REVENT Vacuum cooling

REVENT Vacuum cooling

How does Vacuum cooling work? > The baked goods is moved directly from the oven into a chamber. > A pump lowers the air pressure in the Cooling chamber, following a pre programmed pressure curve. > When the air pressure is reduced, the boiling temperature of the water in the baked goods is reduced, thus the evaporation of water from the baked product is accelerated. When the water evaporates it takes heat out of the product. > At 20 mbar (Vacuum) the boiling temperature of water is 7 C. > The process to cool baked goods to ambient temperature takes 3-6 minutes. > By reducing the baking time the water content in vacuum cooled products will be the same or higher compared with other cooling processes.

Is Vacuum cooling a new technology? > The principles behind the active vacuum cooling process has been known for more than 250 years. The development was stopped 150 years ago, with the invention of the modern refrigerators. > In the 50 s the development of vacuum cooling started again, primarily for cooling of vegetables. > In the 70 s vacuum technology showed promise for baked goods in laboratory settings but the technology and design solutions to build reliable Vacuum cooling systems for volume production in bakeries was not available. > A few years back components and technical solutions reached a level where vacuum cooling can be used efficiently and profitably in volume production of baked products. > Now there are many Vacuum systems installed in Wholesale Bakeries, primarily in Europe and Russia.

Advantages of Vacuum Cooling- Economics > Reduced baking time by 10 to 50% (depending on product) resulting in increased oven capacity and energy savings > Reduced total cooling time (up to 95% vs ambient cooling) > Significant energy savings (up to 50%) for cooling, storing and distribution compared to mechanical and gas cooling systems. > Reduced costs for storage and logistics due to extended shelf life and lower packaging costs due to more stable products. > Reduction of ingredients (butter, nuts, salt etc.) and chemical additives (E-numbers)

Advantages of Vacuum Cooling- Comparison of cooling methods Cost comparison based on a yearly production Production quantity: 36 000 rolls per day. Cost in 1000EUR / year 160 Energy Packaging Logistics Rejects 140 120 100 80 60 40 20 0 Negative cost (saving) when accounting for reduction in baking time and potential to recover energy Vacuum Cooling Freezing CO 2 /N 2

Advantages of Vacuum Cooling- Better Quality and Extended Shelf Life > Increased volume and stability (also for organic products) due to a more consistent and homogenous cooling with vacuum technology. > Long lasting crispiness, optimized and extended freshness within the crumb due to even water distribution in products after vacuum cooling. > Par baked products gain an unparalleled stability, just after being pre-baked and vacuum cooled, making the products less sensitive when slicing, freezing and packaging > Better quality for par baked products due to a better distribution of water in products and a more finished crust.

Results of Vacuum cooling: Toast bread (white) Vacuum cooled Baking time [min]: 20 Baking temperature [ C]: 250 (constant) Standard Baking time [min]: 25 Baking temperature [ C]: 210 (constant) Baking time reduction [%]: 20 Cooling time [min]: 3.5 Core temp. after VC[ C]: 48 Note: The vacuum cooled product shows an airy and constant structure. The volume is bigger and the form more stable.

Results of Vacuum cooling: Sandwiches Vacuum cooled/ Standard Vacuum cooled Standard Baking time [min]: 10 Baking temperature [ C] 200 (decreasing) Baking time [min]: 14 Baking temperature [ C]: 200 (decreasing) Baking time reduction [%]: 29 Cooling time [min]: 3 Core temp. after VC[ C]: 40 Note: The vacuum cooled product didn t fall in like the standard product. The volume is bigger and the crust is thinner but the stability is still better on the vacuum cooled bread.

Results of Vacuum cooling: Appel-Muffins Standard / Vacuum cooled Baking time [min]: 34 Baking temperature [ C]: 160 Standard / Vacuum cooled Baking time [min]: 28 Baking temperature [ C]: 160 Baking time reduction [%]: 17 Cooling time [min]: 3 Core temp. after VC[ C]: 31 Note: Thinner crust and more volume. The Apple filling in the vacuum cooled product sits higher and doesn t sink into the baking good.

Results of Vacuum cooling: Danish Plunder Vacuum cooled Baking time [min]: 15 Baking temperature [ C]: 200 (constant) Standard Baking time [min]: 22 Baking temperature [ C]: 200 (constant) Baking time reduction [%]: 32 Cooling time [min]: 3.5 Core temp. after VC[ C]: 30 Note: Higher volume and a more airy base are positive effects of vacuum cooling. The vacuum cooled product also doesn t have a doughy bottom under the filling.

Results of Vacuum cooling: Croissant Vacuum cooled Baking time [min]: 13.5 Baking temperature [ C]: 190 / 230 Standard Baking time [min]: 20 Baking temperature [ C]: 190 (constant) Baking time reduction [%]: 32.5 Cooling time [min]: 2.5 Core temp. after VC [ C]: 30 Note: Significantly more volume for the vacuum cooled croissant. The crust is more stable after vacuum cooling.

REVENT Vacuum systems Batch (rack) systems Automated (continuous) systems

REVENT batch chamber vacuum systems > Suitable for all types of baked goods > Capacity: 10-14 batches/h > 10 standard designs that match standard racks > Can be customised for other rack sizes, higher capacity, automatic doors etc.

REVENT batch chamber vacuum systems- Standard systems

Custom designed REVENT batch chamber vacuum systems Pass through system Space saving placement of compressor

REVENT Continuous Vacuum Cooling Systems > A more Energy efficient and faster alternative to cooling towers and cooling tunnels that can be applied to all types of baked goods. > During the cooling process the products must be held in a cooling chamber. By using a number of cooling chambers, products are moved through the cooling process with only minimal buffers used to batch products after the oven to load each chamber. > There are two basic design solutions for continuous Vacuum cooling lines: Chambers stacked and products moved with a loader to and from conveyers (as shown in the pictures to the right) Chambers placed side-by-side, level with the tunnel oven. Products are moved on conveyers. (Design example showed on next page) Pictures above show a system that can cool 44 000 Kaiser Rolls/h using 6 cooling chambers

REVENT Continous Vacuum Cooling Systems-Example The picture above shows a compact design with cooling chambers stacked on top of each other. The cooling chambers are pass-through and loading tables move product to and from the cooling chambers.

REVENT Continous Vacuum Cooling Systems-Example The picture above shows a compact design with cooling chambers at the same level as the tunnel oven. Compressors etc. are placed on top of the cooling chambers. The system connects to in- and out-feed conveyers.

Process for implementing Vacuum Cooling 1. Test with customers products to verify impact on product quality, cooling time and baking time reductions 2. Calculate necessary capacity and make basic design 3. Quotation and ROI calculation with customer 4. Any additional tests to verify results 5. Design of Vacuum system 6. Installation and start up. Revent will assist in developing Cooling recipes and perform training