Passing by a bakery you are drawn in by the site and smell of fresh bread, pastries and cakes. But what puts those delicate items from the oven to the store shelf in the best light to stay soft, fresh and looking their best — is more than just a great recipe. It is advanced technology that steps in behind the scenes.
If you are in the commercial baking business you see that proper packaging is your last hope at preventing stale products and damage. Using the right bakery packaging machine may be the key to what does and what doesn’t sell out on the shelf.
In this guide we will look at the key role that advanced packaging technology plays in the baking industry. We will cover what to look for in the equipment, the benefits of modernizing your systems, and how to get past the issues which present themselves in packaging to keep your products fresh and your customers satisfied.
The Role of Advanced Packaging in Baked Goods
In the bakery business freshness is what it’s all about. We see that customers want their croissants to be flaky and their bread to be soft days beyond purchase. What we have is advanced packaging technology which we use to create a secure environment between the product and the outside which in turn preserves the quality.
When you use manual packaging or out of date equipment you are left with human error and inconsistent seals. This in turn allows oxygen and moisture in which in turn speeds up the staling process and promotes mold growth. With advanced packaging technology we see to minimize these issues. It uses precise measures and a tight seal to preserve moisture and flavor and at the same time keep out contaminants.
Also packaging is a huge element of how consumers see your product. We see that which is well packaged comes off as professional, hygienic, and premium. By investing in top technology you guarantee that every item which leaves your facility is flawless which in turn helps to build up trust and brand loyalty with your customers.
Features of Today’s Bakery Packaging Machines
Transforming your production line means looking at what modern technology has to offer. In the case of bakery products we have machines that are very gentle yet powerful. Here are the key features which stand out.
Automated Sealing and Wrapping
Manual wrapping is a time consuming task which also produces variable results. Today we see that automatic flow wrapping and sealing systems which are used in modern machines that process hundreds of products per minute. What we get is a very consistent package which is the same every time and also a very reliable protection against the elements.
Modified Atmosphere Packaging (MAP)
In terms of food packaging, one of the great advances is Modified Atmosphere Packaging (MAP). What this does is to replace the oxygen in the package with a mix of protective gases like nitrogen and carbon dioxide. We know that oxygen is the main cause of mold growth and product staling which is why MAP greatly extends the shelf life of your bakery products without the use of artificial preservatives.
Smart Sensors and Quality Control
You can’t put out a defective or improperly sealed package to the vendors. Today we see that machine technology in the bakery is very advanced which has in-built smart sensors that determine the size and shape of the product. They adjust the wrap film which in turn reduces waste and also see to it that products don’t get crushed. Also there are in-built vision systems which scan each package to see to it that the seal is proper and the label is on right, any which don’t meet quality parameters are rejected.
How Packaging Machinery is Transforming the Bakery Industry
In a specific bakery packaging machine which is a must for the final product wrap, that is only a part of the picture. What really sees transformation is the production floor as a whole which we see as a system of all packaging machinery that comes together.
As your machines which include slicers, weighers, wrappers, and case packers become integrated with each other what you see is a completely fluid workflow. This integration breaks up bottlenecks which in turn also means that delicate baked items are not left out on the conveyer belts for too long. In the event that we do have a jam at the wrapping station what happens is the previous machinery will slow down which in turn also prevents a pileup of crushed bread and ruined pastries.
Connecting to all of your packaging machinery also we have at our disposal real time data. We are able to track exactly what your volume is per hour, monitor film use, and determine when maintenance will be required. This integrated approach to your machinery allows bakery owners to make informed decisions, reduce operation costs, and see an increase in output with minimal stress.
Main Benefits of Improving Your Packaging Systems
Investing in new tech is capital intensive but the return on that investment is great. We will look at how improving your packaging systems will benefit your bakery business.
Extended Shelf Life
As we reported before we have been using MAP and precise heat sealing technologies which has improved your food’s shelf life greatly. What we are seeing is that there is less waste and less customer returns at the grocery store. Also we are able to expand our distribution range, we are able to ship to new cities and states without the issue of products going bad in transit.
Enhanced Brand Appeal
First leaves are important. As your products like cookies and cakes are placed on a shelf with that of the competition the packaging has to stand out. We have put in place advanced machinery which does very complex packaging of materials including printed films and eco friendly wrappers in their sleep. We put in crisp graphics, precise folds and secure seals which we hope will tell the customer that we are into quality which in turn will make them choose our brand.
Increased Operational Efficiency
Labor issues are an issue in manufacturing we see. By the use of automation in packaging we see that which of human labor is reduced. One man can operate a machine that used to have ten hand packers at it. We see this as a way to improve efficiency and also to put your staff into more valuable roles like quality assurance or new product development.
Common Challenges in Bakery Packaging
In spite of the best technology packaging, baked goods present a set of unique issues. To recognize these issues is the first step in solving them.
First out that bakery products are delicate. A heavy hand with the machinery will easily see a flaky pastry crushed or a loaf of bread flattened which in turn will see wasted product and lost revenue. The equipment has to be of a gentle touch which still at the same time is able to process at high speed.
Second, the issue of variable product sizes is a concern. Bakeries almost never deal with a single product. We may be wrapping large artisan breads in the am and small muffins in the pm. Also we see which products to run into the machines which change in size very frequently, which in turn requires a great deal of down time for machine reconfiguration.
Also at issue is the challenge of temperature. We find that wrapping baked goods while hot causes moisture to accumulate within the plastic wrap. That moisture ruins the crumb structure and also encourages mold growth which in turn voids the benefits of packaging.
Effective Solutions for Packaging Roadblocks
Fortunately what you can do is to put together the right strategies for your advanced machinery.
To avoid product damage we recommend to get a good quality bakery packaging machine that offers adjustable belt speeds and gentle action guides. Also many of today’s machines have the use of custom designed pusher bars and soft touch belts which gently support the product as it goes into the wrap film.
To address variable product sizes, look to machinery which has quick changeover features. Today’s technology often includes tool free adjustments and touch screen recipe memory. All you do is hit a button on the screen and the machine will automatically set itself for a different product size within minutes which in turn almost eliminates down time.
To fix issues of temperature and condensation you must work out the kinks in your cooling process prior to the items going into the packaging line. We use spiral cooling towers which give products the time they need to release steam and come to room temperature naturally. Also we have been using micro-perforated films which allow for the escape of any remaining heat at the same time as protecting the baked goods from external contaminants.
FAQs About Bakery Packaging Machines
What is a bakery packaging machine?
Automated equipment which we use for packaging baked goods in protective materials. We put products in bags, pouches or plastic film which in turn protect them from contamination and extend their shelf life.
What role does packaging play in bread’s freshness?
Proper packaging also acts as a barrier to oxygen and moisture. This which in turn prevents bread from drying out and which also keeps mold spores out of the product thus keeping the bread soft and safe to eat for a longer time.
Does one machine do it all in baking?
Yes. Many present day machines are very flexible. We see that they have in them the ability to adjust settings and program memory which in turn allows our equipment to go from packaging large loaves of bread to small cookies with very little down time.
Is it an issue to add a new machine to my existing packaging machinery?
Not always. Today’s machinery is designed for integration. We see universal communication protocols that enable easy sync up of our new machines with what you already have in terms of conveyors, labelers, and boxing equipment.
What is Modified Atmosphere Packaging (MAP)?
MAP is a packaging method which removes oxygen out of the package and puts in protective gases like nitrogen. This also reduces the spoilage process without which the food’s taste or texture is changed.
Conclusion
In order to keep bakery products fresh, safe, and attractive we have to strike a fine balance between art and science. While your recipes may be the base for great taste, it is advanced packaging technology which sees to it that what the customer gets is the flavor you intended.
By going into the purchase of top of the range bakery packaging equipment you protect your fragile products, extend their shelf life, and also greatly improve your operational efficiency. As you implement this tech into all of your packaging systems on the floor you create a smooth, data based operation which is ready to scale.
If you are looking to cut down on food waste and improve your brand’s in store performance then it is time to look at your present packaging systems. Identify what areas can be improved with the use of automation, care in handling, and smart technology. By taking this step forward in your equipment now you will put your bakery at a growth and success advantage in the future.
