THE BAKER S CROWN. Rolls Pastry Bread VACUUM COOLING

Transcription

1 THE BAKER S CROWN Rolls Pastry Bread VACUUM COOLING E

2 REVOLUTIONISING PRESERVATION. KÖNIG MAKES VACUUM COOLING THE LATEST SUCCESS FACTOR FOR BAKERIES AND RETAILERS. The challenge Today, production and sales are taking place at two different locations. Manufacturers must therefore optimise their production outputs while ensuring that their products are at all times available in the right quantities and best quality at the points of sale. up to now, this could be achieved in two ways: with frequent deliveries of fresh goods or frozen products, normally in the form of pre-formed dough. Both options have something in common: high costs. The solution for the future With the Ceovac vacuum technology, you can manufacture and deliver bread, rolls and pastry (such as danish Plunder) as part-baked products. There is an additional advantage: food retailers can also be supplied with part-baked products for sale to consumers in a quality that was previously unavailable. The system is of course also suitable for organic products. The principle The Ceovac vacuum cooling technology applies the principle in which the boiling point of water lowers proportionally with lower air pressure. The patented technology applies this principle to extract the energy required for this process in the form of heat from the product. As a result, the product is cooled down and is stabilised within the shortest possible time. A Stikken trolley with hot part-baked products is brought into the vacuum chamber. The pressure in the chamber is then reduced by means of vacuum pumps so that water evaporates. As a result, the products are cooled down within a few minutes. They can then be stored without freezing at the production plant and eventually finished for consumption days or even weeks later - with practically no loss in quality at retail outlets or at the home of consumers. air pressure relative to elevation above sea level elevation above sea level pressure temperature m 10 3 mbar -76 C Vacuum range m 10 mbar 7 C m 226 mbar 63 C Mount Evert m 312 mbar 70 C With increasing elevation above sea level, the air pressure and thus the boiling point of water are lowered. Mont Blanc m 554 mbar 84 C Munich 530 m 954 mbar 95 C 0 m 1113 mbar 100 C 2

3 Applications: Stabilisation and conservation of part-baked bread, bread rolls and pastry. Practical use of a new technology Part-baked products can be stored at temperatures of +5 C to +10 C or even at room temperature no need for storage freezers or refrigerated transport. Retail outlets can ensure that fresh products are available at their premises in sufficient quantities and that they can be prepared for sale within the shortest possible time and without the need for trained staff. Improved crispy crust on rolls and similar products supplied in polybags to the grocery shops, etc. Improved look and crust; greater volume of finished Plunder-type pastry. Fast cooling of all bread types, irrespective of recipe and size, to firm consistency and/or packaging temperature. Cooling of sheet cakes, bee-sting cakes, pound cakes, Stollen cakes, etc. to firm consistency and/or packaging temperature. Sterile packaging of bakery products by means of fast cooling and pressure compensation after vacuum process under inert gas (e.g. for organic bread). Fast cooling of particularly delicate products such as Panettone. 1 Continuous vacuum cooling 2 Vacuum chambers for batch processing 1 Pre-cooling of part-baked frozen products (bread, bread rolls, pastry, pizza bases, cakes) without shock freezing. Fast cooling of part-baked ready-made pizzas, preventing soggy bases. Production of finished goods at the bakery - turning part-baked products stored under controlled conditions (+ 10 C/80 % air humidity) into fresh bread in practically no time, rolls and pastry - safe, flexible and convenient. 2 3

4 TRIUMPH OF A TECHNOLOGY. CONVINCING ARGUMENTS AT A GLANCE. Quality Improved overall visual appearance Larger product volumes Improved and lasting crust Greater freshness of the crumb Supply of part-baked goods of unrivalled stability Economic efficiency Greater utilisation of oven capacity (plus 25 to 35 %) without the need for additional investment Lower labour costs due to: - optimised lot sizes - reduced extra pay for night shifts and overtime - shorter preparation times - more flexible spread of work over the shifts Significantly prolonged service life of unit components, even in bakeries with three-shift operation Energy and maintenance costs reduced by more than 50% compared with frozen products Considerable saving of resources (baking close to customer at the point of sale) Lower packaging costs (use of reusable containers) Improved efficiency as the products rather than the trays and grills are cooled down Investment Shorter baking times for both pre-baking and finish-baking: - processing capacity increased by up to 30 % at both the bakery and the retail outlet Around-the-clock use of production facilities (production line and storage) Improved utilisation of ovens, provers, etc. Low-cost delivery vehicles compared with refrigerated vans - no need for special delivery routes No need for shock freezers or refrigerated storage facilities (at the bakery and the retail outlet) No rush hours in production: allows for production outside the traditional baking hours. Pre-baking time reduced by around 25%. Vacuum cooling: 2 to 6 minutes, depending on product. Packaging and st or ambient tempe Reduced space re for production. 4

5 Reduced space requirements for production Low investment costs, no need for coolant lines or thermal insulation; supplied as fully wired units Marketing Fresh products available in the store at any time of the day, resulting in greater consumer traffic and thus higher turnover in existing outlets No risk of undersupply - sufficient quantities of part-baked products can be kept in the non-refrigerated store of the shop Elimination of out-of-date or already thawed products at the retail outlet Increased turnover from the sale of part-baked products to consumers, private caterers, party services, etc. Consistent high product quality determined by the bakery Easy handling and finish baking Specialisation and product exchange with partner bakeries Energy savings of up to 50 %, protecting the environment orage at 5 C rature quirements Products can be transported at ambient temperature. Storage in shop without cooling for up to 36 hours. Excellent availability. Finish baking time: 3 to 6 minutes. Satisfied customers, minimum returns. 5

6 PHYSICS AT WORK. VACUUM COOLING IS BASED ON A LAW OF NATURE. Vacuum cooling, and especially the Ceovac technology, helps save time, lower investment costs and reduce the space requirements in bakeries. Ceovac vacuum cooling stands for longer storage life and greater freshness of products without the need for freezing, offering huge advantages in terms of logistics and distribution. The three main factors that have made Ceovac technology a success: 1 During the vacuum cooling process of part-finished wheat and mixed wheat products, starch tends to liquefy, so that water is adsorbed even more intensely and less free starch remains in the product after the vacuum process. The increased binding of starch results in better conservation at temperatures at which storage was previously not possible. 2 The growth of germs during the cooling process is accelerated at temperatures between +60 and +30 C. With conventional cooling (at ambient temperature), bread and cakes are often at these critical temperatures for four to six hours. With the Ceovac technology, the time during which products are kept at these temperatures is reduced to a few minutes, so that moulds and spores of other germs cannot grow. This results in a natural, prolonged resistance to mould. 3 With the Ceovac technology, the baked products are not cooled from the outside to the inside, as is the case with conventional cooling. Instead, they are cooled simultaneously at the outside and inside, preventing moisture migration, preserving the crumb and crust, while the volume of the product increases in many cases and then remains stable during storage. The result: stabilised products of attractive appearance, part-baked products with long shelf life at ambient temperature, excellent mould resistance without preservatives produced at costs that are considerably lower than those for frozen products. 6

7 Part-automatic production, approx. 1,000 kg/hour Manual removal. Two vacuum chamber, 10 to 15 trolleys per hour. Automatic cardboard box removal. Continuous production, approx. 18,000 to 24,000 bread rolls per hour 6 vacuum chambers stacked on top of the other. Removal to packaging unit. Manual feeding product. Frosty times for costs Vacuum cooling is even more attractive when considering all aspects from production to consumption. When taking into account the four areas where the greatest cost savings can be made, most potential users will find out that investment in a vacuum cooling unit pays for itself in as little as 1 to 2 years. Comparison of overall costs: example of bakery outlet Vacuum cooling for part-braked products compared with conventional cooling or CO2/N2 refrigeration technology (carbon dioxide/nitrogen). Production output: approx. 36,000 bread rolls/day or 10.8 million rolls per year Energy Packaging Logistics Returns 0 Vacuum cooling Freezer CO 2 /N 2 Vacuum cooling Freezer CO 2 /N 2 Vacuum cooling Freezer CO 2 /N 2 Vacuum cooling Freezer CO 2 /N 2 Total costs* 244, (0.023 per roll) 407, (0.038 per roll) thousand Euro 510, (0.047 per roll) * not including investment costs, service and maintenance; average costs not taking into account countryspecific cost structures

8 THE BAKER S CROWN headquarters König Maschinen Gesellschaft m.b.h. Stattegger Straße 80 A-8045 Graz Tel.: Fax: info@koenig-rex.com 06/2006