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NanoBAK

NanoBAK. The NanoBAK technology Prof. Klaus Lösche, ttz BILB/EIBT. Project 1 st year meeting 12th April – Holstebro /Denmark. Table of contents. Introduction The NanoBAK System The NanoBAK System - Ripening control with an optimal humidity in the atmosphere

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NanoBAK

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

  2. Table ofcontents • Introduction • The NanoBAK System • The NanoBAK System - Ripening control with an optimal humidity in the atmosphere • The NanoBAK System – Humidity assisted cooling and freezing processes • Conclusions • – Low energy and Premium quality

  3. Table ofcontents • Introduction • The NanoBAK System • The NanoBAK System - Ripening control with an optimal humidity in the atmosphere • The NanoBAK System – Humidity assisted cooling and freezing processes • Conclusions • – Low energy and Premium quality

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

  5. Introduction Current trends in bakery – fermentation control and frozen products • 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.

  6. Introduction Climatic chambers

  7. Low conductivity • Introduction Cooling and freezing are high energy demanding processes and critical stages for the product quality Low cooling and freezing velocity Conventional processingRel. Ambience H.= ~ 80-90 % aW= 0,80-0,96 (depending of it is dough or bread) Desorption Dough:Bread: Drying surfaces Freeze bruning Irregular products Weight loses Weight loses Undiserable colour Undesirable product Crust splitting Skin forming Heterogeneous distribution of temperature Humidity and temperature gradients Low quality Heterogeneous final products

  8. Table ofcontents • Introduction • The NanoBAK Technology • The NanoBAK System - Ripening control with an optimal humidity in the atmosphere • The NanoBAK System – Humidity assisted cooling and freezing processes • Conclusions • – Low energy and Premium quality

  9. 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. 2. The NanoBAK technology 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) Mollierh,x-Diagram

  11. 2. The NanoBAK technology • 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 Piezokeramictransducer (Transducer, Schwinger) 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.

  12. ultrasonic technology electro-humidifier 0,1 2. The NanoBAK technology Droplet size [µm] 10 30 60 100 250 500 750 1000 1500 1,0 0,303 2,68 10,2 27 94 210 313 400 545 sedimentation rate [cm/s] Small drops have nearly no falling, float, can drift 10,0 Falling speed [cm/s] Ultrasonic equipment: < 1,0µmelectro-humidifier:> 50 – 150 µm 100,0 1000,0 0 200 400 600 800 1000 1200 1400 1600 Droplet size [µm]

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

  14. Without condentation problems 2. The NanoBAK technology

  15. The improvement NanoBAK technologyRel. Ambience H.= ~ 99 % Conventional processingRel. Ambience H.= ~ 80-90 % 2. The NanoBAK technology aW= 0,89-0,96 aW= 0,89-0,96 • 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

  16. Table ofcontents • Introduction • The NanoBAK System • The NanoBAK System - Ripening control with an optimal humidity in the atmosphere • The NanoBAK System – Humidity assisted cooling and freezing processes • Conclusions • – Low energy and Premium quality

  17. 3. Case study: retardedfermentation Remark: the temperatures depend on the chamber capacity and the size of the product, as well as on the design and production criteria.

  18. 3. Case study: retardedfermentation expansion expansion Humidity assisted chamber Conventional chamber Retarded fermentation, T =+3°C, 16 hours

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

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

  21. 3. Case study: interruptedfermentation Remark: the temperatures depend on the chamber capacity and the size of the product, as well as on the design and production criteria.

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

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

  24. 3. Case study: interruptedfermentation 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

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

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

  27. Table ofcontents • Introduction • The NanoBAK System • The NanoBAK System - Ripening control with an optimal humidity in the atmosphere • The NanoBAK System – Humidity assisted cooling and freezing processes • Conclusions • – Low energy and Premium quality

  28. Conventional process: shock freezer 4. Case study fullybakedfrozenbread • 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

  29. Crust splitting 4. Case study fullybakedfrozenbread • The crust splitting is evidenced after the freezing stage • Part of the product surface is broken • The storage of the product worst the problematic

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

  31. 4. Case study fullybakedfrozenbread • 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

  32. 4. Case study fullybakedfrozenbread 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°C Chamber at - 20°C, less energy consumption!

  33. 4. Case study: breadcooling Adiabatic cooling

  34. 4. Case study fullybakedfrozenbread Currently under study! • 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

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

  36. The product water loss during the cooling process can be avoided 4. Case study: breadcooling

  37. Table ofcontents • Introduction • The NanoBAK System • The NanoBAK System - Ripening control with an optimal humidity in the atmosphere • The NanoBAK System – Humidity assisted cooling and freezing processes • Conclusions • – Low energy and Premium quality

  38. 5. Conclusions – Low energyandPremium quality • 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

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

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