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Commercial Bakeries - 311812
Cookie & Cracker Manufacturing - 311813
Dry Pasta Manufacturing - 311823
Tortilla Manufacturing - 311830 |
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CHP Market Saturation / Geographic Location / Industry Drivers / Thermal Opportunities / Process Description / Associations / Events / Industry Leaders & Case Studies
• Nearly $22 billion in revenue is generated from the production and sale of fresh and frozen bread, rolls, and other bakery products (excluding cookies and crackers). (U.S. Census Bureau)
Data not available
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• Food Safety – hot water and steam are needed for process cleanliness and sanitation
• Large thermal energy loads
• Escalating energy costs
• Energy Intensive Industry – this sub-sector consumes 3% of the total amount of energy used by the entire food processing industry (ACEEE)
Reciprocating engines, with a power size range of 30kW–8MW, generate engine jacket heat from 180-200°F, and exhaust heat at around 1200 °F. Industrial turbines, with a power range from 1-20+ MW, generates heat from 900-1100°F. This heat can be recovered and used to heat or cool products in a variety of food processing steps such as:
• Rapid cooling capacity needed to lower the temperature of mixed dough
• Strict temperature controls are imposed on the environment where the dough rises
• The products must be cooled upon removal from the ovens to prevent over-baking
Ingredients are combined in a large mixer that also rapidly cools the dough. The dough is divided (most often by weight) into sizes needed for the products. The dough is poured into a mold, and is then conveyed through a chamber that dusts it with flour, seeds, seasonings, etc. The product is allowed to rise in a temperature-controlled environment. The products are baked in gas-fired ovens, and are cooled with cool air to prevent overcooking, before being packaged and sold.
American Bakers Association
American Institute of Baking
Cookie & Snack Bakers Association - September 19-22, 2004
Biscuit & Crackers Manufacturers' Association Technical Conference - October 17-20, 2004
Chicago Baking
Pepperidge Farm -
http://www.foodprocessing-technology.com/projects/pepperidge/index.html
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CHP Market Saturation / Geographic Location / Industry Drivers / Thermal Opportunities / Process Description / Associations / Events / Industry Leaders & Case Studies
• Generates nearly $10 billion in revenue from cookies, crackers, and other related products. (U.S. Census Bureau)
Data not available
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• Food Safety – hot water is used for cleaning and sanitation
• Energy Intensive process
• High Cost of Energy – especially in California , where a large number of plants are located
• Large amounts of heat needed for the ovens
• Cool air required to prevent over-baking
• Hot water needed for cleaning and sanitation
As there are many types of cookies and crackers, the exact manufacturing processes differ greatly from plant to plant. Below is an example of a cookie manufacturing process:
Basic ingredients are combined in a large mixing bowl that can hold up to 2000 lbs of dough. Large mixers blend the ingredients. The sides of the mixing bowl must be scraped clean of dough manually. Special ingredients, such as oats or chocolate chips, are now added to the mixing bowl. The batch is mixed again, and the bowl is once again scraped. An optional third mixing would occur after adding additional flour and water to slightly alter the dough’s consistency. The dough is poured into a hopper that squeezes dough through small openings in the bottom. A blade slices off the correct amount of dough, which drops onto a conveyor belt underneath. The cookies are conveyed through a series of ovens with different heating zones, often ranging from 350º-500º F (176.7º-260º C). The cookies are cooled using cool air upon removal from the oven. The cookies are then packaged, or icing or cream may be added before packaging. (Royal Cake)
American Bakers Association
American Institute of Baking
Cookie & Snack Bakers Association - September 19-22, 2004
Biscuit & Crackers Manufacturers' Association Technical Conference - October 17-20, 2004
N/A
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CHP Market Saturation / Geographic Location / Industry Drivers / Thermal Opportunities / Process Description / Associations / Events / Industry Leaders & Case Studies
• $1.8 billion in the manufacture and sale of dry pasta products (U.S. Census Bureau)
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• Food Safety, Cleanliness, and Sanitation
• High Thermal Load
• Reliable Heat & Power – steady temperature and humidity conditions must be maintained for quality control
• Cool water is used to lower the temperature of the extruder
• Hot air is needed for dryer operation
After harvesting, grain is cleaned, tempered and coarsely milled. The milled wheat is combined with water, eggs, and any other ingredients, and blended in a large mixer. A twin shaft mixer is used to prevent the dough from forming balls. The dough is subjected to a vacuum to remove all air bubbles. The dough moves through an extruder, which forms the dough into a homogenous mass. The extruder is equipped with a cool water jacket to maintain a constant temperature of around 123º F (51º C). Temperatures higher than this will damage the dough. The pasta is extruded through Teflon to give it a smooth appearance and then it is dried to lower the moisture content from around 30% to around 12%. Drying temperature and humidity must be strictly controlled to prevent over-drying, cracking, and spoiling.
Wheat Foods Council
No events currently planned
N/A
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• Food Safety – hot water is used for cleaning and sanitation
• Reliable Power – prevent financial loss due to unplanned power outages
• High energy costs in high production areas – especially Texas and California
• Hot water or steam needed to heat hot plates for tortilla pressing
• Heat needed for ovens used to back tortillas
• Large amount of steam needed to cook and steep corn
• Cool air used to prevent over-baking
There are two types of tortillas, flour-based and corn-based. An example of the process used to produce each is below:
Flour Tortillas:
Ingredients are combined in a large mixer to create the dough. The dough is fed through a rounder, which creates small, round dough balls by weight. The tortillas may be pressed or hand shaped. If the press method of shaping is used, the tortillas are flattened by two hot plates. Otherwise, if the tortillas are hand stretched, the dough balls a fed through a roller that flattens the balls into an oblong shape. The tortillas are then manually stretched into a circular shape. The raw tortillas are cooked in an over, and immediately cooled, before being packaged and sold. (Los Amigos Tortilla Mfg. Inc.)
Corn Tortillas:
Corn kernels are combined with water in a large vat and the mixture is heated by steam injection. After the corn is fully cooked, it is allowed to steep in the warm water for approximately eight hours. The corn is washed and coarsely ground to create a paste called masa. The masa is pressed, cut, and cooked in the three-tier over. The tortillas are cooled to prevent over-baking, packaged, and sold. (Los Amigos Tortilla Mfg. Inc.)
Tortilla Industry Association
AACC/Tortilla Industry Association Annual Meeting - September 19-22, 2004
N/A
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