bakery march april 2011

5/6/2018 Bakery March April 2011

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BR ING H O M ETHE CREMICAFAVOURITES ...

....and let celebrations begin!

i

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ContentsMarch-April 2011

K eep ing ItF resh : Baggersand C los uresBaggers and closuresystems feature newdesigns that allowsmoother operation,less downtime andquicker changeovers

Baking is bel iev ing!Chef Savio Fernandes,Pastry Chef at JWMarriott showed severalways of how EuropeanPastry when blendedwith Indian Mithai createa fusion

We want to encou rage~nd bu ild entrepreneursIn th e bakery Indu strySarita Nair gets a peek into the new bakery venturefloated by leading industryduo, Vishakha Shroff andPrakash Nair

Quality & SafetyT esting of Food in theBakery Indus tr yA technical insight into theimportance of food safetystandards

R e g u l a r sIndus try UpdateMarke t Repor tBusinessTipsProducts

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Editor and Publisher; Pradeep Gopalan Nambiar" Reporter: Prajakta Patil. Editorial con tributors; Sav io Fernandes, Beena Menon, Charmaine D'Souza,Patricia Trinidade, Daniel Koshy, Kunal Arolkar, Sonjuhi Malhotra, Sarita Nair, Manoj Kumar, Yijaya Kandpal)( Marketing Business Head (West): Chetan Salvi )( Dy.Manager Sales (South): Farzana Gandh i)( Business Head (North): Aashish Kohli)( Manager Sales (North): Rajat Sethi )( Support: Amit Hadshi, Madhav Sherigar

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Show Prev iew 48

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M A tiA RM H TR AA ND E DIT OR P RA D~ EP G OP AL AN . N AM B .IA R .

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T HiS JS SU E O F B AK ER 'iB IZ M A GA ZI NE C ON TA IN '. ; 4 8 + 4 P AC ES ( O VE R. A ll P R.lN TE O M A n n C ON TA JN ED IN T HE M AC AZ IN E A RE . ! lA SE .D O N IN FO RM A T IO N F RO M T HO SE fE AT UR ED I N IT . T HE V IE WS , ~ DE AS , C OM M EN TS E XP RE SS ED A RE S OL EL Y O F T HO SE . F EA ll I " E.D A ND T HE E DJTAN[ l P U B l I S H E F ! [H) N OT N E( E5 SA R~ LY S US SC RIS !: T O T HE S AM E .


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Editor'sNoteMarch-April 20115

Time to stand up and win, overGovernment apathyDear readers,Often heard is the {one voice, that industry issues are hardly addressed or demands adequately represented; but rarely a unifiedone. The bakery industry is a casualty most of the t imes when the Union or State budgets are announced.Baked goods today are a dietary need, no longer a luxury one to be weighed in the same scale asother government-coffer-f il ting sectors. Today, l ifestyle changes are turning yesteryear luxury products into common fare, Seldom does the industry getrecognit ion on its own merit or rel ief by way of taxat ion. Subsidies have always been by defaul t and not by design; sadly though,given the fact that i t isthe largest among food-processing sectors,

With so much positive upheaval and investor interest in the sector, it is only time that the industry stood up to beseen and to be heard. Inflation, excise hike, fuel hike - these are all major impediments to fast-track growth. Butthe bright side is a growing youth population with high disposable income; new and big consumers who wil l keep thegrowth story steady.Multiple trade bodies and a non-cohesive approach make i t equally di fficul t to win favours from pol icy makers.Welt-structured trade bodies like BAKEin Kerala, who besides adopting a self-regulated approach, have been success-ful in lobbying effectively at the State level, Our cover story brings you a bouquet of views on how and why govern-ment apathy needs to be addressed.This besides all our regulars and for an those who could not attend the Live Bakery Theatre demonstrations at theBakery Business2010 Show, we bring you recipes from the leading bakery and pastry chefs.Happy reading!

P ra d ee p Go p a la n , Edi tor

M.;.rrufo1


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P a rle , la rg e s t.b is cu it m a k er ,n ow se ts eyeson sn acks b izThe country's top biscuit makerParLeProducts is restructuringits snacks division to emerge as asignificant pLayerin the Rs4,000-crare market. "Snacks is onesegment where we are trail ingbehind and have not been abLeto make much progress in theLastthree years since we forayedinto the segment," according toa report in The Economic Timesquoting a top off icial.Parle Products, which recentlybeat Britannia to become thecountry's Largest biscuit maker,hopes to become the secondlargest snacks player with a one-fifth share in the market by theend of the year. The Mumbai-based company at present hasonLya 5%share in the snacksmarket, which is dominatedby PepsiCo Frito-Lay, whichhoLdsalmost 60%of the marketshare with brands such as Lay's,Kurkure and Cheetos. Other topplayers in the market include lTC,Haldiram's and Balaji Wafers.Apart from snacks, ParleProducts is also betting on thehealth food segment as the nextgrowth drive r, After the success ofActifit Digestive Marie and ActifitSugarfree Cream Cracker biscuits,the company now plans to rol lout more such products under theActifit sub-brand.

Parle Products dominatesIndia's Rs12,000-crore biscuitmarket with a 45%share andis the country's second largestconfectionery maker afterPerfetti , wi th a 15%share in theRs2,500-crore market.

IndustryUpdateMarch-April 20116

Ju b i la n t Fo o d W o rk s to b rin g u sc ha in Du n k in ' Do n u ts to In d iaJubilant Food Works (JFM), which runs restaurant chainDominos Pizza in India, has signed a master franchiseagreement with USleading baked food and coffee chainDunkin'Donuts to bring the brand to India. As part of theagreement, JFW will set up the first Dunkin'Donuts storeearly next year, although it did not specify the location,and expand gradually in the next couple of years. Thefranchise agreement requires Jubi lant to develop atleast 500 Dunkin'Donuts outlets in a span of 15 years. Theagreement does not cover ice-cream maker Baskin Robbinsowned by Dunkin brands, parent of Dunkin'Donuts.The USrestaurant chain, with sales of $6 bilLion, has over9,700 restaurants globally in 31 countries. Dunkin'Donuts, known primarily as a breakfastchain, has seen the popularity of its coffee soar in the US in recent years, competing withStarbucks and McDonaLd's for consumers seeking a small breakfast before heading to work.Domino's India is the fastest growing company across 60 countries. It is confident ofmaintaining a similar growth tor Dunkin'Donuts. With 364 outlets across 87 cit ies, Jubilanthas been a success in ramping up of the Domino's chain. Jubilant's chief executive AjayKauLsaid, "We are in the process of identifying the location for the Dunkin store ..The storecould be in various formats. However, to begin with, the average store size is likely to be750 x 800sq.ft." JFM plans to open 25-30 Dunkin'Donuts stores in three years.

Nigel Travis, CEO, Dunkin'Donuts, said, "Expansion in India is an integral part of theDunkin's international growth plan," adding the company may also look at localising itsfare. Last month, Starbucks Corporation signed a pact with Tata Coffee Ltd to set up retailstores in the country.

O r an a la u nc he s fo o ds e rv ic e u n d e rO s te rb erg b ra n dOrana India Pvt Ltd . , a SUbsidiary ofGrana Denmark one of the leadtng brandin the fruit based IndustriaL raw materialsis entering into the Food service segmentwith its innovative products for HospitaLityindustry under the brand name OSTERBERGwhich is Orana's gLobally reputed brand forfood service. The products wil l be targetedfor Restaurants, cafes, hotels, ice cream.The product rangeindudes GREENICETEA SYRUPS:These are ready to use afterdi lution with water with a goodness ofFruits and green tea. CARBONATESYRUPS:Similar to Ice Tea these can be diluted withCarbonated water to make a carbonate drinkwith a real fruit in it .Apart from regularfruits Company wiU have innovative productsLikeBLackCurrant and green AppLe. FRUITCRUSHES:In this category company will haveinnovative fruits l ike Musk melon, GreenAppLe, Forest Fruit which can go in beverageand Topping application. FRUITFILLINGS:Fruit Fil lings wil l be Launchedin flavours ofBLueberry, strawberry, raspberry, dark cherryand Red Cherry. Fruit fi ll ings can be used asFil ling aswell astopping both for bakery andice cream appLication and are bake stable.Al l the products are manufactured in theworLd class facil ily of Oranawith highestquaLity of fruits. The company expects with

launch of all these innovative products theIndian consumer wil l have excess to highestquality products in the hospitali ty sector.

Iransworld and PCBjo in ha n ds in the ln d i.a nma rk e tTransworLd sets a new milestone. TransworLdand PCBjoin hands in the Indian market,TWE has been appointed as an exclusivedistributor for PCB,Transworld now bringsthe amazing worLd of PCBernbossingaprinting for your Chocolate, Sugar 8;Marshmallow.PCBthrough this tie-up wil l bring theircomplete range of r eady rnade decorations,eye-catching reLief for your chocolates,crumpled look to give a new look, thousandand one transfers to decorate your icecream and mousse. One can mix things upwith different looks and ingredients to offera range of decorations that wi ll steal yourcustomer's heart.In a year, PCBreleases 2 cataLogues-one for spring and one for autumn ~givingrefreshing ideas every 6 months.

Also availabLe, are superblyfinished two and threedimensionaL products .....Lollipops, mini CDs,dolls,eggs, jigsaw puzzles, cards.They provide an amazing ransworl


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B cuit, Bread,Ba ery Product&New nvestorMa n u f o c t u r e r s & E x p or te rs o f:

F ul ly A u to m a ti c T ra v e l l in g D ie s e l/ G a s /E le c tr i c B is c ui t b a k in g l in e ,B re a d B a k in g

L in e , B a k e ry P l a nt / M a c h in e ry . R ota ry R a c kO v e n, P a c k a g in g M a c h in e ry fo r R us t ( T oa st )

& B is c uit r a ng in g f r o m 5 0 g m s to 2 00g m s , 2 & 4 B is c u it s , F FS M a c h in e fo r L iq u id ,

P ow d e r, G ra nu le s , P a s te , T a b l e ts e tc . A ls o w es up ply a ll k in d s o f w r a pp in g m a te ria l/ fi lm s

in R o ll & P a u nc h f o rm s fo r B is c u it s , I h e l o -( a te , D e te rg e n t, S oa p. W e t a k e c om p le teB i s c u i t & B re od l in e o n tu rn k e y b a s i s a nde v e n p ro v id e m on p o w e r & T e c h n im l s u pp o rt. f o r c h e m ic a l s / In g r e d i e n ts .

FM U M B A . I K a n!H a B u s in e s s C e nt r e , B W in g , 2 n d F lo or 2 13 , l a x m l N a g a r, G h a tk o pa r ( Eo s l ) ,H E A D M u m b a i - 4 00 0 7 5 ( M oh a ra s h tr a ) IN D IA T e le p ho ne : 9 1 -2 2 -2 5 00 7 86 0 /6 7 8 6D . F F I C E F ox : 9 1- 2 2 -2 50 0 76 9 6 M o b il e : 9 1- 9 82 07 86 81 9 E -m a i l : a d m i r i n d i a @ v s n l . n e tW e b s i te : w w w . o li fo v e n s .( om / w w w . i n d i a n b i s c u i t p l a n t . c o m

C O R R E S P O N I J E N , ( E A D D R E S S1 /1 F /1 3 /2 , K or a m A li K o p u r v a ,C i v i l lane, N e ar H ow a i K a lh i & D MR e sid e nc e , F a iz a b a d (U .P ) .2 2 4 0 01
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T o p c a k ed e s i g n e r sb a t t l e f o r " b e s tc a k e a r t i s t i na m e r i c a " t i t l e

As the countdownto the RoyaLWeddingcontinues, FoodNetwork puts theicing on the cakewith the seasontwo premiereof Last Cake

Standing. The six-week seriesplaces eight of America's toppastry chefs in intense challengeswith crazy twists as they vie forthe title of "Best Cake Artistin America" and an incredibLe$100,000 grand prize. JustinWillman (Cupcake Wars) serves ashost, with the judging panel led bynotable faces of the ever-popularFood Network Challenge: renownedpastry chef and Denver-basedowner of DBar Desser ts, KeeganGerhard, along with celebratedcake designer and master sugarartist, Kerry Vincent.

These competitors have no"sweet escape" as they faceextreme and grueling challenges.From designing over-the-topmonster cakes, to ones that "singand dance"for a talent show,to those inspired by Marvel'sclassic comic book series, "TheFantastic Four," and SinCity-inspired illusion cakes, thesecompetitors are pushed to theirartistic limits. The competitionheats up midway through theseason as the competi tors enduregame-changing twists including ascavenger hunt around Las Vegas,a round of blackjack and addi tionalsurprise cake chall .enges. Just asthe competitors think they havecompleted their final task, onemore awaits: design a cake thattells the story of their $100,000dream. At the end of this marathoncompeti tion, one cake designer winsthe grand prize and the braggingrights of the Last Cake Standing.


8Pa r l e -G s t i l l r u le s the w o r ld , s a y s aN ie ls e n s tu d yParle -G with its taste and quality has been popular forgenerations of Indian. Parle-G, the glucose biscuit brandfrom Parle Products, has consolidated its position as theworld's largest selling biscuit brand, says a report byNielsen.The study, for last year, says Parle-G has topped brands

l ike Kraft 's Oreo, Wal-Mart's private labels and Mexico'sGamesa in volume sales to lead the 11,2.95-crore Indianbiscuits category. The Nielsen study adds India is theworld's leading market for biscuits, ahead of the US,Mexico, China, Argentina, France, Italy, Germany, Turkeyand Spain.

array of gifts for your customers. Tocomplete innovation in the pastry world,they also have their high quality Velvetsprays, Colours, Gold & Silver Leaves,Isomalt, Sprinkles etc.

Looking for something out of theordinary for your desserts? Something toimpress your guests? look no more It'sright there at TWE.

C ad bu ry s to Lau nch O reoin In d ia b y A p r il E n dAfter much of anticipation from Kraftto launch Oreo in India finally Cadburynow under Krafts food division here inIndia would launch world famous Oreobiscuits. As were the flurry of activitieswere enough for people in the market toguess about the launch and recent beingthe law suit by Kraft against local giantBritannia. As reported in news Cadburywould be launching Oreos by April endand would manufacture the biscuit herelocally. Mrs Bector's Food Speciali ties willsupply locally made Oreos to Cadbury thusbringing down cost of Oreos (HT). IndianBiscuit industry would not be the sameif Krafts goes fa r aggressive launch andmarketing. Competition would be fromlocal Big 3 Britannia, Parle and ITC and

new rnnc's entrants like United Biscuits,Pepsi and Unibic. Recent launch of Treat-0 from Britannia and Dark Fantasy fromIT C can be seen as competition in thissegment .Britannia would be impactedmost as the leader in premium segment ofbiscuits with brands such as Pure magic andCream Treats . Oreo has already takenover Chinese biscuit market being leader inthis category. Imported Oreos was alreadyavailable in select stores across India, atprice tag of Rs 50/- for 14 biscuits. It plansto take on low cost strategy to competewith local brands from Rs 5/ for 3, Rs 7/-for 10 and Rs 20/- for 14 biscuit thus relyingon volumes to make margins (TOI).

It's also big news for biscuit rawmaterial , equipment , packaging suppliersand advertisers. A report in Deccan HeraldConfectionery maker Cadbury India todayannounced its entry into the country'sestimated Rs 12,000 core biscuit marketthrough the launch of 'Oreo' brand from theglobal portfolio of its parent Kraft Foods."The introduction (of Oreo) marks the entryinto a new category in India, with the aimto make the world's favourite biscuit Oreoone of India's favourite biscuits," Cadbury ,India said in a statement. Oreo is around100 years old brand and currently generatesrevenue of USD 1 bil lion globally. In India,the company will be launching the biscuit indark chocolate flavour."Introducing Oreo marks the beginningof our journey in this growing category andwe are readying ourselves to make Oreo apreferred choice with Indian consumers, HKraft Foods President South Asia and Indo-China and Cadbury India Managing DirectorAnand Kripalu said. (source: Deccanherald.com). Cadburys major products havebeen 5 star, Bournvita , Perks, Dairy MilkChocolates with only products from Kraftsfood portfolio being Tang .It would be firsttime that Cad bury India forays into biscuitsegment .Cadb ury wou ld promote Oreo as itsbrand here in India.


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"Partners in excel lence"

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B r i t a n n i . aI n d u s t r i e s Q 3n e t p r o f i t u pIndian food manufacturerBritannia Industries has said it hasmaintained its growth trajectoryin an "intensely competitivemarket", as it recorded a 24%increase in thi rd-quarter prof its.The biscuit and cereal

manufacturer said yesterday (9February) that net profit reachedINR373m, up 23.8% on the year,which it attributed to improvedefficiency and sales.

Operating profit increased 46%to INR475m. Net sales rose 22.5%to INR10.Bbn.

"The company has maintainedits growth trajectory in anintensely competitive market andcontinued to drive innovat ionin the industry," said managingdirector Vinita Bali.

"Britannia cont inues to focuson cost reduction and drivingconsumer up-take to generateprofi table growth."


10Da rk Fa n ta s y fr o m Ir eSunfeast brand of biscuit from ITChas recently launched itspremium cream biscuit"Dark Fantasy" with chocolate andvanilla flavours .. Its cream biscuit for premium segment ofbiscuits priced Rs20f - for 104 g. ITC have launched DarkFantasy biscuit to compete with Britannia s Pure magicand Paries Hide n Seeks premium biscuits. ITC has nowrepresentation in all major categories of biscuits fromglucose, marie ,nice, cream, bourbon and salty.

IP a rle to L au n c h C r eamC r a c ke r V a r ia n tBiscuits andconfectionery majorParle Products isall set to launcha 'cream cracker'variant next month inthe country's easternzone.

This was informed today by companyGroup Product Manager B Krishna Rao afterthe launch of the tenth edition of 'ParleSaraswati Vandana.' under the initiatives of'Parle Center of Excellence' here.Mr Rao said the company had come

up with such product in the western andsouthern regions in India, adding the samewould be launched in the north and the eastin a month's time.

"We are expecting the cream cracker tograb a decent market share. Such biscuits,being digestive, are replete with healthvalues. Currently the company has a marketshare of seven-eight per cent under its'health' port folio Actifit ," Mr Rao added.

Informing that around 70 per cent of thecompany's products were made throughcontract manufacturing, the Group ProductManager said the company eyed a growth of15 per cent this fiscal in its business.

ib a 20]2: fe a tu re s highp ro file s umm it m e etin giba 2012 wil l beginwith the new ibasummit. One daybefo re the tradefai r starts, theinternational summitmeeting for bakersand pastry chefs wi IItake place for the first

time. The key focus will be a dialogue onthe current toptcs within the sector,

iba 2012 will begin with the new ibasummit. On 15 September 2012, oneday before the trade fair starts, theinternational summit meeting for bakers

and pastry chefs will take place for thefirst time. The key focus will be a dialogueon the current topics within the sector.Experts from all over the globe will presenttheir take on current industry questions.For example, the Vice-President ofWelthungerhilfe and former Head of the UNEnvironment Programme (UNEP), Prof. KlausTiipfer, will present a speech on the futureof world nutrition. Further topics addressedduring the talks will be consumer trends,innovative business models and marketingstrategies.

iba is a brand that stands for successand provides the sector with a tremendousboost. In 2012 this will be fur ther enhancedby the iba summit, which witl provide anew strong component for the supportingprogramme ..The meeting has been designedby professionals for professionals. As such,the iba summit offers a unique opportunityto gather information. Furthermore, inbetween sessions, it witl encourage a tivelyexchange of ideas between colleaguesfrom around the world. To t his end, Iwould be very happy if many exhibitorstake advantage of this unique contactplatform with their customers, said PeterBecker, President of the German Bakers'Confederation (ZV)and the InternationalUnion of Bakers (UIB).

Simultaneous interpret ing will beprovided for the entire iba summit, whichis organised by the German Bakers'Confederation. The conference languageswill be German and English. The advancebooking of summit t ickets is alreadyunderway. The event will commence atthe International Congress Centre (ICM)in Munich. At the end of the summit,all par ticipants are invited to attendthe opening evening. Further detailsand registration forms are available viatelephone on +49 (89) 949 55-152; via faxon +49 (89) 949 55-159 or via email at [email protected].

(The above industry news has beencollated from various industry magazines,newspapers & : websites. Hospitality First doesn ot ta ke a ny re sp on sib ility fo r th e a cc ura cy o fthe information provided.)


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. .A l l M A C H I N E S A V A I L A B l E t N ,r x F FERENTS i f S s' C A l P N l T I E S W I T H

lN T E R N A lI lN A L S T I I I N D O OH l b H Q U A L l T ' r ' O U T P l f f

E A S Y O P E R A l l DL E A S T M A l N T E N A N C E

1 1 . 0 \ ' 1 E U E D m C A L I A l E L C O N S U M P T I O N


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MarketReportMarch-April 2011

12G lo b a l lB a k e ry P ro d u c ts M ,a rk e t toRe a c h US$41 0 B i l l io n b y 20 1 5the.global baking industry is currently facing opportu-nit ies aswell aschallenges created by the economiccrisis. The sti ll volatile f inancial scenario is chang-ing the way bakers approach their businesses. Onthe consumption front, simi lar to the US,the bakeryindustry in Europe is witnessing a decline in traditional bakeryproducts. However, the decrease in demand is being offset byrising purchase of bite-sized sweet goods, on-the-go breads,between-meal snacks, easy-to-carry sandwiches and suchother products. There is an increase in the number of on-the-

go bakery product int roductions and new f lavors to meet therequirements of the extremely mobile population of today.With consumer preferences undergoing tremendouschanges, bakers are literally on their toes suiting the productrollouts to the dynamic consumer preferences. Meeting thedemands of the fast paced consumer lifestyles are single-serve, small-size bakery products, leading to an increasing de-mand for breads and rolls, donuts and pastries. There has alsobeen a noticeable shift towards natural and healthy bakeryproducts comprising of vitamins, whole grains and fibers. Bak-ers introduced organic baked goods, breakfast cereals, breadsand biscuits, enriched with nutritional and natural ingredientsin single-serve and portable packaging ..Private label productsgained considerable importance in retailing strategy of savorysnacks, in spite of the disadvantage of ownership and man-agement of inventory. In recent years, however, the bakeryindustry has been plagued with high costs of production andincrease in raw material costs in real terms in many markets.Intense price pressure is another feature of the bakery prod-ucts marketplace in many developed markets of the world.

looking for low prices that would alIow them to stretc h theirf inances The recession resulted in price increase of bakeryraw materials in the last few years. This coupled with rise inenergy costs, resulted in the subsequent increase of bak-ery product prices. The market for bread and other bakeryproducts suffered marginal decline during 2008. On the otherhand, recession brought forth opportunities for cereals.Consumers looking for best value preferred the more reason-ably priced breakfast cereal to other morning goods. Severalbakers adopted a more careful approach during the recession-ary period in terms of product innovations, asconsumers werehesitant about spending money on new, unknown and untriedproducts.Several companies eliminated preservatives and artificialflavors in their products in a bid towards image changeover asmakers of healthier and natural bakery products. About 35%ofthe global cereal product launches in the year 2009 claimedto be funct ional cereals with health benefi ts. The market forbreakfast products in the UKsailed past the recession withease, and the country wi tnessed an increase in the number ofbakery businessesduring the period. Baking industry in the USremained moderately unaffected by the economic crisis. Bakers did however, experience decline in sales in private labels,particularly for products that were not promoted.Europe, driven by Germany, France, Italy, Spain, Finlandand Sweden among others constitutes the largest regionalmarket worldwide, asstated by the new market research reoport on Bakery Products. The United States and Latin Americatrai l behind as the next important market in terms of overallsize. However, with respect to long term growth potential, the

A sia-P acific m arket is projected to take the lead , ex pand ing at the hig hest C A G R of more than 5.0%through 2015. T he segm ent B read /R olls represents the larg est and mo st popular bakery prod uct.Product appearance significantly influences impulsepurchases of bakery items, and therefore constitutes animportant consideration in the purchase of bakery products.Next to appearance is the aroma and price. Attractive displaysplaya vital role in making a purchase decision. Pre baked andfreshly delivered products are among the fastest growing seg-

ments, while frozen dough and scratch mix products exhibitslow growth. On the regional f ront , the bakery industry in theUSunderwent significant changes owing to steady changesin consumer trends, which primarily leaned towards health,convenience and indulgence. Bakers were able to leveragethese pockets of growth by capital izing on the indulgencetrend of consumers through SUitable product innovations thatfocused on health and included functional variants. In-storebakeries are increasingly gaining significance in the bakeryproducts market, especially in the sale of fresh, unwrappedbakery items. This trend is obvtous in the continued expan-sion of major food retail ing chains suchasTescoin the UK,and Carrefour in France. In developed countries the increaseddemand for functional. foods has prompted companies todevelop value-added baked goods. The global market forbakery products is being increasingly consolidated throughthe penetration of major multinational food companies ..Asaresult, international brands like Oreos of Nabisco are expectedto explore into hitherto unexplored territories.With the tumbling of the global economy in the year 2009,an increasing number of consumers are pinching pennies and

Asia~Pacific market is projected to take the lead, expandingat the highest CAGRof more than 5.0%through l015. Thesegment Bread/Rolls represents the largest and most popularbakery product, while the Morning Goods segment is l ikely toemerge asthe fastest growing market over the assessmentperiod 20072015.Key market participants in the report include BahlsenGmbH 8: Co. KG, BAB,Inc, Britannia Industries Ltd, Bruegger'sEnterprises, Inc, Einstein Noah Restaurant Group Inc, GeorgeWeston Foods Ltd, Grupo Bimbo, S.A.B. de C.V, HostessBrands, Inc, Kellogg Company, McDonald's Corporation, NestleChile, Riviana Foods Inc, Sara Lee Corporation, Strauss GroupLtd, The Great Canadian Bagel Ltd, Parle Products Pvt. Ltd,United Biscuits and Yamazaki Baking Co., Ltd.The research report t it led "Bakery Products: A GlobalStrategic BusinessReport" announced by Global Industry Ana~lysts, Inc., provides comprehensive industry overview, markettrends, product overview, product innovations, recent industryactivity and profi les of market players worldwide. Analysis andoverview is provided for major geographic markets such as US,Canada, Japan, Europe,.Asta-Pact f tc , Latin America and RestofWorld. Market anaiytics are provided in terms of value (USS)for product segments including Bread/Rolls, Morning Goods,Cakes/Pastries, Savory Biscuits, Sweet Biscuits and OtherBakery Products. The study also provides historic data for aninsight into market evolution over the period 2000through2006.


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14/52

BusinessTipsMarch-April 2011

lfl

How to Start a BakeryS ta rtin g a bake ry may p ro ve to b e h ig hl y s atis fy in g b ut is ce rta in ly n o ca kewa lk

Never mind the size of your bakery, your decor shouldbe pleasing to the eye. The l ighting and array of yourproducts should be just right to capture interes t ..Beforepurchasing any equipment consult a professional to makesure that they're in good working condition. As far asadvertising is concerned, begin before you set up shop.Send out pamphlets and feelers to homes in the locality.Once you're all set and raring to go you can also put inan advertisement in the local newspaper.

The next important decision is pricing. Don't pr iceyour products too low because you have to leave asufficient margin for profits. Keep a daily account ofexpenses. Try to narrow down your suppliers to thosewho offer the best rates while maintaining an acceptablequality standard. Needless to mention, always buy inbulk for better rates .The most valuable resource no matter what your

scale of operations is manpower. Employees can makeor break your business. Take pains while recruiting andtrain them well. Take inventory at regular intervals andmaintain records of supplies and spillage. Maintain aproper system for keeping accounts of cash inflows andoutf lows, util ization of provisions and getting rid of stalestocks.

Starting a home bakery is relat ively less complicated.The equipment you need is less sophisticated and youcan cater to a number of retailers. Though you need alicense to operate, with the co-operation of purchasersyou can wait until you recover a few of your costs to getone.

While operati ng a bakery you need to keep controlover your costs. Watch every penny. Make sure everycustomer leaves happy. This is the perfect recipe for abooming bakery business ..

y ou need to have the basic know-howand expertise to run a thriving bakerybusiness. Besides, a lot depends on thescale of operations. Youcan operateon a large scale, medium scale or just

stick to being a small homespun unit. But you need tounderstand the nuances of star ting and running a bakerybecause the dynamics differ from other businesses.To run a successful bakery, you'll have to don

two hats: that of an outstanding baker and a shrewdbusinessman. Besides you need to have basic knowledgeof accounting, human resources and management. Thisis because bakeries are involved in both retailing andmanufactu ring operations. You may decide to altogetherset-up a new bakery, begin one in-house or purchasean existing one. In all three cases you'll have to do asWOT (strengths, weaknesses, opportuni ties and threats)analysis. Don't go at it alone. You'll have to take legalopinion. Also consult an accountant to make a study ofes timated costs and future earni ngs. Work out at whatpoint you'll break even and when you can expect profits .The most vital thing to consider while starting a

bakery is the location. Ensure that the location has awide potential customer base. Around 1000-2000 familiesshould serve your purpose. Also, you need to size up yourcompeti tion. Find out how many established bakeriesare already operating in the vicinity. This should tell youwhether it's viable to begin another bakery in the area.While deciding on a location, also figure out if there areschools, colleges or movie theatres in close proximity.Competi tion is not necessari ly a bad thing. Competit ionmay also unintentional ly end up sending business yourway. I t's all about how you use your marketing strategyto turn your competit ion into an advantage.


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CoverstoryMarch April 2011

16

FM 's e xc is e p re he a ttu rn s o ff b a k e rsB ak e r y in d u s t r y , t h e la r g e st a m o n g f o o d p r o c e ss in g s e c t o rs c o n t in u e s t o g e t a r a w d e a l . M a n o j K um a r a n d V ija y a

K a n dp a l s t r i v e s to u n de rs t a nd w h y s u ch g o ve rn m e n t a p a t h y t o a n in du s t r y w it h s ig n if i c a n t c o n t r ib u tio n

Union Budget proposals, announced byfinance minister Pranab Mukehrjee inFebruary, wi ll adversely impact thebakery i.ndustry. The increa.se in exciseduty from 8%to 10%will make productssuch as biscuits, cakes, and pastriescostlier the next financial year. This wilt. put a spoke indemand from consumers, thereby af fecting the earnings

of bakers."The Budget has nothing much to offer. Prices for rawmaterials have gone up because of inflation. Prices ofbread will go high, which will affect the industry as it isthe most consumed bakery product, " Raghuram, directorat bakery equipment maker CSAerotherm, echoes theconcerns of the industry.In its pre-Budget wish list, India's apex body ofindustry ASSOCHAMhad recommended that bakery andconfectionery items must be exempted from centralexcise duty. This move will save the industry from

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17/52

Coverstory

1 7 :maintenance of cumbersome records and proceduralformalities under the Central Excise laws. Anexemption can be given based on turnover as is givento small -scale units under Central excise laws which,at present, is Rs 1.50 crore per annum, the tradelobby had suggested. But the finance minister did notheed to the most pressing issues of the industry whilehe put together the country's Budget for the financialyear 2011-12.

Bakery industry, which has been severely impactedby rising fuel prices besides foodinf1ation, was infact expecting relief in many areas from the financeminister. "I expected the Budget would have reducedexcise duty on bakery products," says Raghuram."Inflation has raisedthe p ri ces of thebakery products andtax has aggravated

the problem,"concurs Mirza Ali whoruns Sarvi Bakers inHyderabad.Not many in theindustry expected theBudget to be so harsh."I expected tax cuts inthe imported and alsoin the domestic bakeryproducts. We alsoexpected the Budgetto lower the taxes onbakery products andkey ingredients likeoil , sugar and flour.

Tax is a bi g burden," Mi rza Ali voices the wishes ofthousands of small -scale bakers across India. "We alsowanted the budget to include stability in the marketand pricing," he adds.

The worst signal for the bakery industry came inthe form of an increase in the prices of petrol anddiesel. This would definitely make transportation ofraw material as well as finished good cost more tothe manufacturers. "The problem with the bakeryindustry is that there are no concessions given to theindustry on the raw material. For instance, wheatis a raw material for maida which in turn is a keyingredient for bakery products," N Krishnamoorthi ,general manager at raw mater ial maker Ruchi SoyaIndustries, told Bakery Biz.

Excise duty- an industry dampnerOverall, the Budget tends to do a balancing actbetween li ft ing economic growth and containingfiscal deficit. "Bakers are not encouraged by thegovernment. There is 16%tax on cakes in spite of itshigh supply and demand level. The government shouldlook at it practically. The industry makes Rs200-300crore a year. There should be reasonable taxation onbakery products," Krishnamoorthi adds.As cakes, pastries and confectionery items arenow excisable; consumers will need to spend more forthese i tems ..However, by rationalising tax structure,the finance minister has given some tax relief to thesalaried people who mostly belong to the middleclass. Income tax exemption for salaried class hasgiven some relief to them, who have been reelingunder high prices of food prices, because they will

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CoverstoryMarch April 2011.18

have more disposable income. This may spur demandfor bakery goods. "The fineprint of the Budget has apositive aspect for the bakery industry. It is tilted towardssparking off demand for bakery products from the middleclass as well as rural population," said a baker who didnot wish to be ident ified.Budget 2011 wi II severely dent the prospects ofauxi liary industries also, which has already been reelingunder inflationary pressure on raw materials.Packaging sector , which is a crucial ally of thebakery industry, for example, will also be hithard, except for corrugated boxes and cartonsmanufactured by stand-alone manufacturers whichhave been given a relief of 4%on excise duty.In the Budget, hefty allocations are madeto NREGAprogramme, which will give a fillipto the rural economy. Bakers can now push theirproducts to the rural . market . Increased outlays

pulses, palm oil, vegetable, bajra, jowar, ragt and othermillets, which would help increase domestic supply.Going forward, what needs to be done to achievethe goals of the industry, individual ly and collectively?Industry veterans have many suggestions. Many feel tradeassociations can do a lot . "State-level associations canplaya major role in getting a deserved recognition atstate level. To give an example, associations in Keralaplayed a key role in bringing down taxeson the bakery products from 12%to 4%,"says Krishnamoorthi. The bakers in Kerala

approached the 140 state legislators and sentthem letters elaborating the contr ibution ofthe bakery industry to Kerala's economy andrequested them to lower the taxes.But, does the government listen toassociations or are they ineffective in makingsolid representat ions, like other industries

" 1 would like to sug g est that reserv ation for the sm all- scale ind ustries should be rem ov ed so thatbig ger com panies should step in to contribute m ore to the bakery ind ustry. fIon rural development and increase in MGNREGAsalary tothe rural workers will result in more money in the handsof rural populace ..This would definitely increase saleof bakery products in these areas. This is the Budget'ssole positive implication for the bakery industry, says aneconomist at a domestic brokerage.Fighting a Iione battleThe bakery industry of India is a varied cluster ofmanufacturers. While the brute major ity of them belongto the unorganised sector, a small but burgeoning numberof them are corporate entities evolving into behemoths.It remains to be seen what these big manufacturers willdoin order to offset the pressure put on them by Budget2.011. The reduction in surcharge on taxes to 5 % from 7.5% would help corporates while there is a slight increasein minimum alternate tax (MAT) from 18%to 18..5%. "Iwould like to suggest that reservation for the small-scaleindustries should be removed so that bigger companies

such as, for instance, liquor or telecom? "Somet imesthey do. 1 think in order to make the industry prominentthere should be more of exposure given to the industry.Food parks must be established for the bakery industryto derive more benefits," says Raghuram. Many in theunorganised sector, however, are weary how seriouslygovernments take associations' demands. "I don't knowmuch about the associations but even without themgovernment should listen to the expectations of thebakers," saysMirza Al i. However, Krishnamoorthi believesthat the government will only help if they see a companygenerating revenue .. "Revenue comes from the tax paid onraw materials. The moment raw materials come from thebakery industry it will surely help the industry to generatemore revenue," he substantiates.Raghuram supports this view. He bel ieves thegovernment must reduce taxes on raw mater ials. "Thereshould be tax exemption on raw materials of bakeryproducts," he asserts. Mirza Ali, on his par t, favours some

"G ov ernm ent should prov id e incentiv es to the bakery ind ustry. T here should be concessions oninv estm ent loans. T here should be slab-based tax ation system that d iv id es a big bakerycom pany from the sm aller ones. IIshould step in to contribute more to the bakeryindustry," Raghuram argues.But this view is not subscribed by the smallmanufacturers who crowd the country's bakeryspace. "Government should provide incentivesto the bakery industry. There should beconcessions on investment loans. There shouldbe slab- based taxation system that divides a bigbakery company from the smaller ones. Thereshould not be uniformed taxation system," saysKrishnamoorthi.In the run-up to the Budget, the bakery industry wasrooting for reduction of cost for raw mater ials, packagingcost, fuel cost, corporate tax, and excise duty as wellas relaxation in labour laws .. I n the Budget, there aretax rebates and incentives for cold chains and storagefor food processing industry. There is an allocation ofcumulative Rs 1,2.00 crore to help higher production of

subsidy on the raw mater ial of bakery products,and adds, "There should be relief throughstability in the pricing of the raw mater ials."

The bakery industry in general feels that thegovernment does not give it the recognition itdeserves since it gets clubbed under the foodprocessing sectors. " I don' t think bakers aregetting due recognit ion. The number of foodprocessing units hasi ncreased but that isn'tenough. Bakery industry has been revolutionisedwith the concept of fresh baked products and if thegovernment isn't interested in an industry like this, it is apity," saysMirza Ali.The bakery industry is optimistic that the governmentwill take a lenient view towards its worries given theimportance of bakery products for the common man andits scope for employment creation at the unorganisedsector.


19/52

o E NG IN EE RIN G IN D US TR IE S)0 India1s irst II R ck Owrt in 1986.,. Fmm Taj & Ambassadc Fright Kitdhens to Ml]nginIs tD hundreds,ofqualitv eenseleus bake' s a over ~ndJa,,. Cannon Ovens are the secret to efficient and qualitv ba'k1ing

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20/52

InterviewMarch-April 2011

20We w a n t to e n c o u ra g e a n d b u i ld '

entrepreneurs in the b a k e ry in d u s t r yWhen a h igh ly te ch nical ba ke ry e xp ert an d aseasoned marketing p rofess iona l team up , anindus tr y devo id o f te chn ical and ma rketing exper tis eis b ou nd to ga in . S arita Nair m eets well kn ownin du stry d uo , V i sh ak ha Sh ro ff a b ak ery in du stryve te ran and Prakash Na ir, a seasoned marketingp ro fession al to ge t a p eek in to th eir n ew v entu re.Besides p l ugg ing th is essen tia l ma rket vo id , th e duoa ims to fa cil ita te e ntry o f n ew in ve sto rs wh il e h elp in gbu il d s ca le and qua lity s tandards among ex is tingp la ye rs a nd more

Let me b eg in w ith th e mo st ob viou sq uestio n, w hy d id yo u de cid e tom ove on? W h at w as th e driver beh inds ta rt in g some th in g on you r own?Monginis has taught me many invaluablelessons and I have thoroughly enjoyedmy tenure of four years there. However,I have nurtured within me, for manyyears now, the dream to do somethingon my own for the bakery industry.The time is right and the marketready and waiting to be explored.The consumer today is more informedand aware of the tastes and sensesof their requirement. The Indianmarket is openi ng up to the ba k eryindustry. You would find a lot of positivedevelopments in the industry like newentrants who are carving a niche ratherthan the traditional bakery business, investors willing toput in their money in the latest global technology, youngIndians who want to do something different in the marketetc ..And this is when I t hought why not do something tosuppor t and encourage them, why not build entrepreneurs.That is how my partner, Mrs. Vishakha Shroff and I t houghtof this business venture. She brings in the technical know-how, having spent around twenty five years as the technicalexpert with Monginis and I bring to the table my experiencein sales and marketing in this industry.

comb in ati on o f t ec hnol ogy andmarketing.Ms. Shroff (Smiles): They call it the"Lethal Combination"!Mr_Nair: We both have a similar vision

and that makes working together exciting.What is th e business m odel th at you areworking on?Mr. Nair: We are working on a 3 tiermodel. The first module we are lookingat revolves around live bakeries whichwould be around 300-350sq ft in space.It incorporates everything involved frombaking to the finishing. The technologyused has a multi-utility unit and willgive owners the power to control theproduction within their premises. Theproducts can be replenished at the

location depending on the demand.The second module involves a larger space of 3000-5000sq

ft. This set up is equipped to meet the demands of 15-Z0smaller bakeries in the vicinity.The third module involves manufacturing units which are

much larger and would be able to cater to the demands ofaround 100-200 retail outlets.

Our brand of products will be manufactured, sold andpromoted in above outlets.

M.s. Shroff: We are also exploring product specific importsand some of the units may cater to this type of productdemand.e w ere th en j oine d b y th e l ady h erse lf, M rs. V ish ak h aShroff.

Ms. Shroff, how does it feel to do something on your ownafter giving so many years to an organization?

'Freedom' is the first word that comes to my mind.Freedom to do what I w ant, the way Iwant to! Isn't that thebeauty of having your own busmess? I c an't wait to share allI have been fortunate to learn in my career with anyone whois willing to learn and do something chaUenging. Maybe fiveyears back Iwould have hesttated to do this. But today, I f eelthe ttme is right .

What ch ang es do you h ope to bring to th e bak ery industrythrough your ini ti at ive?Mr. Nair: Along with encouraging entrepreneurs to set up

new Greenfield projects, we are also looking at revampingthe unorganized bakeries. There are many standalonebakeries in major cities as well as Tier-II cities like Nagpur ,Vapi, and Kolhapur etc which churn out amazing productsand have a huge foHowing in their domain. The Willingnessto learn and upgrade themselves is worth admiring in thesefolks. All they need is a l.ittle support, guidance and someupdatton on the latest trends in bakery, increasing shelfou both seem to be th e perfect team , just th e rig ht


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InterviewMarch-April 201121

life etc. We hope to give them the required support intheir business through consultation by sharing with themknowledge that we have gathered over the years.Ms. Shroff: One needs to have an eye for spot ting talentand nurtur ing it. I remember many years ago there was aroadside vendor in Mumbai who gave these interesting shapesto his sugar candy and thus, attracted a lot of customers. . Iapproached him and asked him if he would be interested inworking for the company. He was a wonderful asset becausehe would create these lovely figures out of sugar and ourcakes would have anything from handmade Easter bunniesto football players. He was very good with his hands. Onecan never underestimate the source of talent. This iswhatwe would like to be involved in. Support anyone who has adream to grow in this industry and nurture them.Y ou did m ention about sh aring your k nowledge and talent,how do you plan to go about that other than th rough thebusiness?Mr. Nair: Skilled manpower in this industry is hard to find.We look forward to star t a baking school in Mumbai andthen grow to few other cities where one can learn the skillsof baking as a fresher or those already in the business canchoose to update themselves with the latest both in termsof product and technology. The staff of a bakery would beexposed and trained in production as well as marketingand also with the soft skills required in this kind of industrywhere the business is completely customer driven.

W hen do you intend to roll out the m odules and th e sch ool?Mr. Nair: The first module will be rolled out by the end ofMarch with our first set-up in Navi Mumbai. We shall makea formal announcement of the brand and inaugurationsoon.Ms. Shroff: We hope to put the baking school in placebefore the end of the next quarter .W h at k ind of response are you receiving from yourcolleagues in th e industry? .Ms. Shrof f: We are quite overwhelmed with the responsewe have been receiving from all around. Everyday we areapproached by people with the zeal to do more. There areexisting bakers who would l ike to revamp their set-up; thereare businessmen who want to invest in our new modules. Wehave companies approaching us to use their products andbakery equipment for our bakery school . Then there are whowish to contribute something back to the industry by sharingtheir knowledge and experience at the school. The vibes areindeed very positive.Mr.Nair: The industry is ready for a change and we arehappy to receive their support and encouragement towardsour initiative.Their radiance ,excitement and enthu siasm werecontagious. A duo on a new journey, that promises to bringabout change, one that seems to be as fruitful for others inthe business as for them. Definitely a space to watch out forin the near future.

O ne can nev er und erestim ate the source of talent. T his is w hat w e w ould like to be inv olv ed i n .S upport anyone w ho has a d ream to g row in this ind ustry and nurture them .

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22/52

FoodSafety

Qua l i t y a : Sa fe ty T e s t in g o fFo o d in the B a k e r y lndustryccess to good quality food has been man's endea-a-our from the earliest days of human existence.As the age old adage goes, "we are what weeat". Research over the ages has shown that ournutr itional status, health, physical and mental

faculties depend on the food we eat,But what exact ly defines "food quality"? While nutrit ional

value of food seems the most obvious answer, it is not thecomplete definition of food quality. Safety of food we con-sumeis of equal importance. Food safety implies the absenceor safe levels of chemicals, microbes and additives in thefood.

Because food products are by nature perishable and havea limited shelf life - especially bakery products - ensuringsafety of food products calls for multiple levels of testing.Some of the Testing that is regularly required by the bakingindustry is mentioned below:Microbiological Testing

The constituents of baked products like fat,wheat and sugar, in either the raw materialor the finished products form; are a suitablemedium for microbiological prol iferation. Foodcan be subjected to microbiological contami-nation at any stage of the life cycle; rightform contamination of raw material, duringpreparation, during storage, during transporta-tion etc . .Micro-organisms have the notorious

quality of spread through a variety of vectors thereby causingcross-contamination which can happen at all stages of thelife cycle. For a food manufacturer it is critical that properHygiene be maintained and ensured at all these stages.

Microbiological Test ing of raw food as well as f inishedproducts is therefore, necessary to ensure the food qualityand safety, Microbiological analysis includes checking forpresence or acceptable levels of micro-organisms. Some ofthe frequently tested microbes are as follows:

.. Total Bacterial load

.. Coliforms

.. E_Coli

.. Salmonella

.. Shigella

. . Staphylococcus aureus

.. Yeast and MouldNutritional Labelling

As per the PFARules, it is compulsoryfor the Nutr itional Information orNutritional Facts per 100 gm or 100mlor per serving (where amount in gmor ml per serving measure needs to bementioned) of the product should begiven on the label. Nutritional label-ling essentially specifies percentageor amount (in grams or milligrams) ofvarious nutrit ional components. Thisinforms health-conscious consumers ofthe quality of food being consumed.Nutritional Labelling involves theanalysis of the food for all or some ofthe following Nutritional parameters:

. . Energy I Calories (Kcal)

.. Carbohydrates

.. Sugars

.. Proteins

.. Fats

.. Saturated Fats

.. Trans Fat

.. Cholesterol

.. Dietary Fibre

.. Vitamins

.. MineralsAccelerated Shelf Life StudyAvariety of baked products have gained mass acceptance dueto their delicious taste and better keeping quality, The life ofa product can be established by doing Accelerated Shelf LifeStudy. In this study the Organolept ic as well as Microbiologicalsuitability for human consumption is analyzed over a periodof time under accelerated conditions to determine for howlong after production and in what conditions the food productis suitable for consumption,Chemical Testing

Chemical testing of food and bakery products includeschecking for a Wide array of organic and inorganic chemicalparameters which indicate their sui tabili ty for consumption:The qualitative analysis of Food products can be broadlydivided into the following:.. Proximate Analysis where general biochemical param-

eters are analysed (like Ash, Water I ACid Insoluble Ash, TotalSolids, Starch and other nutritional parameters mentionedabove)

. . Ult imate Analysis where specific elements or compoundsare analysed. (For e.g. heavy metals, pestictdes, food addi-tives or colorants, preservatives etc.)

Some chemical parameters which have a special applica-tion in bakery industry are

.. Trans fat: Due to the use of hydrogenated vegetable fatsor bakery shorterung.

CONTINUEDON PAGE29


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CELFROST INNOVATIONS Pvr. LTD.(Formerly, Celsius Refrigeration Pvt. Ltd.)C orp , O ffice : 7th Floor, UdyogMinar Udyog Vihar, Phase-V,Gurgaoh - 122 016, Haryana, IndiaPhone: +91 1244308430/4062401. Fax: +91 1244308431, Evmail : [email protected] iona l O f f ices :Ahmedabad Tel: 9375933335Pun jab Tel: 9357615927K olkata : Tel: 9339761988H yderabad : Tel: 9346447254

Chenna iGu rgaonLutknowJodhpu r

Tel: 9345509016Tel ,0124-4062401/02Tel: 9335174580Tel: 9351317208

BangalorePuneMumba iJammu

Tel: 9341230302, 9590047656Tel: 9370573030Tel: 022-25175477/76Tel: 9419132575

I Merrychef I i..incoln I 't:elfrg;tJ,r E,. I Serve.d.

~ T A Y LOR ' I 't:elfrosr I_ PROFESSIONA l.. _
mailto:[email protected]:[email protected]


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Techno l o g y

24

B a g g e rs a n d c l o s u re s y s te m s f e a t u r e n e w d e s ig n s t h a t a ll o w s m o o th e r o p e ra ti o n ,l e s s d o w n t i m e a n d q u i c ke r c h a n g e o v e r slsshan a century ago, bread was sold unwrapped.Not until the first slicer was introduced in the late19205 did it become common to wrap bread topreserve its freshness and moisture. The first slicingmachine was introduced to the baking industryin 1928, and it still stands today as a hallmark

invention - we've all heard the saying,"the greatest thingsince sliced bread."

Bread was originally overwrapped with opaque waxedpaper, and then companies turned to transparent packagingsuch as cellulose film. One of the major problems withoverwrapping bread this way was that once the packagingwas open, it was difficult to close it again ..Bags have beenused the last 50 years, and reclosable clips and ties allowconsumers to re-secure bags after use so that product staysfresher longer.Today, bags prernade from low-density polyethylene(LDPE) are the most common materials for packaging bread

and buns. LOPE is a lower-cost option compared with castpolypropylene, which also is used for packaging bread. LDPEprovides a good moisture barrier, but its optics generally arenot as clear as the cast polypropylene nor its touch as crisp ascellophane ..B re ad b ag ge rsWhen it comes to bagging equipment, bakers desire reliablemachinery and automation systems to eliminate downtime,quick and easy changeover capability, and service and par tsavailabi lity for ongoing maintenance, according to DennisGunnell, vice-president , sales and marketing, FormostFuji Corp., Woodinvi lle, WA. Bakers are also looking for

environmentally friendly systems that use minimal elect ricity,compressed air and materials, he added.Formost Fuji offers two models for bagging bread.

"The GTS is our top-of-the-llne bagger model with a servooverhead option, easy- to-operate touch screen, gentleproduct handling and the latest computer and electronicsystems," Mr. Gunnell. The second, the FFB model fromFormost Fuji, is widely used for tortillas as well as bread,buns, rolls and other varieties of bakery products,With the focus on sustainability, Formost Fuji has worked

to reduce the electrical and air consumption of its machines,according to Mr. Gunnell. In addition, he noted that thecompany continues to make improvements to sanitation,adhering to BISSCwith a 3ADiary-certified model available.

Whereas Formost's baggers use a paddle that pushesthe loaf into the bag, AMF Bakery Systems' two high speedautomated bread baggers - the Mark 60 and the Mark75 - employ scoops that pull the bag over the product,according to Larry Gore, director, sales and marketing,AMF,Richmond, VA.

AMFredesigned its bread baggers during the past coupleyears, and its scoops are now driven by a patented pendulumscoop drive system. "The pendulum rotary system does notstop and start, greatly reducing maintenance requirementsand also increasing longevity of the machine as well as thespeeds at which it can operate versus the traditional earn-operated scoop drive," Mr.Gore observed.

As t heir names suggest, the Mark 60 can bag up to 60 Hbloaves per minute but generally runs in the 50 to 55 bags perminute range, while the Mark 75 is designed to sustain speedsof 60 to 6 5 bags per minute with capability of up to 7 5 t-Ib


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T e chn o l o g y

25loaves per minute.The two baggers operate using the same principles, withthe main difference being the robustness of the equipment,according to Mr.Gore. "The Mark 75 is built heavy duty forthe higher rotation speeds," he noted.AMF also added a patented flusher discharge conveyor,el. iminating the flusher bar on its baggers. The flightedconveyor moves product away from the scoops sothe nextproduct can be bagged. "One of the problems is a flusher barat high speeds has a tendency to kick the product harder,causing i t to turn over," Mr.Gore said. "Our flusher conveyorsets the product down gently onto the conveyor."The THG2000 bread bagger from The Henry Group isamechanical machine that the company has manufactured formany years, and it is "tried, true and proven," according toDarren Jackson, vice-president, business development. TheHenry Group, GreenvHle, TX. "Our bagger is really smooth,and we put a timing belt on it to keep the bagger fromworking against itself," he said.The unit can bag up to 70 loaves per minute, but slicersgenerally are not able to reach that speed. Sl icers usuallyrun about 45 to 55 loaves per minute, thus they are thebottleneck, according to Mr. Jackson.One of the more cri tical operat ions for the baggers isgetting the mouth of the bag open and holding it that wayunti l the loaf is bagged. ."Anything you can do to reduce bagf lutter and keep that bag stable and from moving around wil limprove the bagging situation," Mr. Jackson said.The bread bagger also features automatic bag changers.

The wicket table carries with two sets of bags and a photoeye monitors the current wicket. When one wicket empties,the table sl ides to the next posi tion and keeps baggingwithout interruption, according to Mr. Jackson. "Theautomatic changer enables the operator to do a more such asrun two baggers," he said.Automat ic rotary bag feed tables from Formost Fuj ifacil itate fast changeovers and wicket changes, according toMike Day, Northwest regional manager, Formost Fuji. "Thisworks wel l with just- in-time manufacturing because of theflexibil ity it offers," he added,

AMF's baggers offer a precise bag inflation system thatinjects air into the bag. "Much work has been done overthe past couple years to get a precision system that inf latesthe bag each time, and the wicket table designs have beenreworked to give better support to the bags so the blow-up ismore precise," Mr; Gore explained.AMF also improved the electronics on its packagingmachi nes aswell as the electronic synchronization betweenthe bagger, the slicer and other upstreamequipment, he said.."This eliminates mechanical

connections between the machines, thus saving onmaintenance and downtime," Mr_Gore continued. "Anytimeyou have mechanical chain drives, or even bel t or shaftdrives, you have maintenance you must do on them. OUfmachines are basically electronically synchronized with eachusing their own separate drives."Additionally, the electronics package offers recipe-drivencontrol systems so operators can set up the bagger and slicer

T he T H G2000 b re a d b a g g e r fro m T he H en ry G ro u p is a m ec h a n ica l m ac h in e th a t th e co m pa n y h a sm a nu fa ctu re d fo r m a ny y ea rs , a nd it is " tr ie d , t ru e a nd p ro ven , 1/ a cc or din g to D a rre n J ac ks on ,

v ic e-p r es id e nt b u sin e ss d e ve lo p m e nt.

@ } I -Ol l , l , f Produ.cbl W h c lu d ' e ,: F ' l a n e 1 8 J ) 1 cake Mixe r Do u g ' 5 he a te r P roo fin g l C h am b e r s CQnvliil~tion O V r e J i l sW e lite p re se n t ~

Sp ira l Do u g h K n e a d e r B re a d Silo am , R o ta r y Rac k O v,e :n s E let:lJ ni~ :D e c k Q \ t , e T i l s

Regd . Office: 101 I B V 't i> MO f lo A p a !" lm - e n ts , M a rc l C hU IC h R o ad l, M a rc !. An d e n ( E ) , Mu m 'b ai 400059Tie' l l . ;+ 91 226 51 1 59 64 ,28 21 27 11 ,,28 36 31 1 3 EMAJI..: p l }te r jm b@ y a ho o .c 'O . in


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T e chn o l o g y

26for di fferent products easily. "There are st il l some set-upssuch as guides that have to be done mechanically, but themajority of set-up can be completed with the push of abutton at the operator interface, changing from one productto another, including speeds, lattice set-up at the slicer,etc.," Mr. Gore explained.When bakeries acquire slicers and baggers together fromAMF,the equipment manufacturer offers a new commonconveyor between the two pieces of equipment. This permitssmoother transfer of the sliced loaves to the bagger, allowinghigher speeds and gentler handling of the loaves, he said.The Henry Group integrates both the slicer and tyer withits baggers. "The discharge conveyor on the slicer is slave-driven of f the bagger, soonce i t passesthe blades, we driveoff the slicer into the bagger," Mr.Jackson said. "This isnecessary to get accurate timing between the two pieces ofequipment and because you have a f lighted conveyor to feedthe scoop bay,'Also, every new bagger the company builds is equippedwith a network switch that ties into a bakery's centralsystem. Becauseof this, al l baggers wil l have dedicated IPaddresses. The Henry Group also incorporates color touchscreen panels on all of i ts baggers because that iswhatcustomers want, according to Mr: Jackson.In addit ion to building its own bread bagger,the companyalso reconditions older bread baggers. "If a company has an oldMark 50, we gut i t and build them basically a new bagger, but itcosts about 20%lessthan a new bagger," Mr. Jacksonadded.AMF,the OEMfor the Mark 50, is in the R&D process ofdeveloping a bun bagging machine, according to Mr. Gore..B u n p a ck ag in g"We put a lot of effort into re-energizing our bun baggingbusiness," said Dale (D.J.) LeCrone, c.e.o. of LeMatic, Inc.,

added. "The driving force is that information is power, and i fyou know what is going on ~ what products are running, howfast they are running and if there are any issues on the line -you can continually make better decisions," he said.

Slicers are not a bottleneck for bun baggers, accordingto Mr. LeCrone. Its baggers are capable of running 70pluspackages per minute, depending on package type, and itssl icers can process product for up to 100 bagsper minute, hestated.LeMatic's baggers are versati le and can create a varietyof package formations. Changeovers are straightforward andfairly quick, and they can be automated to the level that abakery needs. "We automate what makes sense and leavemanual where that makes sense," Mr. LeCrone said. " It is notalways cost effective to put a motor on all parts. We haveto be cost compet itive, sosometimes it makes senseto havemanual guide adjustments to keep costs in l ine."C lo s ure s ys te m sAfter bagging, the product enters a closure unit that isgenerally integrated to the bagger. It appl ies either a tablock closure or twist tie on the neck of the LOPEbag. Insteadof plastic clips or twist ties, a bakery could opt for tamper-evident tape, but this closure system is not aspopular as theother two options.The decision to use either tab locks or twist ties isgeneral ly one the bakery wi ll make based on a marketingdecision, according to Mr. LeCrone. Mr. Jackson said certainclosures are preferred in particular markets, not ing that twistties are generally used by bakers in the South.Next year will mark the half-century mark for the firstautomated twist tyer bui lt by Burford Corp., Maysvil le, OK.The company developed its f irst mechanically driven twisttyers in 1961, according to Don Ivey, sales account manager,

L IT h e d r iv in g f o r c e is t h a t in fo rm a t io n is p o w e r , a n d i f y o u k n o w w h a t is g o in g o n - h o w f a s t t h e y a r er u n n in g - y o u c an c o n tin u a ll y m a k e b e t t e r d e c is io n s ," D a le ( D .1 .) L eC ro n e , c .e .o . o f L eM a tic , lnc;"

Jackson, MI. The company builds packagingl ines that take the buns from the cooler, indexand orientate them, slice them, stack them andput them in a bag.LeMatic has made its bun baggers moreoperator-friendly, eliminating manualadjustments. "Our original baggers wereextremely adjustable, and we could run manythings," Mr. LeCrone said. "But because theywere adjustable, people had to be able tounderstand andoperate them. What we found prevalentin today's workplace is that operators arechanging more frequently,and bakeries are even usingtemporary workers in somecases. Sowe have had to makeour machi nes asflexible aspossible with as few adjustmentsas possible .."The OEMbegan incorporatingservo drives about three yearsago to allow smoother operation,longer runs and faster speeds.Also, it improved the informationsystems, allowing Ethernetconnectivity to make the baggeran integral part of the wholebakery system, Mr: LeCrone

Burford. The tyers were reliable but a lotnoisier and required more maintenance becauseof moving chains and parts than today's servo-driven twist tyers, he observed.The company launched its first servo-driventwist tyer in the mid-1990s, and nearly threeyears ago, Burford updated the machine. "Afterhaving our servo twist tyer in the market for 12years, we were looking to do a redesign," saidMitch Lindsey, technical. sales, Burford. "Welistened to complaints from our service techsand plant engineers as to what were commonfailures and what they would like to see

changed, and we incorporatedall we could in the newmachine."

Its newest model featuresbrushless DCmotors thatlast longer than the previousmotors. "When we originallydesigned the servo tyer,brushless motors weren'tavailable," Mr. Ivey said."We also made a lot ofimprovements with newelectroni csthat are nowavailable."

In addition, the new uni tuses less twist-tie material,


27/52

. .Partners in excellence"

Dabonlnternational PVT LTD..New-Delhi - '011-45762222 - [email protected] - 022-28301214 - [email protected] - 080-4160 2213 - sales_bangalore@daboninternationaLcom
mailto:[email protected]:[email protected]:[email protected]:[email protected]


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Technology28

thus companies are able to save on materials, according toMr. Lindsey. "It also consumes approximately 10%less powerthan the previous model ," he added.The new twist tyer features a l ightweight, removablehead. "Ergonomically, it is easier for maintenance to accesseverything," Mr. Lindsey observed. "A sealed-end coder alsoextends the life of the motor. It's been almost three yearssince its launch, and we have not seenfai lures in those areas.That was our hope when we did the redesign."Burford's newest twist tyer can operate at speeds ashighas 110 bagsper minute, and it has proved this by running amachine for several hours at this rate at a bagging machinemanufacturer, according to Mr. Lindsey. "The only way wehave seen it run that fast in production is to be fed by twobaggers," he added.Kwik Lok Corp. , Yakima, WA,is unique in that i t not onlybuilds the bagclosing equipment but also produces the tablock closures that run through the equipment. "There is noneed for two sources of supply to close the bags," said Hal

Mi ller, vice-president of sales. "Kwik Lok is the original; weare not a copy."Kwik Lok offers both fully and semi-automatic bag closingequipment to serve the packaging needs of the bakingindustry from the small morn-and-pop operations to the largecorporate bakeries, he said. "We offer closing equipmentfor high- speed lines, up to 120 bags per minute; machines toclose paper bags; as well as specialty bag closing equipmentfor pita bread and tortillas," Mr. Miller said, noting that thecompany has been in the bag closure businessfor 56years.The company's closures open and close the same way eachtime. "The shape of the Kwik Lok closure does not change,"Mr.Miller added. "It does not become wrinkled and twisted,making it difficult to use. The fact that the closure does notchange shape makes the code always readable when printedon the closure."One of i ts newer pieces of equipment has a standardmodel that allows the machine to apply either a closurelabel or simply a closure without the need for any additionalequipment. Kwik Lok is further deveiopingits laser printingoptions.The manufacturer is able to accommodate bakeries'enhanced printing requirements from "best before" datesto real time and scannable barcodes for t raceabi li ty andpromotional opportunities. "We are seeing an increase in thedesire to offer cross promotion and couponing programs inthe bakery sector and now have the abil ity to of fer scratch-off game possibili ties for fundraising opportunities," Mr.Mi ller added .."We are able to meet this need by using theKwik Lok closure label."

Today's baggers and closure systems are faster,smarter and more eff icient than ever because equipmentmanufacturers continue to look for ways to improve andenhance their machines for today's high-speed bakeries thatrequire less downtime and greater output.

2 A . Cwn C h a J I ll J e r. l , 3 S , N ~ M a r i n e L . i J e : s , M U I O O a i 0 1 00 0 0 0 . I n d i a . : F 1 I J o o o : O ~ 220Q &tn ' , 0 22 6 6 34 6 IJ i1IiF i l l : : 0 2 2 2 2 0 0 6 5 S E 1E . m a I: Si t l ts @ v m I . 1 X I m I A l t J O s J ~ :w w w _ s a : a lh . c o m


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Fo o dS a f e t y

29Qua l i t y & Sa fe ty T e s t in g o f Fo od in the B a k e ry In du s t r yCONTINUEDFROMPAGE22... Rancidity: Asfat is a major ingredient and i t becomingrancid will affect the quality of the food.... Gluten content : Wheat is a rich source of gluten. Prod-

ucts made without wheat are made have to be tested for thepresence or absence gluten before they can be labelling as"Gluten free"Se n so ry E v alu a tio n S tu d ie s

Consumers of all age groups preferbakery products because of theirI attractive appearance, smell, color

& . taste. Two products in the marketmay have the same face value andmay be microbiologically, nutrition-ally and chemically acceptable; butsti ll they perform very differentlywhen it comes to consumer prefer-ence..This is due to the elusiveaspect of human percept ion of in-

tangible aspects like Taste, Flavor, Texture and several morewhich contribute to the Overall Eating ExperienceAl l these features of bakery products which are subjec-t ively judged by the consumer can be scientifically studiedthrough a Sensory Evaluation process. In Sensory EvaluationStudies, a forum of food technologists, who are trained toconsciously judge and evaluate the intangibles in food; studythe various att ributes of the product and give it a tangiblescore.Comparative analysis of various products in the marketcan also be done by this method. Sensory Evaluation Studiesare very helpful to find out whether your product is accept-

able in market and what speci fic attr ibutes can be improvedor changed to increase the chances of market success.Today, the preparation of bakery and confectioneryproducts requires the application of modern, sophisticatedprocessing and production technology. Accuracy and perfec-tion plays a major role in the preparation of good quali typroducts. Over and above this, testing methods asoutl inedabove can give bakeries powerful insights into their productquality ..This helps them improve quality of product, manu-facturing processes and hygiene E t sanitation standards.Ult imately helping them to boost sales and stay one stepahead of the compet it ion. Moreover; many of the tests thatdetermine food quali ty have become mandatory by law andindustry regulation.Tosum up, the specific objectives of testing include:... Imparting the scientific and technical knowledge of foodscience .... Study the factors affecting food acceptance.

... Develop the awareness about food microbiology, foodhygiene and sanitation.+ Enable the entrepreneur to understand the relationshipbetween nutrition and human health.+ Increase the awareness about food laws, regulations andquality control.+ Ensure food safety by doing hygiene audit for industriesfor a check qual ity of air, water, food, swab, beverage etc.which will affect the f inal product.Dr. PriyankaEQUINOXLABEmail: [email protected].: www.equinoxlab.com, www.foodtesting.in
mailto:[email protected]://www.equinoxlab.com%2C/http://www.foodtesting.in/http://www.foodtesting.in/http://www.equinoxlab.com%2C/mailto:[email protected]


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B a k e l t Y o u r s e l fMarch-April 20t1.30

B a k in g is b e lie v in g !B akery B iz brings you recip es dem onstrated by leading bakery and p astry C hefs at th e L iv e BakeryT hea tr e, fr om 8 -1 Oth December , 2 0 1 0 h eld alongside India's only sh ow for bakery andp a stry p ro fe ss io na ls , B ak ery B u sin es s 2 0 1 0

b r e a n this edition of bake it yourself; you will come across

some very interesting and easy recipes that you can1ntroduce / add in your menu. These recipes havebeen demonstrated at the Live Bakery Theatre whichwas held on 8-10th December, 2010 alongside India'sonly show for bakery and pastry professionals, BakeryBusiness 2010. Chef Savio Fernandes, Pastry Chef at JWMarriott showed several ways of how European Pastrywhen blended with Indian Mithai create a fusion.Jamun btuieeIngredientsFresh cream: 1 li treSugar: 200 gramsSaffron: 1 gramsYolks: 16 nosGulab jamun small: 20 nosCointreau: 180 ml

Method.' Pour the cointreau over the gulab jamun E t allow it torest for a couple of hours. Scald the cream, add in the saffron strands E t pour itover the beaten yolks E t. sugar..' In a soup plate place a few drained of jamuns. Pour the brulee mix into the plate E t bake it at 150" C for30 minutes.. ' Chil l E t serve with torched sugar.Rabri apple tartIngredientsRabri: 750 gramsFresh cream: 250 gramsGranny smith apples: 4 nosButter: 50 gramsSugar: 100 gramsMawa: 100 gramsYolks: 12 nosSweet paste: 500 gramsMethod Line an apple pie mould with the sweet paste E t halfbake. ' Heat a pan scorching hot and throw in the diced applesand the sugar till it caramelizes, then stir in the butter. Cool it Scald the cream stir the yolks, sugar E t pour the creamfollowed by the rabri..' Put the apples into the half baked tart moulds E t pour in


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e w F o r N e w E n t e r p r e n u e r s

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~ C IilI" .w i:M i, ~ 'PIiD,Iibr 1 < .! S m r ~ ,~ . ;1~i.1B'ClmIWnr ~ ~~Gl"j,14, Niri'I'iIibl'tiij, ca2.",2MliIlhm; c.I.-flUi!iIUItm,..1111f ,. :vq....Oliliimm, .... - :bu5/'tiS


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B a k e l t Y o u r s e l f

the rabri mix. Grate the mawa on the top of this mix. Bake this at 180' C for30 mins till the custard is baked Serve warm.

Chocolate rasmaiaiIngredientsRasmalai: 20 nosButter: 250gramsIcing sugar: 150 grams

White chocolate: 600 gramsWhipped cream: 1 litreWhipped cream: 200 gramsCondensed milk: 100 gramsAlmond sponge discs: 2 nosMethod Drain the rasmalai &. keep it aside. Cream the butter & : ic ing sugar ti ll l ight & :. fluffy Now pour in the melted chocolate followed by thewhipped cream. Layer the rasmalai with the chocolate mousse & :. allow it

to set for a couple of hours Soak the almond sponge in the rasrnalai milk & : place itin a plate. Stir the condensed milk into the whipped cream &. pourit over the mousse, Place the mousse over the soaked sponge and servechilled.Balsamic strawberry E t jafebiIngredientsStrawberry: 500 gramsBalsamic vinegar: 70 mlDemerara sugar: 200 gramsMascarpone cheese: 200 gramsYolks: 6 nosSugar: 100 gramsWater : 50 mlVanil la essence: 20 mlPepper corn: 5 nosJaleebi: 3 nosWine: 200 mlStrawberry: 200 gramsSugar: 100 gramsTuHle tubes:

Method Place the wine, strawberry & : sugar over a double boi lerfor 20 minutes. Carefully drain of the liquid without pressing the fruit,cool &. keep aside. Boil the sugar and water till soft ball stage. Pour hot sugar into beaten egg yolks & : cont inue to beatti ll the sabayon cools. Fold in softened cheese & :. vanilla essence followed bythe whipped cream. Fill it into the tuille tubes & : keep itaside. Tossstrawberries with balsamic & : sugar, keep it aside fora couple of hours. In a soup plate spoon out some of the balsamicstrawberries, jalebi topped with the mascarpone tuil le. Pour in the cold strawberry wine & : serve.

C hef Martin Fernandez, corporate chef -Iechnical & :Operations, at Euro Foods took the tradi tional routein demonstrating Stollenkonfekt traditional Christmasbread while his pumpkin seed bread caught up with therecent trend in healthy baking.StollenkonfektStollen is a tradi tional German cake, usual ly eaten duringthe Christmas season.It's called Weihnachtsstollen orChriststollen allover Germany. A simi lar cake from the Dutchcuisine is called a Kerststol. In Italian cuisine the panettonealso shows a similar likeness.

I IngredientsI A: Fruit mixture:(To be soak overnight)Sultanas: 750 gramsCandied orange peel: 200 gramsCandied lemon peel: 200 gramsRum: 125 mlAlmonds, chopped: 100 gramsTotal Fruit mixture: 1375gramsB: Starter:

Wheat flour (Maida): 500 gramsYeast: 30 gramsMilk (35" C), approx: 350 mlStarter Total.Weight: 866 gramsMethod 1 Mix all ingredients (Starter) in a spiral mixer for 23minutes Keep mixture aside for 20 minutesc. Dough:Starter Mixture: 866 gramsWheat flour (Maida): 250 gramsRex Bavarian Dark: 250 gramsButter: 250 grams (sof t)Sugar: 250 gramsMarzipan: 125 grams (raw)Spice mix: 10 gramsFruit mixture: 1375 gramsTotal weight: 3376 gramsMethod 2 Mix.a ll ingredients, starter mixture and fruit mixture in aspiral mixer on slow speed for 2 minutes and then on fast for


33/52

w -17 20 APRIL 2012 ,ISING APO RE EXPO

Y iO , U IR R E 'C IP E F O RS , U G C E S S

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www . b a k e r y n p a s t r y . c omOrganised by: Worldwide Associate: Endorsed by: Held in:

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B a k e l t Y o u r s e l f

8 minutes. Maintain Dough temperature at 21' C Bulk fermentation time: 20 ..25 minutes Scaling weight: 600 g Intermediate proof : 15 minutes Baking temperature: 220' C, giving steam, dropping to190" CStollen instructions: Roll

bakery march april 2011

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