By Andrey Bulatov, Sales Support Engineer, AMF Bakery Systems
Minimizing raw material loss during production contributes greatly to the efficiency of any operation and helps combat food waste even as it is being manufactured.
Product waste is a critical issue in industrial bakeries, reflecting broader concerns about food waste globally. In Europe alone, food waste exceeds 88 million tonnes annually, with significant portions arising from the manufacturing and processing sectors. This waste represents a substantial loss of resources and contributes to inefficiencies, reduced Overall Equipment Effectiveness (OEE), and financial losses. To address these challenges, bakery operational teams are focusing on both technological improvements and organizational strategies to minimize scrap and enhance operational efficiency.
Product waste in industrial bakeries can arise from several factors, each contributing to the overall inefficiency of the production process. Understanding these causes is crucial for developing strategies to mitigate waste.
Understanding the causes of waste
Ingredient variability: Changes in the content of basic ingredients can lead to formula deviations, producing off-spec products. For example, long fermentation times, such as the four hours required for burger buns, make it difficult to detect issues immediately after the first mixing stage. When deviations are detected late, entire batches may need to be rejected.
Implementing stringent control over incoming ingredients, with rigorous testing and certification checks, is a possible solution, in this case. Advanced automation, including sensors for temperature, humidity, and moisture content within flour silos, can provide early warnings of deviations. Training operators to adjust water and yeast contents and mixing times in response to detected anomalies can further mitigate waste.
WASTE REDUCTION STRATEGIES
Excessive dough temperature
High dough temperatures can cause over-fermentation, particularly detrimental for soft bread and buns. Maintaining low dough temperatures is crucial, especially during summer months, when ambient temperatures rise.
Utilizing effective cooling systems helps in this scenario, such as AMF Bakery Systems’ mixers equipped with glycol cooling jackets. These systems maintain ideal dough temperatures throughout the mixing process. Additionally, cooling the rounder table ensures that the dough maintains its integrity through subsequent stages.
Weight deviation
Variations in dough piece weights can result in underweight or overweight products, leading to potential product rejections.
A possible solution is to regularly inspect and maintain dough dividers and use advanced technologies, such as AMF’s Flex technology. This technology utilizes servo-driven pumps to ensure precise control over dough weight, significantly reducing deviations. Operators should also continually monitor and adjust settings as needed to maintain consistency.
Proofing and baking processes
Proper proofing and baking are critical to maintaining product quality and minimizing waste. The proofing process involves allowing the dough to rise under controlled temperature and humidity conditions. The final proofing produces an aerated dough with optimum shape and volume when baked. Baking sets the final structure of baked goods, involving simultaneous heat and mass transfer phenomena.
Thermal logging in proofing and baking
Thermal logging involves using data loggers to record temperature profiles during proofing and baking. This technology helps in understanding the heat and mass transfer phenomena occurring in these processes, ensuring the dough reaches optimal conditions for baking. Thermal loggers provide insights into temperature fluctuations and enable bakers to adjust parameters for consistent product quality. By maintaining optimal proofing parameters and adjusting baking zones, bakeries can significantly reduce product waste and improve equipment utilization.
Machinery parameters
Incorrect settings on equipment like depanners, coolers, and sealers can cause significant product and packaging waste. Examples of product loss due to machinery settings may include:
+ Depanners: excessive vacuum pressure can damage the product.
+ Coolers: insufficient cooling timing can lead to slicing issues.
+ Sealers: incorrect sealing temperature can cause both product and packaging waste.
A possible solution is to develop and adhere to Standard Operating Procedures (SOPs) to maintain correct machinery settings. Regular training for operational staff can prevent errors and ensure consistent product quality.
Inefficient use of ingredients
High-value ingredients, such as sesame seeds, are often wasted if not applied efficiently. Traditional seeders using the waterfall principle distribute seeds across the entire baking pan, leading to significant waste.
The material application can be optimized, by using advanced seeders such AMF’s target seeder, which applies seeds directly to the product top, reducing waste by up to 55% compared to the waterfall system. This precision application ensures that fewer seeds are wasted, significantly reducing costs.
Preservative application
Inefficient application of preservatives such as alcohol can lead to waste and workplace hazards. Traditional spray nozzles can cause alcohol waste through evaporation and improper application.
In this case, implementing precise spraying technologies solves potential issues by applying preservatives directly to the product, which minimizes waste and improves process safety. For example, using shower technology ensures that alcohol is applied efficiently, reducing waste and ensuring better preservation.
Recycling options
Recycling dough waste is a viable alternative to landfill disposal. Options include:
+ Partnering with fish farms or pet farms that can use dough waste as feed.
+ Collaborating with biogas producers to convert waste into energy.
Effective recycling of baked scrap can involve sorting and processing it for animal feed or energy production. This not only reduces waste but also creates additional revenue streams and supports sustainability efforts. Developing partnerships with local farms or renewable energy companies can help bakeries efficiently recycle their waste, contributing to a circular economy.
Packaging materials
The choice of packaging materials also impacts waste levels. Non-recyclable or overly thick materials increase waste and costs.
Opt for fully recyclable, thinner packaging materials to reduce waste and costs. Advances in packaging technology allow for the use of materials that are both sustainable and cost-effective.
Reducing waste in industrial bakeries requires a combination of technological advancements, stringent process controls, and continuous staff training. By addressing the root causes of waste and implementing best practices at every stage of production, bakeries can improve efficiency, reduce environmental impact, and achieve better financial performance.
ABOUT THE AUTHOR
Andrey Bulatov has a 16-year background in engineering, including food production. His expertise revolves around delivering complex project management solutions and optimizing high-speed automated line equipment maintenance.
His first role in the baking industry was as Chief Engineer for a Grupo Bimbo bakery in Ukraine, in 2019. Throughout his tenure at Bimbo, Bulatov was at the forefront of implementing numerous energy-saving projects.
In 2024, he joined AMF Bakery Systems, where his focus shifted from bakery operational engineering to application engineering and sales support.
