 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
!
- Know when your product is reaching the intended temperature
- Profile through the proofing process, on through the oven and into the freezer
Click on the profile on the right to see a larger image
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Payback Model
– Scrap Reduction
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. |
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.
Payback Model
- Extended Shelf-Life
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
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| Saved Revenue on 20% fewer returns |
$11,500
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Monthly Saved revenue
|
$11,500
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Payback on an Enzyme / BakeWATCH M.O.L.E.®
Profiling implementation is less than 1 month!!
Download a spreadsheet that you can use to calculate your savings!
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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
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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
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