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General Information

IN THE BAKING BUSINESS: BAKING WITH A PLAN

Are you thinking of starting your own commercial bakery business? Then it’s of paramount importance to consider the outlay and necessity of purchasing the proper bakery equipment. In most instances, it seems even more so when it comes to the baking industry.

The commercial baking industry is highly competitive and relies on more than just your basic dough mixer and baking oven. If differentiating your baking business in terms of consistent quality and reliability is the result you seek, compromising on baking equipment is not an option.

Macadams are committed to providing only the highest quality baking equipment and products by offering full support, maintenance and back-up guarantees. Since the success of your bakery business depends largely on the proficiency and reliability of the bakery equipment used, cost should not be a dominating factor.

The expense of having baking equipment break down without a backup plan far outweighs the cost of investing in premium quality baking systems that come equipped with a proper backup strategy.

Speak to Macadams about an emergency plan to substitute your bakery equipment in case of emergency. This will ensure that your baking business stays up and running, even while your baking equipment is being repaired. This translates into zero downtime and maximum profitability.

At Macadams we provide baking solutions that offer maximum efficiency with flexible finance and maintenance schemes to help make your bakery as resilient and productive as possible.

A CENTURY OF BAKING EXPERIENCE

Macadams has been a leader in the baking industry for more than a century. We’ve seen baking equipment evolve from wood fired bakeries to gas bakeries and hand operated ovens to automated ovens. Along with these evolutions, it was also fascinating to be a part of the developments of so many new baking systems and products over the last century. Even something as simple as a bread moulder has a story of how it came to be.

Bun and bread moulders aren’t simply a clever idea somebody happened to have had. Bread moulders were invented as a result of intense supply shortages during the First World War. The scarcity grew so extreme that the US Government had to encourage housewives not to bake at home, in dire attempt to lower the cost of baking ingredients. Alternative baking methods were created by the government to better control supply. After the war ended, many commercial bakeries had no real purpose any longer. But since people grew accustomed to the convenience, many commercial bakeries were re-instated, privatised and re-invented under new names and brands.

For over a century, our business has thrived on a relentless search for ways to improve the systems that make our customers’ bakeries successful.

Safe to say, that after more than a hundred years of developing and refining premium-baking equipment at MacAdams, you’ll always find the perfect baking solution for any commercial bakery requirement. From rack ovens to deck ovens. Dough mixers to dough moulders. Even automated kneaders, pastry sheeters, biscuit machines, or doughnut fryers for the connoisseur. Macadams will always ensure that your baking endeavours remain fresh and your customers smiling – for today and the next century to come.

PRINCIPLES OF LAYOUT AND DESIGN OF YOUR BAKERY

FLEXIBILITY

It is very important to design a bakery layout where the design is such that it allows for easy movement of equipment and workspace without it becoming a major cost. Electrical points, drainage and water supply must be laid out in such a way that it will accommodate moves.

FOOD SAFETY

Food safety and safe work procedures are two non-compromisable elements of design. They must always take priority in the decision making process.

HYGIENE AND HOUSEKEEPING

It is important that a layout avoids creating small confined areas, which hamper workflow, and creates clutter that is not easy to clean.

DRAINAGE

Consider proper drainage for floor cleaning, oven and prover drains, wash hand basins and wash up areas. Proper grease traps and accessible floor ducts are a priority. The drainage system must be carefully laid out so that it accommodates future change.

EXTRACTION AND VENTILATION

The right extraction is vital especially if the bakery is located in hot climate. Make sure that there is sufficient airflow to keep the bakery comfortable at working temperature. Careful design must go into the airflow systems to ensure airflow does not affect product drying out and skinning the surface of ingredients, components and finished products. Special consideration must be given to air-conditioning in relation to airflow over product displays so that these kinds of problems are avoided.

ELECTRICAL SUPPLY

Before committing to a site make sure that there is adequate 3 phase power supply to take care of immediate and future requirements. Adding additional supply at a later stage is a costly exercise.

WATER SUPPLY

A water supply system within the bakery must be flexible and accessible to allow for equipment and department layout changes.

ELEMENTS OF DESIGN

PRODUCTION AREA

A product range dictates what production areas/departments are needed. It is important that production departments have sufficient space allocation to ensure proper work flow under pressure. Careful consideration must be given to structural facilities that are needed in each department. For example in the baking department, proper extraction and drainage for the ovens and proofers.

STORAGE AREA

Adequate space, shelving and containers space must be provided for. Flour normally requires a separate storage room. Packaging should also be stored in a separate area away from ingredients.

SHELVING

The Shelving within the store must meet the following criteria:

  • Sufficient space allocation to hold storage containers.
  • Strong support to hold weight.
  • Approved smooth surface that is easily cleaned and sanitized.

CONTAINERS

The ingredient storage containers within the store must meet the following criteria:

  • Made from a food safe material.
  • Approved smooth surface that is easily cleaned and sanitized.
  • Tight fitting lid.
  • Clear labeling.
REFRIGERATION AREA

COLD ROOM

Maintaining the cold chain is an important food safety requirement in any food manufacturing business. There must be adequate cold storage space to store all the chilled ingredients. A strict policy of storing cooked separated from raw must be maintained. There must be sufficient refrigeration space to store semi-processed components and unbaked products as back up stock.

WASH UP AREA

A bakery produces a steady flow of dirty pots and utensils. The wash up area must have sufficient workspace and storage racks for these utensils. This area is normally a very wet working area, which should be kept away from the production area. This should also have facilities for hosing down the area at the end of the day.

REFUSE AREA

All bakeries produce an excessive amount of refuse that must be stored safely for collection. It is important that sufficient space and refuse holding bins are allocated to this area and that the area is properly rodent proofed. It is also important that there is a proper water supply with hose and drainage so that this area can be scrubbed down on a regular basis.

WRAPPING/PACKAGING/HOLDING AREA

This area is as important as the production and sales area. It needs to be carefully thought out and designed to ensure smooth product flow with adequate storage and workspace for wrapping and packing product sale.

DISPLAY AREA

Many designs incorporate too much display counter space, which causes high wastage. Rather work on smaller display counters and refill the counters a number of times during the day. Self-service is also a better option for peak periods, so design service systems that showcase product and maintain the right food and safety standards. A display that looks full sells more, Keep the size of your display areas smaller and fill up more frequently from back up stock.

UNDERSTAND THE DIFFERENCES IN BAKEWARE TO GET THE MOST OUT OF YOUR BAKING EQUIPMENT

Bakeware is such an integral part of a modern kitchen that you probably don’t even think about which types you are using.

But it is very important to select the right baking equipment for the task at hand. Here are some facts about the different types of bakeware you can use.

DIFFERENT SIZED BAKEWARE

When you are following a baking recipe requiring you to use bakeware, check you have the proper size pans.

Select baking equipment as close in size as possible to the suggestion in the recipe.

Although this seems obvious, it needs pointing out because deviations in size will lead to changes in cooking times.

Measure volume by filling your bakeware with water and then pouring it into a measuring cup.

BAKEWARE MATERIALS AND HOW TO CARE FOR THEM

Every material has slightly different effects on the food you produce so it’s important to attempt to make them good. For example, bakeware with dark surfaces cause food to brown easily by absorbing oven heat.

On the other hand, this baking equipment conducts heat evenly but its surface reflects heat, so the food does not brown well. So here is a list of some common bakeware materials:

ALUMINUM BAKEWARE

Aluminum bakeware is fantastic for conducting heat and so your food will be evenly baked but the shiny surface prevents browning.

Although it is durable and is unlikely to rust, it is advisable to go for heavy-gauge aluminum bakeware instead of the thinner variety.

Do not use this type of baking equipment to prepare acidic dishes because it will react with and create food that has an off taste. It may also cause more wear and tear than usual.

ANODISED ALUMINUM BAKEWARE

Anodised bakeware- which comes in silver and hard anodised – is much more resilient than other types of bakeware. Silver anodised bakeware has a scratch resistant surface after going through a tough electro-chemical process to harden its outer layer.

Do not use sharp knives to cut food baked in these pans.

With hard anodised bakeware, the aluminum is processed for a much longer time, creating a hardened surface finish that is much thicker than its silver counterpart.

The surface of the baking equipment is not easily damaged but, again, avoid using sharp knives on the surface.

INSULATED

Made from metal with air cushioning the layers, insulated bakeware provides evenly baked food.

It is best to get a non-stick version since food is otherwise likely to stick to this sort of bakeware.

NON STICK BAKEWARE

Non stick bakeware is usually steel or aluminum non-stick coating, allowing food to easily peel off from the surface of the bakeware.

This baking equipment works very well with muffins and cakes.

Some non stick coating can give bakeware a darker surface, absorbing heat more quickly, ensuring your food is not overly browned.

When washing your bakeware, use hot soapy water and drying thoroughly, place in a warm oven and dry completely.

Avoid using metal scouring pads or abrasive materials to clean.