Interview Production Research

68 Pages·2017·8.35 MB·English

www.bakingbiscuit.com
Production Interview Research 04
The new Coop site Kaak – efficiency and Controlled flour
17
in Schafisheim consistency functionality
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EDITORIAL
Exploiting niches
Whether it’s pop-up bakeries or unicorn bakeries,
hybrid baked goods like the hamdog – half ham-
burger bun, half hotdog roll –, a cappuccino with a
Visit us!
picture of the customer spread out on the foamed
23.9.17-26.9.17
milk, or cookie fries – which look like French fries
but are really cookies: the sector is highly creative, in Stuttgart, Germany
and many new and sometimes not so new ideas Hall 7, Booth E49
are tried out. The inventors are sometimes career
changers or caterers, and sometimes just “ordinary”
people wanting to try their skill or test a new idea.
By that I mean individuals who don’t possess any
specialist technical or baking knowledge, are not CSB
trained as bakers or confectioners and don’t known
++ Bastian Borchfeld
the industry or the market, but they do have the
Editor-in-Chief
courage to experiment with something new. Often
Your comments or suggestions
because they think there’s a market for such products,
are always appreciated:
or they believe they can do it better than the others.
phone: [phone]
Sometimes the courage and clever marketing pays [email protected]
off, the new product is a winner and the media
pounce on the inventor accordingly. That’s how Seri Wada has caused a sensation
in Switzerland since 2015. Wada gave up his job as a client advisor in the finance
business and wanted to bake the best baguette in the country. For this he taught
himself baking, and today he makes a living by selling his baked products. He also
organizes seminars and has set himself new goals: to manufacture Switzerland’s
best croissant.
Among the professionals there are also successful entrepreneurs who have created
a new product and occupy a niche. The best example is the New York confectioner
Dominique Ansel, inventor of the Cronut. He caused a furor in 2013 with his hybrid
How much does
between a donut and a croissant. Ansel now also operates a branch in London, and
is again trying to make headlines with new ideas. For example there are now Cookie-
Shots (milk in a chocolate-chip cookie cup) or a Banoffe Pie (banana cake from a your software
paella pan), or even a Welsh Rarebit Croissant (a croissant filled with béchamel
sauce with Guinness Worcestershire cheddar).
know about bread?
Only successful stories make it to the media, of course, which also motivates career
changers to imitate them. That’s generally a good idea and certainly an asset to the
baking sector as well. As a professional, the question that now arises is whether
these trends are a bandwagon worth jumping onto. The question is unanswerable, Ours knows a good deal.
because only with hindsight is it clear whether a new product has really become
established, or it’s just a nine-days wonder. One thing can be said with certainty,
Industry-specific processes,
however: unless the quality is right, the baked item or product will vanish from
the market again very quickly. Implementing an obsession, painting a rainbow on integration of machines and
the shop window, posting it all on the Internet and then selling a unicorn cake with
systems, monitoring and reporting,
inadequate quality may work once, but not in the long run.
traceability, quality management
As a professional, however, just to lean back and smile about the new players in the
and much more.
market is the wrong response. If you already have direct access to customers, e.g. in a
The CSB-System is the business
branch, it’s better to take up some idea or other and to implement it professionally.
Even if it is just hype and will never become a trend. In any case, watching new software for the bread and bakery
ideas and product developments or implementing them oneself is worthwhile. The goods industry. The end-to-end
best strategy of all is to have an idea or a vision and then to put it into practice. A
solution encompasses ERP,
certain amount of courage and ideas of one’s own certainly help to stand out from
the competitors and get oneself noticed. Maybe it would be a good idea to have a FACTORY ERP® and MES.
3-D printer in the branch, or you could show how sponge doughs and sourdoughs And best-practice standards come
mature – either in a glass showcase or in wooden tubs, or by a live broadcast from
as part of the package.
the fermentation room in the production unit.
T
Wishing you great success, MEN Would you like to know exactly why
E
S
RTI industry leaders count on CSB?
E
V
D
Bastian Borchfeld A
www.csb.com
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06 PRODUCTION
++ June 2013 ++ September 2013
All in one
The new Coop site in Schafisheim provides maximum flexibility. Approx. 600 employees make
around 600 different products on a total of 24 lines.
+
The Swiss retailer Coop started a new bakery strategy contain the warehouse and technical plant. In addition there
in 2008. The intention on the one hand was to reduce are goods receiving and goods distribution departments. The
costs, and on the other the wish to improve the quality of Coop new building also contains a frozen product warehouse with
baked products. Moreover, through focusing on particular 17,000 pallet storage spaces. The bakery and confectionery
sites and investing in new technology, the company wanted are on the upper floors.
to achieve its vision of “CO -neutral” production in 2023.
2
This strategy has now been implemented, and the newly- Step by step
built production facility in Schafisheim is one of the results. The building’s design concept, and a multistory building,
The location, one of the Coop’s present five production presented special challenges, but a new building at ground
units, is a completely new build. Explaining the decision to level on a “green field” site is hardly feasible in Switzerland
choose the site, specialist bakeries department Manager for space and cost reasons. For example, as explained by Reto
Reto Weber says: “We were attracted by Schafisheim because Weber, one square meter of building land costs more than
the required area was available and the municipality has good CHF 400.
connections to the A1 motorway and the T5 expressway.”
Patrick Mürset, Manager of the Schafisheim bakery, adds As well as the good location close to Zürich and the good
that: “There is also a rail link through the Coop’s existing connections, the municipality of Schafisheim also helped
central distribution warehouse for the northwest and central
regions of Switzerland.” A bridge also connects the newly-
built bakery to the distribution center. This link, which is
162 meters long, is used to transport goods to the distribution
center, e.g. baked products and dough pieces, but employees
can also use the link bridge.
A multi-story building
Experts prepared the production site’s design concept in
2011, followed by laying the foundation stone in June 2013.
A gravel quarry acted as the starting point for the new building.
The total area of the bakery building is 48,000 m² and its
total height is 54 meters. However, only around 29 meters
of the building are visible, since approx. 25 meters are an
underground structure. The building stands in the former
gravel pit, which came into existence as a result of gravel
extraction. Its stability is ensured by 282 supporting piles
driven into the ground.
m
© f2
Eight of the total of 15 floors are below ground. Each indi-
++ Outdoor and indoor silos supply raw materials to the production
vidual floor has its own function. The lower floors, for example, operation. The emergency stairway can be seen in the background
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PRODUCTION PRODUCTION 07
coop©
meline
all pics in this ti
++ September 2013 ++ May 2014 ++ November 2014 ++ Machines are set up
with the building project. It gave full support to the Coop. Flow of goods
Staff processed all the applications promptly, and approvals Everything was ready in May 2016, and the staff manufactured
were granted quickly. On the other hand, however, the site the first products at the new site. Nowadays there are 24 lines
logistics is challenging. For example, there are numerous in operation, and 600 employees produce a range of approx.
goods and supply elevators to transport goods internally. 600 articles round the clock, seven days a week. Schafisheim
There are also mezzanine floors for pipework and electric Bakery Manager Patrick Mürset says the annual raw materials
cables, as well as stairways, emergency staircases and safe demands are around 40,000 tons of flour, approx. 700 tons of
protection rooms. To ensure safety for the new building, butter and an estimated 250 tons of eggs. Annual production
the Coop established its own works fire brigade, which was is around 60,000 tons/year of baked goods and dough. This
recruited from the site’s employees and was appropriately makes the production unit Switzerland’s biggest bakery.
trained. There is also a sprinkler system that required the
installation of nearly 100 km of pipework. The factory processes almost 100% wheat flour, but hardly
any rye flour or other types of flour. The outdoor silos,
The team led by specialist bakeries department manager eight in all (6 x 60 tons for various flours and 2 x 45 tons for
Reto Weber commissioned the site step by step, and to some sugar and salt), supply the production lines. In addition
extent floor by floor. Weber says one of the biggest challenges there are a further eight indoor silos with capacities of 12 tons
in this task was bringing the plant in and coordinating the each, and 30 silos for small ingredients. The yeast is process-
plant constructors. For example, the team needed to coordinate ready and is delivered in liquid form. There is space for this
around 1,350 truckloads of plant components. The company raw material in four tanks holding 25 m3 each. Reto Weber
invested a total of around CHF 100 million in new bakery and Patrick Mürset rely on “classical” Diosna and San
plant alone, not including the cost of the building itself. Cassiano batch mixers to knead the dough. On the other
m m
© f2 © f2
++ The plants were brought in through large air-locks ++ Various switches and buffers ensure the required flexibility
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08 PRODUCTION
++ Batch mixers supply dough to the ++ Frozen baked products are packed in cartons. Niverplast lines ++ Staff also produce fresh dough for the
lines, and provide greater flexibility form the cartons and automatically pack the baked goods. Then the chiller shelf, e.g. pizza dough as shown
than continuous mixers cartons enter the warehouse here
m
f2©
all pics
++ Reto Weber (l.), Manager of the specialist bakeries department, ++ The confectionery area has a Dübor TSA 800 automatic release agent sprayer to
and Patrick Mürset, Manager of the Schafisheim bakery grease the sponge cake molds
hand, the production plant has no continuous mixers, because although a Mecatherm plant takes care of pre-portioning the
the site’s concept is “multi, not mono”. Flexibility is required dough as well as making the dough strands. After proofing,
in the production unit. The company depends on soft the dough pieces then move into Mecatherm single-deck
dough lines in the bakery, to guarantee traditional bread tunnel ovens. The processes used for twisted breads include
production. The use of sponge dough is part of this, and technology from France – a Mecatherm line for soft doughs.
more recently so are wood-fired ovens. Reto Weber and This involves a Tradivider pre-portioning the dough into a
Patrick Mürset considered it was important to have the shaping strip, after which needle-pads remove the dough
option to intervene manually in the processes. Moreover, piece and deposit it onto a conveyor belt. A Block RT II takes
most of the lines can manufacture both fresh baked goods care of the long-molding. Rolling in a seed and grain mix,
and frozen products. and twisting the breads, is done manually and ensures that
the baked products have an individual touch. The bakery
By hand also has classical bread lines with conical rounders.
The bakery contains a total of 12 production lines. Leading
articles in the “fresh breads” area include: pfünderli (a 500 g The total baking area available in the bakery is around 1,500 m2.
loaf), ruch (brown wheat bread from a wood oven) and halb- In addition to Mecatherm ovens, there are also multi-deck
weiss, krustenkranz (a ring of white bread buns), weggli thermo-oil ovens from Kaak and WP, and Fritsch wood-fired
(milk roll), plait and Tessiner (Ticino bread from high- ovens with 24 hearths, which are heated using wood pellets.
extraction white flour). The output of fresh bread per night The thermo-oil for the thermo-oil ovens is heated in an
is approx. 50,000 packs. The hourly output of frozen bread external building, the central heating plant, where energy
for baking-off on the spot in shops is approx. 100 pallets. is generated from wood chips (45 m3/day) and flour mill
Plaiting yeast bread braids, for example, is done by hand, byproducts (12 m3/day), e.g. bran. The power output is
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PRODUCTION
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10 PRODUCTION
© f2m © f2m
++ Staff plait the braids ++ The dough pieces are deposited onto peelbords
m
© f2
++ Braids leave the tunnel oven, cool down and enter a spiral freezer, after which they go to the packing station
around 2.5 Megawatts. This biomass heating will help the of frozen products, just like the proportion of organic baked
Coop to achieve fully CO-neutral production by 2023. Waste goods under the Coop’s Knospe (Bud) brand. At the same time,
2
heat is also utilized, e.g. to obtain hot water. Swiss customers often ask for regional artisan products,
which is why the Coop also invested in wood-fired ovens,
Complex and flexible because consumers are also willing to pay a higher price for
The confectionery department has a total of 12 production original artisan baked products. On the other hand, there
lines. Leading articles here include organic pizza dough and are only a few opportunities for growth in export business,
doughs for puff pastry and cakes, ready rolled out and sold because the Swiss Franc is very strong compared to the Euro.
in the chiller shelf. There are also other Danish and puff Nonetheless, part of the fresh pizza dough is supplied to Italy.
pastry dough products, crème slices and gateaux, as well as
sponge cakes. The output volume of crème slices, for example, Total capacity utilization at the Schafisheim site is around
is approx. 120,000 pieces in one campaign week. 80%, so there is still room for further expansion, and there
are also reserves of space within the production area.
Reto Weber is certain that the choice of plants and the require-
ments applying to the production operation make the Furthermore, the site could also be enlarged from a structural
Schafisheim site one of Europe’s most flexible works. The point of view – although that’s still a vision for the future.
lines for fresh baked goods also produce frozen products, of
which 80 to 90% are part-baked. There are also concepts with Investment today is in personnel and in the company’s own
which the baked products no longer need any baking-off, trainees. The first apprentices will start in their own training
just thawing out, e.g. lye plaits. Weber thinks frozen products workshop in 2017. The Coop also plans to enlarge the in-store
account for more than 60% of the output of baked goods. In bakeries in its branches, so supermarket customers can see
this respect, the employees produce mainly breads (around how the dough and end-products are made. Moreover, those
75%). Apart from that, they also make fresh doughs, bread responsible have already adopted the next bakery strategy
rolls and pastry products. Patrick Mürset, Manager of the concept called 2020+, which is designed to lead the bakeries
Schafisheim bakery, expects further growth in the proportion into the future. +++
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