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Bakery Academy is an expert in bakery product development, by working hard to stay bakery experts on ingredients, their functionalities, interactions and their related processes. The complexity of applying knowledge in the development of new bakery products is our daily job. Whether it is transferring a successful product from abroad to your local bakery and ingredients, creating something completely new and unheard of or finetuning the last bit of your development. Our bakery experts will help facilitate your next innovation to stay on top of your market. Considering that there are several thousand varieties of breads, cakes, biscuits and pastries it is near to impossible to master them all by heart. However by approaching each product from the bakery process involved combining with a formulation coming from our bakery knowledge database we have a great starting point. Our product development consultant will transfer this to your local ingredients to develop specifically to your requirements: local taste, ingredients, desired shelf life and the installed production line.
Bread are one of the cornerstones of the bakery business and consist of many varieties ranging from flatbreads to pan breads and everything in between. Working on breads we focus on creating:
– Our own bread improver system
– Baking without improver system
– Changing costs
– Extending shelf life
– Using different grains and pseudo-cereals
– Trying different fermentation techniques for various purposes
– Improving nutritional profile by protein enrichment or fibre enrichment
Where crackers used to be a variant of bread and predominantly unfermented, today it is so much more. Crackers have either a plain or a more savoury profile and can be both fermented as unfermented.
Techniques like laminating, sheet-and-cut and occasionally extruding are used here on creating relatively thin and dry products. Both the fermented (either yeast or enzyme) as unfermented (plain or with additives) can be found in our bakery product database. We transfer a lot of renowned products to local ingredients and production lines: famous products in new markets.
The definition of cookies will vary per country and culture, as some will it cakes and other biscuits. We distinguish here the fact that use one of the following techniques: depositing, wire-cut or extrusion. Next to that they have certain spread during baking due to the high levels of fat and/ or sugar in the formulation. Depending on the choice of ingredients and the ratios in the formulations we can create soft or hard cookies. By using extrusion techniques we can use up to three different coloured doughs with a centerfilling, creating a hard biscuit with a soft centre. The development of these cookie products can also be done with various inclusions such as nuts and fruits.
As breads, several different kind of biscuits have been brought to market. Where the predominant technique here rotary moulding is, also sheet-and-cut is applied a lot. Both techniques have their own restrictions towards the consistency of the dough. Biscuits lend themselves very well to be sandwiched with a cream or marshmallow filling and chocolate. The Wagonwheels, Oreo, Petit Beurre, Maria and Digestive biscuits are probably the most famous and imitated ones our product development consultants are asked to transfer to local ingredients and recipes.
Although pastry is also used as a collective for several bakery products we intend here the puff pastry, filo types together with the pies (shortcrust, pound/inlay and crumble). Some products, considered to be sweet crusts, can be ranged under cookies or cakes (e.g. mooncakes) as well, but are often placed into the pastry category. The principle of the pastry product is that the filling(s) will make that the product becomes savoury or sweet, the dough itself is quite neutral tasting.
Especially processing, techniques and control are a central key into creating good products and the feeling and passion for this are often only transferred by applying the master-apprentice principle. Our bakery research here focusses on controlling moisture migration by changing minor ingredients and process development for taste and texture control.
Cakes are next to breads one of the most broad categories with several thousand different type of cake products. Traditionally a lot of cakes use eggs, but considering local habits more and more cakes are nowadays produced vegan (no eggs and milk). We distinguish seven categories within cakes:
– Foam cakes, e.g. angel, chiffon, macaron
– Aerated, e.g. layer cakes, swiss roll, ladyfingers
– Pound cakes
– High ratio cakes, e.g. brownies
– Small cakes & hybrids, e.g. cupcakes, muffins, frangipanes
– Waffles, e.g. Belgian types
We have developed our own models in order to control single or multi-layered cakes and their intended shelf life. Together we can adapt that intelligence to your local taste and texture, and even exchanging ingredients for either allergenic or nutritional goals are within range.
Wafers can be rolled, flat or hollow. Thin and crisp or slightly thicker and strong, most of the time filled with a cream or a low moisture filling. Each shape and equipment need adaptation on formulation in combination with the available ingredients. The baking times are short and special flours and starches are used in order to prevent gluten lumps in the batter.
Creating more crispier products or look critical to the material costs are some of the challenges we often undertake here, were interactions of ingredients and fillings are a key focus. Special attention we have here for creating wafers with different nutritional profiles, such as high protein wafers or reduced carbohydrate (or sugar) products.
Depending on the availability or supply some industrial bakeries need to develop their own fillings, coatings, toppings, etc. Our bakery consultants have worked and adapted several: based on fat, water or fruit. Processing is here often as important as the choice of the raw materials and can when in own hand be perfectly designed for taste and shelf for the final product where it is applied in or on.
Within the team or our bakery consultants we strive to try several ingredients and techniques in a continuously manner within our research. Sometimes this leads to new concepts such as instant clean label custard or tasteful glutenfree breads. In other occasions we can take apart improver systems for breads or cakes and reassemble with other ingredients with similar or improved properties against sometimes lower costs.
Recently we’re focussing more on the possibilities proteins and fibres can do to create different textures and nutritional profiles. On the change of nutritional profiles we have done quite a lot in the field of reformulating several bread, cakes and biscuits (and their fillings) with less to no sodium and/ or fat and/ or sugar.