Baking&Snack - June 2014 - 92

A needle-equipped drum makes adjustments
between patterns and shapes easy when it
comes to removing finished waffles.
Franz Haas Machinery of America

Waffle lines find new uses
At the 2013 International Baking Industry Exposition (IBIE),
Masdac International showcased a production line that it
hoped US and Canadian bakers would recognize but with a
product that is completely new to them. The manju character cake hails from Japan. This small filled cake is produced
on an automated line that functions very much like a waffle
line with batter deposited into moulds that are then baked
and depanned.
"In the end, it's a similar process to waffle making, but
it's a cake product, so it's more like a Belgian waffle, the
soft ones, and then it's filled, explained Matthijs Sillevis
"
Smitt, sales manager, North and South America, Masdac
International, represented in North America by Naegele,
Inc. By featuring the line at IBIE, Mr. Sillevis Smitt hopes to
bring the filled cakes to the US, and he already has several
bakers interested. "We are in an advanced stage with
some very important bakeries interested in this concept to
Americanize it, he said.
"
The filled cakes have already found success beyond
Asia, in Italy. While red bean filling is popular in Japan, it
was replaced in Italy with flavors more suitable to local
tastes: chocolate, marmalade and milk fillings. The line was
adapted to European food equipment regulations. So far,
Mr. Sillevis Smitt said the equipment meets US regulations. All that needs to be done now is adjust the product
itself to satisfy American palates.
Mr. Sillevis Smitt expects manju-like cakes to do well
in the US because they can cater to seasonal demand.
Different moulds allow bakers to make shapes specific to
different holidays, seasons and other special occasions. He
sees plenty of potential for quick-service restaurant chains
to offer these cakes as breakfast, dessert or snack items
made by contract manufacturers. "The products will be different in shape and maybe even size, but they all come off
the same line, he said.
"

cutting costs is a priority. When TSA Griddles delved
into waffle equipment, eliminating a major cost of griddle maintenance - the upkeep of non-stick coatings -
was a driving goal.
Industrial griddle plates with non-stick coatings need
to be re-coated every two to eight weeks, depending on
the type of waffles being produced on them. This process often requires shipping the plates to a facility where
the old coating is blasted off and the new one is added.
"It creates a lot of costs and downtime, and the environmental footprint is horrendous," Mr. Forrest said.
"We've eliminated all of that." By removing this need,
Mr. Forrest estimated that bakers can save a half million
dollars a year and experience a two- to three-year return
on investment.
To eliminate this process while still maintaining easy
depanning, TSA Griddles creates waffle moulds with a
naturally slick surface. This plus gravity make the waffles
easy to remove without the aid of ongoing oil application or non-stick coating. Mr. Forrest said as an added
benefit, the moulds can be aggressively cleaned and
scrubbed because operators don't have to fear chipping
the non-stick coating. "We also use brushes to clean the

Filled character cakes popular in Japan, produced by a process similar to waffles,
are making inroads around the world and maybe have a future in the US.
Masdac International

92 Baking & Snack June 2014 / www.bakingandsnack.com

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