Establishing a complete setup for sourdough production in industrial bakeries poses several challenges. The fermentation process must be taken into account and the equipment must be able to replicate handcraft techniques to handle this delicate dough
Once a specialty synonymous with craft bakeries, artisan products are now in high demand in the baked goods aisle, too, as a better-for-you alternative to products that are traditionally produced in industrial volumes. It’s not just bread: artisan-style products comprise any products with a handmade feel and carefully selected, simple ingredients, that are usually found in local bakery shops. They can range from crusty sourdough loaves to buns with different seed assortments or braided rolls. Sourdough specialties are among the baked goods that continue to amass a dedicated following of loyal admirers (and consumers).
However, processing sourdough in industrial operations must cater to the sourdough’s properties for consistent results that can successfully capitalize on this trend. The right equipment will support the production of sourdough products (and a suite of other artisan-style products). Emerging solutions make use of Artificial Intelligence tools and machine learning to predict and adjust processes, for example. Vision systems also bring valuable insights to production, while process improvements with the use of robotics are also on the rise. Adaptability is key.
Defining the technology lineup for sourdough starts with a comprehensive analysis of the products on the to-bake list: building a mono-line that will process the one specialty 24/7 will be approached in a completely different way compared to a line that will be used for an entire assortment of products which use dough of similar characteristics with sourdough, for instance. The flexibility needed will contribute to the setup of the line, as will the process management needs.
Delicate dough: handle with care!
Artisan sourdough bread is praised for craftsmanship for good reason. The dough is often very delicate and requires an experienced hand to handle it to enhance its properties and avoid harming its structure. Absolutely no stretching or breaking is allowed.
Establishing an optimum process flow is fundamental to timing each step with respect to the dough’s development. “Streamlining processes is made possible by controlling each process in detail, to match the type of product and its requirements. The dough determines the settings of the line,” AMF’s specialist underlines.
Baking sourdough?
+ Baking curve: product-specific, set to decline. For example: 280/255/230°C, depending on the bread type.
+ Airflow: typical air speed between 1.5-3.5 m/s (coloraider/convection)
+ Humidity (moisture should always be ensured at the beginning of the baking process:
– Without steam, dewpoint at 60°C
– With steam, around 80°C dewpoint
– Ending at 20-40°C dewpoint
In high-volume operations, “For sourdough and any highly-hydrated doughs, gentle reduction in the sheeting process is key to determining the design of an automated line,” AMF Bakery Systems’ specialists underline. Such gentle handling can be ensured with the AMF Tromp sheeting lines, which can be finetuned for all types of dough in the artisan-style category. The AMF Tromp Stress–Free Artisan (SFA) Bread Line is designed specifically for this purpose, with dough-reducing technology that maintains the dough’s integrity throughout the process.
Low-stress sheeting and rolling out of the dough sheet mean its properties will be kept intact. “As much as possible, the bubbles and the process inside the dough must be allowed to develop undisturbed. In this way, the dough can quickly recover to its ideal characteristics,” AMF underlines. This is ensured by recipe-driven, automated lines, with a single point of control for the entire process. Quick changeovers also ensure a smooth production flow, essential for high-volume operations. The AMF Tromp sheeting line does not require any tools for changeovers, to expedite the process and ensure safety. It also comes with recipe-driven software, for efficiency and convenience in use.
Full-scale craftsmanship
To mass produce crusty products that are found in artisan bakeries, sheeting must be accompanied by the correct processes upstream, when the dough is created and developed, and downstream, when the products are baked.
AMF’s horizontal mixers, for example, can work in optimum conditions with doughs of any consistency, including soft and delicate sourdoughs. They monitor the mixing process at every stage and, with the help of the company’s dedicated Dough Guardian, a patented technology, adjustments can be made in real-time, to ensure consistent results over time. In addition, “AMF Fusion has kneaders and mixers that are suitable for sourdoughs, but also fully-automated fermentation systems, using AGVs, fermentation rooms, large dough bins, and software to monitor this process, with no human interaction needed,” they explain a possible line-up for a true ‘bakery of the future’.
”Streamlining processes is made possible by controlling each process in detail, to match the type of product and its requirements. The dough determines the settings of the line.”
AMF Bakery Systems specialists
Proofing can also raise challenges for sourdoughs, which need accurate resting control to develop the coveted artisan rise and crust. Here, AMF can offer a range of systems to choose from, including step, spiral, or continuous proofers. “We accommodate high-hydration and long fermentation times for dough, to create those nice artisanal products, with lots of bubbles inside and crusty outside,” AMF highlights. Even dough with no fermentation times can be processed: they can be sheeted directly on the line, if flexibility is needed.
AMF can provide several oven technology options in the AMF Den Boer range, to complete a sourdough line. Stone-floor ovens are a popular choice currently for any artisan specialty, and Den Boer ovens include them, along with precise burner control and gap detection technology, to ensure product uniformity. Direct-fired gas ovens are also very popular choices. “We see a rise in impingement technology (indirect), electric and hydrogen baking, or hybrid models to combine fueling options,” AMF observes market dynamics. These technologies ensure the consistent production of crusty specialties.
Decorations are the finishing touch for handmade creations, and they can also be automated, from scoring various patterns to sprinkling seeds or nuts, and even applying glazes. All these systems feature material recirculation solutions, so no costly ingredients go to waste. “Using seeding, (water) scoring for a crusty top, enrobing seeds on the bottom, are trends we see more and more in premium products,” AMF specialists observe. Decoration choices for beautiful creations are many, from seeds to nuts and fruits. Depending on the product, inclusions can also be added to the dough, for example, by mixing in olives.
And, to always have a view of the complete process, AMFConnect can provide a digital map of the entire line, with smart features to ensure process flow continuity. The company developed Bakery Intelligence solutions that cover everything from mixing, make-up and proofing to baking, cooling, conveying and packaging.
These kinds of lines are built for large volumes: average large sites easily run 2 tons of mixed dough per hour. “Our sheeting lines by TROMP can handle these volumes,” AMF specialists note. They are engineered and configured to specific needs, and aligned with existing processes or equipment.
To establish the optimum equipment setup, testing can be carried out first, at the AMF Innovation Center, to validate products at full-scale. A team of bakers and food technologists can support testing there, along with ingredient suppliers. The rest is up to the imagination, to envision and create unique sourdough specialties that convey an artisanal look and feel.
A second article on sourdough will be published in the next issue of Baking+Biscuit International.
