Proofing is a vital component to the quality of every bakery product and is a key step in industrial baking production lines. From the first proof to intermediate to the final proof, proofing provides the dough the environment needed to rise the appropriate amount in order to be ready for the next stage of the process. Industrial baking proofers provide a range of options to meet the needs of a variety of products and process.
Proofing Objectives Proofing ovens create a controlled environment to allow a dough product to rise the specified amount. This is mainly achieved through the combination of heat and humidity. However, the challenge is to provide air circulation, consistent heat, and humidity throughout the proofer without any lost costs of operation. Humidity can be achieved through several methods, including with cold water atomizers using compressed air. Maintaining a consistent temperature throughout the proofer is important and can be assisted with air movement in the proofer facilitated by high-efficiency fans. The throughput of a proofer and its cleaning requirements determine how much product can be created over time by an industrial bakery with that piece of equipment. For some bakery operations, proofing can be accelerated by proofing sheets of dough instead of individual units. First Proof Industrial first proofers provide bulk fermentation for an entire batch of dough. The first proof is done before the dough is cut or shaped, and provides additional flexibility and control of the baking process and resulting product. Important characteristics of a first proofer include selecting the right type of infeed system, which is determined by the type and quality of dough your production line produces. Intermediate and Final Proof Intermediate and final proofs are not the same. The former gives yeast-risen dough the opportunity to rest and recover from the deformation of dividing and rounding, while the latter promotes leavening to bring the product to its ideal volume for baking. This means that intermediate proofers can actually operate at ambient temperature and humidity, as long as it will not cause dough surfaces to dry. Like first proofers, final proofers must be temperature and humidity controlled to create the precise conditions for a reliable final product. 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. Pies and quiches are both built from a pastry crust base, with quiches having a filling thickened with eggs and pies having a variety of fillings as well as a top crust or “lid.” Between these two products, there is a wide number of filling options that create a large market for industrially produced pies and quiches. Industrial baking production lines for pies and quiches encompass ingredients, technologies, and processes that support rapid and economical production while leveraging different fillings. For example, the Rademaker Pie & Quiche production line can produce up to 20,000 pieces an hour.
Product Base Pies and quiches can be produced at different sizes, generally between 80mm and 250mm. The crust base can be placed in different containers which can, like foil or paper trays, be shipped with the product. Other potential containers include various platens. The production line starts with the conveyor, which begins by ensuring that the indented foil tray is accurately placed. Dough Placement Pies may be produced in two different ways, from a (laminated) dough sheet or from a dough puck. Dough sheeting equipment requires the crust to be cut out and the dough scraps to be recycled in the production line. Dough pucks are placed into indented trays and are then pressed to form the crust, resulting in minimal, if any, scrap dough. Filling Depositing The next step in the process is to deposit the filling into each piece. There are a range of depositors for pies and quiches depending on the type of filling being used. Depositor categories include liquid, semi-liquid, or viscous fillings, each with or without chunks or other ingredients mixed in. These added materials can be fruit, meat, or vegetables. Dough lid In pies, if a top crust is included, there are several methods to create the lid depending on the type of lid desired. This can range from a flat dough lid, to a decorative lid, to a lattice cover, and everything in between. Equipment options include lids placed by an extruder, rotary moulders for decorative lids, or lattice units. The lid is then sealed to the pie base by crimping. This process can also be customized to create a decorative pattern or a simple crimp. Outfeed Processes The completed pieces are then fed into different systems depending on how the final product is delivered to customers. Pies and quiches can be frozen for consumers to bake at home or the product can be baked onsite. Artisan Capital Partners tailors bakery 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. |
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