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Adding Artisan Bread to your BakeryBy Michael Eggebrecht
Artisan Baking Resources, Inc &
The Bread Baker’s Guild of America
James Rath - Tom Cat Bakery, On what is artisan bread:
Making a craft product from quality ingredients without the use of additives, dough conditioners and shelf life extenders. Using pure unadulterated ingredients. Practicing principle methods, handling the dough correctly, process… decision making involved during the process at mixing, fermentation, and after proofing. If you take those away then I can’t call it artisan. Doesn’t have to be made by hand.
1
Adding artisan Bread to your Bakery
What we will cover
• Artisan Bread and Commercial Bread
• Bakery Tour
• Fundamentals of Producing Artisan Bread
• Equipment for the artisan baker
• Layout and Design
2
3
Artisan Baking
Crust Crumb
4
Artisan Bread Characteristics
Commercial Bread Characteristics
Commercial Italian Bread & Baguette
5
Why Add Artisan Bread To your bakery?
• Organic, Non-GMO, and all natural
Ingredients
• Artisan bread hits on several trends at
once:
• Fewer Ingredients
• Clean label
• Unique flavors
• Whole Grain
• Better for you
6
7
Micro Bakery – Hand shaping
8
Instore Bakery
9
German Bakery– Medium size wholesale
10
An American artisan bakery– Medium
size wholesale
11
A Growing Wholesale Bakery
12
Hardtner Bakery - Germany
13
Small Industrial Bakery
14
Baker Hahn
Luxembourg
15
Bakery Hahn, Luxembourg
Ruetz Bakery, Austria – Small
Industrial
16
Coop Bakery – Switzerland, Large
Industrial Artisan Bakery
17
What Type of Bakery do you have?
• Retail
• Wholesale
• Retail and Wholesale
• Cottage Bakery / Micro Bakery
• In-store Bakery
• Industrial
18
Fundamentals of Producing
Artisan Bread
Ingredients
Baker’s Math and Prefermented Flour
Preferment Types
Bell Curve of Baking
19
20
Flour Types
• Unbleached white flour
• Protein 10.5% - 12.5%
• Whole Wheat Flour
• Fine and Coarse Grind
• Rye
• Light, Medium, Dark, Meal and Pumpernickel
• Various other grains
Unbleached white Flour
• Protein
• Indicates the amount of
gluten available in flour
• Ash
• Measures the amount of
mineral content which
remains in the flour after
milling
• Falling Number
• Measures the enzymatic
activity in the flour
• Stability
• This is an indication of the
flour’s mixing tolerance
level 21
Farinograph of Quality Bread flour
22
23
Farinograph of Low Quality Bread
flour
24
Yeast Types and amounts
• Fresh Yeast
• Dry Active Yeast
• Instant Yeast
• Deactivated Yeast
25
Other Ingredients in Artisan Bread
• Water
• Beer
• Salt
• Honey
• Grains and seeds
• Malt
• Ascorbic Acid
26
Ascorbic Acid as a dough
conditioner
• Ascorbic Acid is an excellent clean-label dough
conditioner. To make your own mix, mix
together the following:
• 990 grams Flour
• 10 grams Ascorbic Acid
• Use this mix in amounts from .1% - 1%
Baker’s Math Review
• When writing a formula, the easiest method is to do so
using what is known as baker's percentage, or baker's
math. In using baker's percentage, each ingredient in a
formula is expressed as a percentage of the flour weight,
and the flour weight is always expressed as 100%.
27
Ingredients Dough Weight Baker’s Math
Flour 50# 100%
Water 33# ?
Salt 1# ?
Yeast .6# ?
Baker’s math Continued
28
Ingredients Dough Weight Baker’s Percent
Flour 50# 100%
Water 33# 66%
Salt 1# 2%
Yeast .6# 1.2%
Prefermented Flour
Prefermented flour is simply the amount of
flour that fermented in the preferment or
starter. This amount is usually described in a
percentage of the total flour used in the
formula.
29
Baker’s Percentage and
Prefermented flour
30
Ingredients Total % Total Amount Poolish % Poolish Amount
Flour 100% 100.00 lb 100% 33.00 lb
Water 66% 66.00 lb 100% 33.00 lb
Salt 2% 2.0 lb
Yeast 1.25% 1.25 lb .1% .033 lb
Prefermented Flour 33%
Final Dough Formula
31
Final Dough Amount
Flour 67.00
Water 33.00
Salt 2.00
Yeast 1.21
Poolish 66.033
Preferments
Yeasted Preferments
• PÂTE FERMENTÉE
• BIGA
• POOLISH
• SPONGE
Natural Preferments
• LEVAIN
• LIQUID LEVAIN
• SOURDOUGH SPONGE
• RYE SOUR
• WHOLE WHEAT
STARTER
32
Advantages of
Using Preferments
There are a number
of important benefits
to the correct use of
preferments, and
they all result from
the gradual, slow
fermentation that is
occurring during the
maturing of the
preferment:
33
Yeasted Preferments
• Yeasted Preferments are simply
preferments that are started with
commercial yeast and used entirely and
started again anew for the next batch of
bread.
34
Poolish
• Poolish is a preferment with
origins, clearly, in Poland. It
initially was used in pastry
production. As its use spread
throughout Europe it became
common in bread. Today it is
literally used worldwide, from
South America to England, from
Japan to the United States. It is by
definition made with equal weights
of flour and water (that is, it is
100% hydration), and a small
portion of yeast. Note the absence
of salt.
35
Biga and Sponge
Sponge after Mixing Sponge when ready
36
Fermentation Guide
• The above yeast levels greatly depend on time
and temperature. These amounts are given for
a room that is between 65 and 70 degrees.
37
Fermentation
time3hours 7 to 8 hours
12 to 15
hours
Quantity of
Fresh Yeast1.5% .7% .1%
Natural Preferments
• One important way in which a sourdough
and levain are different from pâte
fermentée, biga, and poolish, is that the
sourdough and levain can be perpetuated
for months, years, decades, and even
centuries.
38
Liquid Levain
• Liquid Levain is a
levain that is at least
100% hydration
(equal parts flour and
water) and can be as
much as 150%
hydration.
39
Stiff or Hard Levain
• Stiff Levain or Sourdough is
what most people think of
when talking about natural
starters or preferments. This is
the how the famous Boudin
Bakery in San Francisco has
been making their famous
bread since 1850. However
the stiff levain can be
fermented at many different
temperatures to bring out all
types of flavor and acidity.
40
Rye Sour
41
• Typically fed once per
day at 5% - 10%
starter to flour ratio.
• Many times the
starter contains all of
the rye flour in the
formula.
• The starter is often
very stiff at mixing
Natural Preferment Feeding
schedule
• Once per day
• Twice per day
• 3 times per day
• Changing consistency
and temperature
during build
• 10 hours before use.
• 10-12 hours before
use
• 8 hours before use
• Usually 2 or 3 builds
in a day. Most
complex.
42
Liquid Levain
1 feed
Liquid Levain
2 Feeds
Stiff Levain
2 Feeds
Stiff Levain
3 Feeds
5% - 20% PF 20% - 33% 33% - 50% 50% - 100%
*Percentage based on amount of flour in the feed
Benefit of using preferments: Dough
Structure enhanced
• Dough structure is
strengthened. A
characteristic of all
preferments is the
development of
acidity as a result of
fermentation activity,
and this acidity has a
strengthening effect
on the gluten
structure. 43
Benefits of using preferments:
Production Time Reduced
• Overall production time is
reduced. Above all, to
attain the best bread we
must give sufficient time
for its development. Bread
that is mixed and two or
three hours later is baked
will always lack character
when compared with bread
that contains a well-
developed preferment with
sufficient Prefermented
Flour.
44
Benefits of using preferments: Bring
out Different Enzymes
• Liquid preferments typically offer the
advantage of good extensibility in the final
dough due to the protease activity that is
common in highly hydrated preferments.
This can help in the shaping of baguettes
and other long shaped products.
45
Preferment Standards
• Poolish & Biga: Typically between 20% -
40% prefermeneted flour
• Natural Starters: Typically between 5% -
25% prefermented flour
46
Things to think about when
choosing your preferment
• Production Schedule
• Skill Level of Bakers or staff
• Do you already use a certain preferment?
• Flavor desired
• Quantity to make
47
AUTOLYSE
• Autolysing your
dough is a great tool
to help reduce mixing
time.
48
Bulk Fermentation
• Time and temperature
• Corrections should be made if temperature is off DDT
49
The Bell Curve of Baking
50
Lifespan of bread dough
Weak Weak
Strong
Dough
Strengethen
• Mixing
• Folding the dough
• Fermentation that results
in a moderate PH
• Lower water
• Ascorbic Acid
Weaken
• Excessive Mixing
• Excessive fermentation
that results in a very low
PH
• Not enough fermentation
• High water
• Protease enzymes from
liquid starters
• Deactivated yeast
51
Mixing and Fermentation
• The more you mix
the less you ferment
• The more you plan
to ferment the less
you need to mix
52
The Bell Curve of Baking
53
Multiple Factors at Play
Weak Weak
Strong
Mixing Water
Fermentation Acid
Weak Weak weakWeak
Weak Weak
Strong Strong
Strong
Automating Strong & Weak dough
Strong dough Weak dough
54
EQUIPMENT
55
Reason’s to use automation
• Can we find skilled baker’s?
• Employee retention
• Labor Cost and training
• Workman’s comp and medical insurance
• Fluctuation in daily production
• Inconsistencies in products
• Competing against larger bakeries
• The medium-sized-Bakery Curse56
Levain and Poolish Tanks
57
Mixer styles - spiral mixer
Spiral mixers give better consistency and dough development with less friction than a planetary mixer and minimal temperature increase. Spiral mixers come in many different sizes and are capable of mixing down to 15% of their listed capacity.
58
Mixer Styles – Spiral with
Removable Bowl
59
Mixer styles – Spiral with Tilting
Bowl
60
Mixer Styles - Fork Mixer or Oblique
Mainly used in France and in some craft
bakeries here in the USA; It is a little
gentler with the dough than Spiral and
planetary mixers. The shape of the hook
is like an upside-down fork. The bowl
rotation is created by dough friction
against the hook on the bowl wall and is
used to slow down the bowl.
The main drawback of the Fork Mixer is
that it must be at least 50% full.
61
Types of Make-Up Equipment
• Modular
• Single machine like a baguette moulder
• Many touch points by human hands
• Lest efficient
• Systemized - Example: dividing, rounding,
resting, shaping and depositing.
• More costly
• Fewer correction points by bakers
62
Which was hand shaped?
63
Bread and roll dividers
Hydraulic Dividers
In artisan production, this is the most commonly used divider. These dividers contain square or round chambers and usually 20 or 24 cuts. The dough is pre-scaled according to the dough piece weight, multiplied by the number of cuts of the divider. For example, a 20-part divider for a 1-pound piece of dough will be 20 pounds of dough block.
64
Hydraulic Divider with Shaping Grids
65
Bread and roll dividers
66
Divider Rounder
• This divider is mostly for rolls with weight range from 1¼ to 5 ounces, according to the model. Some manufacturers offer head-changing capabilities for different numbers of cuts and weights.
• Difficult to use in excess of 3,000 pieces per is pre-scaled according to the dough piece weight, multiplied by the number of cuts of the divider. For example, a 20-part divider for a 1-pound piece of dough will be 20 pounds of dough block.
Bread Molders
Horizontal Bread Molder
The horizontal bread molder was designed for pan bread but new models have been designed for baguettes, batard, and small breads.
A dough piece is laminated between two rollers then carried by a conveyor under a roll chain. This action curls the flat piece of dough into a short log that goes under a pressure plate to tighten the curl and elongate if needed. Adjustments can be made according to the weight and desired shape.
67
Bread Molders
Baguette or French Bread Molder
• The French bread molder got its
name because it comes from
France and is designed to
produce baguettes. The action of
this molder is similar to the
horizontal molder except for the
pressure plate, which is replaced
by two vertical felt belts running at
different speeds in opposite
directions.
68
Stress-Free Dividers: square cut
69
Stress Free dividers for Rolls with square
cut with rounding
70
Piston Dividers for Rolls
• High weight
accuracy
• Fastest dividing
• Only young, firm
dough can be
divided
• Must be used in
conjunction with a
lifting device.
71
Comparing Roll Dividers
Piston Divider
• High weight accuracy
• Typically only young firm
dough
• No square cut option
• More rough on dough
• Higher speeds possible
Square Cut Divider
• Lower weight accuracy
• Can handle both young
and fermented dough
• Can handle higher
hydrated dough
• Not as fast
72
Lifting and loading dough
• The Tote Lift is one
way to handle
dough.
• This lift can
accommodate
many different
totes.
73
Batard
Ciabatta
Products
Piston Divider with work station
Rye bread
Wheat bread
Bread Line with Piston Divider,
Conical Rounder, Overhead Proofer
and Molder
75
Piston Bread Line Making Baguettes
76
Sheeting & Laminating Lines
77
Sheeting Lines
Spreading belts Cutting & Seperating
78
Proofer-Retarders
79
Oven stylesRack Oven
Rack Ovens are very efficient ovens because they
save labor after panning, the tray is set on the same
rack to be baked. They save space because of the
shelf-like design.
Rack Ovens are very good for many products like
buns, rolls and pastries. However they are not the oven
of choice for breads that need a crust and require a lot
of oven spring. Many artisan bakeries will have 1-3
rack ovens for every deck oven.
80
Electric Deck Ovens
Electric ovens are useful for smaller size bakeries, or when a gas or exhaust flue is not possible due to the constraints of a high-rise or an apartment above the bakery. They have two thermostats at the top and bottom of each deck, which enables the baker to bake different products at the same time at different temperatures. Small decks are usually electric.
Electric ovens need a great deal of amperage to operate, which reduces the availability for other equipment without an upgrade to the electrical panel. A three-phase power line is a must.
81
Deck Ovens
Deck ovens have multiple baking chambers that are set on top of each other. They are heated by electric elements or gas and have different heat exchanger sources. The surface, which is also called the “hearth” or deck, is usually made from recombined refractory cement and bricks. In Europe, these ovens are used for pastry and bread, especially in quality bakeries.
Deck ovens come in multiple sizes and can utilize electric or gas energy. Gas models come with cyclothermic, steam tubes or thermo oil heat exchangers. The choice is determined by volume and desired aspects of the bake, because each one provides a different result, especially on the crust and in oven spring.
82
Steam tube ovens
The Steam Tube oven transfers heat through tubes that are enclosed, and filled partially with water. When the water passes through the tube in front of the burner it turns to steam and begins to circulate through part of the oven. These ovens have these tubes from front to back and the steam moves clockwise through the oven inside its own self contained pipe. Early on in the baking cycle the steam is very efficient in transferring the heat to the decks.
83
Steam tube oven
• Enclosed Steel tubes
contain water to carry
the heat around the
decks.
• Notice the brick and
concrete for thermal
mass
84
Inside a steam tube oven
85
Cyclothermic ovens
Cyclothermic technology has been around for almost 100 years. To this day it is still the most popular oven in Germany and the Eastern portion of Europe. The Cyclothermic oven is based on simple technology that uses air to move the heat to the baking chambers. The air moves inside panels above and below the baking chamber. It has slightly less mass than steam tube ovens, but can recover more quickly to the fluctuations of the baking cycle. It can be adjusted to raise or lower the temperature depending on the needs of the baker. In most cases the decks recovery fully in 6 – 8 minutes and can even be adjusted in temperature for the specific bread. Some manufactures’ offer a Combitherm option where you can have 2 different baking zones in the same oven. This is achieved by the use of dampers that control the heat flow to the top decks.
86
Cyclothermic heating system
87
Thermal oil deck ovensThermal Oil is the most resilient heat of the three. Thermal Oil technology has not been around as long as Steam Tube and Cyclothermic technology but it gives you a massive amount of heat to each baking chamber with only a minor drop in temperature during the loading phase. A Thermal oil oven consist of two parts; the first being the oven and the second is a remote boiler that heats the oil that is then pumped to the oven from another area of the bakery through pipes that usually run across the ceiling of the bakery. These large boilers can run up to five ovens in some cases. The oil is pumped through the ovens like the steam in a steam tube oven, but then returns to the boiler to be reheated. These ovens only experience a minor drop in heat when loaded with cool dough and have claims to be the most energy efficient on the market. The down side to these ovens is that the baker cannot adjust the baking temperature from bake to bake or even one hour to the next. These ovens have such an over whelming amount of mass that it is almost impossible to fluctuate the temperature during a shift. The other major disappointment is the price tag! Everyone knows that equipment is expensive, but these ovens are often 3 to 4 times more than the other two types of ovens. These ovens are designed for Par Bake plants that have a massive amount of output of one product during a shift.
88
Thermal Oil Multi-Deck Tunnel Oven
89
Thermal Oil Boilers needed to
support ovens
90
What production deck oven to
choose?
Steam Tube
• Heavy oven with lots
of thermal mass
• Slower to change heat
• Preheat temp close to
actual baking temp
• Drier bake
• Needs less recovery
time when back-
loading, will eventually
need a lot of time.
• Most often only 4
decks high
• Not easily moved
Cyclothermic
• Less thermal
mass
• Can adjust
temperature over
the baking shift
• Preheat temp
higher than baking
temp. (empty oven
can raise too high)
• Moist bake
• Recovery is
consistent when
given time
• Can be moved
91
Thermal Oil
• Best heat recovery
• Hard to adjust temp
• Can have many
decks for large
capacity
• Most often paired
with a automated
loader
• Installation cost
very high
• Mostly suited for
par-baked frozen
bread
Calculating Deck Oven Size
There are 2 ways to calculate the oven
size required for your bakery.
1. Calculate the number of pieces per deck
and the amount of baking and recovery
time needed.
2. Use the manufacturers formula of lbs per
square meter per hour which is usually 18
- 25 lbs per square meter per hour
92
Control Panels
Touch screens are nice
but always check and
see if they have a
manual backup option
93
Oven LoadersAn oven loader is a piece of equipment that replaces the oven peel and helps load the deck oven rapidly. The proofed dough is positioned on the loader belt, and the entire frame goes inside the oven. It spans the entire length of the deck and the width of the loading window. The frame is locked and pulled back, at which point the belt turns and drops the dough on top of the deck. The reverse action is used to unload baked bread. The most common loader for deck ovens is manual; however, electric loaders are available, as well as automatic ones for large production, as shown in the picture on the left.
94
Oven Loaders
95
96
Layout & design
97
How much bread are you going to make?
• Take the 100-1,000-10,000 test
• How many loaves do you want to make?• 100 per day?
• 1,000 per day?
• 10,000 per day?
• More per day?
• What do you have to do different in each category?
98
Identify your space requirements
Your facilities space is the one finite factor that
many other decisions stem from.
Look into the future and see what your bakery
will look like when running at full capacity.
Unless a space expansion is possible in the
future you must envision your bakery at full
capacity today and set aside space in the
beginning for future equipment purchases.
Keep in mind that your bakery must be
balanced.
99
Designing a
Bakery
• How many square
feet ?
• Menu categories?
• Stages in
production
• Balance every
stage to meet your
production goals
100
How Much Space Do I Need?
Bread A simple calculation for bread production:
1.5 lbs of dough per square foot is max!
.75 lb to 1 lb is expected.
Example:1000 square feet of *production space can produce
around 1500 lbs of bread in a 24 hour shift. This would be at the maximum capacity for most bakeries.
* Production space is everything that is not retail or administration offices.
101
P.I.M.P
• People
• Ingredients
• Machines
• Process
102
Production Space allocation
• Receiving
• Storage - Dry &
Cold/Freezer
• Mixing
• Bulk Fermentation
• Storage - Rack & Wares
• Make up Area –
Bread/Pastry
103
• Dish Room
• Proofing/retarding
• Baking
• Cooling
• Packaging
• Shipping
Ancillary Space
• Employee Entrance
• Locker Room
• Employee restroom
• Cloak Room
• Break Room
• Kitchen
• Outside Smoking
• Maintenance Room
• Admin
• Office
• Archive Storage
• Conference room
• Production office
• Retail space
• Seating
• Indoor/outdoor
• Restrooms
104
Work Flow considerations
• One way traffic if
possible
• Keeping like menu
items together
• Number of steps to
the next process
105
2,000 SF Bakery
106
7500 SF Wholesale Bakery
107
108
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8/28/2014 6:11:13 PM
Q-1
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Conceptual Task Sequence &
Equipment purchase
• Secure building and
establish a move in date
• Get final quotes and spec
sheets on equipment and
lead times
• Finalize your architectural
drawing including:
• Work flow
• Utility hookups
• Order equipment
• Establish your delivery and
install dates.
• Finalize your equipment
requirements. • Know your manufacturer’s
equipment requirements.
• Schedule Installation and
training• Baker and technician
• Give plenty of time to get new
equipment working properly
109
Distribution Channels
• How are you
getting your
products to
market?
• Retail sales
• Kiosks
• DSD
• Grocer
• Farmers markets
• Par-Baked Frozen
110
Thank you!
Sources• Delmar Learning Center
• TMB Baking
• Advanced Bread & Pastry by Michelle Suas
• Bread by Jeffrey Hamelman
• WP Bakery Group
• Gemini Bakery Equipment
• Merand Bakery Equipment
• Bloemhof
• Erika Record
• JAC Moulder and dividers
• ABR, Inc
•
111
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