Blog | Bakery Concepts International


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bakery capacity, production, effcient, save money, bakery, mixing, baking technology

5 Ways to Increase Bakery Capacity

In the food industry, bakeries are looking to do more with less. A report published by Technavio on bakery trends for 2017 found bakeries are looking for efficient equipment that’s well made and can cut time.

No matter the size or the type of your operation, you probably have similar goals. Having equipment that can do more while costing you less is always ideal. If you’re running at or near maximum bakery capacity and searching for options, here are some ideas:

1. Energy Efficient Equipment

Energy costs are no joke. Thankfully, there is more equipment coming into the market that is making an effort to be more efficient for energy usage. Also, look for equipment that is efficient in every aspect. Equipment that is designed and works well can go a long way in cutting wasted time—and money—in  your operation.

2. Smart Equipment

Now more than ever, we’re seeing the amazing ways technology can innovate the food industry. Many types of equipment today have automated features, presets, and other smart technology that can help with product quality, time savings, and labor costs.

3. Better products

What in your baking formula can you adjust? How about speeding up the process and increasing your outputs? With bread products, you could try no-time dough. Or increase the hydration of your dry ingredients to speed up mixing time and use less yeast.

4. Higher process efficiency

Make sure other aspects of your operations are running smoothly. Have all your safety plans in place, and review Sanitation SOPs. Keep up preventative maintenance. The smoother your operation runs, the less hiccups it will experience.

5. Financing and leasing options

If there equipment you have your eye on that would work wonders for your plant, look into what financing is available. Or depending on your situation, leasing a piece of equipment may be the right fit. If the equipment has a good ROI, it’s a good ways to get it without a large investment up front.

Helping bakery capacity through mixing

Rapidojet mixing bakery capacity

One thing many maxed-out plants that have found which gives them a whole new bakery capacity is Rapidojet. This patented technology dramatically decreases mix time, decreases fermentation time and increases yield. It’s also highly energy efficient. From hydrating dough to sprouting grains, you’ll be amazed at how it will impact your output.

Learn how Rapidojet technology can increase your capacity.   


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bakery equipment engineering

The Future of Bakery Engineering

If there’s one thing we all want to see, it’s the baking and food industry grow. I’m not just talking about expanding our product lines and sales, but laying the groundwork for expanding ideas and inspiring young leaders; making room for innovation and a fresh way of approaching problems.

That’s why I’m a supporter of the  American Society of Baking and their commitment to community, integrity, education and leadership. This group of commercial baking professionals, food technologists, engineering, equipment, ingredient and service experts know that by creating a space to share and spark ideas, baking technology can make great leaps forward. ASB offers educational material, webinars, and the BakingTech conference, among other things.

The Future of Baking Engineers

One challenge facing the baking industry right now is a gap between a retiring skilled workforce and younger, qualified replacements. In the July issue of the ASB Magazine, Executive Director of ASB Kent Van Amburg says, “Industry wide, companies are facing a shortage of skilled employees…We want to help promising individuals find the educational training to build careers in this field.”

A recent study by ASB and ABA, The Workforce Gap in U.S. Commercial Baking: Trends, Challenges and Solutions, revealed that the baking industry desperately needs engineers, machinists and maintenance personnel. So ASB started the Engineering/Maintenance Scholarship Program, which awards five $4,000 scholarships to help aspiring engineering students get the education they need to make a difference in the baking industry.

“We focused our funding on those areas and immediately found incredible individuals who are passionate about making a name for themselves in this industry,” Van Amburg said in the ASB Magazine article.

Innovation for Hydration

Helping support engineers in the baking industry really does make a difference by opening the door for innovation. BCI’s patented Rapidojet Technology owes its start to Food Engineer and Inventor Dr. Bernhard Noll. He came up with an idea to revolutionize the way we approach hydration and mixing.

future engineering Rapidojet

Dr. Noll doing a Rapidojet demonstration.

Now, bakeries are seeing up to a 65% reduction in mixing time and 8% higher yields with biga, and huge cuts in labor, power and equipment costs. All because someone took a chance to think outside the box. The soaking time for bran and other grains has been eliminated while instant hydration of 300% has been achieved.

If we want to take our businesses and products beyond the safety of “it’s always been done this way,” then it’s time to start looking to the future and how we can get there, together.

To find out how you can be a part of the future of hydration and mixing, email me about Rapidojet at ken@bakeryconcepts.net.


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no-time dough

No Time to Waste? Go with No-time Dough!

Your time is valuable. So I’ll get right to the point. The patented technology of Rapidojet gives you dough that’s ready to go in no-time.

Sound nice? I’m sure you are always looking for ways to speed up your process, getting more of your product out on the market. Yet some areas (like baking or mixing) can hurt product quality if corners are cut. However, Rapidojet does just the opposite: it cuts time and improves the product. Then you can focus on improving other aspects of your production line and product.

Why is it no-time dough?

The idea is that we instantly do most of the mixing AND hydration in one step with Rapidojet. In the first step of the process, it combines flour and water under high pressure. The flour falls through our Mixing Chamber where it is shot with the water. It comes out the bottom, into the bowl, already developed and hydrated.

This means 100% of the flour and 100% of the water are processed through Rapidojet into the existing, legacy mixing bowl. The bowl is then moved to the existing, legacy mixer where salt, yeast, dough conditioner, etc. are added.

Pre-hydration of flour results in a fully developed dough with a short time.

Because we’ve already created the gluten development and increased hydration (total yield) by about 8%, the Minors only need to be incorporated into the dough. This will take about 4-5 minutes maximum. We’re talking a 65% reduction in mix time! Think about your new mixing capacity with this reduced mix time.

But we aren’t just talking about a dough that’s ready to go in a matter of minutes. This no-time dough is also better functioning than dough mixed in a traditional mixer. In the first step, Rapidojet technology improves the process of binding dry and wet ingredients. Gluten is fully hydrated, and more water is bound. This increases shelf life, texture, volume, strength and more.

More savings, more time

When you cut the time of your process, you are cutting more costs, like labor and power usage. The need for ice and glycol is also substantially reduced, because the process does not heat up your dough. Dough conditioner can also be used in much smaller quantities—or not at all!

Could no-time dough revolutionize your bakery? Send me an email at ken@bakeryconcepts.net and let’s talk about the patented Rapidojet technology.


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Bread scoring

Cut Through the Competition with Water Scorers!

Let’s talk about bread scoring. When talking production lines, it may not be the first equipment that is addressed. However, innovative equipment can speed up your process AND improve product quality.

Bread scoring is more than pretty lines on a loaf (although it does play a key role in visual appeal). It is a crucial part in crust development and expansion. The slits allow for rising gases to escape, preventing split seams. Scoring can also influence color, crust, length—so you want to get it right.

Artisan, hand-made loaves usually come to mind when talking about scoring. And this is where bakeries starting to expand have to ask themselves: how do you keep the hand-made feel, while speeding up your line with automated equipment? Scoring machines are a great place to start.

Water Scorers

I truly believe water scoring is the way of the future. It eliminates slicing blades, which can break and cause food safety concerns. It also gives you more flexibility, precision and control for the whole process. If you are looking for a true artisan-approach to water scoring, I suggest Beor’s Leonardo automatic scoring machine to speed up your process and improve your bread.

While the Leonardo is not the first to use water to score, it is unique. What really sets it apart is its flexibility and intelligence. It can follow the contour of the bread, instead of just cutting in a straight line like many other automated scorers. This gives it that hand-scored feel, leaving your final product looking natural and rustic.

While it gives your bread the impression of a labor-intensive process, it really is a time-saver for you. One great feature is the Leonardo can score bread on any fluted pan, tray or board. So you don’t have to transfer or manipulate your product before scoring. And it can acknowledge if loaves are not evenly placed on the board, and adjust accordingly.

Top 5 reasons to use Beor’s Leonardo:

  • Photoelectric Cell Laser – adjusts automatically with height variations and irregular placement of dough pieces.
  • Adjustable to any type of tray or board up to 1 meter by 1 meters.
  • Save presets in the program HMI.
  • Artistic! three types of scoring – Herringbone score, Crisscross score and Straight score.
  • Eliminates the use of blades

See it in action:

As your bakery grows, so will your equipment. So why not invest in something that will make your production and product better, without sacrificing what got you to where you are in the first place?

To learn more about Beor’s Leonardo automated scoring machine, and how it can help your company, contact me at ken@bakeryconcepts.net.


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biga-bakery concepts- rapidojet

Watch your Biga Yield Grow!

You bake with preferments to improve bread’s texture, aroma and hydration all with less yeast. So why not improve your biga so it can in turn better enhance your products? By optimizing your biga to the max, you will see big advantages in terms of yield and product quality.

How do I optimize Biga?

The key to biga working wonders in your products is its hydration. This Italian-style stiff preferment has a 50-60% water absorption. It plays an important role in hydrating flour during the mixing process. But what if by just changing the way you mix, you could drastically improve that hydration, along with other things?

To truly optimize biga, try a Rapidojet mixer. It shoots free-falling dry ingredients with a high pressure stream of water, instantly hydrating them. With the Rapidojet technology, we can pre-hydrate 100% of the ingredient flour with 100% of the ingredient water to the existing mixer.

Then, the minors and micros such as salt, yeast and dough conditioner are added at the bowl and the mixing process is finished. A fully-hydrated mixed dough is a happy one, and is proven to increase yield.

Biga mixed with Rapidojet, sees  at least a 4% higher total yield when all the flour is pre-hydrated into the existing mixer. Other customers have realized a total increase in yield via more homogeneous hydration of 8% with the same degree of “dough feel” and machinability.

Get huge cost savings, QUICK!

For Biga, there is at least 50% less mixing time in the existing mixer when all flour is pre-hydrated via Rapidojet and minors and micros are added at the bowl. Most other customers are seeing a reduction of 65% in mix time. At only 1.5 kW hr. / ton of output vs. the normal 15 kW hr. / ton from a typical horzontal mixer, Rapidojet represents a HUGE amount of energy savings.

Impressed yet? Here are a few other benefits you can expect with the Rapidojet technology:

  1. Significant reduction in the amount of ice or glycol required to keep the dough cool.
  2. The need for dough conditioners is drastically lowered.
  3. Reduced need for yeast or accelerated proofing.
  4. Longer shelf life because of the more homogeneous bond between drys and liquids. This slows starch retrogradation, the primary cause of staling.
  5. Increased consistency of the final baked product.

You bake with biga to improve your products. So why not mix with Rapidojet to improve your biga yield?

Read more about how the Rapidojet technology is transforming mixing, or send me an email at ken@bakeryconcepts.net.