It’s quite possible that the world cannot have too much pizza. With a $134 billion market that continues to see double digit growth, it is hard to see the limit of the market opportunity. To help bakeries deliver on the growing demand, industrial pizza production lines have continued to develop to make pizza production faster, simpler, and more cost effective. These production lines can also be paired with fast freezers to prepare pizzas for frozen food markets. Equipment manufactures and second hand sellers are able to work with each bakery to identify which production line strategy best fits your pizza production goals.
Dough production and sheeting equipment works with a variety of doughs by managing different widths and heights. For example, lavash, a thin bread from Armenia, is around 0.6mm thick, whereas pizza bases may be 25mm thick or more. Due to this dough variety, each manufacturer has a different take on the pizza production line, offering a variety of solutions that meet specific use cases. For example, Rademaker, Rondo, and others have developed sophisticated dough sheeting technologies. Using dough sheeting provides several benefits over traditional preparation techniques. It allows for consistency throughout the dough, as well as flexibility in the type of dough, size, and style. Sheeting can also allow for continuous proofing of the dough prior to stamping if needed. And no dough is wasted after the crust is stamped from the sheet as it is recycled into the production line. This process allows the Rademaker pizza production line to produce up to 9,000 kg of dough per hour.
Pizza Topping Line
Once the dough is prepared, it moves through the production line for toppings. This starts with sauce depositing. Each sauce placement accurately measures the quantity and placement of the sauce at high-volume. Following the sauce is topping strewing. Toppings may be deposited by blanketing the pizza with waterfall strewing or by placing individual toppings in the center of each pizza with targeted strewing to keep the rim of the pizza (crust) free from toppings. Both of these processes can work with multiple toppings and deposit them evenly on each pizza.
Artisan Capital Partners tailors solutions and services designed to create liquidity from industrial bakery assets while consistently managing transaction risk. Artisan Capital Partners helps bakeries manage assessing equipment, dismantling, and transportation, as well as design, installation, and testing to provide bakeries with a liquidity event that meets their goals.
De-panning systems may bring to mind some of the more futuristic looking components of an industrial bakery production line. And while that is an accurate picture, there are many ways to de-pan product quickly and efficiently. De-panning systems are a crucial component of many industrial baking operations, and as there are a wide variety of goods produced in bakeries, there are also a variety of de-panning methods and equipment. Whether you are baking loaves of bread, cookies, or croissants, there is an industrial baking equipment solution that is right for your production line.
Suction de-panners involve a robotic arm that operates as a vacuum with suction heads that are tailored to the type of product being de-panned. These heads are typically interchangeable, and can be used in production lines for baguettes, bread, and muffins, among others. Like with most de-panners, these are highly modular and the number and arrangement of the vacuum heads can be customized to the needs of the production line.
This type of de-panner is ideal for transferring particularly delicate baked products from their trays to the cooling conveyor. It is comprised of an automated head that has rows of needles extending at an angle, which is lowered over the product so the needles pierce the center and, due to the slight angle of the needle, are able to gently lift it from its tray and deposit it on the next portion of the production line. Needle de-panners can be useful for products that might be damaged by suction de-panners, for example with flaky pastries like croissants. These de-panners also have the benefits of requiring less energy to operate and a lower noise level than their vacuum-operated counterpart.
Other types of De-panners
In addition to the de-panners outlined above, there are a few other mechanized methods for de-panning. Some de-panners will use a head with “fingers”, such as the Kaak Fakir De-Panner, that push products off flat baking trays as they pass through the machine on the conveyor belt, directing them onto the cooling conveyor. There are also turn-over de-panners that lift and flip the whole tray in one quick motion, placing the products upside-down on the line.
Artisan Capital Partners is your source for updating and replacing your industrial bakery equipment. Contact us today to discuss your needs.
It is through innovative technologies that the pastries that are produced at an industrial scale manage to not only look uniform and consistent, but also taste like an appetizing handmade confection that came out of a pastry chef’s kitchen. Industrial baking operations rely on quality equipment to achieve these results, including refurbished used pastry make-up lines. As you consider how to construct your bakery’s make-up line, it can be helpful to familiarize yourself with the various components and equipment involved in order to create a process that works best for your bakery and a purchase that makes sense for your business.
As the dough begins rolling along the conveyor belt, some make-up lines may include multiple cutters; for example, cutting a sheet of pastry dough first into long lengths that in the next components have a filling placed on top and are folded, and then go through a second guillotine cutter to create the individual pastries. There are many types of cutters and trimmers that can be used at different intervals of your make-up line to create the desired effect for your pastries.
Like cutters, there is much variability in depositor features, allowing them to be useful in a wide range of pastry make-up lines, from pain-au-chocolate to apple turnovers to sausage rolls. Depositors use various shaped nozzles to apply filling and/or decorative toppings such as icing to the pastry and can be placed at the middle or end of a make-up line.
Folding and shaping
This component forms and shapes the pastry using conical rollers, folding shoes, or decorational rollers, and a combination of them can be used if several types are needed. Palmiers, for example, are typically produced with a make-up line that has three folders to create their delicate palm-like curls.
Leveling and pressing
In order to create a smooth uniform surface to gently compact a pastry, levelers or pressers are incorporated in the line. Pressers can also be used to add further embellishments to the pastry surface by indenting a desired pattern. These components are typically situated on the make-up line after the depositor and before final finishes such as a glaze are applied.
Spinning disk sprayer
For pastries that call for a glossy finish or a coating of egg yolk to enhance the color of the pastry after it bakes, think of the enticing hue of your favorite croissant, a spinning disk sprayer is employed in the make-up line. After the pastry has been shaped into its final form, the sprayers can coat the surface of the pastry with ease and may be the last component in your line before the finished product heads off to the oven.
Artisan Capital Partners sources a variety of industrial bakery equipment. If your business is looking to sell your current equipment and upgrade to new industrial baking machines, contact us today.
Before the 1800s, “made by hand” was not needed for clarification. In the last 200 years, that has changed. Today, the production line is the backbone of a worldwide system that generates the goods that sustain us all. A few key innovations have helped create this transition to the industrial baking production line equipment that produces our food today.
Harnessing energy supply
In many ways, the development of production and assembly lines started with the ability to control and direct energy. Previously, work needed to be done directly at the source of energy – for example, next to a stream that is turning a water wheel. The invention of the steam engine in the late 18th century led to the first industrial revolution. The steam engine, and later electricity, allowed workers and factories themselves to have power delivered to a specific location.
The assembly line
After electricity allowed for factories to specialize different work in the same building, companies began to work on how to optimize workflows within factories. According to Wikipedia, this started before electricity with the adoption of interchangeable parts and the standardization of components in industrial practices in the early 1800s. This allowed for increased specialization and trade of goods, as a company no longer needed to make every component specifically for each product. According to Robert Domm’s book, Michigan Yesterday & Today, the next step came with car production, with the assembly line patented by Ransom Olds in 1901. This concept would be taken a step further when Henry Ford incorporated conveyor belts to produce the Model T and revolutionized commercial production processes.
Another technological breakthrough that expanded the industrial food production market was the cold chain. The cold chain now allows food to be made and shipped long distances with a long life-span while still maintaining freshness. One important innovation was the discovery that flash freezing creates smaller ice crystals, which helps maintain the food products’ original structure and flavor. In 1924, after working on developing a freezing process for several years, Clarence Birdseye developed the first commercially viable flash freezing product for fish. His company sold 5 years later to Goldman Sachs, eventually becoming General Foods, now part of Kraft Foods. In 1940, Frederick McKinley Jones patented a roof mounted cooling system for a truck, connecting the cold chain to stores throughout the country.
These innovations of controlling energy supply to create factories, the development of assembly and production lines to optimize those factories, and the development of the cold chain to bring industrial bakery products to stores throughout the country are a few of the innovations that have created the modern food production industry the feeds the world today.
Artisan Capital Partners has a variety of industrial baking equipment available, both new and used. Contact us today to find your next industrial baking equipment solution.
If you are installing a new set of industrial baking equipment in your business, you may be feeling anxious or overwhelmed by the impending project. The idea of altering or all together stopping production schedules would make any business owner pause, but it is often a necessary project and the process can be planned for when you know what to expect. As providers of second hand and refurbished industrial baking equipment, Artisan Capital Partners have helped many business owners usher in the exciting change of new equipment installation, as well as help them resell their used industrial baking equipment.
What supportive components and teams are needed?
When bringing in a new line of equipment, there will likely be several supportive components needed for both installation and the new operations. For installation, it is important to consider where the equipment drop site will be, the entrance that can accommodate the dimensions of the new equipment, and any machinery like fork lifts that may be needed to retrieve the equipment and correctly place it within your production line. This may also include accounting for how much weight the floor on which the equipment will operate can hold, as well as the teams you need on hand to facilitate the equipment's placement.
You will also need to consider what adjustments are necessary for the operation of your new equipment. The placement of the equipment may create a need for lighting, wiring, or piping to be relocated or upgraded to support it. Lastly, it is imperative to prepare for a test run—create a test kit with all the pieces of production, including a skilled team of your employees to run and oversee the test.
What is needed to prepare for your new operations?
Often a new bakery production line is required due to a business's growing operations and demand. Installation may mean you need to adjust your production schedule or cease operations for the duration of installation. This timeframe can be utilized to ramp up other production operations, like increasing or re-sourcing collateral production materials such as ingredients or packaging materials. It is also important to revise or create safety procedures to govern use of the new equipment, as well as update operation and maintenance protocols, including becoming knowledgeable about the industrial bakery equipment warranty. Finally, it can be helpful to prepare your sales or distribution teams for the altered or increased sales you may expect with your industrial bakery equipment installation.