Bakery Process Optimizations
Identifying opportunities most overlook
to explore how we can help you increase productivity and decrease costs.
Most optimization consultants focus on a single aspect of your business - for example, energy usage. In contrast, Cargill Optimizing Services takes a comprehensive approach, examining potential opportunities throughout your bakery operation. We'll help you gain a deeper understanding of your entire process and implement cost-effective solutions for reducing water and energy use, increasing bakery yield, enhancing capacity and more.
Leveraging more than 150 years of Cargill expertise
As the world's leading provider of food and agricultural products and with over 1,200 plants of our own, Cargill is constantly looking for ways to use energy and raw materials more efficiently. Leverage our unmatched expertise in modeling and optimizing agri-food processes - plus a deep knowledge of the bakery market - to gain a valuable partner dedicated to helping your business succeed.
Utilizing specialized simulation tools
Cargill Optimizing Services process engineering experts employ state of-the art process simulation tools that are fully customizable to accurately model your facility's real-world operating conditions. Utilizing the comprehensive Cargill Agri-Food Library of unit operations, our modeling tools can pinpoint a variety of areas where your bakery's efficiency can be enhanced.
Capturing significant savings and improvements
From bakery to meats and beyond, Cargill Optimizing Services has helped businesses across virtually every agri-food industry identify opportunities for significant savings and process improvements.
Three Key Opportunities for Bakery Efficiencies
Charles Sanderson, Technical Director, Cargill Optimizing Services
Despite differences in scale, format and product, many baking plants share characteristics and face common challenges. Cargill Optimizing Services has been successful in helping both fresh and frozen bakers through a holistic approach and application of specialized tools.
One key challenge many bakeries face is in accurately calculating--and then maximizing--the overall process yield (or mass of raw materials sold as final product). While relatively simple in concept, accurate yield calculations are complicated by a number of factors:
- Water, and often ice, are added to the dough during mixing, and part of this water is then evaporated for baked products
- Proofing of the dough converts some of the sugars and starches in the flour into C02, which leads to a loss of mass
- Proofing often requires recycling of mature dough to seed fresh dough. Shaping and trimming can also lead to recycles
- Process disturbances can lead to waste production, but often this waste is either weighed only in aggregate (or not at all)
Cargill Optimizing Services modeling tools are very effective in developing bakery mass and energy balances, accounting for proofing, baking and other unavoidable losses. This provides an accurate target yield and estimates the avoidable losses at different points in the process. The model also mitigates the complexities associated with recycle streams and incomplete measurements.
Once the loss points have been identified, some can be eliminated easily - while other root causes can be difficult to ascertain. To address this, Cargill Optimizing Services has used statistical analysis to identify which operating factors correlate to product loss - dough temperature in one case, perhaps; production run length in another. Armed with this understanding of loss drivers, operating teams can eliminate waste, thus reducing raw material and utility costs, and often increasing production capacity.
True cost of manufacturing
Many organizations have focused on reducing inventory. Usually, this is a good thing, but taken too far, it forces frequent product change-overs, which can lead to capacity loss and raw material wastage. Unfortunately, the transition costs can be difficult to quantify, so the overall best operating schedule is not always clear.
Using models, Cargill Optimizing Services can quantify the true cost of manufacturing of each product in multi-product facilities, and in quantifying the transition costs. This allows the true cost of specific operating schedules to be investigated, and for cost mitigation strategies to be developed. Accurate quantification and estimation of transition costs can enhance capacity, reduce waste and minimize expense while still managing working capital.
Cargill Optimizing Services has decades of experience in heat integration analysis - finding the most cost-efficient ways to match hot streams that are cooled (or wasted) with areas that are heated.
In addition, Cargill Optimizing Services has found opportunities to reduce electricity use through refrigeration system optimization. In many cases, though, Cargill Optimizing Services has found that the interaction with the process offers greater potential for savings. In the case of a bakery, this may be implemented by pre-cooling product upstream of a spiral freezer, or in optimizing the cooling temperature of the dough mixer.
Cargill Optimizing Services has also been successful in developing Computational Fluid Dynamic models of the airflow patterns inside spiral freezers. The knowledge we gain can be used to investigate energy savings via a better understanding of the combined impact of air temperature, product transit speed, changes in fan speed and location, or equipment layout modification. It can also provide valuable insight into the surface and internal temperatures of products moving through the freezer, highlighting potential capacity increases or mitigating quality concerns such as final core temperature. Energy is a big cost driver in many facilities. Cargill Optimizing Services' top down approach to your entire process can reveal multiple opportunities to improve efficiency.
To explore an engagement with Cargill Optimizing Services, please contact us today. We look forward to hearing from you.
With more than 500 projects completed that have less than one year to payback, Cargill Optimizing Services understands how to decrease costs and increase yields in the food and beverage industry.