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Cut energy expenses by cutting down on baking time

Cut energy expenses by cutting down on baking time

Industry
Wholemeal bread sits sliced on a wooden counter.

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Sustainability has become a hot topic of discussion in recent times. We’re witnessing firsthand the harsh realities of climate change, dwindling resources, and the devastating impact of human activity on our environment.

As energy prices fluctuate and living expenses soar, there’s a mounting pressure for tighter regulations to curb emissions. It’s a wake-up call for both consumers and industries, underscoring the urgent need for environmental responsibility.

Energy conservation isn’t just a nicety anymore—it’s a make-or-break factor for staying competitive. Yet, improving the energy efficiency of an industrial bakery is no walk in the park. It’s a complex puzzle, involving considerations ranging from product types and operational processes to company policies and practices.

In response to the growing demand for energy efficiency and sustainability in the baking industry, Lallemand Baking Solutions has developed the Baking Time Reduction (BTR) solution. This clean label enzymatic solution aims to support bakeries in achieving their sustainability goals while maintaining the quality of their baked products.

BTR is designed to alter the water retention capacity of dough, allowing for consistent dough and final baked product characteristics while shortening baking times. This innovative approach increases operational flexibility and presents various opportunities to enhance baking process energy efficiency.

By incorporating the BTR solution, baking times can be reduced by up to 33 per cent compared to conventional methods. This enables bakeries to boost throughput, particularly in situations where oven capacity limits production, without requiring additional energy input or compromising product quality.

Furthermore, BTR facilitates energy conservation by enabling baking at lower oven temperatures. This advantage is particularly advantageous for bakeries with limited capacity or setups that cannot accommodate increased throughput.

In instances where downtime for heating or cooling during product transitions is inevitable, BTR allows for baking different formulations at the same oven temperature. This ensures consistent baking results while optimising energy efficiency.

In the production of dried baked goods like breadcrumbs, croutons, and rusks, significant energy is expended on water evaporation. BTR mitigates this by reducing the initial product humidity before the drying stage, thereby minimising energy consumption to achieve the desired final humidity.

Effective water management is crucial for sustainability alongside energy savings, especially considering the global water scarcity issue. BTR offers the added benefit of reducing water usage in formulations, complementing its energy-saving features.

The BTR solution contains enzymes commonly found in baking additives, carefully chosen and used in specific amounts to maintain the desired qualities of the product while using less energy to bake it.

To reduce baking time with BTR, it’s crucial to decrease the amount of water in the recipe. This is done by using enzymes like xylanases and amylases to change how the dough holds water.

Xylanases break down specific components of the flour, releasing water that helps develop gluten. This allows for good dough formation even with less water, reducing the need for heat during baking.

Another important aspect of baking is achieving the right crust color. When baking time is shortened, there’s a concern that the crust won’t brown properly. To address this, BTR includes enzymes that help release more sugars from the flour. These sugars contribute to browning through the Maillard reaction, ensuring the crust looks just right.

The amount of water in a recipe affects dough yield, which is crucial for maximising profits in baking.

While removing water might seem like a loss, BTR actually maintains or increases dough yield. With BTR, even though less dough is produced from the same amount of flour compared to traditional methods, smaller pieces of dough can be used to achieve the same final weight after baking. This means less weight loss during baking, resulting in equal or higher overall yield compared to standard recipes.

To assess the energy-saving potential of the Lallemand BTR solution, pertinent data was gathered during industrial scale trials for parbaked baguette production. Presented below are the recipes along with the average baking time and gas consumption, offering insights into the solution’s efficacy.

The results demonstrated a significant trend in energy savings when utilising the Lallemand BTR solution.

On average, the trials revealed a 19 per cent reduction in energy consumption compared to conventional baking processes. This energy saving was a result of a 23 per cent decrease in bake time. Relevant quality parameters of the baked products, such as crust color and final humidity, were not affected by the process and formulation changes.

It is important to acknowledge that the energy-saving impact of the BTR solution may vary depending on the specific circumstances of individual bakeries.

Factors such as equipment configuration, production volume, and product specifications can influence the extent of energy savings achieved.

Therefore, to unlock the full potential for your bakery, get in touch with your Lallemand local representative for personalised guidance.

 

 


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