How to reduce bread waste?

21 Feb How to reduce bread waste?

There is an increasing number of properly adapted yeasts to guarantee the final proofing of dough that has been pre-proofed at room temperature. The goal is to be able to guarantee a comprehensive range of fresh, long-lasting loaves without generating any wastage or losses.
At certain in-store bakeries, this can account for up to 50% of the day’s output. To take the example of recycling: in Germany, unsold bread is collected every evening for revalorisation in various other industries. This means either as a fermentation substrate for sourdough (Isernhager process), or for the manufacture of breadcrumbs and other products in the food-processing industry, or even in animal feed.

Long-lasting also means cost reduction. We may, in effect, observe a growing demand for “replacers”. Replacers reduce the use of costly products such as butter, eggs or sugar and permit the production of so-called “light” formulations.

What solutions exist for constant supplies of fresh bread?

Bakery chains try to find solutions to reduce the wastage linked to stocks of unsold products remaining at the end of the day, while being able to offer fresh bread at all times of day. Several solutions have been tried out:

Non-stop production all day long.This, however, means having a team of professionals always on hand, but does not necessarily reduce the number of unsold products at the end of the day.

Re-baking of part-baked loaves at the end of the day.For many professionals, this solution does not equate with being able to offer fresh quality products, because fresh products keep less well after baking.

Purchasing some products from other bakeries.Dough pieces can be delivered either in pre-baked form, or as refrigerated dough. In the latter case, the dough is sent either in block form, then divided and shaped on site, or in the form of pre-shaped pieces. The main products developed from refrigerated dough include pizzas and bread rolls. The problem with this last solution is the often complicated logistics involved and means that the dough must be kept for 5 days before fermentation can start!

In order to improve the refrigerated dough technique, Lesaffre proposes cold-controlled fermentation. This offers longer preservation times, while retaining all the advantages of refrigerated dough compared to part-baked. Nevertheless, the success of the technology, associated with this yeast, necessarily entails an augmentation of the range (larger loaves, Viennese pastries). Finally, baking off a refrigerated dough involves more handling. Store chains therefore need to train their bakers in order to strengthen the advantage presented by refrigerated dough.

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