Real Efficiency Is the Result of Many Small Improvements

Up to 30% of a large bakery’s output may be lost due to never reaching the consumer, as it is not sold before the best-before date. Poor design of the distribution network of perishable goods, ineffective inventory management, and uncertain customer demand may contribute to higher food waste due to product expiration resulting from aging inventory. Other loss avenues are inefficient ovens, wasted opportunities to recover heat, and faulty products because of improper inspection equipment. New solutions are available for these issues and using them in a coherent strategy can help bakeries become more efficient.

Inspection Prevents Faulty Products from Reaching Consumers

At the end of 2023, Fortress Technology acquired Dynamic Inspection in New Zealand, opening the company’s fourth global manufacturing hub for metal detectors, X-ray, checkweighers and combination inspection equipment. This means that producers of baked goods across APAC and Oceania will have access soon to a much larger portfolio of GFSI-compliant production inspection equipment.  

“Having served the APAC region for several decades, Fortress has observed a shift in requirements and risk profiles,” says Eric Garr, Regional Sales Manager at Fortress Technology. “A number of countries have been modernizing their inspection systems, although the level of investment and the selection of inspection equipment does vary regionally. Many of these developments are aligned to rapid urbanization. New Zealand, Australia and neighboring APAC countries are generally the countries setting the new food safety standards.” 

When it comes to contaminant detection, Metal detection continues, in most cases, to offer the best price-for-performance value in most bakery applications and helps to ensure products are safe for consumption. Inspecting products after packaging using an end-of-line metal detection system is the most important critical control point (CCP). Generally speaking, metal detectors are capable of phasing out and running biscuits and cookies packaged in metalized film with a good level of sensitivity. However, if pure aluminum foil is being used, a ferrous in foil metal detector, or X-ray may be advisable. 

Each sector and product application has its own set of more prevalent risks, says Garr. “For example, contamination hazards on a bread production line can be very different to a packet of snacks or biscuits. Mitigating any contaminant risk early on in the production process results in considerably fewer rejects compared to only inspecting finished, packaged products. It also enables a commercial bakery to identify where the source of a potential problem may be. Whenever an ingredient is added, or where there are multiple mixing, rolling, cutting and baking processes, there is an increased chance of a contaminant entering the production chain.”  

AutoPhase available on Fortress metal detectors is a useful software feature. It works by tracking long term changes within wet products, adapting and syncing to new characteristics over a product run. This can include slight changes in batch conditions in baked bread, which may vary very slightly between recipes. AutoPhase accommodates this gradual change without compromising metal detector sensitivity.

In-line checkweighing for bakeries can also be extremely valuable. This helps to mitigate the risk of a batch being out of tolerance before the baking process. Where there might appear to be a need for multiple machines to cope with the increase in upstream output, Fortress recommends closely examining the options. “For example, could a multi-lane system offer a better return on investment in a smaller footprint?,” says Garr. “Is it possible to channel multiple product lanes through a larger aperture? What sort of reject system is required?” Combination systems provide an alternative space-saver. Combining a checkweigher with metal detection or X-ray or, both, can result in a far smaller footprint than stand-alone units would occupy. 

All of these technologies, from the popular Stealth metal detector to the Fortress Raptor checkweighing and combination series and multi-aperture, multi-lane inspection systems, and our new X-ray, can be customized to fit most bakery configurations.

Post-installation, Fortress offers a very personalized service and support to customers. Known for being robust and well designed, providing a system has been well maintained, a Fortress metal detector can run efficiently for 20+ years.

Management Software and Automation

Bakery management software is a game-changer in streamlining various processes. From inventory management to order tracking, this specialized software optimizes operations and reduces human error, allowing bakeries to focus on their passion for baking. Cybake bakery software, for example, is proven to reduce costs, increase sales and improve efficiency. It provides analytics and integrates smoothly with your accounts, e-commerce, POS, labeling and weighing systems.

Read the rest of the interview in our new supplement, Asia Pacific Overview.