Baking & Snack - October 2021 - 80

PIZZA & FLATBREAD PROCESSING
Weissbach said, it's critical to avoid dough loops and other
tension on the dough sheet. Rondo's gluten-free pizza lines
start with an independently driven three-roller extruder.
" By precisely setting each roller speed, we can make
the dough compact without creating surface tension or
without having water separation, " he said.
Perhaps the biggest challenges come initially when
ramping up a new BFY flatbread product.
" Those BFY flatbreads are often developed on a
Accurate portioning
controls ingredient
costs while providing
labor savings
and enhancing the
quality of pizza and
flatbreads.
Reiser
point, gluten-free and other better-for-you (BFY) items
have caused processing challenges for years, but now the
industry seems to have a better handle on it.
AMF Tromp offers customized systems for expanding
its gluten-free baked goods lines with various dough
structures, moisture levels and other challenges.
" These kinds of 'new' and healthier doughs are not
standard and are not processed like a traditional dough, "
Mr. Besems said. " Each recipe seems to be unique, and it
is hard to find a standard for producing them. "
Mr. Zeak said BFY doughs contain a variety of ingredients,
including alternative grains, nut flours, cheese
and vegetables that can be more difficult to process due
to the varied consistency of the dough mixture, which
ranges from a fluid, sticky batter to a stiff, viscous dough.
He added custom-engineered processing may include
specialized systems for transferring dough to the divider
and other downstream processes or specific depositing
and forming systems tailored to accommodate a range
of dough consistencies.
For gluten-free dough, Mr. Murphy said the main obstacle
involves stickiness.
" The ability to apply processing aids such as corn
starches or oils is key, " he said. " Transfers during the
process also become a challenge because of the binding
of the doughs and the ability to have a good release during
the process. "
Mr. Moline said gluten-free flatbreads fall under the
broader category of dough that doesn't have any type of
strength and elasticity.
" You have to be extremely gentle with the dough, " he
observed. " You cannot do a lot of work to this dough at
any one time. It's subject to tearing, weight control and a
laundry list of issues that can produce a poor product if
you don't process it in the right way. "
Dough tensioning monitoring systems, he added, minimize
BFY product damage by automatically adjusting the
entire line to tweaks in the process and reducing the need
for additional operators working in the makeup area.
Without binding agents or a gluten network, Mr.
80 Baking & Snack October 2021 / www.bakingbusiness.com
benchtop when a lot of people aren't involved in the process,
so it takes more time to take the product from the
bench to the production line, " said Cesar Zelaya, bakery
sales and technology manager for Handtmann. " As they
increase the nutritional value of the product, you often
don't have all of the ingredients or 'tools' that normally
help when you are automating the process, so you have
to be flexible. You often need to adjust equipment so it
can handle high-hydration dough where the consistency
is more like a batter because there is so much water in it. "
Handtmann offers a series of systems, including its SE
442 cutting unit along with a VF 600B dividing machine
for doughs that may have various consistencies.
With higher absorption rates and increased fermentation
times, Mr. Kelly said softer doughs require gentle
processing.
" One key to dealing with these types of doughs is
eliminating falling heights from each of the reduction
stations, " he said. " A dough sheet proofer can also be
added to increase fermentation time prior to makeup. "
Other challenges include high ingredient and labor
costs and a demand for greater product throughput
rates. Mr. Zeak said accurate portion weight control of
the dough is paramount to prevent costly product giveaway.
Reiser's Vemag provides weight control through its
double-screw portioning technology and process check
feedback systems that regulate the divider.
And to top it off
In the foodservice industry, Panera Bread reported that
sales of its flatbread pizzas have been so brisk since they
were introduced last October that the St. Louis-based
company is reportedly adding new varieties to its menus.
Dave White, chief executive officer, Quantum
Technical Services, pointed out the latest topping trends
include a plethora of plant-based ingredients, frozen
mozzarella balls and a greater variety of cheeses.
Workforce issues, he added, are also driving automation.
" With the effects of COVID and labor shortages,
flatbread and pizza manufacturers are desperate to automate, "
Mr. White explained. " They need specialized
equipment to apply ingredients to their products that
were previously applied by hand. "
Mr. Zeak said the latest meat, dairy and produce top
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