Baking & Snack - April 2022 - 62

COOKIE & BAR PROCESSING
SANITARY DESIGN BECOMES
THE SIGN OF THE TIMES
feed rollers to make a sheet or optional kibbler before it
heads up an incline to either a wirecut machine or rotary
moulder. Using servo gearmotors on the wirecut machine
allows for quick adjustments and better accuracy
and less maintenance. Separate feed roll drives provide
better control and versatility to create a wider variety of
products on a single line. Wirecut operations feature an
adjustable feed roll cap on the wirecut for bars or cookies
with various sized inclusions.
" Typically for wirecut cookies, you need an 8-mm
feed roll gap to push the dough through for 'best' product
weight control, " he said. " However, if you're using
10-, 12- or 20-mm inclusions, like chocolate chunks,
that would smear on the roll. We can open our rolls
up and allow those inclusions to pass through without
breaking apart or smearing the inclusions. That works
well with gourmet-style cookies or bars that have a lot of
inclusions in them. "
To produce bars with an inner filling, Mr. Christie
added, manufacturers typically need two hoppers - one
for the inner filling and the other for the outside portion.
The filling hopper provides product to the inner die
nozzle within the die system. This is done by either using
the feed rollers or a separate pump system. As the filling
emerges out of the die, the outer part of the bar is created
conventionally through feed rolls.
When it comes to snacking, new product innovation
is blurring the lines between cookies and bars. Advances
in new technology, however, now allow manufacturers
to offer consumers a wider variety of options, whether
they're healthy, indulgent or a little bit of both.
When it comes food safety, cookie producers
face challenges on multiple fronts.
In addition to the bacterial concerns,
which are often remedied during the " kill
step " as the products travel through the
baking process, eggs, nuts, milk, wheat
and other significant allergens require
more than a little elbow grease to ensure
the equipment remains clean between
product changeovers.
" With microbes, you typically have an
oven that acts as a kill step that gets rid of
them, " noted Dan Christie, sales manager,
North America, Spooner Vicars Bakery
Systems, a Middleby Bakery company.
" But that doesn't work with an allergen.
The only way you can deal with an allergen
is through removal. A kill step won't
take care of it. That's why you see dedicated
lines when it comes to allergens like
a peanut product. "
It's also why hygienic design is so
critical for cookie and bar manufacturers,
which have seen more than their fair
share of costly recalls involving crosscontamination
and unlabeled allergens
over the years.
" We need to focus on ease of cleaning
for product changeovers and allergen
cleanings, and tackling these issues really
needs to start at a design level, " said Katie
Winkle, sales director, Baker Perkins.
*
TURNING CHICKPEAS INTO
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62 Baking & Snack April 2022 / www.bakingbusiness.com
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Ready-to-eat status
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Baking & Snack - April 2022

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