Baking & Snack - August 2022 - 51

our White Bread Done Right and the Good Seed varieties,
there's no white flour in these doughs. "
Final doughs exit the mixer into an AMF chunker.
An overhead dough conveyor keeps the dough moving
quickly to the AMF ram and shear divider. If the dough
sits for too long, it will become too dense to process, so
automation is critical during makeup. Dough pieces are
shaped in an AMF conical rounder before being sent to
one of two conveyors that convey the dough overhead
to two AMF sheeters. The dough pieces are reduced by
a series of rollers and then rolled up again before a pressure
board presses the air out, ensuring a solid grain in
the final product. A Gemini Bakery Equipment seeder
applied the seeds on the outside of The Good Seed variety
being produced during Baking & Snack's visit.
Another pressure board presses the seeds into the dough
pieces before they are panned and sent to the conveyorized
proofer for a 55-minute ride. Lost seeds are reclaimed
and cycled back through the system.
After proofing, the pans travels to the AMF single-lap
oven where a loader bar automatically pushes them into
the oven to bake for 30 minutes. The new oven technology
delivers a more efficient bake that keeps the majority
of the heat inside the oven, leaving those standing nearby
to question if it's actually an oven at all. The traditional
heat expected to come off the oven just isn't there.
As the baked loaves come out of the oven, a Capway
Automation depanner removes and reorients the loaves to
enter the enclosed cooler. The hot pans are taken up to an
overhead conveyor where they are rapidly cooled, keeping
the bakery's environment from getting too hot for people
or product. Afterward, the pans pass through a Henry
Group pan cleaner before being used again.
As bread enters the dual spiral cooler, the dehumidified,
refrigerated air being cycled through the
cooler ensures the bread is cooled to the optimal temwww.bakingbusiness.com
/ August 2022 Baking & Snack 51
perature for slicing and packaging every time.
Once bread leaves the cooler at a relatively cool 100°F,
it's inspected by a Sightline Vision System, which collects
data on width, height and color.
" This helps us maintain our quality standards, " Mr.
Luciano explained.
Fortress Technology metal detection then checks for
any food safety issues.
Within-spec product is then sent to one of four packaging
lines. DKB loaves are sliced and then bagged by
Bettendorf Stanford slicers and baggers. The bags are
sealed with a Kwik Lok clip. The packages are trayed,
then stacked by four Pulver tray stackers.
The entire process takes longer than a more conventional
Nature's Own loaf: 3.5 hours vs. 2 hours. Much of that extra
time comes from the mixing process and cooling, hence
Top: Bread is
automatically loaded
into the indirect
gas-fired, single-lap
oven. The oven's efficiency
has lowered
the bakery's gas
usage.
Bottom: Controls
are critical for DKB
bread as the window
for variability with
these doughs is
tighter than conventional
breads.
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