According to Technomic’s new study, the 2009 Technomic Top 25 Bakery Cafe Chains Restaurant Report, system-wide sales for the bakery-café industry grew 12 percent in 2008 to $4.5 billion, led by Panera Bread, Einstein Bros. Bagels and Au Bon Pain, with $2.6 billion, $393 million and $307 million respectively.
"The consumer trade-down from full-service to limited-service formats that solidified through 2008 and into 2009 allowed fast-casual bakery cafes to truly shine," said Darren Tristano, executive vice president at Technomic. "The appeal of moderately priced, high-quality menu offerings served in contemporary ambiance, as well as consumer perception of value for this format, has more than likely strengthened over the past year."
Among the trends, products, and findings included in the report:
Health and nutrition: Einstein Bros. Bagels' Lighter Fare Menus.
Expansion of breakfast offerings: Atlanta Bread Company, Corner Bakery Café, and Panera Bread.
Revamped catering programs: Au Bon Pain's Hot Lunch line.
Value equation: La Madeleine's Choose Two Menu, Einstein Bros. Bagels' Snack-Out menu, Au Bon Pain's small-bite Portions menu.
Nontraditional sites and urban locations: airports, college campuses, military bases, medical centers and hotels.
Social media: use of Facebook and Twitter to promote new and limited-time offerings.
Bakery cafe chains' units expanded by 6.6 percent to 3,107 locations.
Paradise Bakery & Cafe was the sales growth leader at 30.7 percent. Le Pain Quotidien was the leader in store count growth rate at 29.6 percent.
Source: Technomic Inc
Source : pakwatan.com
Bisk Farm has three plants in West Bengal and is planning to open a new plant in Karanatka ,Bangalore .
5/1 Acharya Jagadish Chandra Bose Road,
Kolkata - 700 020
West Bengal, India.
Phone : +91-033-2281-8219/8369.
Fax : +91-033-2283-3510
Listed below are the world top 10 food and beverages companies . With globalization and economic liberalization spreading around the world these companies are represented in most of the countries .
|Company and Country||Sales ( USD Billion )|
|Nestle ( Switzerland)||96|
|Unilever ( UK , Holland)||59|
|Kraft Foods Inc ( USA)||37|
|Coca-Cola ( USA)||29|
|SAB Miller ( UK )||21|
|Danone ( France )||19|
|Pernod Ricard ( France )||10|
Source:World Investment Report UN ,2009
IIHM ( Indian Institute s of Hotel Management at Delhi , Mumbai , Bhopal , Chennai , Kolkatta , Ahmedabad )
CFTRI , Mysore
B.Sc. with Food and Nutrition
Kakatiya University, Warangal 506009
University of Calcutta, Calcutta 700073
Dr. Babasaheb Ambedkar Marabwada University, Aurangabad 431004
University of Delhi, Delhi 110007
University of Mysore, Mysore 570073
B.Sc. with Food Preservation
University of Madras, Chennai-600005
University of Calcutta, Calcutta-700073 B.Tech. (Food Engineering)
Chitrakoot Gramodaya Vishwavidyalaya, Distt. Satna 485331
Jadavpur University (after B.Sc.) Calcutta 700032
Kanpur University, Kanpur 208024 (UP) (M.Tech. is also available) B.Sc. Tech (after B.Sc.)
Nagpur University, Nagpur 440001
University of Bombay, Port, Mumbai 400032 (M.Sc. Tech is available in Food Technology and in Fermentation Technology). M.Sc. (Food Science)
Andhra University, Visakhapatnam 530003 (A.P.) M.Sc. Food Technology
Govind Ballabh Pant University of Agriculture and Technology Pantnagar 263145 (U.P.) (M.Sc. Food and Nutrition is offered by the faculty of Home Science). M.Sc. in Food and Fermentation Technology and Food Sc, Tech.
Guru Nanak Dev University, Amritsar 143005 (Punjab) M.Sc. (Food and Nutrition)
University of Mysore, Mysore 570005 (after Home Science)
Tamil Nadu Agricultural University, Coimbatore 641003
University of Agricultural Sciences, Krishinagar, Dharwad 580003
“Our new initiatives build on about 40 packaging reduction projects completed in 2008 and reflect the way we continuously look for means to improve the packaging of our products and reduce our environmental footprint,” said Daniel S. Miller, Research and Development manager of packaging development at Hormel Foods. “In this process, we work with our suppliers to find innovative solutions.”
New packaging reduction highlights and projected savings include:
The elimination of extra room in the Jennie-O Turkey Store® burgers carton is expected to have an annual paperboard savings of more than 175,000 pounds.
Lloyd’s® barbeque tubs no longer have an extra paper sleeve. This modification will eliminate enough solid waste to fill 22 garbage trucks and save more than 660,000 pounds of paper fiber annually.
Reducing the thickness of the glass used to produce each jar of Hormel® bacon bits will produce annual material savings around 411,000 pounds.
Reconfiguration of the shipping box for Hormel® Compleats® microwave meals removed 23 percent of the material required to make the previous corrugated packaging box and generated an annual materials savings of 1.2 million pounds. In addition, changes to the size of the carton flaps of the product and reallocation of materials resulted in annual savings of more than 980 million pounds of solid waste.
Hormel® party trays packaging was redesigned to eliminate the need for shrink wrap to produce an annual savings of approximately 100,000 pounds. The corrugated case to ship the product will be smaller, resulting in a corrugated material savings of more than 174,000 pounds per year.
Redesign of the shipping box for Hormel® pork ribs, butts and bone-in offers more strength while creating an annual corrugated materials savings of about 2.4 million pounds.
Reducing the height, width and length of each box used to ship Hormel® pepperoni, increased the amount of product on each pallet, saving materials and reducing the number of trailers needed each year. The anticipated savings is 188,000 pounds of wood fiber annually and 49,000 pounds of corrugated.
Changes to the shipping of canned food products made by Hormel Foods will result in efficiencies that reduce the number of pallets needed annually by 14,573 and require less plastic and bundling film.
These packaging reduction projects are part of the overall corporate responsibility strategy and goals set by Hormel Foods.
Source : Hormel Foods
|SNO||NAME OF THE MANUFACTURER||ITEMS|
|1||PRIMA ENGINEERING||Biscuit plant and machinery|
|2||NEW ERA INDUSTRIES||Biscuit Plant and machinery|
|3||AIFSO||Biscuit Plant and machinery|
|4||SUNBEAM INDUSTRIES||Biscuit Plant and machinery|
|5||MANGAL ENGINEERING||Biscuit Plant and machinery|
|6||SARLA INDUSTRIES||Biscuit palnt and machinery|
|7||MIRANDA ENGINEERING||Bulk Handling|
|8||INDCON PROJECTS||Bulk Handling|
|9||SARLA ENGINEERING||Cooling conveyor|
|10||KAPS ENGINEER||Sugar Grinder,Biscuit grinder|
|11||PRAGATI ENGINEERING||Moulders and Cutters|
|12||ESPEE ENGINEERS||Biscuit palnt and machinery ,erection of Biscuit plants|
|13||PROMESE ENGINEERS||Erection and Comissioning of Biscuit Plant.|
|14||G C DUTTA AND SONS||Cotton Conveyors|
|15||SCANDIA BELTING||Cotton Conveyors|
|16||AARJAY SYSTEMS PVT LTD||Automation|
|18||AVISTAR||Moulders and cutters|
|19||ACUSHARP||Knifes and blades|
|20||MULTIPACK SYSTEM PVT LTD||Packing machines|
|21||BOSCH PACKAGING( INDIA)||Packing Machines|
|22||KHOSLA PRECISION||Packing Machines|
|23||NEW INDO PACKING MACHINE||Packing machines|
|24||ITW SIGNODE ( INDIA)||Taping Machines or carton sealing machines|
|26||CONTROL PRINT||Printing dry and ink jet|
|27||BAKSHI ENTERPRISE||Markem Printers|
|28||ISF||Milk chillers and handling system|
|29||TECHNOFOUR SYSTEMS||Metal detectors and Check Weighers|
|30||METLLER TALEDO (INDIA)||Metal detectors and check weigher s|
|31||HABASIT ( INDIA)||PU conveyors|
|32||FORECH INDIA||PU conveyors|
|33||K DHARMALINGAM||Endless Webs|
|34||VIVEK ENGINEERS||Sugar,flour , salt and Milk sprinkler|
|37||RAJNI COMBUSTION||Weishaupt burners|
|39||NARI WIRE NETTING INDUSTRIES||Oven Bands|
|40||ROSHAN INDUSTRIES||Oven Bands|
|41||LLYOD INSULATION||Insulation material|
|42||UP TWIGA||Insulation material|
|45||CHADHA SALES PVT LTD||Chillers|
|46||ADMIR OVENS||Biscuit Plant and machinery|
|49||BLUE STAR LTD||Air conditioning and cold storage|
|50||GODREJ MATERIAL HANDLING DIVISION||Pallets and material handling|
|51||RIECO INDUSTRIES||Bulk Handling|
|54||SUPER TECH||Knifes and blades|
|55||SEPERATION ENGINEERS||Vibration gyro screens for flour sifting|
|58||THERMAX||Vam and Boilers|
|60||NILKAMAL||Plastic trays and bins|
|61||SUPREME INDUSTRIES||Plastic trays and bins|
Packaging material are critical component of bakery products . Packaging consists of primary packaging meant for product and secondary packaging for transit .Packaging material s includes kraft paper conversion into Cartons .
Major packaging material used are Wrappers/Laminates( BOPP) , CBBS ( Cartons made up of Kraft paper converted by converters ) ,HDPE ,LDPE ,Tapes ,Kraft Paper , Converters ,Stickers , Polythene etc .
Below are the major supplier of packaging item to various bakeries in India .
|LOCATION||NAME OF THE COMPANY|
HINDUSTAN ADHESIVE TAPES
It was established in year 1950 and has got manufacturing base in USA ,India and Australia . Unibic products are exported to countries like United Kingdom, South East Asia, New Zealand, Canada and the United States.
Major Products :Speciality Cookies ,Shortbread ,Pies,Biscuits and Cakes
Major Brands :ANZAC ,Ericas Kitchen with large flavours and variants
ANZAC is one of the Unibics major brands popular in different countries . Brief history tells you how ANZAC was created
During world war 1 in year 1914 troops New Zealand ( NZ ) and Australian ( A) Army corps ( AC)were stationed at Galliopli tape in turkey . Women folks used send these special cookies to the army men as symbols that they are thought off back home . Thus came the ANZAC cookies .
Contact:Unibic Australia Pty Ltd PO Box 3231 Broadmeadows Victoria 3047 Australia
Telephone: +61 3 9355 9100
Fax: +61 3 9355 9199
A subsidiary of UNIBIC Australia, UNIBIC India Pvt. Ltd., has its factory and infrastructure in Bangalore with state of the art machines from Italy. It is the first company to be setup with “wire cutting” technology that is the only method available to make a real cookie. In addition to providing world-class cookies, UNIBIC India Pvt. Ltd also has the necessary equipment and packaging machinery for exports, which being both captive and strategic partners, require world approved standards. To this end UNIBIC India Pvt. Ltd has just got its HACCP (Hazard Analysis and Critical Control Point) certification from BRC (British Retailers Consortium) certification.
Major Brands- ANZAC cookies ,Jamz,Bradman Choco chip cookies,CashewButter cookies ,
CEO&MD : Nikhil Sen : An old hand in biscuit industry Has long stint with Britannia Industries Ltd and was COO of Britannia Industries Ltd . prior to his new assignment in UNIBIC INDIA PVT LTD
51/1A Heggadadevanapura Village
Huskur Road, Alur Post
BANGALORE 562 123
Ph: 080 23712007, 08, 09,10
Fax: 080 2371 2006
Temperature plays a vital role in dough consistency which in turn impact the quality of bread or biscuit . Bakers have to maintain the dough temperature after mixing for better results after baking . Ambient temperature varies as per the season s a expert bakers has to arrange various method to maintain dough temperature . Average temperature maintained could be different in different locations .However temperature ranging from 28 –32 deg c provides better results at this part of the world .
Following factors effects dough temperature
- Mixing duration
- Water temperature
- Ingredients temperature
All Mixers Manufacturers have Mixers with jackets around the mixer body . Operators can feed this jackets with cold or hot water as per requirement . Cold water is circulated through chilling plants .Hot water generally circulated by boilers or hot water generators .
Dough temperatures get impacted by ingredients temperatures.Ingredients with low temperature can be fed into mixers to maintain dough temperatures . Areas where ambient temperature reached 45 – 40 deg c its important to store this ingredients in cold storages or air conditioned places.
Some places Ice is added manually to maintain dough temperatures or for certain varieties like choco chips ice is added to maintain the dough temperatures so as chips does not starts melting during the process.
Other methods used in most advanced bakeries are
- CO2 Injection in mixing bowl
- Flour cooling
- Breaker bars and Agitator in mixers
A-10, Ghantakarna Mahavir Commercial Market,
Near New Cloth Market
Sarangpur, Ahmedabad - 380002
Web Site : http://www.paragpackaging.com/
E-mail I.D : firstname.lastname@example.org
Offi : 079-22180566
Following are the rate for Bopp Tape,
(A) BOPP SELF ADHESIVE TAPES BROWN / TRANSPERENT
72mm x 65mtr. 48 Roll Per Carton.1350/-
48mm x 65mtr. 72 Roll Per Carton.1350/-
24mm x 65mtr.144 Roll Per Carton.1350/-
(B) BOPP SELF ADHESIVE TAPES BROWN / TRANSPERENT / MILKY WHITE
Single Color Printed (Any color)
72mm x 65mtr.48 Roll Per Carton.1550/-
48mm x 65mtr.72 Roll Per Carton.1550/-
24mm x 65mtr.144 Roll Per Carton.1550/-
1.Quantity:Printing Order Minimum 5 Cartoon
2. First Time Cylinder Charges Extra
We also have a business in the following,
Ø AIR BUBBLE ROLLS/ SHEETS,
Ø EX.POLYETHYLENE FOAM,
Ø MASKING TAPE,
Ø DOUBLE SIDE TISSUE TAPE & OTHER INDUSTRIAL TAPES
UBI uses a consumer led approach for key brands in key markets. It aims to meet consumer needs in the three main global snacking trends – health, pleasure and convenience. This consumer focus, combined with excellent products and relevant brand values, has made UBI a growth engine of the UB group.
To further accelerate this growth, UBI is increasing its marketing investment in key markets, in addition to entering into new markets with great potential.
Our key markets
Canada, USA, Sweden, Greece, Italy, Portugal, Middle East, Australia, India and Nigeria.
Our key brands
McVitie’s, Fruit & Form, Carr’s, Delacre and BN
Case study - Nigeria
An good example of UB International is seen in Nigeria. McVitie’s has been a recognised and established brand within Nigeria since the 1980s when it was the number one imported biscuit brand.
A Government embargo on imported biscuits resulted in UB’s biscuits being banned and subsequently sales were lost in the Nigerian market. In order to maintain a presence in this market, UB set up a local co-manufacturing agreement to make biscuits in Nigeria.
UB International is now re-building distribution and expanding production capabilities to develop a range of locally Nigerian produced products to meet consumer demand.
Marketing efforts need to work creatively to take advantage of the opportunities in a developing market. Significant efforts have been put into developing a route to market, including the aptly named “go slow” – an important route to market for FMCG. In the capital, Lagos, constant traffic jams create rolling malls where the “go slow boys” sell products between the cars. Depending on the time of day, drivers are offered different products and McVitie’s Digestive time is mid-morning.
Although there are around 500,000 stores in Nigeria, only 20 of these are supermarkets. The vast majority of stores are small kiosks or simply tabletops. A successful piece of POS designed to adapt to such stores has been the introduction of a hanger, which is used to hang 10 packs of McVitie’s Digestives. This is used extensively and has the added advantage of acting as a hanging billboard for the brand.
In 2008 UB International is expecting sales from Nigeria to be six times more in volume than in 2007.
Case study – Middle East
McVitie’s Digestive is very popular in the Middle East, outperforming the growth of the biscuit category. UB International’s core business in the Middle East comes from McVitie’s Digestive, McVitie’s Digestive Light, McVitie’s Chocolate Digestive and McVitie’ HobNobs. Lead markets are Saudi Arabia and the United Arab Emirates and Ub has a very effective operational structure that makes its products available in the entire Gulf.
Revenue in the Middle East region is growing due to new product launches, marketing support and excellent execution of displays in store.
In some areas McVitie’s Light Digestive is out performing McVitie’s Original Digestive. This has encouraged UB International to launch Fruit & Form biscuits to further meet the consumer health trend. The reception by the trade has been so positive that some retailers have positioned the biscuits both with the cereal bars and in the 'health' aisle.
This Enterprise Resource Planning helps these bakeries in maintaining datas which can be utilised for better results . Numerous reports can be generated from this ERP and various master lists are maintained such as Vendors , Creditors , Debtors , Dealers , Transporter, Employee ,Asset , Production units , Recipes , Product mix , Material List etc
SAP has been the most popular of all the software as it has modules for which are helpful in
- Materials Management
- Finance Management Module
- Production Management Module
- Sales management Module
- Stores and warehousing Module
- Maintenance Management Module
- HR Module
Big Companies have added advantage as all information from different locations can be obtained at a click . Data collected can be utilised for better product mix , cost savings , better production plan with help of MRP runs . ERP software helps in taking decision such as
- Which location has the most cost advantage
- Which plant to be loaded
- What is the best price of raw material and from where to procure from
- Sales figure
- ABC analysis
- Price trends
- Costing of the product
- Material Variance vis a vis Standards
- Plant Break Down Analysis
- What was the last purchase price of any item
- Deliveries and vendor analysis.Stock ,Inventory related reports
ERP has become an important tool for senior management to take informed and precise decision.
Bigger plants with more than two or three production line of Bread or Biscuit ovens with six or seven zones can emit considerable amount of flue gases which consists of carbon monoxides, Sulphur Oxides ,Nitrogen oxides which are dangerous for health and if not monitored can result in polluting neighbourhood .
Emission limits and stack parameter as per the Act .CPCB ( Central Pollution Control Board) national air ambient quality
Stack Height = 15meter or more
Air pollution can be minimised with following steps
- Use flue gas analyser for stack monitoring in regular intervals
- Do regular burner maintenance
- Substitute if possible diesel oil to LPG or Natural Gas
- Use high pressure monoblock burners
- Get low sulphur diesel oil
Noise Pollution can be controlled by following steps
Safe limit prescribed in Act is 70 db in night time and 75 db in day time as CPCB standards
- Monitor noise through decibel meter .
- DG set room to be to be lined with acoustic lining
- Maintain equipment with maintenance schedule s
- Use equipments with enclosure
- Use screw compressors instead of reciprocating compressor
- Silencers in stack for DG Sets.
- Put anti - vibration pad where ever possible for machinery .
Get more information on water standards and air standards on http://www.cpcb.nic.in/
United biscuit would test launch its product from this facility in first quarter of 2010 . The brands it would go in for world famous Digestive biscuit McVities . The Indian operations is headed by Jayant Kapare . For last year it has been scouting for manufacturing unit and now its has finally taken oven this biscuit manufacturing plant in Himachal Pradesh .
UB would have to face tough competition from already entrenched players like Britannia , Parle and ITC . UB has to work it out a recipe compatible with Indian taste and to market aggressively for brand recall.As history shows that Foreign brands could not make much headway in Indian biscuit market .
Product like Britannia Digestive , Marie Gold , Nutri Choice and ITC s Marie lite would give to tough competition . Indian biscuit market is worth Rs 6000.00 crore and fiercely competitive with dozens of local players apart from the BIG 3 ,namely Cremica , Priya gold , Dukes and Bisk farm.It would be interesting to see how Indian players respond to UB s McVities.
United Biscuits is owned by private global investment firm Blackstone and European private equity firm PAI .
read more on
1. Bakery OvenDouble deckFour trays eachGas / Electric operated
2. Waffle Baking Machine
3. Heated Display counter for patties and puffs (preffered: three side glass and rotating shelves)
4. Single door cake rotatory display fridge- Vertical
5. Pastry Display fridgeFrost freeSize: 3ft, 4ft, 5ft, 8ft length
6. Commercial refrigeration equipment- Double door, Refrigerator/ Deep freezer for freezing the cakes and pasteries after icing
7. High speed planetary mixtureWith three attachmentsCapacity: 20 litres
Machinery related to Food Industry:
1. Pizza Oven Conveyor typeGas / Electric operatedMinimum width OF Conveyor belt 20"with 28"n long Heating chamber minimum
2. Softy MachineSingle flavourEconomical Model
3. Horizontal 3 door cold storage fridge
4. 8' Long three door horizontal deep freezer
5. Generator Set 62 KVA (Silent)
If you have got above second hand machines please contact undersigned
Shri Balaji Foods
91 98154 44448
E- Commerce a new tool for bakeries to save cost and build profits-Popular retail brands of bakery in China
A recent article in china daily which highlights the popularity of online shops in China for popular bakeries cafes . Popular bakeries like Ebeecake, Waffle boy and 21 Cake all have gone for online stores for their bakery product .People find doing online business is economical and less time consuming .
Traditional bakery retail chain majors like Holiland , Weiduomei , Bread Talk and Paris Baguette are adopting different strategies for growth and sales .
Holiland has chosen the franchise path to open more than 1000 retail cafes.
Weiduomei has turned to western -style bakery cafe.
Bread Talk is focusing on gaining a foothold in high-end shopping malls and office buildings, reinforcing its niche image.
Chinese bakery market is growing with 20% rate year to year basis.Western-style bread and cakes have become daily necessities for many urban consumers in China . Competitive land scape has made bakeries to adopt different strategies in market .
Bakeries all over world have many ways in manufacturing process to reduce energy bills which includes thermal and electrical energy. Apart from the basic production line there are utilities such as Air compressors , Air conditioning ,Refrigeration , Hot water generators , Boilers ,Chillers , Effluent treatment plant , Conveyors ,Generators ,Air washers , Cold Rooms and Lightening .Not only can a bakery reduce energy costs and greenhouse gas emissions, but it can impact its bottom line
Here are few tips and Ideas for energy savings in bakery plant .
- Eliminate improper cabling
- Check alignment
- Use synchronous motor to improve power factor .
- Provide proper ventilation .
- Maintain high power factor as lower power factor reduce s the motor efficiency and
also reduces the efficiency of electrical distribution .Lower power factor results
when motors of plant runs below the full load ratings.
- Low wattage lighting s ( CFL )are now available in ratings of 18/20 watts with good lux ratings with retrofit could replace conventional tube lights and bulbs .
- Occupancy sensor
- We can save energy by having VFD installed for motor .
- Screw compressors have far superior performance then other type of compressors
- Select compressors which have ' motor stop arrangement ' in which motors stops
on longer unload period.
- Have cooling arrangement for incoming air .
- Proper insulation of pipes of chilled water ,cu piping for refrigerant can
results in energy savings.
- Temperature can be set as per requirement & not going for extremes can
help in reducing energy consumptions
- Avoid over sizing select the refrigeration cap as per the load .
- Consider gas powered refrigeration equipment to minimize the electrical
- Connect refrigerated water load in series .
- Waste heat generated can be utilized for heating water and pre heat in
take air . recuperates and heat exchangers can be installed to use
waste heat from flue gases .
- Insulation are required for various industrial application such as Ovens.
Furnaces,heaters,boilers,storage tanks,piping's,steam.chilled water pipelines
etc .These insulations are made up of mineral wool,silica , alumina and mulite .
Insulation can save heat losses considerably .While selecting insulation material
check thermal properties,physical and chemical specifications
Repair damaged insulation
- Schedule pumps to turn off whenever possible .Putting up level sensors , float
valves or pressure switches
- Avoid recirculation through bypass lines
- Minimize throttling
- Use two speed or variable speed drives for cooling tower fan control if the fans are
few .Stage the cooling tower fans with on -off control .
- Turn off unnecessary cooling tower fan s when the load s are reduced.
- Control cooling tower fans based on leaving water temperatures
- Periodically clean plugged cooling tower water distribution nozzles
- Provide separate lighting transformer for control of lighting systems.
- Locate substation near the load centers to minimize energy losses in cables and also improve
- Install capacitors with automatic power factor control panel to maintain a power factor of not less
than 0.9. Install capacitors near the load points wherever possible or at the sub distribution board.
The best practical method would be to install capacitors at larger capacity motors and at the
substation for all other loads.
- Identify under loaded motors and examine the possibility of replacing them with the appropriate
capacity motor or alternatively fix retrofitting devices that are available to save energy.
Fuel consumption can be reduced by installation of fuel efficient burners .With advent of new technologies one can get fuel efficient burners . For example dual stage high pressure weishaupt burners . Its a monoblock burner with inbuilt blower s in the burner.
Other important factors of combustion is air -fuel ratio . All manufacturers of burner provides exact ration of air fuel .
Regular maintenance of burners also helps in reducing fuel consumption .
These are few ideas to reduce energy cost in bakery plants . You can suggest other ways to save cost in bakeries .do write to us about your energy saving ideas.
More ideas on http://www.shumaonline.com/costreduction_energy.html
Bakers Pride is a major brand of cookies in gulf and middle eastern countries .Bakers Pride has been launched in Qatar by Britannia Industries Ltd a major biscuit manufacturer in India . Earlier Bakers Pride was owned by K R Group of Companies. In 2007 Britannia bought this company from KR group and now its 100% subsidiary of Britannia Industries Ltd , India . Qatar Distributors are Ali Bin Ali Group, one of Qatar’s largest retail and distribution companies.
Qatari biscuit market is estimated to be around USD 30.0million and average biscuit consumption is 0.5 kg per capita . Britannia s see huge opportunity of promoting its biscuit in Qatar.The Baker’s Pride indulgent range of cookies includes Danish, butter, chocolate, double chocolate chip cookies and the newly introduced Baker’s Pride shortbread available in different sizes varying from 100 grams to specially designed tins in 400 grams.
Baker sPride brand covers products like Chocolates , Fruit rolls , Cookies and is manufactured at Sohar factory in sultanate of Oman called Al Sallan Foods Company .
Recently the Bakers Pride packaging and brands has been re launched through major change in design and logo by none other than by internationally acclaimed designer Jane Thorn, who has been involved with names such as Sainsbury’s and Heinz, to align the packaging with the new Baker’s Pride brand.
NABIL or National Biscuit Industries are the main competitor in Oman .
Source :ThePenisularQatar .com
Large bakery plants which are highly automated uses conveyors , material handling equipments and conveyors . Chain drives are frequently used in bakery plants for rollers , conveyors , band drives , blowers and chain for trays , bearings for rotating equipments .These equipments are always in contact with food raw or finished . Chances are there when they can contaminate the food items with lubricant if not done properly. To avoid this problem one can put food grade lubricant instead of conventional non- food grade lubricant or oil. Equipments were we can expect a food contact are mixers , molders , dividers , oven , packing machines and accessories like oil spray , milk spray ,flour sifters , screw conveyors , sugar grinders and biscuit grinders .spreading units , conches mixers ,laminators , depositors and gauge rolls. Compressed air does carry lubricating oil with it .special filters are attached at the output of the compressor to trap this oil. Oil free compressor are available but a bit costlier than normal compressor. Seals and gaskets generates leaks and spillages of lubricants .
These equipments need lubrication in intervals for smooth running and proper functioning of machines .Now due to new technology in lubrication and oil industry we can get food grade lubricants . Here in Indian bakery plants it is still to be popular . There are some misconception about food grade lubricants .
A lubricant qualifies as food grade when, in the event of a contamination, it is present in no more than 10 mg per kg of the foodstuff in question and must not cause any physiological hazard or affect the food's odor and taste in any way. Food-grade lubricants, such Shell Cassida, are special blends of base fluids and additives, and should be approved by the US FDA and registered by NSF International in the H1 category.
All major food safety management systems recommends using food grade lubricant in food processing and packaging companies .HACCP,GMPS,BRC,ISO22000,1SO14000,SQF,IFS
Food Grade Lubricants can be categorised into following groups
- Gear Box Fluids
- Hydraulic Fluids
- Conveyor Fluids
- Speciality Fluids
Major misconception s and facts about application of food grade in bakery plants.
Legend #1: Contamination by machinery lubricants with food and beverage during manufacturing doesn't happen.
Fact #1: It happens more often than we think. Most contamination is detected before the product leaves the plant - but some aren't.
Legend #2: I am pretty sure that the lubricants I use in my plant are all food grade.
Fact #2: Food grade lubricants are made from components approved by the U.S. Food and Drug Administration (FDA) for incidental contact with food. You can verify whether the lubricant is food grade or not by asking for a declaration of the formulation from the lubricant supplier, or by checking whether the product is H1 registered with a third party certifier such as NSF International.
Food-grade lubricants are readily available in the United States and a growing number of food and beverage manufacturers are using them. Any food or beverage processor not using food-grade lubricants is courting a huge risk. The FDA has set a "zero tolerance" for contamination by non-food grade lubricants and also governs the components that are allowed to make up a food grade lubricant. The US Department of Agriculture (USDA) formerly approved lubricants as H1 ("for incidental food contact") and published the list in what was commonly known as the "White Book." The USDA ceased this activity in 1998. NSF International has since taken over the "White Book" and now registers lubricants as H1 food grade. You can verify whether the lubricants in your plant are food grade by checking the list of NSF H1 certified non-food compounds on www.nsf.org
Legend #3: Food-grade lubricant performance is inferior to traditional lubricants. The lubricants don't meet the demands of my applications.
Fact # 3: Synthetic food grade lubricants are designed to meet a wide range of applications and generally outperform traditional food grade mineral oils.
Machinery used in food and beverage processing has many moving parts requiring lubricants to maintain reliable and efficient operation. Food and beverage contamination can occur from drips off chains, hydraulic hose failure, oil leaks from seals and gearboxes, or a release of compressed air containing an oily mist. Using traditional non-food grade industrial oils and greases is inappropriate in these settings.
Food-grade synthetic lubricants, such as Shell Cassida®, are odorless, tasteless and generally outperform established mineral oil-based lubricants. They are specially engineered for high performance remaining effective in the sub-zero cold of freezers and the high heat of ovens. Their increased oxidation and thermal stability, compared to a traditional mineral or white oil-based food grade lubricant, can extend equipment life and reduce downtime, which lowers maintenance costs.
As the FDA restricts the type and concentration of additives allowed to enhance food-grade lubricant performance, the critical performance factor lies in the lubricant's base oil itself. Synthetic base oil has superior technical characteristics over traditional white mineral oils.
Synthetic food-grade lubricants are designed for use in food and beverage manufacturing applications, improving lubrication properties and performance and offering excellent water resistance. Food-grade lubricants are harmless if accidentally consumed in quantities below the maximum FDA-prescribed level of 10 ppm (10 parts per million).
Legend #4: Food-grade lubricants cost more than mineral oil products.
Fact #4: Synthetic food-grade lubricants actually cost less in the long run, because they not only reduce overall maintenance costs, but also can reduce the risk of potential liabilities from using non-food grade lubricants.
Synthetics do cost more than traditional mineral oils, but the initial cost of the synthetic brings subsequent returns, against which a food grade mineral oil-based lubricant cannot compete. Further, damages that could arise from not using H1-approved food-grade lubricants are immeasurable.
According to the Japanese Institute of Plant Maintenance (JIPM), "up to 65% of mechanical equipment failures can be attributed to some form of lubrication deficiency."2 Lubrication failures lead directly to production losses, so a robust lubrication program plays an effective part in plant management.
Lubrication quality has a significant impact on equipment life. Field experience and case studies show that food-grade synthetics have a longer product life and need to be replaced less frequently in machinery. In many instances, results demonstrate up to four times more life with synthetic oils.
Legend #5: None of my equipment actually requires food-grade lubricants for food safety.
Fact #5: Food grade lubricants should be used wherever there is a chance of incidental contact with food or beverage products during manufacturing.
Lubricants used in manufacturing facilities can make their way into the food we eat. Oil and grease droplets can seep from bearings and conveyors, can seamers, bakery ovens and other critical points of operation.
Plant quality managers and maintenance managers should identify areas of potential lubricant contamination. Companies can assist by conducting a Lubrication Contamination Control Point (LCCP) survey, which forms part of the plant Food Safety Plan. For example, a Shell LCCP Survey is based on Hazard Analysis Critical Control Point (HACCP) principles and examines where the risks are in a plant, what they are and what can be done about reducing and managing them.
Food and beverage processing plants must prevent accidental lubricant contamination, which could potentially harm consumers and damage a company's brand and reputation. Synthetic food-grade lubricants can help minimize these risks, adding a buffer against contaminating our food supply.
Source :Shell Oil Co( Facts and Legend )
Major Food grade lubricants brands
Report, based on a consumer survey, reveals that while the adoption of private labels began with its value proposition, consumers perceive these store brands are offering quality at par with other national brands.
New Sets of manufacturers have sprung up to cater this private label requirements or manufacturers with idle capacity see this as good opportunity .Bringing extra jobs and employment .
Major food retailers like Reliance, Aditya Birla and Food Bazaar all have their private label bakery products . Private label foods have already been practised by retail giants like Wall Mart , Carrefour and Tesco .In addition to private label products they have live bakeries placed in their food courts.
Big Brands manufacturers have to innovate , launch new products with lower price strategy to counter this private label products invasion. Trade margins to be re worked with big retailers .
Chocolate biscuits , Cream biscuits , Crackers , Plain biscuits and Kids biscuit
Afghans,Belgian Cremes ,Cameo Cremes ,Chit Chat ,Chocolate Fingers ,Choc Thins ,Cookie Bear Chocolate Chippies ,Cookie Bear Hundreds and Thousands ,Cookie Bear PartyTime Wafers ,Cookie Bear Shrewsbury ,Cookie Bear Stripes ,Digestives ,Dundee ,Fruitli ,Gingernuts,
Krispie ,Lemon Treats ,Macaroon ,MallowPuffs ,Malt ,Meal Mates ,Melting Moments ,Milk Arrowroot ,Mint Treat ,Pasties ,Sensations ,Shortbread ,Snax ,Squiggles ,Swiss Cremes ,ToffeePops ,Wheaten ,
Employees - 800 employees working at two factories papa kura and wiri- Auckland
Griffins Foods Limited,P O Box 76072,Manukau City 2241,New Zealand
What ever the reason being definitly company would gain on cost of prodution as labor in Fiji would be available at lower payout.
Many bakery manufacturers would move production base to other countries to enter the local market and also take the cost advantage .
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These Oil spray are used for cracker biscuit s ,hence if planning for cracker variety need to have this Oil spray unit . It can be of portable in nature or wheels are provided on the platform on which this oil spray rest .
Oil spray works on principle of mist formation due to high rotation of Disc .Number of spinning disc varies as per the width of conveyor . Oil spray unit can have sets of 2 ,3 or 4 spinning disc . These disc are directly coupled to motor s . Oil is imparted on these disc through nozzle and oil are pumped through pu tubes to the Spinning disc.Uniformity of spray or oil deposition can be checked
Baked biscuit which passes the Oil spray unit on stripper conveyor .Excess oil is collected and returned to the reservoir tank.General body is made up stainless steel .
Major problem occurs during winter seasons in case of intermittent production of Crackers the oil freezes and chokes pu tube s and these have to be heated to melt the solid fat in these tubes .
Parts of Oil Spray Unit
- Storage Tank
- Reservoir tank( Insulated )
- Valve to monitor the flow
- Spinning Disc
Most popular Oil spray manufacturer is Arcall.
Fat and Oils are major ingredients for any baked goods . These oils and fats are bought in bulk by these bakery manufacturers . Chances of fat or oil being rancid becomes high if stored for a longer period .This rancid fat or oil can then effect the quality of baked items . Fat and oil can be checked for rancidity prior to production by instrument called rancimant .
What Is Rancidity?
Rancidity is a very general term and in its most general meaning, it refers to the spoilage of a food in such a way that it becomes undesirable (and usually unsafe) for consumption. When people say that a food has "gone bad," what they're usually talking about is rancidity. Most of the time, but not always, rancidity can change the odors or flavors of a food in such a way that it becomes very unpleasant to smell or taste.
While most any food can technically become rancid, this term applies particularly to oils. Oils can be especially susceptible to rancidity because their chemistry can make them exceptionally susceptible to oxygen damage. When food scientists talk about rancidity, they are often talking about a specific type of rancidity involving oxygen damage to foods, and this type of rancidity is called "oxidative rancidity." During the process of oxidative rancidity, oxygen molecules interact with the structure of the oil and damage its natural structure in a way that can change its odor, its taste, and its safety for consumption. Chemical reaction produces butryic acid which gives the foul smell and taste .
Rancidity is caused by hydrolysis and oxidation. Heat, moisture and exposure to light will increase these chemical reactions and thus increase the likelihood of the onset of rancidity. Anti –oxidant added in during dough preparation prevents or delays oxidation hence the rancidity of oil or fat .
How to measure the level of Rancidity?
Apparatus called Rancimat is used to calculate effect of antioxidant on oil and fat . Other methods like used for determination of rancidity are Peroxide value ( Primary Oxidation)and Anisidine value( Secondary Oxidation) in fat or oil .Peroxide value provides the extent of rancidity present in the oil.Peroxide value is found by formation of iodine when oil or fat are reacts with iodine ion. Totox value are also used to check the quality of oil and fat .
Totox Value = Anisidine value + 2x Peroxide value
The 743 Rancimat is an instrument with two separately thermostatted heating blocks, each holding up to four reaction vessels containing 2 to 10g of sample.This means that samples can be run at one or two different temperatures.
Up to four different instruments can be linked to a single PC via serial interfaces.Up to 32 samples at eight different temperatures can be measured.
The short-chain carboxylic acids formed by the oxidation at elevated temperatures are collected in the deionised water and the conductivity measured.
The conductivity time curve is shown live for each measuring point.
The induction time is determined automatically from the second derivative of the measuring curve.
I have been writing on bakery industry for last one year along with that I have collected few snaps/picture through my Kodak digital camera whenever possible and had few selective biscuits brand which ever I can lay my hand on . You can find all sorts of packaging and shapes of biscuit. Please check this out hope you would like these pictures .In case you have any such pictures do send it me .
Fat or Oil perform various role in these bakery products . Few of important role are mentioned below
- Heat Transfer
It provides the flavour , lubricates the dough and retain gases to give texture as it give lift to the bread loaf . Retains moisture and helps in machinability /slicing .
Fats and oil are used in biscuit to shorten the gluten formation . Fat also helps in machining , moisture retention , creaming .
Fats and oil in cake manufacturing helps in aeration,tenderising , emulsification and creaming and icing application .
Heat tranfers , binding for coatings
Use of fat results in flakes ,texture , shelflife
- improving efficiency
- low energy
- low maintenance
- Food grade parts
Few of the popular bakery equipment in the market are
- Tweedy mixers - Baker Perkins
- Accurist2 Divider- Baker Perkins
- Multitex4 dough Moulder- Baker Perkins
- Electric modular ovens - Sopaco s
- Bellift 275 Nozzle Depositor-Beldos
- Bell cake depositor-Beldos
- Crusto Bread Line -Rademaker
- Modular laminating concept-Rondo
- Eco -nova system in oven - MIWE( Michael Wenz GmbH)
- FTM Oven - Mecatherm
- Capway Ovens
These machine are easy to maintain , versatile for different products and with less changeover time .
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