Baking & Snack - August 2017 - 97

Rotary moulding systems now provide quick die removal and belt replacement
to limit downtime.
Reading Bakery Systems

While certain types of cookie production might not
create much scrap dough, some types such as rotary
cut can. "Rotary-cut cookies can produce around 30%
rework, depending on the die layout," Mr. Pallottini
said. "Reading has designed a system to feed this
dough directly into the back half of the sheeting head
to minimize any scrap."
Reclaiming dough depends on a number of factors, according to Mr. Zelaya. "Depending on dough
formulation and ingredients present, processing
time and percentage generated, some dough can be
more susceptible to accepting scrap," he said, noting
that doughs with inclusions are not always reworkfriendly. Decreasing the temperature of the scrap
dough is helpful, he added.
Mr. Knott made a similar observation. "In some
cases, it helps with the continuous process to heat the
return on scrap dough," he said. "Typically during
the sheeting process, the dough cools down. And in
a lot of cases, we like to add heaters to the rework to
process it more easily into the fresh dough; it mixes
easier if it's a little warmer."
Additionally, bakers must be mindful of fat, especially in laminated sweet goods, as it can affect the
formulation or product quality.
Mr. Fontaine suggested that reclaimed dough can
be added back in up to 5% in the final stage of mixing
if there is enough time for even dispersion.
Another issue is lot traceability in the event of a recall, and Mr. Fontaine advised that reclaimed dough
should be used in same-day production for tracking
purposes. Any dough held overnight for reuse, he
said, must take both the formula and lot tracking into
consideration.
"For example, shortbread could be held and mixed
in the following day, but the dough should then be
treated as an ingredient and given its own lot number," he said. "This will link the scrap to the previous
day's production and lot numbers for that dough so it
can be traced properly."
Controlling waste will ultimately manage not only
cost but also quality. By looking at the overall process,
asking the right questions up front and thinking a
little outside the box, bakers can come up with new
solutions to keep the waste at bay.

Find resources for suppliers who can help minimize
waste by visiting www.esourcebaking.com. Browse
by category under Equipment, and click on Makeup/
Deposit/Form for listings.

Waste happens
Bakers and suppliers work together to minimize
as much scrap as possible. But, inevitably, it happens, be it unused dough or damaged or rejected
finished product.
Typically that waste is sent out for animal feed,
which often adds another layer of time and labor.
But are there ways to simplify the disposal of
wasted food?
Enagon LLC recently developed a food-grade
pressure wave interface mill that uses a combination of centrifugal action, grinding action and
sound waves to dry and mill almost any solid
waste into a fine powder.
"A baker could drop in a type of waste such as
cookies, and the machine would dry it and grind
it down into a fine powder," said Jonathan Arkin,
regional sales manager, Arkin Sales, Inc., which
represents Enagon.
Mr. Arkin noted that the energy cost is the biggest investment in breaking down product waste,
and the Enagon mill can mitigate much of that.
"If you eliminate the cost of gas or electricity to
heat it, then it opens up more ability to reuse that
material," he said.
For bread products, Bühler, Inc., also helps
bakers return discarded finished product back into
the process as an ingredient through dry rework.
Bühler's technology shreds, dries and grinds rejected product, enabling bakers to add it back into
the formula with other dry ingredients, according
to a paper recently published by the company.
As technology advances, bakers have new options
for reworking food before turning it over for feed.

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