The search for authentic products is a growing trend among consumers; it is not by chance that ‘authentic’ is the word of the year in 2023. When it comes to baguettes, it is simply a must-have attribute.
While recipe variations for baguettes and bread rolls are not only to be expected but also make for unique selling points, high hydration rates and long dough resting times are the calling card of more sophisticated, authentic premium products.
MECATHERM developed the MecaAuthentik production line specifically to perfect the production of baguettes, especially the Authentik Baguette, which is described as a synthesis of the traditional and the industrial baguette, and characterized by a high hydration rate and a thin and shiny crust, with an open scoring, meeting the requirements of large-scale distribution. The resting time directly influences the final product. “In the case of the Authentik baguette, for example, a resting stage before dividing makes the crumb appear more open, the volume bigger, the scoring wider and the product tastier, it also allows for reduced improvers for a improvers for a healthier product,” MECATHERM details.
Divide, mold and conquer
Dough dividing and molding also play a role in the final results. For dough division, the MecaAuthentik line integrates the M-NS divider, which can divide a wide range of doughs from (single mix) straight dough to high-hydration rested dough. Volumetric dividers are also an available option, for perfect consistency between the pieces of dough. To ensure consistent results throughout production cycles, the M-NS divider monitors the dough density in real-time to reduce weight fluctuations that might occur. “Even when the dough density varies, the set weight remains the same. The divider can eject any dough piece that is non-conforming to the set tolerance,” MECATHERM explains. These pieces are then recycled so no product is lost.
The latter process is handled by the new M-RT molder, which was recently unveiled at iba. Handling the dough pieces smoothly, avoiding any impact, is key to preserving the product quality. “The dough pieces are brought to the molder on an inclined ramp, which is more adapted to hydrated and rested doughs than the vertical elevator that can be used for straight dough types,” Mélanie Salvi, Product Manager, explains. An isothermal intermediate proofer incorporated in the M-RT molder offers a controlled environment in terms of temperature and humidity, preventing the dough pieces from drying and sticking. Dough pieces are gradually molded: “Alternating phases of mechanical action with resting periods makes it possible to strengthen the gluten network without tearing it, and to obtain a controlled volume. The unique cassette stretcher, developed by MECATHERM, gives the final shape, without tearing the dough pieces to the products before depositing.
“The precise management of hygrometry results in accurate control of crust thickness, softness and water loss of the product.”
Xavier Gotti, Oven Product Manager, MECATHERM
The M-RT was designed to process a variety of products and dough types, including hydrated, long-resting time formulations. The new-generation M-RT molder was specifically designed to be easy to maintain, easy to clean and easy to operate. It is also equipped with an innovative system for the precise recentering of products by a camera, resulting in pieces with consistent shape and mass distribution. Duplicates are also detected and automatically ejected from the production line.
The M-NS divider combined with the new M-RT molder makes a tandem specially adapted to hydrated doughs: “They both keep the dough pieces in constant motion during the process – unlike sheeting technology – to preserve the softness of the surface of the dough pieces. The M-RT molder requires very little additional flour and contributes to preserving the dough’s quality, ensuring the thin crust and well-developed aromas of the final baguettes or bread rolls,” Salvi explains.
Another piece of equipment from MECATHERM’s partner ABI LTD can be integrated into the MecaAuthentik line: the KATANA robotic scoring solution. With this system, scoring is adapted to the position and orientation of the dough piece. Moreover, it can adjust the length and space between cuts if the product is longer, shorter, or wider than expected to always ensure the desired scoring homogeneity on products. “KATANA’s range of tools includes ultrasonic blades that provide great flexibility for scoring both low-water and highly hydrated products. By oscillating up to 35,000 times per second, the blade will smoothly open the bread little by little to ensure perfect scoring of the dough, even for specialties with flour or toppings.” KATANA now comes with a new, waterjet scoring tool, specifically developed for precise scoring, to preserve dough quality. “The waterjet scoring tool offers the possibility for bakers to personalize their products with complex patterns of scoring,” Alexandre Goasmat, Robotics and Automation product manager at ABI underlines more opportunities to perfect authentic custom products.
Alyson Slapkauskas, ABI LTD CEO, presents the KATANA system at iba
Oven and out
The baking technology and the choice of oven will also impact the product’s crust, look, shape and development. The new M-VT vertical oven, also launched at iba, can be integrated into the MecaAuthentik production line to offer precise baking parameters, thanks to independent modules as well as its conveying system and a new Hygrometry Control System. “The precise management of hygrometry results in accurate control of crust thickness, softness and water loss of the product,” Xavier Gotti, Oven product manager at MECATHERM illustrates. The compact M-VT oven can be used for baking a wide range of products, including crusty bread, soft bread, pastry and patisserie, and was designed to maximize baking efficiency for industrial bakeries, with several features that help lower energy consumption. “For more rustic products, baking on stone will give the bakers more appropriate results, with a thick crust and appropriate coloration,” the French specialists recommend.
Consistent results
Consistent results are ensured, with thorough monitoring in place: several sensors are positioned at different steps of the molding process. Moreover, the ABI EYE-Q quality control system developed by ABI LTD can be added to several steps of the production line in order to identify out-of-standard products early on in the process. For instance, the EYE-Q, powered by AI, can control the product quality at the depositing stage. By analyzing trends and deviations in production, the EYE-Q helps operators adjust the machine when irregularities are detected. “The system sends operators instant alerts that suggest corrective actions. By identifying the issue at the source, EYE-Q improves production consistency. If associated with a rejection system such as a pick and place robot for example, it is possible to reject defective products and even refeed them at the start of the process, if the system is in place before baking,” Alexandre Goasmat adds.
Proofing with equipment such as the vertical M-UB or M-VS proofers is another production step where homogenous results can be achieved.
In turn, the M-VT oven plays a decisive role in achieving homogeneous products consistently, thanks to several developments such as the new, shockless conveying system, which was completely redesigned, allowing the intrinsic quality of the products to be preserved while they are not yet solidified. In addition, ”A new airflow circuit design optimizes the precision of the baking process, ensuring excellent product homogeneity,” Xavier Gotti highlights.
Industrial setups
For customization requests of the MecaAuthentik line, the opportunity to maximize profit is the goal. With ever-increasing product diversity, various aspects come into play, from machine changeovers to handling different processing times. “One of the challenges is understanding the product flow throughout the production line and what happens during changeovers,” the specialists observe.
Industrial production volumes are the goal: the biggest baguette production lines made by MECATHERM can process up to 3.5 tons of dough per hour, or from 8,000 to 10,000 baguettes. Manufacturing fully baked Authentik Baguettes implies a complete process of 4.5 hours up to 5 hours.
A smart plan for sustainable production
The baguette line benefits from the M-Plan software, which helps operators visualize the production flow to identify the optimal production plan. The M-Plan digital tool is dedicated to production scenario simulation. “It enables manufacturers to simulate production changeovers and determine the best changeover scenario. As a result, they can prevent issues from arising during real production changeovers. This reduces consequent product damage and losses,” François Retailleau explains.
As a complementary solution, ‘recipe follow-up’ is available on MECATHERM HMIs to bring additional support to operators during production changeovers, to ensure each product is made under optimal process conditions. “This feature follows up on the production batch progress along the line, checking that every piece of equipment is fully set up to match the product recipe it is currently dealing with,” Retailleau explains.
Equipment solutions such as buffers can go a long way to keeping production uninterrupted during (unexpected) line stops. The M-VD cooler can also be used as a buffer, for example.
MECATHERM is developing several new solutions throughout the production line to improve its sustainability. These include an energy recovery system suitable to use with the M-VT oven, to enable additional energy consumption along the entire line. The energy recovery system helps reduce energy losses and generates energy savings by recycling the vapor energy extracted from the oven. Another notable novelty is the new Hygro Control System that accurately manages the fresh, dry air that enters the oven and extracts the humid air. “Manufacturers will not only enjoy energy savings, but will also find their daily work is facilitated. They can now automatically open the dampers and regulate dry air intake and steam management in each baking chamber,” Xavier Gotti explains. The Hygro Control System was developed together with the new M-VT oven, but the feature can be retrofitted on other oven models, too.
In order to reduce energy consumption during the cooling step, MECATHERM is also developing a Smart Cooling System. This system enables the recovery of outside fresh air, which is injected inside the cooler, limiting the use of the air-conditioner.
With numerous new technology upgrades, all interpretations of what makes a baguette authentic on a specific market or for a certain manufacturer can be translated into a stable production flow for industrial bakeries. Complex solutions contribute to making manufacturing easy.
