Presentation is loading. Please wait.

Presentation is loading. Please wait.

Bäckerei- und Getreidetechnologie NanoBAK The NanoBAK technology Prof. Klaus Lösche, ttz BILB/EIBT Project 1 st year meeting 12th April – Holstebro/Denmark.

Similar presentations


Presentation on theme: "Bäckerei- und Getreidetechnologie NanoBAK The NanoBAK technology Prof. Klaus Lösche, ttz BILB/EIBT Project 1 st year meeting 12th April – Holstebro/Denmark."— Presentation transcript:

1 Bäckerei- und Getreidetechnologie NanoBAK The NanoBAK technology Prof. Klaus Lösche, ttz BILB/EIBT Project 1 st year meeting 12th April – Holstebro/Denmark

2 Bäckerei- und Getreidetechnologie Table of contents 1.Introduction 2.The NanoBAK System 3.The NanoBAK System - Ripening control with an optimal humidity in the atmosphere 4.The NanoBAK System – Humidity assisted cooling and freezing processes 5.Conclusions – Low energy and Premium quality

3 Bäckerei- und Getreidetechnologie Table of contents 1.Introduction 2.The NanoBAK System 3.The NanoBAK System - Ripening control with an optimal humidity in the atmosphere 4.The NanoBAK System – Humidity assisted cooling and freezing processes 5.Conclusions – Low energy and Premium quality

4 Bäckerei- und Getreidetechnologie Fuente: Chen. C.S., Lebensm.-Wiss.U. Technol., 18, 192-196, 1985 High energy demand 1.Introduction

5 Bäckerei- und Getreidetechnologie The ripening control: retarded dough, interrupted dough, frozen dough. Bake-off processes: par-baked and fully baked frozen products, pre-fermented dough, fully fermented and frozen dough, etc. Cooling after baking: For packaging, for slicing, for post processing. Current trends in bakery – fermentation control and frozen products 1.Introduction

6 Bäckerei- und Getreidetechnologie Slow fermentation Delayed fermentation Interrupted fermentation Deep-freezing Control of the fermentation through less amount of yeast. It takes place at room temperature. Craft bakeries. The fermentation speed is delayed through a quick decrease of the dough temperature. T range: +5°C to -6°C. Interruption of the fermentation through a quick decrease of the dough temperature. T range: -7° to -18°C. Long storage at lower temperatures than -18°C. Maximum storage time: 8h. Storage up to 72 h at aprox. 0°C, 80-85% RH. Storage up to 72 h (90h) at aprox. -10°C, 80-85% RH. Storage for several months Lower than -25°C, 75% RH The fermentation process takes place during storage. Final fermentation in a climatic chamber with optimal conditions depending on product. Final fermentation in a climatic chamber: gradual change of temperature (1- 2h, 3-10°C) followed by fermentation in optimal conditions depending on product characteristics. Variations: Dough Par baked products Baked products Climatic chambers 1.Introduction

7 Bäckerei- und Getreidetechnologie Cooling and freezing are high energy demanding processes and critical stages for the product quality Conventional processing Rel. Ambience H.= ~ 80-90 % Desorption Dough:Bread: Drying surfacesFreeze bruning Irregular productsWeight loses Weight losesUndiserable colour Undesirable productCrust splitting a W = 0,80-0,96 (depending of it is dough or bread) Low cooling and freezing velocity Skin forming Heterogeneous distribution of temperature Humidity and temperature gradients Low quality Heterogeneous final products Low conductivity 1.Introduction

8 Bäckerei- und Getreidetechnologie Table of contents 1.Introduction 2.The NanoBAK Technology 3.The NanoBAK System - Ripening control with an optimal humidity in the atmosphere 4.The NanoBAK System – Humidity assisted cooling and freezing processes 5.Conclusions – Low energy and Premium quality

9 Bäckerei- und Getreidetechnologie Ultrasound based humidification system which generates a cold fog (mist) with water drops of around 1 micron Cooling and freezing with assisted humidity For assuring: - High relative humidity in the chamber - Better humidity distribution (without sedimentation, without condensation) - Better conductivity - Saving yeast- and enzyme- activities in the surface - Less turbulences Energy saving 2. The NanoBAK technology

10 Bäckerei- und Getreidetechnologie Mollier h,x-Diagram With a relative humidity of 70 % with +30°C 1kg air contains approx. 19g water With a relative humidity of 75 % at +5°C, 1kg air contains approx. 5g water (retarder) 2. The NanoBAK technology

11 Bäckerei- und Getreidetechnologie Mechanical oscillations of the water surface that liberate the aerosol droplets Size of the water droplets depending upon the ultrasonic frequency (minimum 1MHZ), being down to 1 micron and generating a cold fog Mass-output, energetically efficient The aerosol (~ 0.001 -0,005mm) is delivered by the air flow in the chamber and is distributed very fast and homogenously within the ambient air. Piezokeramic transducer (Transducer, Schwinger) 2. The NanoBAK technology

12 Bäckerei- und Getreidetechnologie 2. The NanoBAK technology

13 Bäckerei- und Getreidetechnologie An optimized humidity distribution in the chamber is achieved through the cold fog Simulation of the humidity distribution in a climatic chamber with the MICROTEC system Optimal humidity distribution 2. The NanoBAK technology

14 Bäckerei- und Getreidetechnologie 2. The NanoBAK technology Without condentation problems

15 Bäckerei- und Getreidetechnologie - Dried surface - Water loses and mass transfers ( crust splitting) - Condensation on the surface - Sticky dough - Quality loses -No drying effects, no condensation problems - homogenous Temperature and Humidity distribution - Water loses and mass transfer are minimized, so that the crust stress and consequently splitting is avoided - High quality products and low energy demand a W = 0,89-0,96 2. The NanoBAK technology Conventional processing Rel. Ambience H.= ~ 80-90 % NanoBAK technology Rel. Ambience H.= ~ 99 % The improvement

16 Bäckerei- und Getreidetechnologie Table of contents 1.Introduction 2.The NanoBAK System 3.The NanoBAK System - Ripening control with an optimal humidity in the atmosphere 4.The NanoBAK System – Humidity assisted cooling and freezing processes 5.Conclusions – Low energy and Premium quality

17 Bäckerei- und Getreidetechnologie 3. Case study: retarded fermentation Remark: the temperatures depend on the chamber capacity and the size of the product, as well as on the design and production criteria.

18 Bäckerei- und Getreidetechnologie expansion Conventional chamber Humidity assisted chamber Retarded fermentation, T =+3°C, 16 hours 3. Case study: retarded fermentation

19 Bäckerei- und Getreidetechnologie 3. Case study: retarded fermentation Conventional chamber Humidity assisted chamber Retarded fermentation, T =+3°C, 16 hours

20 Bäckerei- und Getreidetechnologie Conventional chamber Hours Crispiness retention + Color + Crispiness Conventional process Humidity assisted Humidity assisted chamber Retarded fermentation: T = +3°C, 16 hours 3. Case study: retarded fermentation

21 Bäckerei- und Getreidetechnologie 3. Case study: interrupted fermentation Remark: the temperatures depend on the chamber capacity and the size of the product, as well as on the design and production criteria.

22 Bäckerei- und Getreidetechnologie Conventional chamber dough properties: sticky, wet and rough surface. Humidity assisted chamber properties: easily handling dough, humid inside but dry and smooth surface. expansion Interrupted fermentation, T = -10°C, 20 hours 3. Case study: interrupted fermentation

23 Bäckerei- und Getreidetechnologie Conventional chamber Humidity assisted chamber Interrupted fermentation, T =-10°C, 20 hours 3. Case study: interrupted fermentation

24 Bäckerei- und Getreidetechnologie Conventional chamber with an electric humidifier (only able to work until +5°C) Energy consumption of the interrupted process, 20 hours = 44,40 KWh Chamber with the humidity assisted system though cold fog (during the whole process) Energy consumption of the interrupted process, 20 hours = 27,80 KWh 3. Case study: interrupted fermentation

25 Bäckerei- und Getreidetechnologie High conductivity, better mass and heat transfer, faster browning: Energy saving Low conductivity, limited mass and heat transfer Humidity assisted Conventional process Interrupted fermentation, T -10°C, 20 hours 3. Case study: interrupted fermentation

26 Bäckerei- und Getreidetechnologie Influence of the additional humidity on the enzymatic activity and/or the browning reaction (same baking conditions) Decrease of the baking time 3. Case study: interrupted fermentation Conventional chamber Humidity assisted chamber Interrupted fermentation, T =-10°C, 20 hours

27 Bäckerei- und Getreidetechnologie Table of contents 1.Introduction 2.The NanoBAK System 3.The NanoBAK System - Ripening control with an optimal humidity in the atmosphere 4.The NanoBAK System – Humidity assisted cooling and freezing processes 5.Conclusions – Low energy and Premium quality

28 Bäckerei- und Getreidetechnologie Conventional process: shock freezer The freshly baked bread (previously cooled down) is frozen in a chamber at – 40°C (until -7°C on the core) and afterwards stored at -18 °C (or even -25°C) Advantages: - Fast freezing Disadvantages: - High energy consumption - Water loses up to 4% - Quality loses due to crust splitting - Freezer burn 4. Case study fully baked frozen bread

29 Bäckerei- und Getreidetechnologie Crust splitting - The crust splitting is evidenced after the freezing stage - Part of the product surface is broken - The storage of the product worst the problematic 4. Case study fully baked frozen bread

30 Bäckerei- und Getreidetechnologie a)Thermodynamic problem due to the temperature gradient b) Gas pressure drop/ the gas bubbles contract Hypothesis for the crust splitting problematic: - Humidity diffusion to the cold crust - Condensation below the crust -Possibility of crystal formation below the crust -Expansion of ice will cause crust splitting Congel. Dry air Source: Prof. Le Bail (ENITIAA, Francia) 4. Case study fully baked frozen bread

31 Bäckerei- und Getreidetechnologie Freezing process with additional humidity (at controlled intervals) From 95°C until -10°C in the core (-20°C in the chamber), followed by storage at -18°C Advantages: - Better quality - Avoidance of water loses - Minimum crust splitting - Better conductivity = energy saving 4. Case study fully baked frozen bread

32 Bäckerei- und Getreidetechnologie Fully baked Baguette Shock freezer immediately after baking (-40°C) until -10°C in the core followed by storage at -18°C (with packaging) Fully baked Baguette Humidity assisted freezing (-20°C) until -10°C in the core followed by storage at -18°C (with packaging) Chamber at - 40°CChamber at - 20°C, less energy consumption! 4. Case study fully baked frozen bread

33 Bäckerei- und Getreidetechnologie 4. Case study: bread cooling Adiabatic cooling

34 Bäckerei- und Getreidetechnologie Step 1 Adiabatic cooling with humidity contribution (discountinously) Freshly baked bread, from 95°C to +30 °C (core) (chamber at 20°C) Advantages: - Better final quality - No refrigeration system necessary, energy saving Step 2 Humidity asssisted freezing (interval) From 30°C up to -10°C in the core (chamber at -20°C) Advantages: - Better conductivity = energy saving - Better quality - Avoidance of the weight loses - Avoidance of the crust splitting and the freezer burn Currently under study! 4. Case study fully baked frozen bread

35 Bäckerei- und Getreidetechnologie Figure 2: bread after 30 minutes In a humidity assisted chamber at +1°C Figure 1: bread after 30 minutes in a conventional chamber at +1°C Case study: 1000g bread. Pictures taken using a thermograph after 30 minutes of cooling in a chamber at +1°C 27,3 °C 21,5 °C Cooling process after baking 4. Case study: bread cooling

36 Bäckerei- und Getreidetechnologie The product water loss during the cooling process can be avoided 4. Case study: bread cooling

37 Bäckerei- und Getreidetechnologie Table of contents 1.Introduction 2.The NanoBAK System 3.The NanoBAK System - Ripening control with an optimal humidity in the atmosphere 4.The NanoBAK System – Humidity assisted cooling and freezing processes 5.Conclusions – Low energy and Premium quality

38 Bäckerei- und Getreidetechnologie Refrigeration technologies have enormously contributed to the growth, among others, of the bakery industry (starting by 1980/1985) Refrigeration technologies provide the bakery sector, both craft and industrial bakeries, with a great potential for innovation and development The way to optimal climatic techniques is driven by the final product quality and the energy demand The humidity assistance during the cooling and freezing stages improves enormously the current trendy processes and contributes to the energy reduction Optimal humidity conditions in the chamber and in the dough/bread are achieved Improvement of the bread and baked products quality: premium quality thanks to the humidity in the atmosphere At the same time, a significant energy saving can be achieved leading to an important reduction of costs 5. Conclusions – Low energy and Premium quality

39 Bäckerei- und Getreidetechnologie Prof. Klaus Lösche ttz BILB/EIBT Am Lunedeich 12 27572 Bremerhaven Tel. : +49 471 97297-13 Fax.: +49 471 97297-22 Vielen Dank für Ihre Aufmerksamkeit Thank you for your attention Bäckerei- und Getreidetechnologie


Download ppt "Bäckerei- und Getreidetechnologie NanoBAK The NanoBAK technology Prof. Klaus Lösche, ttz BILB/EIBT Project 1 st year meeting 12th April – Holstebro/Denmark."

Similar presentations


Ads by Google