INNOVATIONS IN SUSTAINABLE BAKERY PRODUCTION


make this process faster, more accurate, and more sustainable. Instead of relying on manual logs, operators just need to enter vendor lot codes directly into the system. The system then generates internal lot codes and prints barcodes to be attached to ingredients, which can be tracked throughout production, picking, and delivery. This complete digital traceability allows bakeries to act immediately in the event of a recall, pinpointing affected products without resorting to mass disposal, helping reduce food waste.


Going further The argument for investing in more sustainable production lines goes well beyond reducing waste. Lower energy and water consumption, more streamlined changeovers, and more efficient use of raw materials all contribute to leaner operations which can translate directly into cost savings, helping bakeries maintain margins in a sector where input costs are volatile. Ronald Hoiting, Marketing &


Communications at Rademaker, pointed out that the adoption of new technology can make sustainable production lines much easier to achieve. “Digitalisation, for example, enables us not only to monitor the performance and energy consumption of our machines but also to optimise them – contributing to a better CO₂ balance,” he says. One of the easiest and quickest ways to


reduce the CO₂ footprint of an operation is to decrease energy consumption and here the use of more energy motors on equipment has a big role to play. Electric motors are fundamental to almost every stage of industrial bakery production, powering everything from dough mixers and conveyor belts to cooling tunnels and slicing machines. They drive the mechanical movements that keep production lines running smoothly and efficiently. Because motors are so ubiquitous on the factory floor and are often operating continuously, their energy consumption quickly adds up making the use of efficient motors a critical element in the overall sustainability of the bakery process. Upgrading to more energy efficient motors


can help reduce both energy consumption and environmental footprints. The International Efficiency (IE) rating system classifies motor efficiency from IE1 (standard efficiency) to IE4 (super premium efficiency). Selecting motors with a higher IE rating will help ensure that less energy is wasted as heat, allowing more of it to be used for productive work. This supports sustainability goals and also aligns with


tightening energy regulations in many regions. So, when specifying new bakery equipment, it is important to consider the efficiency class of the motors that will be included. While higher-efficiency motors may come with a higher upfront cost, the long- term savings in energy use and maintenance often outweigh the initial investment cost. “Sustainability is also improved with the use


of more durable machines and equipment,” continues Ronald. “The longer the life lifespan of equipment the proportionally smaller its ecological footprint will be. Moreover, maintenance costs for spare and wear parts will also be reduced with the use of quality, robust equipment, and the resulting decreased downtime will further enhance efficiency having a positive impact the CO2 footprint.”


However, we are aware that bakeries also face higher operational costs due to energy tariffs and capital costs for plant infrastructure upgrades. The E-Bake G2 addresses these concerns by significantly lowering energy consumption and reducing both installed power and total cost of ownership, when compared to conventional electric ovens.” The oven – which is engineered to produce


both soft and hard dough cookies and crackers – has been optimised exclusively for electric operation, which offers significant CO₂ emission reductions. The baking chamber of the oven has


been redesigned with a reduced internal volume to minimise heat loss and positions heating elements closer to the product, improving thermal efficiency. The inclusion


Ronald pointed to cleanability of equipment as being another, less obvious, focus area for improving sustainability. “Machines that are easy to clean require less downtime and also generate less polluted wastewater,” he says.


Electrification Earlier this year GEA introduced the E-Bake G2, an electric industrial baking oven designed to deliver enhanced energy efficiency and improved process control to meet the evolving need for sustainable bakeries. Marco Girimondo, Product Manager at GEA,


says: “Our Voice of the Customer research highlighted a growing interest in sustainable baking solutions, particularly electric baking.


of micro-convection technology, featuring localised air flow systems, is said to help ensure uniform heat distribution and reduce temperature gradients By addressing food waste and embracing


modern technologies that can help make production processes more sustainable, bakeries can reduce their environmental footprint and also build resilience into their operations. In a competitive and resource- constrained marketplace, the combination of responsibility and efficiency is rapidly becoming the hallmark of a successful modern bakery. Equally important are the reputational benefits. Sustainability has become a core purchasing criterion for retailers and consumers alike.


16 • KENNEDY’S BAKERY PRODUCTION • OCTOBER/NOVEMBER 2025


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