Baking&Snack - March 2014 - 38

(Left) Dozens of freshly
baked loaves of hearth
bread cascade out of the
steel-plated oven.
(Right) The bakery's bread
line produces no-stress
dough sheets to make ciabatta and other Europeanstyle products.

revealed the FSSC 22000 program better handled its
data, lot tracking, recall processes and ingredient and
supply chain management. Additionally, IHB is exploring installation of a recipe management system to provide better traceability and other front-end controls to
its process. "Our business is based on producing artisan
products that are reliable and repeatable day after day,"
he added.
About 150 employees work in the bakery, which produces breads and rolls seven days a week. Currently, capacity averages around 50% in the separate mixing and
makeup area that includes two bread lines and two roll
lines. The bakery also has an encrusting line. The baking
area, which houses a variety of tunnel and rack ovens,
operates at 80% capacity. IHB is looking to expand its
oven throughput to alleviate the bottleneck in this area.
IHB uses a Contemar bulk ingredient handling system with three, 30-tonne (66,000-lb) fabric silos holding European-style flour and a 15-tonne (33,000-lb) silo
for whole grains. Minor ingredients are pre-scaled in a
separate area. Two Peerless 2,000-lb mixers - as well as
a smaller, older horizontal mixer and several spiral mixers - feed the makeup lines.
Two Rheon 2,200-lb artisan bread lines with V4 extruders create continuous, low-stress sheets that travel
through a series of reduction rollers to reduce the thickness of the sheet. One string line produces mainly baguettes and ciabatta breads and rolls. "It tends to run
higher-volume products with fewer changeovers,"
Dennis Rossetti said. The second Rheon line also creates
rounds and boules.
After trimming off the sides, the continuous dough

38 Baking & Snack March 2014 / www.bakingandsnack.com

Frozen: The new fresh
Italian Home Bakery doesn't believe in doing anything half-baked, including frozen
products. While some companies swear
by the par-baked format, IHB believes
retailers and foodservice operators will
prefer fully baked frozen in the long run.
"Their push is on reducing their labor,
"
said John Rossetti, senior vice-president
and CFO. "We're producing a product that
our customers don't have to finish. It's
shelf ready. They don't need additional
labor or a footprint for baking it off.
"
And if a retailer wants that fresh-baked
aroma, the bread and rolls just need
about 3 to 8 or 10 minutes in the oven
- depending on their size - to refresh
them.
"Basically, we're trying to create a
product that's as good as what we provide
with our fresh business, noted Dennis
"
Rossetti, president and COO.
sheet enters scaling rollers that send a signal to the line's
guillotine to create dough pieces based on a specific
weight or length. The lines also have a circular cutter for
creating ciabatta rolls.
To make oval and round loaves on the second line,
dough pieces divert on a 90° conveyor from the Rheon
sheeting system to a Kaak Group makeup system. After
passing through a conical rounder, the pieces receive a

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