industrial production of artisan breads · industrial production of artisan breads ibie october...

Industrial Production of Artisan Breads

IBIE October 11th 2016

Frank Devos (VP R&D) - David Deblauwe (Regional Product Mgr Bakery Flavors)

Agenda

• What are artisan breads ?

• Upscaling to industry

• Tasting session

Through the Eyes of the Consumer

Artisan Breads for the Professional

process• Lean simple recipe • gentle process • Time !

Visual

• Crust with shred• Dusting Flour

• Open crumb• Off-white color

• Irregular shape• Variety

Position• Story• Point of Sales• Packaging

Texture• Crust hard or soft• Crumb slight rubbery

Flavor• Crust notes• Fermentation notes• Mild to sour

Fundamentals of Artisan Baking

26/09/2016, Page 5

From Artisan to Industry ?

Hurdles & solutions

26/09/2016, Page 6

Hurdles to Overcome

26/09/2016, Page 7

(sponge) Ingredients-mixing

Bulk proof

Divide & Make up Final proof Bake Cool &

pack

26/09/2016, Page 8

1h 3

0’

Bre

ad &

Bun

High Speed Bread & Bun Line Artisan

preferment Ingredients-mixing

Bulk proof

Divide & Make up Final proof Bake Cool &

pack

26/09/2016, Page 9

++++ ++

clean label ++++ +++ ++no stress !

1h 3

0’

24h +

4h

Bre

ad &

Bun

Art

isan

High Speed Bread & Bun Line Artisan

Why use Preferments?

26/09/2016, Page 10

TASTE

Bio-chemicalLeavening

Acidification

RheologicalExtensibility

Machinability

NutritionEg GI lowering

Starch digestibility

Finished BreadHolistic health

Diversity / tradition

Families of Preferments

26/09/2016, Page 11

Mixture of flour, water and commercial baker’s yeast

(Saccharomyces cerevisiae)

Mixture of flour, water and Lactic Acid Bacteria (LAB) &

wild yeasts

Fermented for 2-12 hours Fermented for >12 hours

Sponge - flour brew –poolish - biga

Sourdough – starter – sour – levain – masa madre…

Make Your Own Sourdough?

26/09/2016, Page 12

DaxnerBertrand

ready-to-usesourdough

26/09/2016, Page 13

mixing

proofing

moulding

baking

long fermentation

sourdough process

Shelf life stableConsistency

Flavor differentiation

Or Buy as Ingredient?

preferment Ingredients-mixing

Bulk proof

Divide & Make up Final proof Bake Cool &

pack

26/09/2016, Page 14

++++ ++

clean label ++++ +++ ++no stress !

1h 3

0’

24h +

4h

Bre

ad &

Bun

Art

isan

High Speed Bread & Bun Line Artisan

Ingredients

26/09/2016, Page 15

Trends

Ingredients

26/09/2016, Page 16

Basic Ingredients

YEAST SALT

High hydration : 65%

PREFERMENT

or

26/09/2016, Page 17

Functional Ingredients

Ingredients

ToleranceFreshness & Moistness

Mold Control

Clean label or organic dough conditioners

Freshness enzymesCorrect packaging

Fermented wheatClean room

Pasteurisation

Mixing

• Critical : dough development with maximum water

• Mixer design to incorporate more water

– Hydra (Sancassiano)

– Rapidojet

– ...

• Process

– Autolysis : 20-60 min

– Bassinage

26/09/2016, Page 18

preferment Ingredients-mixing

Bulk proof

Divide & Make up Final proof Bake Cool &

pack

26/09/2016, Page 19

++++ ++

clean label ++++ +++ ++no stress !

1h 3

0’

24h +

4h

Bre

ad &

Bun

Art

isan

High Speed Bread & Bun Line Artisan

Bulk Fermentation

26/09/2016, Page 20

• Minimum 45 minutes (mostly 1-2h’)

• Temperature control

• Why important?

– Open crumb

– Rubbery – cohesive texture

– Flavor

Dividing & Make-up

26/09/2016, Page 21

Solution : Stress-free Lamination Lines

26/09/2016, Page 22

Rheon

26/09/2016, Page 23

Koenig Menes

Rondo

Driem Kaak

Dough Extrusion

Multi Roller

Cutting

Final Make-up

preferment Ingredients-mixing

Bulk proof

Divide & Make up Final proof Bake Cool &

pack

26/09/2016, Page 24

++++ ++

clean label ++++ +++ ++no stress !

1h 3

0’

24h +

4h

Bre

ad &

Bun

Art

isan

High Speed Bread & Bun Line Artisan

Baking

• Type

– Crust: Thick or soft / thin

– Parbaked: White or fully colored

• Create ideal heat transfer

– Bottom heat

26/09/2016, Page 25

Mecatherm

Selling & Road to Market – Many Options

• Fresh, Frozen or Packed Ambient

• Parbaked or Thaw & Serve

• Packaging• Paper (+window) prefered by consumers

Can artisan bread & industrial production go

hand in hand?

26/09/2016, Page 27

Let’s Taste !

Questions ?

fdevos@puratos.comddeblauwe@puratos.com

Thank You!