Space is a precious commodity, especially so in bakeries pursuing growth. What’s more, a strategic location is hard, sometimes even impossible, to leave behind. Compact solutions transform bakeries into valuable real estate. A solution that literally steps up to this task, flexibly covering proofing and cooling, is the step cabinet.
Long fermentation baked goods are among the strongest movements in modern bakery trends. As the dough takes the time to perfect its structure, this exercise in patience must be sustained with the solution that offers both minimum footprint and maximum storage space, creating all the required conditions for the dough’s nurturing rest in a controlled environment. How to compensate for longer proofing times to balance the production workflow? Taking as little space as possible is a great solution in this case.
One alternative that is compact by design is the step cabinet. Also known as a paternoster, it is ideal where space is limited and the output is high, making use of the vertical space to save the floor surface occupied. In this category of solutions, the Step Cabinet developed by AMF Den Boer is also multi-use: it can be flexibly utilized as a proofer, a cooler, or a buffer if required. It can be designed to use the height of the facility, also taking into account the total weight of the products and that of the baking trays or peelboards. “We have built step cabinets for peelboards up to 2.5 meters long and 1 meter wide, so the range and capacity of products can be immense,” AMF Bakery Systems specialists explain.
The efficiency of the cooling process is also a critical factor, equally important to the machine’s footprint. AMF developed the Step Cabinet together with specialists in climatization and enclosures to optimize the environment control technology, with the help of humidity and temperature sensors. Custom setup is a given: “When our customers need more control, we can measure the temperature and humidity at multiple locations within the enclosure. The actual environment can be seen and adjusted anytime via the HMI,” the specialist details.
The integration of this multi-functional cabinet with the system handling the baking trays and peelboards is a thoroughly thought-out process, to ensure the equipment stays future-ready over time, AMF observes. “As a solution for a process step within a system built for multiple operating stages, the high-level optional software solution that AMF can already provide is recipe control within the complete system,” for instance. Product changes can be managed easily with it: “In an optimally integrated system, the AMF software ‘travels’ with the product through the system. The program controls and adjusts every conveyor and machine that, combined, make up a process step. The operator does not have to manually change any settings in the system.”
Long fermentation, immediate premiumization
Bread with sourdough has firmly established itself as an important part of a healthier diet. Research shows that it ranks third among consumers’ favorites, after ‘bread rich in fibre’ and ‘breads with more grains’. It is preferred over varieties in the categories: ‘high in protein, low in salt’ and ‘gluten free’. Reconsidering the way bread is fermented can bring new opportunities in product development. Extended sourdough fermentation – typically, around 20 hours – results in more premium bread characteristics. A well-executed long fermentation ensures breads have a rustic look on the crust, a more open and ‘waxy’ crumb that has a cohesive, moist and elastic-like texture, and a rich flavor.
Source: Puratos – ‘How long fermentation is changing the baking industry’
A fail-proof process
Great products made consistently require similarly stable process steps. The system ensures the required proofing conditions to meet this goal. Using a vision system (AI-based, perhaps) could be an interesting future opportunity to make the process completely fail-safe through an automated feedback loop from the proofed products to the proofer. AMF already provides such a system with product recognition, used after the oven and for ingredient depositing on pizza. For proofing, this could also help with the mitigation of accidental parameter changes.
All variables accounted for
For consistent results, all changing surrounding parameters are taken into consideration, from the system’s placement, seasonal changes and the facility’s layout.
For proofing, AMF’s Step Cabinet incorporates systems that use hot and cold water, as well as steam, or a combination of these. “For cooling and freezing, we use evaporators that use cold water or other media that are standard in that field, depending on the requirements,” AMF explains.
The step cabinet can work in any climate and season, from Nordic countries to the equator. Fluctuations coming from seasonal changes are largely avoided by using enclosures with small openings, only for the trays or peelboards to fit through, via a conveyor, in a complete stainless-steel frame with climate control integration. “Our specialized partner has multiple decades of experience that helps us in creating the solution that the customer needs, even during hot summers and cold winters,” the specialist highlights. Narrow infeed and outfeed access does not mean the machine is difficult to clean and maintain – these aspects are covered by its easy-access design.
“In an optimally integrated system, the AMF software ‘travels’ with the product through the system. The program controls and adjusts every conveyor and machine that, combined, make up a process step. The operator does not have to manually change any settings in the system.”
AMF Bakery System specialists
Planning for unplanned events
The Step Cabinet can also be used as a buffer in production, whenever the need arises. It can safely help pause processes – the duration afforded depending on the product behavior during this stage. In most cases, buffering is done in the ambient conditions of the production facility, which also depend on each product being made. The exact amount of time should be determined according to the product, AMF observes. For example: “When cake is buffered too long and is then sent to a depanner, the condensation between the baking form and the cake will cause problems during depanning; bread may get soggy if it does not move along on time.”
Considering everything from system design to its integration and its process optimization, the Den Boer Cabinet Proofer is a flexible solution for any proofing times – including long-fermentation products. For these on-trend varieties, it helps develop the intense aroma and the appreciated acidity that makes them so popular. This is the proofing process behind products described as high-quality and authentic and perceived as healthier and more nutritious than conventional alternatives.