolioandyourproductdesigns,partofwhichwewillcoverinthisarticle.
Thesecondarticlefocusesondefiningyourtypeofproduct,withessentialparametersforshelflife,factorydesignand
consequencesfromthat.
Inthethirdandfinalarticlewewillfocusonequipmentchoicesbyleadingyouthroughtwopopularproducts.

(http://biscuitpeople.com/wp
content/uploads/2014/12/jos
vast.jpg)
JosVast,Managing
Partner,Bakery
Academy

Brands,innovativedesignorprovenconcepts?
Whendecidingonequipmentpricefortheequipmentisonlypartofyourinvestment.CostofOwnershipismuchmoreimportantformostcustomers.
Longevityandavailabilityofparts,robustnessofframesandsoftwarearesometimesnotconsideredwhenbuying,butplayavitalroleinthedaytoday
operation.Anotherthingtoconsidermightbethefactthattheproductionlineormachine(s)havebeendeliveredandworkingproperlyalreadyto
severalothermanufacturersforthesameintendeduse.
Onthelongrunyourcompanyonlycanandwillcontinueexistingwhenithasaminimumonunscheduleddowntime,maintenancecost,fastproduct
changeoversandaminimumofwaste/scrabproduction.
Firstdecision:Products
Intheprevioustwoarticleswediscussedalargeamountofinformationyouneedtocollectanddecideuponbeforestarting.Perhapsitisworthwhileto
mentionthateverychoiceoftenimpliesawholerangeofnewquestions,someeasysomenot.Aswecurrentlyarelookingtodecideuponequipment
weneedtochooseforasetofproductstoworkfrom.Wewillhowevernotconsidertheingredientsbeingused,asyourcanwriteanarticleonthatfor
eachproduct.
Wewillconsiderinthearticlehereaftertwoverypopularproducts:OreofromMondelezandCaramelbiscuit/SpeculoosfromLotusBakeries.

Theproductsarequitedryandcanbeconsideredinthecategory:LowAw,lowmoistureandlongshelflife(asdiscussedinpreviousarticle).
Furthermoretheysharethefactthattheyarerotarymouldedandconsideredashortdoughbiscuit.TheOreohasasecondaryprocessingstepcalled
sandwiching.
Seconddecision:Operatingcapacity
Thetimethatyouwanttoproduce,ispartlyphilosophy,beliefscombinedwithalargedoseofcommonsenseandeconomics.Secondlyyouneedto
considerthatexperiencelearnsthatwhenembracingnewtechnologyforyouandyourcompanyyouwillneedatleast1yeartomasteritandthus
beforecomingprofitable.
Dependingoncountryslegislation,unions,religion,etc.onecandecideforworkinganywherebetween5and7daysaweekandanoperatingtimeup
to24hoursaday.Thebestorganisedmediumsizedbusinesswewitnessedoperated56daysaweekbetween16and24hours,whereingenerala
smallnightshiftwaspresentforcleaningandstartingupagaintheproductionlines.Weknowfromourownbusinesswehadthatworking724
sometimescannotbeprofitableatall:524madeanenormousprofitandinthelast224hourswehadtoproducewelostalltheweeksprofitdueto
highfailcostsandhigherpayoftheproductionteam.Somakesurethatsomewhereinyourplansyouwillaccountforthis.
Thirddecision:Mixing
Bothproductsaresocalledshortdoughs,thatmeanstheyshouldhavealowglutendevelopment.
Thelowglutendevelopmentisduetoarelativelyhighfatandlowwatercontent.Oftenthesugarcontentistoohightoletthecrystalsbecompletely
dissolvedintheavailablewateroftheformulation.Thewayandamountsugarcrystalsareallowedtodissolvehaveacrucialeffectontextureand
shapeofthebiscuits.Thereforesomechooseforrestingtimesofatleast24hrs.incertainshortdoughproducts.
Duetothefightforwatertheflourwillnotbecompletelyhydratedandthuswillthedoughhaveavaryingviscosity,especiallythroughoutthefirst30
minutes.
Themixingcanbedoneingeneralinbatchorcontinuesmixers,wereeachhavetheirprosandconstothem.Duetothefactthatsettingupabakery
oftenmeansonedoesntwantacomplexandcostlystart,wewilldiscardcontinuesmixershere.Batchmixerscanbeboughtverticalandhorizontal,
wherebyfarthemoststartwithaverticalbatchmixerwithasetofbowlsinourbusinesscasewewilllookattheverticalbatchmixer.Thishasthe
preferenceduetoalowerintensityofmixing,thereforeminimisingtheriskofovermixingbyaccidentoftheseshortdoughs.
Thesizeofthemixingbowldependsontheparametersthatneedtobeset,leadingfromcapacity(kg/hr),thenumberofmixingbowls,standing/
restingtimeandmixingprogramme.Ingeneralourtwoproductsaremadein2stages,thefirst(creaming)mixeslongerthanthesecondstage
combinedwitharestingtimeof30minutesorlonger.Thishoweverwilldependonthecompositionofourdough,thespecificationsoftheingredients
usedandtheamountofreturndough/scrabusedintheformulationmostimportantisthatitisconsistenteveryhourofeverydayineveryweek,as
thiswillgivethemostconsistentproduct.
Fourthdecision:Forming
Ingeneralaretheretwowaystoformthedoughpieces:sheetandcutormould.Mouldingmeanslittletonoreturndoughandnovariationsindough
propertiesduetoreturndough.Anotheradvantagecanbethatwhendecidedformouldingarotarymoulddoesnttakeupalotofspace.Furthermore
theshapeofthemouldallowscertainshapesandforms/imprintsmoreeasy.Howeverwhenworkingwithverysmallmouldorverythickdoughpieces,
rotarymouldingcanbeachallenge.
DuetotheshapeandimprintoftheCaramelbiscuitandOreobiscuitwewillchoosearotarymouldingmachine,asmostoriginalandimitating
manufacturerscurrentlydo.Theywaythedoughisdividedinthehopperandatwhatspeeditisfedtothehopperwewillalsochooseabuffersystem
whichwillfeedthehopperofthemachine.Thisistoovercomenumerousproblemsleadingtowasteinacontinuingproduction.
Nexttodecideisthewidthyouwillbeworkingat,oftenstartingfrom300mmto1800mm.Youwillneedtoconsiderthefollowing:thewiderthe
mouldingroll,theweightwillincreaseandcannotbemanuallylifted/exchanged.Secondlyyouwillneedtoadaptyouoventotheworkingwidthorvice
versa.Itisoftenamatterofproductcostprice,requiredcapacityandthenumberofchangeoverstobemade.Thirdlytherotarymouldshouldbeable
tokeepupwiththebakingtime,verylongovenswithshortbakingtimesrequirehighoutputexpressedinmeterspersecond.Wehaveseenworkingup
to14m/s.
Fifthdecision:Baking
Togetthemostconsistentendproductduringdaysandweekswewillconsideratunnelovenwithacontinuesovenbeltorbakingband.Fromthe
rotarymoulderdoughpieceswillbehandedontothebeltandbebakedanywherebetween2.520minutesonaverage,dependingonsizeandweight.
Bakingcanbedoneingenerallyspeakingtwoways:directlyorindirectly.Dependingonthelengthofanovenandtheamountofrequestedintervention
options,ovenaredividedincompartments,atleasttwo.Weseemorehybridchoicesnowadays,wherebotharecombinedinoneoven,howeverwe
questionthisforveryshortbakingtimes.Ingeneralitdoesntmatterwhichtypeyouchooseasitisoftenamatterofopinionofthedeveloper,the
supplierandconsultantyouchoose.Generallyspeakingweseemorehybridoven,whereatleastthelastsectionoftheovenisbuiltindirectlywiththe
objectiveforamoreevenbrowningandmoisturelossoftheproducts.
Theobservermighthavenoticedthatwediscardtheelectricitybasedovens,weseethatthesearenotasenergyefficientastheotherovensandoften
muchmoreproductvariationsgiveinthemeansofcolouranddrynessandthereforeplaylessaroleinmoreindustrialisedenvironment.
Thechoiceofthewidthoftheovenbeltismadeinaccordancewiththewidthoftherotarymouldingmachine.Thereforeournextchoicetomakeisat
whichlengththeovenincombinationwiththebakingtimesisrequiredandthewayyouwanttodividetheheatduringbaking(top/bottom)andextract
moisture.Anothercontributortothemagazinebiscuitpeople.com,Mr.IanDavidsonfromBakerPacifichaswrittenextensivelyonthetopicofbaking
(http://biscuitpeople.com/biscuitbakingprocess/)andovendesigns(http://biscuitpeople.com/biscuitbakingovens/),wethereforewillnot
continuecoveringthistopichere.

Thebakingtimeoftheproductsinourbusinesscasesvarybetween12and20minutes,wethereforeprefer4sectionsof2directlygasfiredand2
indirectlyheatedsections.Bothproductscanbeperfectlymadeona(semi)closedsteelbelt.Whentheselleroftheovenisabletoprogrammean
automatedmoisturecontentineachsection,youcanperfectlycontrolyourproductsendqualityweveseenthisonceoperatingperfectly.
Sixthdecision:Cooling
Dependingonyourproductcharacteristics,thewayofcoolingistobedecidedupon.Thiscanbedonebylengthyconveyorsorspiralcoolingtowers
withallvaryingdesignofthebelt(closedorvaryingmesh).Thelengthofthebeltscanvaryfrom0,57timesthebakingtime.Dependingonhowthe
furtherprocessingwillbe,aftercoolingtheycanbestackedorfedtoamachineforsecondaryprocessing.
Itisadvisabletomakethatthereisaverygentleandgradualcooling,tolettheheatandtheremainingmoisturemoveawayfromtheproduct.If
chosentoworkwithanopenbelt,youshouldmakeatleastoneturn/fliptoletexcessheatandmoisturefromthebottomtheevaporateaswell.In
generalnoforcedconvectionisapplicablefortheseproductsandforcertainproductsthisshouldbeavoided,topreventchecking,breakingand
curvingtoohappen.
Seventhdecision:Secondaryprocessing
Towardsecondaryprocessingonecanconsidersandwiching(orcookiecapping),applyingacoating,chocolateorjam/jellyorevenacombinationof
theseprocesses.Herethemostimportantpartwillbethattheproductorformulationusedisinbalancewiththebiscuit,thereforemaintainingtexture
andpreventinganexcessdosageleadingtohighcosts.
FortheproductionoftheOreowewillneedasandwichingmachine:placingcreambetweentwoindividualbiscuitsandifwewouldliketomakethe
completeOreoassortmentwewouldalsoneedtoconsiderapplyingcoatingandchocolate.Thiswillmakeithoweververycostlytostartup,especially
asthecaramelbiscuitdoesntneedanysecondaryprocessing.
Whenchoosingforsecondaryprocessingoneneedstorealisethatforusingrealchocolateyouneedtemperingmachine(makingsurethechocolate
crystallisesandshines)andacoolingconveyor.Whenmakingcream,jellyorothercoatingsitmightbethatthereisaneedforvariousvesselsand
mixers.FortheOreowewillworkwithalargemixingvesselandahopperfeedingthecreamingandsandwichingstage.Dependingontheingredients
chosenonecanalsochoosetoworkwithacontinuesaerator,regulatingspecificweightandtemperatureofthecream.
Eightdecision:Packaging
Veryimportantinthisdecisionpartisyourcurrentclimate.Allbakeryproductshavearelativehumidity,calledAw.IngeneralMoisturedoestransfer
fromahighhumiditytoalowerhumidityuntilthereisabalancebetweentheproductanditsenvironment.Basedonthisknowledgeyoucandecide
uponitwillbeatin,trayorfilm/foilinwhichyourproductswillbepacked.
Tomaintainthetextureyouwillneedtocontrolthewatervapourtransmissioninpackagedproductduringstorage.Topreventcertainoxidation
(especiallywhenworkingwithcertainfats,seeds,nutsandfruits)oneneedstocontroltheoxygenvapourtransmissionofthepackagedproduct.This
combinedwiththespeedonwhichthefilmwillrun,willspecifytherequirementforthefilmanditssealingtemperatures.
Anotherthingtoconsiderwillbethepacksizeandifitwillconsistofoneormoreproductsandifitwillneedtobeamultipack(multiplesinglewrapped
productsinawrap).
FortheCaramelbiscuitandOreoweconsidersingleandduowrapped,largeandmultipacks.Thisimpliesinthisbusinesscaseweneedasetof
conveyors,bypassesandbuffersand2flowwrappers.Dependingonamountofbiscuitsrunningfromthelineweneedtodecideontypeandmakeof
theflowwrappers.
Althoughwehavecoveredquiteextensivelyinthepastthreearticlesalotfromtheaspectsofsettingupabakerywehaventcoveredalotofother
things,suchassettingupaqualitymanagementsystemlikeHACCP,BRC,IFS,ISO,etc.Wehavetriedtogiveyoupointersandideastothinkand
rethinkwhenconsideringstartingandsettingupabakery.Thekeytosuccessistobepreparedandthinkofalmosteveryaspectofyourbusiness.Asa
groupofconsultantswearemorethanhappytohelpyouclarifyyourneeds,goalsandaccordingbudgets.Wetrytodoevery2yearsalargerproject,
wherewehelpsetupabakeryfromstarttofinish:planning,(product)development,trainingandcommissioningwhereingeneralthesetrajectories
take11,5yearsthroughputtime.
February2015
Authors:
JosVastMsc.,ManagingPartner&SeniorConsultant
KeesVast,Partner&SeniorConsultant
info@bakeryacademy.com
(http://www.bakeryacademy.com/en/)

February23,
2015

(http://blogplay.com)
COMMENTS

ourexperts(http://biscuitpeople.com/category/ourexperts/)

technology(http://biscuitpeople.com/category/technology/)

Youmustbeloggedin(http://biscuitpeople.com/wplogin.php?redirect_to=http%3A%2F%2Fbiscuitpeople.com%2Fsettingupabakery3%2F)toposta
comment.

(http://biscuitpeople.com/wp
content/plugins/oiopub
direct/modules/tracker/go.php?id=2)

SPOTLIGHT
CargillsnewMarketing&
CommunicationsDirector
(http://biscuitpeople.com/cargills
newmarketingand
communicationsdirector/)

(http://biscuitpeople.com/cargillsnew
marketingandcommunications
director/)
<<1|2|3|4|5|6>>

OUREXPERTS

(http://biscuitpeople.com/processmanualforvegetablecrackers/)
ProcessmanualforVegetableCrackers(http://biscuitpeople.com/processmanualforvegetablecrackers/)
Thisarticleprovidesthecompleteinformationrequiredtomakevegetablecrackers.Thefollowingnotesintroducethemainsectionsofthe
document.RecipesInallcases

(http://biscuitpeople.com/settingupabakery3/)
SettingupaBakery(3)(http://biscuitpeople.com/settingupabakery3/)
ThisserieswillcoveravarioustopicsaroundsettingupaBakery,andinparticularanindustrialsizefactorymakingbakeryproducts.As
consultantswho

(http://biscuitpeople.com/biscuitovenconveyorbands/)
Biscuitovenconveyorbands(http://biscuitpeople.com/biscuitovenconveyorbands/)
Therearethreemajortypesofovenbandsforconveyingthedoughpiecesthroughtheoven.Eachtypeofbandhasparticularbaking
characteristicsin

INTERVIEW

(http://biscuitpeople.com/innovationdna/)
InnovationinitsDNA(http://biscuitpeople.com/innovationdna/)
February6,2015
BiscuitPeopleaskedAmandaHicks,CoCEOofAutoBake,abouthercompanyssuccessanditsplansforthefuture.AutoBakessuccesscanbe
directlyattributedtotheSerpentinewhichwasdesigned

(http://biscuitpeople.com/expansionefficiencyaim/)
Expansionandefficiencyistheaim(http://biscuitpeople.com/expansionefficiencyaim/)
January7,2015
BiscuitPeopleaskedJooCostaCEOatDanCake(Portugal),SA,somequestionsaboutthebiscuitindustryandhowhesawthemarketfortheyear
ahead.Whatdoyousee

(http://biscuitpeople.com/focusonexcellence/)
Focusonexcellence(http://biscuitpeople.com/focusonexcellence/)
November11,2014
TheMarkelBakeryGroupnowcomprisesthreemajorplayersintheglobalbakingindustrytheTrompGroup,basedinTheNetherlands,beingthe
latestaddition.WeaskedCEOKen

Newsletter
Emailaddress:
Youremailaddress
Signup

Copyright2015biscuitpeople

(https://twitter.com/biscuit_people)

(https://www.facebook.com/pages/biscuitpe

(https://www.linkedin.com/profile/view?
id=54292462&goback=%2Enmp_*1_*1_*1_

(http://www.youtube.com/channel/UCoUFH
WeuseCOOKIES,butalsoBISCUITS,CRACKERS,CAKES...,toensurethatwegiveyouthebestexperienceonourwebsite.Ifyoucontinuewithout
changingyoursettings,we\'llassumethatyouarehappytoreceiveallcookiesfromthiswebsite.Ifyouwouldliketochangeyourpreferencesyoumaydo
sobyfollowingtheinstructions. Noproblem Findoutmore(http://biscuitpeople.com/cookiepolicy)