Rising to the Occasion

All stages of baking are essential but quite critical to the whole process. Proofing is the processing stage whereby the mixed dough is allowed to rest and get better to best serve the baked goods for which it has been mixed. There are some major players in this core sector as Andre Erasmus finds out.

Proofing, as we all know, is that stage in which the baker will allow the dough to rise. Often, in basic yeast bread recipes, the dough will be proofed twice – the first proofing will be in a covered bowl. The second and final proofing will be in a bread pan. Each time the bread is allowed to rise. All too often the proofing process is dismissed as a simple rest period for the dough before baking.

However, in reality, the dough is doing anything but ʽrestingʼ. During proofing, yeast is busily converting the sugars (glucose) in the dough into energy for themselves, producing carbon dioxide and ethanol as waste products.

Most of the ethanol evaporates during baking, and what little amount remains adds flavor to the bread. It is the carbon dioxide that is responsible for the light, spongy texture of the finished loaf.

As the dough proofs, carbon dioxide bubbles form, giving structure to the dough that remains when the loaf is removed from the oven. These carbon dioxide bubbles are what separate leavened from unleavened bread; they are why a loaf of bread and a cracker have such different textures despite both beginning with flour and water. The addition of yeast, and the time to allow it to convert sugars to carbon dioxide, is what makes bread so addictively delicious.

Rising again

In baking terms, proofing is the second rise in the baking process. The dough has already been allowed to rise once; the resulting carbon dioxide is why recipes will often instruct the baker to let the dough rise until it has doubled in size. After the dough is formed into its final shape, it is allowed to proof, or rise a second time, before baking.

Sounds simple, but to make this happen the artisan or industrial baker requires specially designed proofing equipment that is necessary to obtain consistent results.

Consistency, after all, is what the baker and the customer desire and, besides this, a well-designed proofer will increase profits for any bakery, as well as improve flavor and texture in the finished bread.

So, a quick trip to major manufacturers will show what is available out there.

And, even though many are based in Europe or the United States, they are global suppliers and either have offices or agents in the Asia Pacific regions.

Equipment makes perfect

Take Scandinavian giant, Sveba-Dahlen, for example. Besides agents, it has offices in Hong Kong and China with the former covering Hong Kong, Macau, Japan, South Korea, Taiwan, The Philippines, Thailand, Vietnam, Singapore, Malaysia, Indonesia, Myanmar and Laos.

With close to 50 years of experience of manufacturing fermentation lines, Sveba-Dahlen’s lines are manufactured in one or two level versions, and the size is calculated to meet capacity requirements and the layout of the bakery.

The maximum band width is four meters and the bands are threaded over the full width.

A modular plastic belt is commonly selected where tins or plates are used. The fermentation channel is well insulated with cellular plastic and lined externally and internally with aluminum sheets or plastic. Most of the side panels can easily be removed to facilitate cleaning of the band.

In line with keeping abreast of ever-changing technology, the company’s Fermatic Q4 has been developed to meet evolving production requirements with regard to techniques for freezing-proving, retarding-proving and dough-on-demand trends.

The equipment offers improved taste and aroma as the enzymes in the dough have time to develop. This delivers higher quality in the baked bread.

Quite important is the fact that the speed of fans can be adjusted according to individual requirements and circulate precisely the right amount of air to process the dough as gently as possible.

The fans have precisely the speed required in each phase of the program, thus providing an energy efficient and quiet cabinet.

The automatic system controls all processes in the cabinet, ensuring that the dough is protected against drying out and is handled as carefully as possible.
The Fermatic Q4 gives the baker greater freedom and the opportunity to influence times and settings to suit the individual working day and the pace of the work.

Sveba-Dahlen also offers conveyor provers which are manufactured in length according to the requested proving time of the product. The company’s swing prover is available in two different models, one with stainless steel covers and one with an automatic climate unit built into an insulated room.

A module system in widths of up to three meters can be adjusted in height and length according to capacity and required proving time.

The swings for loaves are with easy removable textile tubes and for round bread cups or baskets are used.  

Helping dough grow

Another major player in this specialized sector is Benier, part of the Netherlands-based Kaak Group.

In the design of Benier proofers, particular importance was attached to providing ideal conditions for dough processing. The design and material are selected so that technological and process requirements are fully met.

Realization of the proofer concept is determined by aspects like capacity, also for determination of the type of infeed system and residence times where the contents are determined by the capacity.

Also important is climate control where design and functionality depend on the dough guidance and quality requirements, as well as the ambient conditions and capacity of the proofer.

Benier proofers are built by means of a clever modular system using high-quality materials. This has the result that the ambient factors in the proofer are identical.

The system with its clear lines is easily accessible, hygienic and solid. Plastic sliding windows at the front offer a clear view of the inside of the proofer.

In the proofer, selection can be made between a 6, 8 or 12-part swing design. The removable proofer pockets are made completely of a dough-repellent plastic for optimal aeration. In the turning device, sterile UV lamps can be fitted if necessary. Pusher systems can only be used with proofers in a 12-part swing design.

There is a choice of dough infeed systems with Benier.

The single infeed introduces the dough pieces on the left or right side of the swing. With each rotation of the swing, the dough is moved one position further.

With double infeed systems, from the center, two dough pieces are introduced with each rotation of the swing. With each rotation, the dough pieces are moved to the next position on the swing (both to the left and right).

A pusher infeed system is good for high capacity needs as the cycle time for feeding the balls of dough also becomes more critical.

In this case, Benier recommends the pusher infeed systems. The dough pieces are fed into the swings simultaneously in groups of four or twelve. Due to the synchronization of infeed rate, swing and pusher movements, the dough pieces are reliably placed in the proofer pockets with the aid of the HCI pusher system.