INNOVATIONS IN SUSTAINABLE BAKERY PRODUCTION
quality control teams to spot defects early in the manufacturing process, which can reduce the volume of product rejected later in the process after value has been added to it.
Driving down losses Phil Brown, Sales Director at Fortress Technology, argues that deploying a combination of inspection,
vision and
automatic reporting technologies can help to address food waste issues. “Beyond quality control, modern contaminant detection, check- weighing and vision inspection systems are capable of driving down and eliminating food loss and resulting in bottom line savings while meeting Corporate & Social Responsibility (CSR) targets,” he says. When it comes to inspection systems,
one of the most common sources of waste is due to false rejects, which occur when a good product is identified as containing a contaminant or when packaged products are at an incorrect weight. “So, when specifying inspection systems, reliability and accuracy is key,” continues Phil. “Line vibrations can cause false readings, resulting in the rejection of otherwise sellable products.” Fortress Technology designs its metal detectors, X-ray, check-weighing and combination systems with a heavier framework to reduce environmental vibrations which can significantly reduce the risk of false contaminant and weight rejects. Phil also pointed to machinery performance
issues as being another major cause of waste in the bakery production process. “False rejects, machinery stoppages and, worst case scenario, product recalls can swiftly have an adverse effect on profitability and brand reputation. However, the manual process of monitoring system performance and carrying out tests by hand can affect productivity and is often prone to human errors. “Automatic testing can offer a repeatable
methodology to ensure a metal detector, checkweigher or X-ray system is working as it should. All Fortress Technology systems, for example, feature a paperless, fully auditable Conformity of Production (COP) test routine. Rather than relying on operators to schedule, perform, document and submit inspection performance checks, the machines pre- configure every test by retailer and product being inspected, alerting QA managers when an evaluation is overdue. “Operators simply need to select from a list
of pre-programmed retailer COP parameters. Once a test is performed, a dated due
Automatic testing offers a repeatable methodology to ensure a metal detector, checkweigher or X-ray system is performing as it should be (image courtesy Fortress Technology).
DIGITALISATION AND DATA-LED TOOLS ARE
PROVING PARTICULARLY USEFUL TOOLS TO HELP REDUCE WASTE DURING PRODUCTION
execution system (MES) to its enterprise- resource management (ERP) bakery management software system. The module was developed to provide a modern, mobile and eco-friendly alternative to the traditional error-prone paper systems and spreadsheets that have always dominated bakery production environments. The move to paperless manufacturing is
diligence report is created and signed by the operative on screen. By using automation to follow these principles, it becomes impossible to bypass a step in the process, increasing the transparency and traceability of machine performance audits and leaving no room for error.”
Going paperless With sustainability becoming one of the most pressing priorities for bakeries today, reducing waste, cutting energy use, and creating more efficient, transparent operations are no longer optional – they are essential requirements for ongoing success. According to bakery software company
Cybake, for many bakeries, achieving the right balance between production efficiency and environmental responsibility starts with one crucial step – going digital. Cybake has recently added paperless lot tracking, traceability and manufacturing
not just about convenience, it can also offer sustainability benefits, according to Cybake. Its argument is that traditional paper-based prep sheets and manual recordkeeping contribute to material waste and production line inefficiency. A paperless MES removes the need for paper trails, replacing them with digital workflows that can be displayed on tablets and mobile screens, allowing operators to see instantly what products to make, the quantities required, and the exact methods they need to follow, complete with clear, image-based instructions that can be tailored to the bakery’s own equipment. This reduces confusion, cuts down on repetitive paperwork, and ensures that every production process is optimised for minimal waste and maximum efficiency. By replacing manual documentation
with real-time digital guidance, bakeries not only save thousands of sheets of paper annually but also lower their operational footprint – another small, yet important, step toward greener production. When it comes to traceability, bakeries
need to be able to go one step forward and one step backwards – tracing ingredients from suppliers and finished goods to customers. Cybake’s paperless MES can
OCTOBER/NOVEMBER 2025 • KENNEDY’S BAKERY PRODUCTION • 15
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