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Multi-plant dividing and moulding investment

Date: 12 May 2009

Accurist 9000 Divider

Albany Bakeries continues its quality improvement programme

Leading South African baker Albany Bakeries is making a multi-plant investment in new dividing and moulding equipment from Baker Perkins as part of its continuing programme of quality improvement.

The latest phase involves the installation of 12 Accurist dough dividers and seven conical moulders in ten of Albany’s 13 regional bakeries and complements previous investments in upgraded mixing, dividing and final moulding equipment.

Albany is a subsidiary of Tiger Brands, a major South African food and healthcare company, and produces leading brands such as Superior, Olde Cape and D’light.  Demand for packaged bread continues to grow in South Africa, where it enjoys a reputation as an affordable luxury food. The new machines will play a key part in increasing efficiency and reducing costs, particularly giveaway, in Albany’s bakeries at a time of volatile ingredient pricing and difficult economic conditions.

The latest order for Baker Perkins Accurist dividers was placed after careful consideration of all the machines on the market and comparison of the dividers from several suppliers currently installed in Albany bakeries.

The decision to buy from Baker Perkins was based on a combination of excellence in equipment and service, provided in co-operation with local distributor Techquip, led by co-owner Zack Marques.  The scope of the project extends from supply, through installation and commissioning, to full production.

Accurist dividers have set the industry standard for consistent scaling accuracy for over 20 years.  Bakeries can expect a Standard Deviation of just 2.5 to 3.5 grams on a 780 gram loaf, achieved over 10,000 hours of operation with no replacement parts.

Other recent Albany investments with Baker Perkins include a full mixing and forming line at their Pretoria bakery, several Accurist dividers, and upgrades to installed mixers and final moulders.

Albany Bakeries are taking advantage of a series of improvements that Baker Perkins has made recently to its bread mixing and forming machinery, which boost product quality and plant efficiency through gentle dough handling.  Creating the ideal dough structure in the mixer, then handling the dough delicately through the dividing, rounding and moulding stages, preserves the integrity of the dough structure and results in a loaf with higher consumer appeal.

Tweedy mixers have been upgraded with the Pressure Vacuum system to deliver quality enhancements and cost savings, including increased yield, improved crumb colour and softness, longer shelf life, and reduced additive costs.

By fitting Multitex4 heads to existing machines, Albany achieved significant quality improvements. A four-roll moulding head typically increases volume and cell count by around 10%, with an improved crumb structure.  These benefits translate into a strong, straight-sided shape, up to 18% softer and with a finer, more even texture. Consumers appreciate the improved appearance and greater resilience of each slice, as well as the additional softness which leads to an extended shelf life.

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