Baking&Snack - July 2013 - 28

ACE BAKERY

of product development and master baker. Fed by gravity,
the dough enters the first of three sets of reduction rollers
followed by a satellite roller head. A guillotine cutter turns
the solid sheet into separate strips. Then, they go through
a set of moulder belts that lengthen the logs, creating the
string-shaped dough piece characteristic of baguettes.
For shorter baguettes or dinner rolls, another cutter portions the dough to the desired lengths. After
moulding, the dough
pieces drop automatically onto peel boards.
Loaded peels move into
the Mecatherm vertical
proofer, which operates at 22 to 25°C (72
to 77°F). Leaving the
proofer, dough pieces
are slit shallowly on
their top surfaces, with
seed toppings added
according to variety.
“When we look at
technology, we seek
to
replicate
what
we do by hand,” Mr.
With loaves entering at the top of
the spiral conveyor, bread cools
under ambient conditions in the
temperature-controlled bakery.

Mariathas said. “This makeup line is highly automated, but the technology we chose enhances the process
and the finished product.”
Continuing on to the next room, which houses the
Mecatherm stone-hearth tunnel oven, filled peels line
up in front of the oven. The oven loader picks the dough
pieces up off the peels, carries them into the oven entrance and slowly retracts, leaving the pieces on the
heated stone hearth. Steam is applied immediately
thereafter. Loaves move slowly and smoothly through
the zoned baking chamber.
Gaffney, like Vaughan, makes par-baked loaves. The
company defines par-baked as 85% finished and frozen.
Par-baked loaves slide down the discharge plate at the
oven exit, and a conveyor carries them to an Alit Aliflex
ambient-temperature spiral cooler. After they finish
their trip around that spiral, another conveyor moves
them along into the Alit spiral freezer. Engineers timed
the ambient cooling system to bring the internal temperature of the par-baked loaves and rolls down to 100°F
before they enter the freezer maintained at -35°F.
ACE installed a LeMatic band slicer between the cooling and freezing spirals, allowing preparation of sliced
rolls should customers require.
Leaving the freezer, all products pass through a
Fortress Technology metal detector. A Capway conveyor, equipped with white plastic belting, moves the
solidly frozen baguettes into the packing stations.
Operators count the loaves and bundle them into
polyfilm-lined shipping cartons. A 3M-Matic case

Building an artisan incubator
ACE Bakery wants artisan food producers to flourish and
succeed, so it developed an incubator program to celebrate
its 20 years of artisan baking. “We’re sponsoring other artisan companies to showcase their products in a big event at
Toronto this summer, explained Lee Andrews, president,
”
ACE B akery, Toronto.
The company selected 20 individuals from food artisans across Canada to hold two workshops guided by
ACE’s panel of Artisan Incubator Tastemakers. The public is
invited, and topics are as varied as the artisans themselves
— distilling, foraging, fermentation, cheese-, sausage- and
chocolate-making and more. And locations include some of
the city’s top culinary venues. As part of the program, ACE
Bakery offered a two-day workshop on artisan bread given
by its master baker, Marcus Mariathas.
“The ACE Bakery Artisan Incubator is a celebration of the
joys of artisan food, the importance of local and sustainable
food producers and the vital contribution of artisan entrepreneurs to communities across Canada, the company said.
”
Par-baked loaves leave the oven, traveling to cooling and freezing operations.
28

/ Baking & Snack / July 2013



Baking&Snack - July 2013

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