breadtalk nr. 8
TRANSCRIPT
KEEPS YOU UP TO DATE ABOUT WHAT’S COOKING IN THE BAKERY
IN THIS ISSUE >
no.no.no.
Year 4 no. 8 February 2015
>BTE South AfricaBTE is the official distributor of WP Haton andWP Bakery Group products in South Africa.In 2014 it was 40 years ago that ownerBern Triebiger started his company.
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> DecoSeederThe demand for decorated bread is growing fast worldwide. More and more consumers’ link seeded loaves to artisanal production, health food, organic base and a better taste.
> Salt reductionLast year, WP Haton organized in collaboration with dough specialist IsernHäger, a seminar titled ‘Salt reduction and maintaining the taste’.
Local Red Cross happy with WP Haton cheque!“After my retirement I will certainly
continue my work in healthcare.
It’s a different world where I
feel really at home.” This was the
last sentence from the interview
with our colleague Jan Beurskens
in BakkerStaal, the Dutch WP
Haton paper of November 2007. Unfortunately, in 2013 a cardiac
arrest made an abrupt end to Jan’s
great intention. For years Jan was a
volunteer on the Red Cross flagship
“Henry Dunant”. Jan’s passion and
enthusiasm will never be forgotten
by his colleagues and was
decisive to place a
“Jan Beurskens Red Cross
money-box” at our test
bakery Breadlab.
Similarly, every visitor now hears
Jan’s story and his colleagues give
whenever a donation for each baked
bread. Last year, in the presence
of Jan’s wife Sjan, son Mike and
the entire WP Haton staff, Mr. Jan
Perquin (chairman Red Cross Peel
& Maas) and Mr. Wim Hoeben (vice
president) gets the first proceeds
cheque handed over by managing
director Mr. Henk Snellink.
The gratefully received cheque,
Red Cross Peel & Maas devotes in
its entirety to holiday activities,
where also Jan’s passion was.
bakery Breadlab.
by his colleagues and was
“Jan Beurskens Red Cross
Jan Perquin en Sjan Beurkens
BTE 40 years successfully in business!
BTE is the official distributor of WP Haton and WP Bakery Group
products in South Africa. In 2014 it was 40 years ago that owner
Bernd Triebiger started his company as a young immigrant.
Market report South Africa
Bernd grew up in Eastern Germany
in a large family, owners of a farm
and local restaurant. As a young
boy he worked in the family
business next going to school.
When he graduated, he spread his
wings and left for Switzerland
where he worked a long time for
Siemens. At that time it was
difficult to return back home and
he decided to emigrate from
Europe in order to use his freedom.
South Africa was the next station
and would turn out to be his final
home country. Bernd landed in
Cape Town and started as a waiter
in the German Club. After a while
he found a job with an import
agent from Germany, of course a
member of the German Club, and
here he learned the trade of
importing, distributing, selling
and servicing the food business.
Very fast he understood that there
were good opportunities in South
Africa and in 1974 he decided
to start his own business Bernd
Triebiger Enterprises, nowadays a
leading importer of meat, poultry,
bakery and food equipment from
all over the world. Next to the
importing and servicing of
equipment, BTE is also a leading
manufacturer of spices and
packaging material for the meat
industry. BTE nowadays employs
more than 100 people and has its
own factories where they produce
domestically spices and other
products for the industry. BTE has
offices in Johannesburg, Durban
and Cape Town, from where all
cities and far away corners of the
country are being worked on.
WP in South AfricaWP had in the seventies its own
manufacturing facility in the
country and produced mainly
ovens and distributed machinery
that was imported. Whereas WP
was totally focussed on the bakery
business, BTE spread their wings
in the nineties into products with
a fast turnover in order to cover
the cost of distribution and also
servicing the meat, poultry and
food business as well as the bakery
industry. Both companies became
bakery equipment producers; BTE
produced Baker Perkins equipment
under licence in Durban and WP
tunnel ovens and Matador ovens
as well as final and intermediate
proofers in Johannesburg. At that
time both companies were market
leaders with large production
facilities, a large distribution and
service network. When Apartheid
ended and Nelson Mandela became
president, many things ended
positively. The country opened itself
again to the world, and many rules
and laws were set overboard.
One of the first things that was
done, was the ending of the
subsidies on many products also
on bread. Bakeries were on their
own and were forced to really
compete against each other. This
resulted in a complete restructuring
of the South African bread industry;
from 200 bigger bakeries only
80 are still in business. The bakeries
had a difficult time. There was a lot
of used equipment in the market,
many small bakery shops were set
up, investments in new equipment
in the industry lowered to nearly
zero. For many years, from 1995-
2005, there were no investments
done and both companies
independently from each other
ended their production and closed
their bakery activities in South
Africa. BTE continued however
successfully with spices and
packaging materials and became
stepwise a large player in that
part of industry. In 2001 both
companies decided to join efforts
in the bakery industry and BTE
became the sole importer for
WP bakery equipment. Since
then a large number of WP Haton
machines and WP industrial ovens
as well as complete systems for the
bread industry have been supplied
to the large players in South Africa.
But not only the big bakeries are
supplied, also the independent and
smaller bakeries use nowadays WP
equipment, which makes us very
proud. Large investments are done
to modernise existing bakeries, to
improve efficiency and quality and
extend production capacities in
green field bakeries. BTE and WP
are very successful in supplying the
latest toast production technology
-Easy Toast- and together they are
the industrial leaders.
Dough DoctorPart 4: Bread and water
In the bakery world the saying is:
in order to improve the quality of
bread, the best ingredient is water.
Water helps to improve the quality
of the bread, read the tenderness,
and is the cheapest and easiest
way to add, because it is always
available.
The fact is that there are numerous
breads like ciabatta and allinson or
whole meal bread that contain large
percentages of water (up to 90%).
These products have a distinctive
wet crumb which gives the bread
a long lasting tenderness. The slack
dough hinders on the other hand
the gain of a regular fine crumb
structure as wanted in many other
tin or hearth baked breads. It is the
trick to find out the right balance
between enough water for a tender
crumb and the same time to find
the right viscosity, in order to roll
out and form the dough properly.
The water contents depends on a
few factors: Type of bread Type of dough
Amount and type of ingredients Quality of the flour
Generally speaking 1/3 of the
water added to flour is absorbed
by the insoluble wheat protein.
It is precisely the wheat protein
with the water that forms gluten
chains. This requires the wheat
proteins to form to a cohesive
gluten network.
This can be done by
1. Making use of time (autolysis)
2. By mixing (energy insertion)
3. By applying additives -
emulsifiers in cooperation with
enzymes
1. AutolysisA good example of autolysis is the
method used in many Mediterranean
countries in making ciabattas,
baguettes and other products
whereby leaven is used. By giving
the dough a lot of time top roof, the
gluten will be formed more or less
naturally. Wheat flour contains
enzymes and other elements which
are responsible for unrolling the
protein molecules. The formed
gluten network often has a stretchy
character. Combines with a lower
dough temperature and a low yeast
dose, the baker can make a tasteful
final product with a nice open,
crispy crust and a perfect taste.
2. Energy insertionBy mixing the gluten formation will
be accelerated. The more intensive
mixing, the shorter the process will
be. Shorter mixing however results
in higher dough temperatures,
which is not always wanted,
especially in countries where one
does not always has access to colder
or ice water. In these cases a
continuous mixer will help. Some
wheat properties have so much
protein that it is almost impossible
to develop gluten in one single
mixing process. In this case the
flour, water and part of the yeast is
rested for a certain time in order to
develop the gluten. At the same time
there will be more enzymatic action
(naturally) whereby the dough
development and flavour
improvement arises.
3. AdditivesEmulsifiers, added enzymes and
other additive scan accelerate the
unrolling of the protein globules
so that the gluten network not only
is developed faster but also better
formed. All-in all the correct water
absorption in dough ensures that
the gluten is formed in the right
way by the right mixing process,
ingredients and time.
It is important to find the right
balance between a stiffer dough
and a slack dough. If a dough is too
slack, by having added too much
water this causes a few drawbacks: Less gluten formation Sticking during the forming
process Difficult forming
A bit firmer dough is easier to
handle and more evenly degassed
than a slack dough. In many cases
this will result in a more even
crumb structure. Conclusion: the
right amount of water is of the
utmost importance for a good
quality of the final product.
Jan Zweistra, alias the dough doctor
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© www.wp-haton.com
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MowingA combiner harvests the wheat, rye or spelt in the summer.
Mowing
Bread making by WP Haton
Final proofi ng Baking
And than fi nally...
Milling Mixing
The dough is deposited by hand or automatically in the pans and is proofed during 60 minutes in a humid and warm climate in the fi nal proofer. Dough that has undergone much rising produces a fl uffy crumb that is soft and has much consistancy and taste. After the fi nal proof time the bread can be decorated with seeds or with a knife or scissors.
Before baking the bread can be decorated with a knife or scissors or decorated with seeds. Now the dough is ready to be baked in the oven. During baking the dough is steamed and cooked/baked. The dough gets colour and a crust. The inside stays moist and airy while the outside gets harder. The baking time determines the taste, the bite and the character of the fi nal bread.
The breads are cooled down and are ready for slicing and packing and shipment to the consumer.
Bread panIn the bread pan the bread gets its fi nal shape.
Wheat grain
SiftingVarious sieves are used to separate the grain from the chaff.
Brown bread
YeastFlour Salt Improver Water
Toast bread
2 hours
Open top Hearth bread
White bread
TreshingTreshing the wheat: the grain is separated from the wheat.
MillingBy milling the grain fl our - the most important base for bread is made.
For white bread the bran is sifted out of the fl our.
Kneading
Proofi ng
Wheat grainThe wheat grain consists out of a germ, the bran (the outer layer) and the fl our kernel.
During mixing all ingredients are evenly distributed and by kneading the gluten is activated. The dough becomes elastic by kneading. Sometimes the dough must rest approx. 30 min. to get the right taste and texture.
Time(60 min.)
Relative humidity
Temperature
200 - 260 ˚C20-45 min.
15 min. 30 min.
Cooling Slicing Packaging
Mowing, sifting, milling, mixing, dividing, sheeting, proofi ng, baking, packaging. Your daily bread is the result of a long and artisan production process. WP Haton is one of the international key suppliers of bread making equipment. This chart shows the position of WP Haton equipment in the total process and its importance.
Mowing, sifting, milling, mixing, dividing, sheeting, proofi ng, baking, packaging. Your daily Mowing, sifting, milling, mixing, dividing, sheeting, proofi ng, baking, packaging. Your daily Mowing, sifting, milling, mixing, dividing, sheeting, proofi ng, baking, packaging. Your daily Mowing, sifting, milling, mixing, dividing, sheeting, proofi ng, baking, packaging. Your daily
Bread, the making of...
The dough is now ready for making bread. First the dough is divided in equal portions with a high weight accuracy and in a dough friendly manner. Hereafter the dough is preformed, proofed to get the right balance between elasticity and extensibility. Now the dough can
be formed in the moulder (degassing-curling-moulding).
Dividing Rounding + proofi ng Sheeting Curling Moulding
Final proofing time is 60 minutes.
Just before baking, turn up site
down on peel board, and bake
with steam on 220 degrees for
35 minutes.
Pre-proofing 90 minutes, divide
and let it proof in the intermediate
proofer for 30 minutes.
Use long moulder Combi U with
curved pressure board with V and
put the dough in rye flour.
Wheat rye bread with buttermilk Ingredients80% whole wheat flour
20 % broken rye grain
20 % leaven
2 % salt
1 % bread improvers
1 % fresh yeast
50 % water
20 % buttermilk
Put the buttermilk and the broken
rye grain together (24 hours ahead
of mixing).
Take all ingredients and make a
nice smooth dough, temperature
26 degrees.RECIPE >
DecoSeederNew product
The fact is that seeded loaves not
only look better but also bring
more margin in the bakery.
There is seeded loaves and
seeded dough. Especially for seeded dough
(seeds not on top but all around
the dough pieces), WP Haton
has developed a new device -
the DecoSeeder. This unit can be used in
industrial lines behind sheeting
and moulding for seeding the
moulded dough pieces all around.
This ensures: Exact weighing of each dough piece even at high speed Counting and calculating the average weight of each stroke and
each piston of the divider Trend analysis Feed back to divider in order to keep the weights constant Ejecting even at high speeds < 9000 pieces per hour Statistics program ensuring an alibi for the production period
Watch your weight!The 700 series of the WP Haton divider range can be linked now to the latest checkweigher technology of OCS.
Each machine is equipped with a
stand-alone plc but linked to each
other.
This ensures a continuous
production with simple and easy
operation with the highest possible
weight accuracy.
If you want to check the weight
accuracy of your existing divider
please demand for our weight
watching program: bluevalue@
wp-haton.com.
For more information about
this successful couple (B 700 /
Checkweigher) please contact
The demand for decorated bread is growing fast worldwide.
More and more consumers’ link seeded loaves to artisanal
production, health food, organic base and a better taste.
The machine can be used in lines
with capacities of up to 4200
loaves per hour. The seeder is not seeding the
dough, but the dough is rolled
in a seeded bed. This assures that only the amount
of seeds is used that is necessary
for the decoration. The seeder is not working
continuously and therefore
saving seeds.
Access of seeds are discharged by
a conveyor sideways and
recycled. This guarantees an efficient
production, nearly no waste,
effective sheeting, and hygienic
recycling. By using containers various types
of seeds can be used.
For more information please
contact www. wp-haton.com.
COLOPHON >Draft en realization
Spiegel crossmedia communicatie
www.spiegel.nl
Editors
Jan van den Berg and Wilma Jansen
Photography
Spiegel crossmedia communicatie
WP Haton
Printing
Van Stiphout Grafische communicatie
WP Haton
Industrieterrein 13
5981 NK Panningen NL
P.O. Box 7025
5980 AA Panningen NL
Tel. +31 (0)77 3071860
Fax +31 (0)77 3075148
www.wp-haton.com
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EXHIBITION CALENDAR
Bakery China 2015Shanghai12.05 - 15.05.2015Shanghai New International
Expo Centre
Shanghai - China
www.bakery-china.de/en/
fair-overview
IBA 2015Munich1.09 - 17.09.2015Messegelände München
“An der Point” (GPS)
Munich - Germany
www.iba.de/en
Broodway 2015Kortrijk27.09 - 30.09.2015Kortrijk Xpo
Doorniksesteenweg 216
8500 Kortrijk - Belgium
www.broodway.be
Last year, WP Haton organized in
collaboration with dough specialist
IsernHäger, a seminar titled ‘Salt
reduction and maintaining the
taste’.
In the Netherlands, salt reduction in
bread is a hot topic that engages
food industry, healthcare and
government. The bakery sector
continuously works towards bread
production with less salt contents.
Special salts are developed,
containing less sodium but still
providing good dough develop-
ment and baking quality. Also in
different (pre-) mixes the salt level
is reduced, collected by raw
material suppliers with other
additives. Salt reduction in bread,
without additional additives and
maintaining the taste, is certainly
possible. A welcome development
partly because of the health claims
in bread and the consumer demand
for products without additives.
The less additives, the fewer the
number of ingredient declarations,
a welcome trend given the new
labelling law (since December
2014). Clean label-products are
for more reasons popular.
TasteHow can a baker produce tasty
bread without bread improvers and
also adding less salt, less sugar and
fat? In Germany it is not a problem
In Germany it’s no point using 2 to 2.5 percent of salt in bread. Salt addition in the Netherlands
goes back to 1.5 percent. With the right preparation even 1.2 percent salt can be achieved, sug-
gests dough specialist IsernHäger from Germany. But a lower use of salt has an effect on the taste
and the dough characteristics. This can be resolved by working with pre-dough’s and leaven.
to bake bread with less salt,
maintaining taste and quality.
Because of its rich history in the
bread baking area and knowledge
of the baking process, the company
IsernHäger appears well able to get
taste into bread and keeping high
product quality, without bread
improvers, while the salt level is
significant reduced. The desire in
the Netherlands for salt reduction
in bread goes towards 1.5 percent.
‘With the right preparation even
1.2 percent is achievable, says
Martin Albers, key-account-
manager and food technologist
from IsernHäger. ‘Lower than 1.2
percent cannot be, because than
the bread will taste metallic’, he
explains. Working with leaven
obviates the loss of salt, according
to Albers, which is reflected in the
taste. A certain acidity gives the
same effect of salt taste. By adding
leaven, the bread remains just as
tasty as before with a higher
percentage of salt.
Breadlab (test bakery WP Haton)The organizers emphasize that the
leaven IsernHäger applied into
practice at WP Haton’s Breadlab, is
not the acid leaven bakers and
consumers may associate with the
German bread. It is rather the
opposite; adding a cooked dough
with durum meal for example,
creates a smooth flavour suitable
for brioches. During the seminar
various dough’s were produced in
Breadlab. Ciabatta and baguette
with pre-dough, white tin bread
with leaven dough for a lower salt
level, seeded hearth bread with a
cooked dough. The brioche dough
Marc de Wit, Master Baker WP Haton & Jens Stadtländer, Master Baker IsernHäger
Jens en Marc preparing tasty bread with reduced salt
Bread with a low salt level and a good taste
IsernHäger holds seminar on salt reduction
that was made, contained less
butter, sugar and egg. The taste
was just fine because of adding a
pre-dough with durum meal.
The various types of bread were
extensively tasted by the
participants. WP Haton’s test baker
Marc de Wit is enthusiastic about
the process and the result, both
taste and dough processing.
The bakers present were surprised
about the taste. The lower salt
content was barely perceptible
thanks to the application of an
acidic pre-dough. WP Haton
showed in his test bakery various
artisanal dough make up systems.
The baguette dough was admittedly
slack, but due to a longer mix time,
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a longer proof time and the use of
pre-dough, well to process by the
dough make up line Crustica.
Strike out bread improversIsernHäger claims to remove at
least half of the improvers with this
approach. “The idea is to really
re-establish the product together,”
says Albers. “It doesn’t help to
exchange or replace ingredients.”
They are repairing the damage
inflicted, in his vision. The problem
with wanting to improve the
properties and taste of bread is,
according to Albers, that soon an
improver is added to every problem
to be solved. And with the
following problem another one!
“In fact, you paste every time a
new patch”, says the German food
technologist. “It’s the art to start
again, at the very basics. More than
flour and water is not necessary.”
As a baker for example prefers
more volume in his tin bread, he
can use a yeast pre-dough.
Thanks to Anne Mieke Ravenshorst, editor
Dutch bakery magazine “Bakkerswereld”