Saturday, May 19, 2012
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How do you know your Baking Process in in control?

Why Profile?

Time-Temperature Profiling Is Critical

  • When staling is an issue!
  • When color consistency is an issue!
  • When baking uniformity is an issue!
  • When energy costs are significant!
  • When Specialty Enzymes are introduced into the recipe for quality and shelf-life enhancement!

Why Adopt Profiling?

  • Product quality and consistency
  • Extended shelf-life (Specialty Enzyme enabler)
  • Yield improvements / scrap reduction
  • Optimized throughput
  • 10% reductions in the bake cycle have been reported
  • “Copy exact” in distributed locations (replicability)

Benefits of the M.O.L.E. ® Profiler in Time-Temperature Profiling For Baking Ovens

  • Provides Reliable data-based decisions
  • Provides weight-loss control
  • Provides Precision process repeatability
  • Produces consistent high quality product output
  • Facilitates batch-to-batch consistency/repeatability (same line)
  • Facilitates process and output quality replicability (plant-to-plant)
  • Accelerates process / product problem debug
  • Provides competitive advantage based on quality consistency
  • Enables minimization of ingredients
  • Enables optimal use of specialty enzymes
  • Enables efficient energy usage (natural gas)
  • Enables assurance or proper time - temperature profile after a mechanical breakdown

Profile Cooling & Freezing Applications too!

  • You can profile both cooling and freezing applications with the same kit !
    • Ambient air
    • Product
  • Know when your product is reaching the intended temperature
  • Profile through the proofing process, on through the oven and into the freezer
    • One continuous run

Click on the profile on the right to see a larger image

Profile of a cooling application

Payback Model – Scrap Reduction

 

If only one fourth of the yield loss is saved by improved Time - Temperature profiles

Payback on an BakeWATCH® M.O.L.E.® Profiling Program implementation is about 4 months!!

Additionally, if we can reduce a $20,000 per month natural gas bill by 8% (from a 10% cycle time reduction), the additional savings drops payback to under 3 months for just one shift.

Large-Bakery Production

(reducing scrap inside the bakery)

Loaves per minute - "Production Rate
120
Yield* cumulative through baking cycle
98%
8-hour shift production rate (loaves)
50,000
Loss (loaves) 2%
1,000
Loss @ $.35 gross margin / - loaf /shift
$350
Lost Revenue per month per shift (20 days)
$7,000
* Typical: Top too dark; sides under-baked,etc.

Download a spreadsheet that you can use to calculate your savings!

Payback Model - Extended Shelf-Life

 

 

Payback on an Enzyme / BakeWATCH M.O.L.E.® Profiling implementation is less than 1 month!!

Retail Throughput

(extending shelf-life through Specialty Enzymes and Profiling)

Placed on shelves (loaves / day from large bakery)
$50,000
“Sale-fail” (5% don't sell within their shelf life)
5%
Resultant loaves returned - daily average
2,500
Lost daily revenue at $1.50 / loaf ($.35 gross)
$2,875
@ 20 baking days / month - loss
$57,500
Saved Revenue on 20% fewer returns
$11,500
Monthly Saved revenue
$11,500

 Download a spreadsheet that you can use to calculate your savings!

Process Improvement Example

“Initial” Bake Oven Profile- from the BakeWATCH® M.O.L.E.® Profiler

  • Product does not reach 200 Deg. until exit of oven
  • Product is under baked
  • Product needed more time in this oven
  • Some side to side temperature variation
  • Color would likely be off
 Output of the M.O.L.E.(r) software showing the initial profile
   

Actual “Optimized” Bake Oven Profile- from the BakeWATCH M.O.L.E.® Profiler

  • Product reached the desired 200 Deg. temperature
  • Temperature was reached at 80% of the distance through the oven
  • Bake oven temperatures in the final zones were even and stable
  • Good browning and consistent quality
 Output of the M.O.L.E.(r) software showing the profile after it has been optimized

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