Bakers have production options with breakfast breads | 2021-08-06
Breakfast breads have always been a part of the bread aisle. Whether they’re packed with fruits, nuts, and seeds, or feature an aromatic cinnamon or other indulgent swirl in the center, these products aren’t going anywhere.
“It’s a mainstay of any bread aisle,” said David Moline, vice president of sales and marketing, Moline Machinery.
These inclusions and swirls that make breakfast breads so appealing to consumers also have their own production needs, whether it’s modular equipment and rapid sanitation for flexibility, or processing. soft dough for the integrity of inclusions. Designing a production line up front to meet these needs can lead bakers to distribute these reliable products.
From a production standpoint, marbled breads bring together two different bread doughs while swirl breads roll a base dough around a smear, dry fillings, and even inclusions. Bakers can choose from several processing routes to make these patterns appear in their breadcrumbs.
“Marbling could be done by having two bread lines side by side delivering different colored doughs and then combining those pieces in the moulder,” said Patricia Kennedy, president of WP Bakery Group USA. “The other way is to flip the dough and add additives and swirl the dough.”
Bakers can also use coextrusion to bring two different doughs together. The dough is extruded into two strands which twist together when exiting the machine, creating the marbled effect. Rheon USA’s coextrusion technology can not only twist two varieties of dough together, it can also add separate fillings to each type of dough.
“In total, we can extrude and twist two colors of dough and two different fillings,” said John Giacoio, vice president, sales and marketing, Rheon USA. “Visually it makes a nice product, but when you bite into the bread you also get the added surprise of a topping. “
Stratification can also provide a swirl in a loaf. While traditional layering layers butter and dough, the butter can be replaced with chocolate or other fillings. Combined with a sidewinder, the rolling creates a bread product with thinner swirls.
“With this method, we also use a stress-free system, so the quality is unmatched and the number of vortices can reach several dozen, giving you a beautiful product,” Mr. Giacoio said.
Historically, however, swirled breads have been made using sheet technology. Typically, automated swirl bread production includes a rolling line to create the basic bread dough sheet. Then, the depositors apply the filling or a strainer to add inclusions like fruits or nuts. A sidewinder then rolls up the dough. While a guillotine can cut bread into its final bread shape, Mr Giacoio said Rheon’s shutter system can provide a rounded end rather than the blunt cut.
“This type of laminating system will give you high quality bread with nice cell structure and up to six vortices,” he said.
With foil technology, bakers can fully automate the marbling effect.
“Combining different textures and colors of dough, layering and rolling them to create that swirling look is a process that we automate to ensure consistent product quality, whereas previously this was only done by the artisan baker”, said Bruce Campbell, vice president, paste. processing technologies, AMF Bakery Systems.
Automation also allows bakers to customize their processes for a wide range of products. AMF can combine up to three different colors of dough into a marbled bread using its rolling technology, said Hans Besems, Executive Product Manager, AMF Tromp. By using toppings and layers of cinnamon, sugar, and other ingredients, bakers can get creative.
“Our unique lamination technology gives us the ability to create separate layers and therefore colors of bread,” he said. “As you roll them up, the mottled pattern will appear. “
However, marbling multiple bread doughs to create a pattern requires a lot of additional tooling. Bakeries need additional mixers and hoppers to feed the different doughs into the rolling line to create top and bottom sheets.
“Not only will this require additional maintenance and upkeep, but you will also need additional training and, in some cases, additional manpower to produce these loaves,” said Randy Kelly, specialist in sales applications, Fritsch USA, a Multivac company.
Managing two different pastes to ensure product quality is consistent at the end of the line also requires finesse in planning production, scheduling, and streamlining product changes.
“You have to make sure that both types of dough are ready to be fed to the rolling line at the same time,” explained Kelly. “It also helps to process the dough in a timely manner, because you don’t want the dough to gauze or go up the production line. “
This article is an excerpt from the July 2021 issue of Baking & Snack. To read the full article on Specialty Pan Bread, click here.