Bakery Technical Facts Production that can Disturb Case Study

Bakery Technical Facts Production that can Disturb Case Study

As a business owner after you followed all the good advises about Bakery Technical Facts Production and finally opened your Bakery production you realize after a while that not only the taste and the size of your bakery products are not consistent but also your expenses are higher than your benefits. At this point  you might need the advise of a production professional.

 

Bakery Technical Facts Production
Bakery Technical Facts Production

 

Below is a case study preliminary report that I sent to one of my clients concerning an overview of its medium volume bakery and Pastry production ( around 4000 pieces per day).As you will see it is always a matter of opinion and to some extend self pride and refusal to admit mistakes at certain corporate levels. As usual I really had to convince my client that what was going wrong in his production was not necessarily what he had evaluated about Bakery Technical Facts Production .

 

Bakery Technical Facts Production
Bakery Technical Facts Production

Bakery Technical Facts Production

 

Below was my first report to owner:

agreed or not I believe  that the Bakery is in serious need of improvement if we aim for sustainable quality standard we pretend to provide to our customers. I noticed many inconsistencies and below are the most significant ones:

  • Uneven and often inaccurate  proving and cooking time resulting of inconsistent final products.
  • Inconsistent shape, look and taste of the products .
  • Inconsistent portioning throughout the bread production resulting of product losses.
  • Inaccurate  production timing creating inappropriate or excessive cold storage time and therefore lack of freshness.
  • Disturbances and deviations with  schedule tables and logistics resulting in lateness and risks of penalties from customers.

 

Bakery Technical Facts Production
Bakery Technical Facts Production

 

What are the reasons of such situation?

  • There is only one oven in the bakery production, therefore the all production timeline is solely dictated by queuing at the oven door. Even if it has been already optimized, each cooking session just cannot be regulated according to each specific product, irrelevant of its composition or size. For example breads and Danish requires a different cooking time and temperature, but they are often proved and cooked together due to delivery schedule constraint.
  • Most of bakery product should be produce within a certain amount of time which again can be different. A 100 gr brioche would take 35 mn to prove, then it has to be put in the oven immediately at 185 degrees for 15 mn . while a 35 gr hard roll will need 20 mn proving and 12 mn baking at 210 C with steam. Unfortunately the situation does not allow the team to do that and most of the time all products are proved in the same proving chamber and should queue to wait next oven rotation, creating inconsistent results.

 

Bakery Technical Facts Production
Bakery Technical Facts Production

Bakery Technical Facts Production

  • Last minute orders cannot be added in the already overwhelmed production, therefore the team have to overproduce to anticipate last minute orders. This not only creates waste but it also disturbing the whole material requisition process and therefore the purchasing procedures.

 

  • To produce freshly baked is therefore very limited and production generally takes place well in advance and stays in cold storage more than necessary.
  • As consequence cold storage are overloaded at time which increase electricity and maintenance bills.
  • Most of manipulation been performed by hands at present time 1 CDP and 1 Demi Chef in charge for the whole bakery production are therefore insufficient to ensure a 24 hours bakery production . Consequently high employees turnover added with a very low competency level contribute to the disorganization.

 

  • Space and storage capacity of bakery production are insufficient to maintain proper conditions and cleanliness.
  • Low temperature water necessary to ensure high quality dough is not available in the kitchen.
  • Equipment to produce lower amount of dough is not available and less than 5 KG must be made in the big capacity mixer ( 25 kg) which is damaging for the dough let alone the electricity waste.

 

Bakery Technical Facts Production

 

Bakery Technical Facts Production
high capacity dough mixers

Bakery Technical Facts Production

Immediate measures to improve the situation:

  • Training of culinary education sessions for employees and daily workers as well.

 

Bakery Technical Facts Production
Team member culinary training

Bakery Technical Facts Production

  • Raising employees awareness for hygiene and sanitation
  • Improve all best practices to increase efficiency and reduce time motion work.
  • Revise and adapt all product  recipes to improve shelf life and taste
  • Monitoring and Coaching of both PIC on daily bases
  • Purchase of utensils to ease handwork

 

 

However the core of the problem remains and needs to be tackled right the way because we are increasing rapidly our production. Doing everything by hand is not the solution and some technology must be added to ensure quality and consistency . I believe that we should proceed with the purchase of a number of equipment :

  • Convection oven 6 racks more suitable for danish baking
  • Dough mixer 18 KG for medium size quantities
  • Dough mixer 5 kg for smaller quantities such as doughnuts
  • Dough divider to ensure speed and size consistency
  • Dough molder to ensure regular shape of rolls

 

Bakery Technical Facts Production
rack full of danish rolls

Bakery Technical Facts Production

This assessment aims to give a better understanding to all and hope for a quick responds to support field operations and improve customers satisfaction.

At the end the owner purchased half of the equipment I requested, improving significantly but not completely the quality of the production. Better than nothing.

 

Bakery Technical Facts Production
purchased equipment

Bakery Technical Facts Production

Feel free to send me your comments.

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