Air Management Technologies Inc., Lewisburg, Pa., offers a self-contained, spiral-cooling system that not only offers commercial and industrial wholesale bakers the benefits of keeping finished products at consistent temperatures, it also uses less than one-third of the energy used by traditional refrigeration systems, providing substantial energy and annual greenhouse gas savings. Other benefits include enhanced filtration for mold and particulate removal, positive pressurization to prevent infiltration of plant air, enhanced air distribution, sanitation benefits, corrosion protection and an enhanced design to prevent mold growth from cooling coils.According to the company, the system was designed to help bakeries control their cooling processes and realize food safety and quality benefits. The spiral cooling system accomplishes this by using outside air to provide free cooling during a majority of the year, depending on climatic conditions. When the outside air temperature is above 75 deg. F, the system uses mechanical cooling. Air pulled from the center of the cooler can be exhausted, recirculated or mixed with outdoor air, depending on the mode of operation and room pressurization requirements.Air Management Technologies’ Oxidizer/Oven Heat Recovery System, recognized in the 2010 B.E.S.T. in Baking program, uses oven waste heat normally lost to the atmosphere to eliminate or substantially reduce the need for boilers and other heating methods. Systems currently in place in numerous large and small bakeries have seen annual greenhouse gas reductions from 400-1,000 tons. These systems typically supply process usage points, including proofers, water heaters, tray washers, fermentation rooms, feed-water preheat and nonprocess loads, such as preheating outside air, space heating and absorption cooling.According to the company, it has added several new developments since being recognized in the 2010 B.E.S.T. in Baking program, including a micro-turbine option, which provides additional energy savings and backup generation in event of a power failure sufficient to rack-off product from ovens and so on, and the Organic Rankine Cycle, which allows electricity production directly from the waste-heat stream.

American Pan Co., a Bundy Baking Solution, Urbana, Ohio, introduces a new baking screen/baguette pan with a patent-pending TabLock attachment that eliminates rivets and allows bakers to quickly change baking screens.The pan is designed so the screen can be easily removed from the frame and be replaced by personnel at the bakery. This offer bakeries several environmental benefits: They don’t have to ship pans back to the manufacturer or service center to have the screens drilled out, replaced and shipped back. This reduces fuel consumption and carbon dioxide emissions generated by transporting baking screens back and forth. It also reduces energy consumption associated with the power tools needed to remove and replace the screens and the energy and raw-material consumption for manufacturing, due to its extended pan life. Solid waste is also cut because the screens and frame are recyclable.The new pan design also lowers downtime. Bakers no longer have to wait days or weeks for new screens while the pans are shipped, repaired and returned. The screens can be replaced in-house, as needed in little time. Employee safety increases, because the time-consuming removal of rivets is eliminated. Food safety is improved, the company adds, because with no rivets, the TabLock design eliminates the possibility of contamination from metal shavings or rivet ends in baked goods.

AMF Bakery Systems’ patented Emisshield, a patented nano-emissive technology, can lower energy consumption by as much as 20% for increased sustainability in high-speed, commercial bakeries. According to the Richmond, Va.-based company, reducing the energy needed to bake each loaf of bread can improve the sustainability of baking operations and reduce their carbon footprints.Emisshield systems improve the uniformity and waveband width of the infrared heat produced by a gas oven, resulting in more efficient heating of the bread. This increases overall oven efficiency, providing energy savings, production increases, reduced air emissions, downtime and maintenance and improves product quality.Emisshield can be applied as an add-on to existing or new gas ovens and is currently being tested in continuous ovens.

Auto-Bake Pty. Ltd., Hornsby, New South Wales, Australia, is a global designer and supplier of fully automated, industrial baking ovens and systems. Internationally renowned for its innovative Serpentine technology, Auto-Bake’s compact, cost-efficient, continuous-baking solutions are custom-configured for a diverse range of baking applications.The heart of the technology is the compact Serpentine oven, which conveys trays across multiple, horizontal levels in a distinctive S-shape, achieving a footprint one-tenth the size of a conventional tunnel oven. This space-saving technology has also been incorporated into Auto-Bake’s proofing and cooling modules. The Serpentine configuration facilitates precise thermal zoning and baking control, affording superior energy efficiency. The oven can be fully tailored and precision-engineered.According to Auto-Bake, its systems accelerate their return on investment: Reduced energy and water consumption; a space-saving footprint; reduced changeover time; easy use, maintenance and operation; easy cleaning; labor savings; heat control throughout the individual oven zones; and robotic de-panning for less product movement and waste.

As the baking industry continues to develop more entries for the growing health and wellness category, it is turning more often to Briess Malt & Ingredients Co., Chilton, Wis., a manufacturer of value-added grain- and starch-based ingredients, for unique solutions to formulating challenges. The product lines of natural sweeteners, 100% pure malted ingredients and 100% pure pre-gelatinized grains are helping bakers reformulate or develop new products to achieve label claims such as “whole grain,” “contains no corn syrup,” “natural,” “organic,” “gluten-free” and “heart healthy.”Manufacturers of all types of baked goods, particularly specialty breads and doughs, are using a variety of standard or custom ingredients from Briess to achieve specific label claims while also improving the flavor, color and/or processing of better-for-you foods. For example, a custom Briess blend of pre-gelatinized grains helped one manufacturer achieve its target “whole-grain” claim while also enhancing the eye appeal of its line of premium, whole-grain breads.Several manufacturers of frozen white bread doughs or pizza crusts incorporate a small percentage of a standard but unique specialty malt extract for improved processing and enhanced flavor, crumb and browning. In both instances, the Briess technical staff worked closely with the manufacturers’ R&D teams to develop these solutions.

Briess employs minimal, but energy-demanding processes in the production of specialty malts, natural sweeteners and pre-gelatinized grains. Water, heat, time and milling are applied in a variety of levels and sequences necessary to pre-cook the grains and develop their characteristic colors, flavors and textures.

Eight years ago, Briess formalized a sustainability initiative dubbed “Green With Briess,” dedicated to decreasing energy consumption and CO2 emissions without impacting its product portfolio. Through a combination of volunteer energy audits, capital improvements and processing changes, Briess has reduced energy consumption and emissions to the equivalent of nearly 10 million fewer miles being driven each year since 2006.

By increasing efficiencies, Briess can commit additional resources into research, product innovation and custom product development. In turn, this helps many manufacturers expand their health and wellness platforms and respond to growing consumer demand for healthy, good-for-you foods made from minimally processed, natural ingredients.

The company says that respecting the environment and making a conscious effort to minimize its environmental impact associated with operations remains the Briess commitment to the environment and the industries it serves.

The D-CARBONATOR from ChemxWorks Inc., Poway, Calif., removes carbon buildup and fats, oils and grease from commercial kitchen and bakery equipment. Carbon can build up on equipment over time as a thick, hard crust, making it extremely difficult and laborious to remove. Besides being unsightly and unhygienic, the buildup also is a heat barrier, requiring more heat to be transferred through the insulating barrier.The D-CARBONATOR is made from high-quality stainless steel and is fully insulated. It is thermostatically-controlled, maintains the solution temperature at 185 deg. F. and requires no plumbing. On casters, it can be wheeled to a water source or filled with water using a hose when the monthly detergent refill is required. (A drain hose is included.) A lifting basket inside the unit facilitates filling and emptying. A monthly refill indicator light changes from green to red when the detergent needs to be replaced. The dampener hinges allow for steam to escape when the unit is opened and prevents the lid from crushing fingers. A gasket also contains the steam.Operators place equipment to be cleaned in a heated, aluminum-safe solution of water and non-hazardous detergent in the D-CARBONATOR. Initial soak times depend on the carbon buildup and can vary from a few hours to an overnight soak. Items that are removed are fully sanitized and require only a light rinse before using.According to ChemxWorks, the D-CARBONATOR offers commercial bakers an efficient and cost-effective method of cleaning sheet pans, baking pans, hood filters and a variety of other baking equipment. They can choose from a number of models tailored for various applications and industries; the largest models can hold entire baking racks.

Water and electricity consumption is reduced immediately. Chemical consumption is also reduced dramatically because the water and detergent remain in the unit for a month at a time. Labor can also be reduced. Once the carbon is removed, baking times can be shortened with possible additional baking cycles in the same amount of time.

Daabon Organic USA Inc., Miami, offers all-natural, certified organic palm oil products for use in various baking applications, such pies, cookies, crackers, biscuits, fried items, covertures and fillings, as well as by producers in related industries, such as nut butter and spread manufacturers. The products are kosher, nonhydrogenated, vegan and free of genetically modified organisms (GMOs) and carry sustainability certifications from the Roundtable for Sustainable Palm Oil (RSPO) and the Rainforest Alliance.The palm oil offers numerous nutritional benefits (it contains beneficial short- and medium-chain fatty acids and has notable amounts of vitamin E) and great taste and baking performance. It is cost-effective, resists oxidation and rancidity, which extends shelf life and offers the same (or better) functionality as oils or shortenings that cost more, according to the company.In addition, Daabon’s palm oil products allow food manufacturers to prove their commitment to sustainability and drive additional business from conscious consumers to their brands.Daabon USA is part of a vertically integrated supply chain owned by Daabon Group, a family-owned company that has focused on natural and sustainable agriculture and business practices for decades. Because it is vertically integrated, Daabon can develop, use, manage and maintain sustainability practices in all aspects of its palm oil production.

Daabon’s goal for sustainable and organic agricultural production is a closed energy cycle. It strives to make a positive environmental impact through comprehensive system design integration of plantations, production facilities and environmental conservation. Daabon also has integrated several environmental programs into its business model: Water-resource and solid-waste management; methane recapture; and preservation of biodiversity.

The EcoFlex modulating, fan-powered economizer from Enervex Inc., Alpharetta, Ga., is an inline draft fan with an integrated, compact, radiator-style, heat-recovery module. The fan is built in stainless steel, so it can be used with any type of condensing or noncondensing heating appliance. The control measures the pressure in the venting system and modulates the fan speed to ensure the outlet pressure of the appliance remains within the appliance manufacturer’s required range. The system enables operators to preheat a hot water return, boiler makeup water, steam boiler feed water and circulating makeup water, as well as provide hot water for various processes.EcoFlex is suitable for companies with appliances that exhaust waste heat into the atmosphere or need preheated water, such as bakeries, breweries and industrial manufacturers with a boiler plant or baking appliance requiring more than 4,000 MBH (1,000 British Thermal Units) input.The design seamlessly resolves issues related to a traditional-style economizer. It allows any appliance to operate more efficiently, while providing preheated water for use in several ways. The integrated modulating fan provides perfect outlet pressures on all appliances to ensure the most efficient firing rates possible, even in applications where one EcoFlex system serves multiple appliances. The radiator-style heat exchanger provides a 50% gain in efficiency compared to many conventional economizers, the company reports. According to Enervex, a typical payback is four to seven years, but in some instances, energy grants have reduced the payback to less than one year.

Las Vegas-based Hayon Manufacturing Corp.’s Hayon Automatic Pan Greaser offers a simple, cost-effective method for spray-greasing pans or applying egg wash and glaze to baked goods.The “Select-A-Spray” operating system sprays a continuous pattern evenly over each pan or product and recycles any overspray in the process, so there is no application waste. The spraying occurs within the machine’s operating hood, significantly reducing any airborne mist, for a healthy and safe work environment. A 100% release rate helps preserve the life-span of baking pans and reduces the amount of water needed to achieve a thoroughly clean pan after bake-off.According to Hayon, some customers reported using as many as 1,800 aerosol spray cans a day before purchasing the Automatic Pan Greaser. (The average customer reported using as many as 100 cans per day, or 36,000 cans per year, per bakery). Other alternatives can deplete natural resources and expired hand brushes eventually end up as landfill waste.Hayon equipment is able to operate on single-phase, 100-volt circuitry, making it energy-efficient. It also has no disposable parts, and the filters can be washed and reused indefinitely. Preparing each new unit for delivery incorporates the company’s final step of its environmental commitment by using recycled corrugated for custom shipping cases. According to the company, most customers experience a financial return on their investment within six months of purchasing an automatic pan greaser, due to labor savings and elimination of costs associated with purchasing aerosol cans, other liners or hand brushes.

Meyer Laboratory Inc., Blue Springs, Mo., manufactures water-based sanitation chemicals and systems and provides packaging designed to help maximize productivity and eliminate excess water use. The company’s packaging and manufacturing process helps eliminate the need for excess shipping and packaging disposal, enabling customers to reduce waste and limit the amount of material going into landfills.Meyer Laboratory’s sanitation and general cleaning products and systems use the least amount of product possible to do the job required for food safety. Its super-concentrate program allows for smaller shipping containers with less drum, tank or tote handling, providing less to dispose of, which saves energy used in transportation.Focusing on using the least aggressive materials possible to accomplish a cleaning task, Meyer Laboratory says it’s helping make less of an impact on the environment and making the cleaning job as safe as possible for customers’ employees. The ability to dilute through hands-off systems allows for less waste and misuse, helping to protect the plant, equipment, employees and environment.Meyer says its program users typically see a reduction in costs of sanitation chemical products. In addition, less packaging and higher dilutions eliminates packaging waste and excess handling.

Oberlin Filter Co. offers a specialized version of its automatic pressure filter for commercial fryers ranging from 300-+2,000 gal. According to the Waukesha, Wis., company, the Gen 4 Sanitary filter can filter frying oil to a degree that food producers will never have to change the oil. In addition, the filter can control oil quality, color and free fatty acids. The Oberlin Filter also has less than a one-year payback, says the company.

Picard Ovens Inc., a manufacturer of commercial bakery and foodservice ovens in Victoriaville, Quebec, redesigned its Revolution oven to be energy-efficient and cost-effective by incorporating an optional steam system that doesn’t require a boiler or increased energy expenditure. The steam system uses the available steam in the oven, instead of using a boiler, to produce and transfer steam to the oven.The oven’s footprint is also reduced and its burner has been updated to the PowerMax high-power, modulating burner system. According to the company, the PowerMax provides the best blend of air pressure to ensure an efficient flame that lowers itself to save energy and only functions at 50% capacity to keep a constant temperature. The oven’s new AeroMax gentle ventilation system keeps heat from escaping during loading and unloading. Operators will see almost no fluctuation of temperature with the door open.Picard Oven’s research and development team takes advantage of SolidWorks Sustainability Xpress software features. (SolidWorks Sustainability from Dassault Systèmes SolidWorks Corp., Waltham, Mass., allows users to measure the environmental impact of the products they design in the company’s software). Picard says its Revolution ovens offer operators an estimated 40% reduction in energy use, and the steam option won’t increase energy use.

Robbie Fantastic Flexibles’ Fresh N Tasty Bakery Pouch is a flexible, all-in-one pouch that enables retailers to provide consumers with a window for viewing contents, a resealable closure and a proprietary film base that promotes freshness. The pouch also offers a more environmentally-friendly alternative to clear, rigid, plastic clamshells.Designed for use by processors and retailers, the Fresh N Tasty Pouch can be shipped with baked goods from processors to retailers, or retailers can use the pouch in-store to package their own freshly baked goods. The pouch is packed 250 to a box, and can be stored behind a counter. It offers ample print space—front, back and bottom, and the proprietary film base and air-tight zipper keep contents fresh longer and reduce the amount of baked goods that retailers need to pull from shelves.Robbie, Lenexa, Kan., used Life Cycle Inventory Analysis studies between a flexible pouch and a plastic clamshell to design its new packaging. The first study calculated the raw materials, electricity and energy used, as well as the transportation of raw materials used, to manufacture a single package. The second study included a logistics study calculating transportation requirements (trucks, pallets, boxes) concerning delivery to customers. The company compared the results on a truckload basis of 780,000 pouches.The first study found that the new package requires 75% less fossil fuels and emits 79% less carbon dioxide during manufacturing compared to a rigid container. When disposed of, the new package also takes up 69% less space in the landfill.

The second study revealed a savings of 2,746 lb. in shipping cases, or 13.3 trees saved. In addition, 54% fewer pallets were needed to ship the same amount of packaging, again saving 5.6 trees needed to make 56 pallets. Additionally, the study showed that 600,000 more packages can fit into a truck, saving 77% in diesel fuel and CO2 emissions.

Shaffer Mixers & Processing Equipment’s new NEMA 4X hybrid mixer combines the design features from a traditional enclosed-frame and an open-frame mixer, including enhancements in energy efficiency (direct drive) and sanitation (open-frame and water-tight enclosure designs).Designed for industrial bakeries that require a horizontal dough mixer, the NEMA 4X offers practical, environmental sustainability for the baking industry. According to the Urbana, Ohio, Bundy Baking Solutions company, the new design enables bakers to reduce their greenhouse gas emissions (carbon footprint), significantly reduce sanitation time and water usage and reduce energy use.The NEMA 4X also helps save on shipping weight because the hybrid frame mixer weighs up to 10% less than an enclosed-frame mixer of the same capacity. The direct-drive design also eliminates several maintenance and wear points, thus reducing maintenance costs and demands on maintenance personnel.Water-tight enclosures for the operator panel and hydraulic system housing, coupled with open-frame construction for the bowl and drive area make this mixer quick to sanitize. The NEMA 4X water-tight control panel and hydraulic system enclosure also allow bakeries to spray down the mixer without taking additional time to protect the enclosures.

The GS Nexus from SPX Flow Technology, Delavan, Wis., is a high-capacity, low-energy, scraped surface heat exchanger (SSHE) that uses CO2 as a cooling medium. Suitable for manufacturing various food products, it’s also suitable for making in-house shortening and bakery filling creams. It increases production capacity by reducing the time required for mixing the shortening from boxes. It offers the highest hygienic standards and reduces the risk of product contamination with an enclosed system design. It allows for internal quality control of all raw materials by controlling the in-house shortening process and eliminates the need for warehouse space used to store boxed shortening. Human involvement is minimal, which can lower labor costs.The GS Nexus requires less energy per production hour for in-house shortening production, according to SPX Flow Technology, adding  that this is the result of long-term research of different cooling media in connection with an optimal scraper design and drive configuration.Additionally, using CO2 as refrigerant allows operators to install and use heat-recovery systems to save energy. Using a heat-recovery system with the GS Nexus affords useable water of up to 90 deg. C, which can be used for other purposes in the production plant.According to SPX Flow Technology, the GS Nexus helps manufacturers reduce their overall energy consumption, saving production costs. There’s less manual handling and waste disposal, due to the lack of boxed shortening, which is also beneficial for the environment.

The TMB Baking Cool Water Oven Steam Condensing Unit from TMB Baking, South San Francisco, Calif., converts steam exhaust from a bakery oven into clean, dry air and water. The unit converts steam to water by running it through a water chiller. The water exits the bottom of the unit, while the dry air passes through a cleanable carbon filter that eliminates odors from the airflow, allowing the air to be returned into the bakery.According to TMB Baking, each year, the Environmental Protection Agency (EPA) pays more attention to bakery emissions. The TMB Baking Cool Water Oven Steam Condensing Unit eliminates oven steam exhaust—one of the more visible bakery emissions—possibly decreasing the scrutiny bakeries might receive from the EPA.By eliminating the release of steam exhaust into the atmosphere, the unit can improve the environment by allowing water to be processed through municipal or private water-treatment plants.