Baking & Snack - March 2022 - 34

BANNETON BAKERY
A dough sheet is
cut into triangles,
which are then
aligned prior to
curling and bending
before receiving an
egg wash prior to
proofing.
toward the end of the week right before the lines are
thoroughly cleaned and verified as food safe by Neogen
Reveal 3D test kits. As a part of its food safety program,
products are regularly baked off by quality control
specialists.
Currently, the bakery uses bagged flour and other ingredients,
although the company is exploring automatic
material handling systems, including bulk flour silos,
and a possible rail spur for delivery. However, Victor
Litinetsky is searching for a system that can replicate its
current process for storing chilled flour that's brought up
to ambient temperature for mixing. Overall, the bakery
is kept at about 64˚F or cooler to prevent the delicate,
laminated dough from prematurely rising during the
protracted process.
In all, the bakery has about 5 miles of conveyors, including
the production lines that average 200 feet long
along with spiral coolers, freezers and more. The original
facility houses one Canol slab line and two similar
Canol makeup lines that can create different laminated
products. Flour and other ingredients are mixed in three
Mfitaly spiral mixers to create 400- to 800-lb batches of
dough. After resting, the dough is initially sheeted and
laminated with 100% butter; it's then cut into 3-foot
slabs before they're racked and receive extensive fermentation
time in the chilled retarder. Victor Litinetsky
pointed out that it often takes a full day to go from mixing
to packaging.
" We do it like in the olden days - the way it used to
be done to create authentic, artisan-style Danish and
croissants, " he said. " We give the dough the time it needs
to age and temper to provide its flavor and texture. "
After retarding, the dough slabs are manually placed
34 Baking & Snack March 2022 / www.bakingbusiness.com
and partially overlapped on the makeup line to create
the initial sheet, using a series of reduction stations,
flour dusters and a cross roller to achieve the desired
width and thickness.
On one line during Baking & Snack's visit in
December, employees deftly created the bakery's signature
hand-twisted Danish that's swirled into a concentric
circle with a dimple in the center for its customers to
later add a topping of their choice.
The pieces then enter a Tecnopool spiral proofer before
heading to a continuous Tecnopool spiral freezer set
at -20®F for about an hour.
Depending on their sizes, 84 to 200 frozen products
are then counted and receive metal detection before case
packing, checkweighing, tape sealing, palletizing and
storing in the computerized, warehouse freezer.
A bigger, better bakery
The newly expanded facility with 45-foot ceilings houses
two larger, more versatile Rademaker makeup lines that
can turn out 20% to 30% more FTO products, including
filled sweet and savory croissants and other pastries as
well as artisan breads in the near future.
Two Diosna wendel mixers rely on multiple bowls to
create batches that are about twice the size as ones in the
original bakery. After sheeting and applying butter, the
dough is folded over and sealed before passing through
a reduction station toward the first laminator. After folding,
the sheet is flour-dusted and reduced again before
receiving a second lamination at a reduction station
prior to being cut into 20-lb slabs by a guillotine. Mr.
Rittershausen noted the racks of dough are then labeled
for lot tracking prior to retarding.
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Baking & Snack - March 2022

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