Fall is Doughnut Season (add an NIR for the perfect Baker’s Dozen)

In the northeast, fall ushers in crisp, cool air, vibrantly colored leaves… and doughnut season.

Perfectly glazed Krispy Kreme Doughnuts

Whether you’re getting your round, deep-fried cake from roadside from the Pennsylvania Amish or from a commercial bakery, quality is key. Krispy Kreme has been serving up delicious doughnuts for generations in the USA and even across the globe, so you may have heard of them. Their mission statement says in no uncertain terms: To make the most awesome doughnuts on the planet every single day.

Most doughnut aficionados believe that Krispy Kreme does make the most awesome doughnuts on the plant. So, the question becomes: how do they execute that mission statement with such incredible consistency? The BUCHI Studios team took a little road trip to their plant in Winston Salem, NC to find out.

The Winston Salem plant prepares the powder blends that will ultimately be used to create “sweet fluffy clouds of deliciousness” in Krispy Kreme bakeries throughout the USA, as well as the concentrates, or key powder ingredients, used in bakeries around the globe. The Quality team is focused on providing consistency in their mixes to ensure that sweet taste experience from Nibley, Utah to England or even Thailand. Near-infrared (NIR) spectroscopy has become an important measurement tool to that end.

“Anything coming in… we want to be able to test it as quickly as we can as soon as we can, so that we know all the way through the process it’s already been tested, it’s been approved, it’s okay and we can continue.

Rob Paxton, Krispy Kreme Donuts

The use of NIR to provide quantitative or qualitative measurements on flours or even proprietary mixes is not new, and its prevalence in the industry is a consequence of the technique’s very fast measurement times (from fractions of a seconds to seconds) that simultaneously deliver critical sample properties like moisture, protein, fat and ash, to name a few.

NIR is used at Krispy Kreme to ensure that incoming ingredients meet specifications before entering the process, to monitor critical parameters (like moisture, protein and fat) during blending, and to ensure that the concentrates meet stringent quantitative criteria before being shipped to bakeries worldwide.

Krispy Kreme plant worker empties bag of flour to be used to for proprietary powder mix.

BUCHI offers three NIR products to meet the needs of flour millers and bakeries. Of those, Krispy Kreme has implemented the NIRMaster and NIR-Online. The NIRMaster is a rugged, at-line NIR product with hygienic design well-suited for the food industry. This Fourier-transform (FT) NIR product is designed to provide the ultimate in spectroscopic performance, enabling exceptionally accurate and consistent sample measurements. The NIR-Online is an NIR product of extreme ruggedness that can be directly attached to process equipment like hoppers or blenders, or suspended over conveyors, and provide real-time process monitoring feedback. The difference between the dispersive NIR technology of the online sensor and FT-NIR was drawn out in a prior blog, however, both technologies have an important role to play in food processing and testing.

krispy kreme testimonial

Dollars to donuts, NIR can provide reliable measurements that can support quality control and production… but don’t take our word for it! Watch the Krispy Kreme customer testimonial.

More on: the use of NIR in milling and bakery

Quality control of raw materials and ingredients

At uploading bulk flour or at bakery sites, NIR can be used to prevent unsatisfactory loads of raw materials, check that shipments conform to specifications, determine the quality of whole and ground grains, and quantify important factors of raw materials for better quality of finished products.

Quality control of bakery mixtures and dough

At a production site, NIR can be used to predict flour yield, water absorption and dough development time, quantify baking mixture ingredients or composition (e.g. %-moisture, %-protein), determine ash content affecting baking performance, and determine starch damage and water absorption during the milling process.

Quality control of finished products

At a production site or packing area, NIR can be used to control the quality of finished products (e.g. bread, biscuits, flour, confectionery, pasta and breakfast cereal), ensure compliance with any statutory composition requirements (e.g. moisture content of bread), or provide data for nutritional labeling.

Learn more: webinar

To learn even more about how NIR is used in flour milling (the backbone ingredient for bakery applications), you can check out the streaming webinar below.

Do-nut Fear: NIR Quick-Start is Here

For those flour or bakery producers who are interested in following in the sweet footsteps of the Krispy Kreme NIR program, BUCHI offers a broad portfolio of quick-start pre-calibrations to start collecting measurements of common ingredients right away. For the more customized blends, we have NIRWare software and Auto-cal to support the NIRMaster and NIR-Online method development, respectively. We have Application Specialists to support training for in-house calibration development using NIRWare. For online applications, AutoCal is a simple push or click button allowing to directly time stamp a sample. The sample is manually collected up- or downstream (with the optional by-pass sampler a time stamped sample is even automatically collected!) at a sampling point and subjected to internal or external reference analytics. Afterwards resulting values (e.g. protein, moisture and fat mass percentage) are directly entered into the software and the calibration is automatically updated.

Auto-cal is also integrated into the operating software of the BUCHI at-line NIR product ProxiMate which is a great fit for the food industry due to the ease of use, ruggedness and hygienic design.

Measuring a flour sample on the new BUCHI ProxiMate at-line NIR system.

Visit our NIR Applications Finder to configure your solution based on the ingredients or products that are important to you, download the NIR Milling and Bakery Applications brochure, or contact us to discuss your applications.

Things are really getting cheesy at BUCHI.

When prodded, I suppose many at BUCHI would agree that some of the cheesiest members of the team belong to the NIR group.

Maybe that’s something to be proud of!

More cheese, please!

Cheese is delicious, after all. With a global market of around $100 Billion USD, I think there is a general agreement on the matter.

There are many ways to consume cheese, of course. Processed cheese products like fondue have their place on the cheese continuum, particular around special events like graduation parties and weddings that seem to dominate our summer calendars.

Manufacturing processed cheese products like fondue is a complex task, with special emphasis on key quality parameters like total solids and fat content.

These products are typically produced by blending one or more shredded natural cheeses with additional ingredients, such as: emulsifying salts, condiments, flavors and other goodies. This mixture is then heated and sheared until a homogeneous molten mass is obtained which can be poured into heart- or graduation-capped shaped molds or other shapes for future devouring.

In order to consistently deliver the same great-tasting product, real-time control of key quality attributes is a must. Monitoring total solids content, fat, salt, pH, homogeneity and more during a blend can allow for real-time process adjustments to meet all of the quality targets and avoid having to rework a batch. The end result: tasty cheese products (read: make money) and improved manufacturing efficiency (read: save money).

While traditional laboratory methods exist for determining the quality parameters, issues with representative sampling and the method collection times are rate-limiting.

Want to learn more? Contact Us and request Short Note #357, or ask to speak with an Applications Specialist to learn more about how you can implement NIR for better process control in cheese manufacturing.

You can also visit our NIR-Online Solutions page to learn more.

If cheese quality is on your mind, but an on-line solution isn’t a good fit, BUCHI also has milk & dairy solutions for our off-line and at-line NIR. You can use our NIR Applications Finder on-line tool to configure the perfect NIR solution for you. Choose your industry and products, then get a full listing of available pre-calibrated applications, plus a quote.

Among our pre-calibrated parameters, you’ll find: dry matter, moisture, fat, protein, lactose, fatty acids, total sugar, ash and more.

Use our new NIR Application Finder to get the latest in Pre-Calibrated Solutions for your industry.

Interested in an application that isn’t listed? Fear not! We have a team of Application Scientists at the ready. Reach them using our Application Support Request Form .

If you’re looking for the full gamut of our published cheese & dairy applications, check out the BUCHI Application Finder. You’ll find methods related to:

  • Extraction
  • Spray Drying
  • Kjeldahl for protein determination
  • Near-infrared spectroscopy

Stay cheesy, my friends!

Next at bat: BUCHI @ PROCESS EXPO

Summer might be coming to a close, but our PROCESS EXPO pre-game is just heating up!

HOF Weekend 1957 Game_action_no acc #_CSU

The global food equipment and technology show PROCESS EXPO is being held in Chicago, home of the defending World Series Champions. You can catch us there September 19-22. In the spirit of the game and in anticipation for the Fall Pennant Races, the BUCHI Booth will be hosting a Wii Sports Home Run Derby competition! Be sure to stop by and take a swing for a chance to win some swag.

While you wait to step up to the plate, check out the NIR-Online, our in-line near-infrared sensor that will help you hit a Grand Slam in process control!

Not into baseball? BUCHI has something for you industry, including classical Kjeldahl reference methods and near-infrared spectroscopy (NIRS) for food analysis, in addition to spray-drying, encapsulation and freeze-drying.

Looking for a way around those long QC queues? Check out our NIRSolutions for the PROCESS EXPO industry sectors: 

Confectionery, Baking and Snack

We already blogged about some of the sweet stuff BUCHI can do in the chocolate industry, but our products can provide quantitative measurements for much more:

  • Whole & ground cereals (e.g. wheat, semolina, barley, rice, corn/maize)
  • Hulls & bran
  • Oil seed meals
  • Fats & oils (e.g. vegetable oils and animal fats)
  • Egg &  milk derivatives (e.g. egg powder, liquid egg, milk powder)
  • Dry pasta & noodles
  • Ready-meals (e.g. lasagna, frozen pizza)
  • Confectionary (e.g. chocolate, cocoa & derivatives)

Meat, Poultry and Seafood

Protein builds muscle, and BUCHI has flexed some muscles in the QC of many meats and meat products, including:

  • Animal meat (e.g. beef, pork, turkey, wild animals)
  • Fish meat
  • Sausage
  • Animal flour
  • Fish meal
  • Pig adipose tissue

Dairy

Our BUCHI NIR products are used to make sure that the stuff that goes into milk and milk products are in-spec, including:

  • Milk
  • Yogurt and fresh cheese
  • Hard, semi-hard and soft cheese
  • Processed cheese
  • Butter
  • Milk creams
  • Milk powders

Frozen and Prepared Foods

When you don’t have time to cook or time for long lab turn-around times, BUCHI NIR has methods developed for:

  • Dry pasta/noodles
  • Ready-meals (e.g. lasagna, meat pie, meat & fish ready noodles, frozen pizza)

Beverage

Drink up! BUCHI NIR can be used for quality control of beverages:

  • Distillers grains
  • Milk powders
  • Chocolate (e.g. cocoa & derivatives)

Getting hungry for more information?

Check out our Application Finder on the BUCHI website or Contact us to talk about your specific application needs.

 

Feed Manufacturing: Profit with In-line NIR Process Control

The BUCHI Crew is hitting the road this week for the 2017 International Production & Processing Expo (IPPE) in Atlanta, Georgia. Sounds peachy! Find us in Hall C, Booth 205.

IPPE is hailed as the largest annual trade show for the poultry, meat and feed industries. The show focuses on innovation, education, global reach and networking. So, what does BUCHI have to offer these industries? Let’s talk about real-time process monitoring and how it plays into profitability. 

Is moisture content in feed synonymous with profit margin? Talk to a feed producer and you’re likely to see a head nodding in agreement.

How valuable would it be to have a continuous read-out of the moisture content of your feed at points along the process where you can still adjust your process to reach a moisture target? Sounds like money in the bank, and BUCHI near-infrared (NIR) spectroscopy is a proven tool for the job. It’s also possible to monitor other critical feed parameters, like protein and fat, simultaneously.

Check out this short note showing how a BUCHI NIR-Online® process analyzer was used to monitor fat, protein, moisture and crude fiber after the mixing step in a feed operation. Or, read below for a case study at the German RKW mill that produces 75,000K tons of mixed feed annually and uses BUCHI IR-Online® to improve profitability.

The production process

At the RKW Kehl production facility the process begins with a check of raw materials for upcoming orders. The feed is predominately composed of soy and maize cereals, with minerals, vitamins and amino-acid supplementation. Feed composition is obtained by the required moisture, fat, protein, crude fiber and starch of each recipe. Due to the inherent variability of these nutrients in the incoming raw materials, the ratio of raw components needed to fulfill the nutrient profile of each recipe must be recalculated daily.

Mixtures under scrutiny

Raw materials are selected, scaled and mixed according to ordered batch recipes using the process control system. The quality control group determines whether a feed mixture falls below a required protein or fat content, or if moisture needs adjusted to meet specifications. Prior to the installation of the NIR-Online® process analyzers, the answers to these questions came from traditional laboratory analysis with long wait times. Now, the answers are streaming in real-time using the NIR-Online® device at the end of the mixing unit.

Near-infrared (NIR) light emitted from the sensors illuminates product through an installed window resulting in absorption by the sample, which is characteristic of its composition.  These readings are visualized in process charts by personnel in the switch room. If preset parameters are over- or under-run, corrective adjustments can be made immediately. Integration of the NIR-Online® products with the existing process control system provides the opportunity for automatically generated, highly detailed process documentation.

In-line control

“[Because the process can be stopped or adjusted early in production if specifications are not met] the utilization of NIR-Online® has minimized expensive rejects and complaints,” said Mr. Lühr, as he described the financial advantages of the NIR-Online® solution. “This benefit is further increased with the possibility of adjusting moisture content in real time.”

The NIR-Online® process software calculates the difference between the in-line property measurement and the batch set point without stopping production, ensuring moisture addition is precisely controlled for each batch.

“If we are able to converge within 0.5% of the moisture set point of a batch, we can sell more than 375 tons of additional mixed feed per year – a substantial benefit. “The investment in NIR-Online® technology will be paid for in a few months”, Mr. Lühr stated.

Find out more

Use the BUCHI Application Finder to explore additional application notes related to NIR in the feed industry. Or, Contact Us to get details on the broad array of feed materials and properties that can be measured by NIR.

Looking for a different technology? Click here to see results that include applications for all of the BUCHI product solutions for the feed industry, including: Kjeldahl, Dumas, extraction and spray-drying.