Optimizing Bakery Efficiency: A case study in seed adhesion using Gecko

We recently received a request from the maintenance and production manager of a prominent industrial bakery. Their specific concern revolved around adhering sesame seeds to the top of loafs of bread, which are subsequently either partially baked or frozen.

In pursuit of quality, they stipulate a minimum quantity of sesame seeds atop their loaves upon delivery. In their commitment to meeting these standards and compensating for potential seed detachment, they resorted to overapplication of costly sesame seeds.

Prior to reaching out to us, the bakery relied on the standard automatic nozzles that came with their production line. Regrettably, this system could only utilize water as an adhesive to affix the seeds to the bun. This, in turn, gave rise to several evident challenges:

• • Water proves to be an inadequate adhesive for maintaining seed adhesion to the bread surface.
• • Seeds detach from the loafs during the production, packaging, and transportation stages, leading to a significant decline in perceived quality.

To ensure a consistent minimum amount of sesame seeds on the buns and to prevent the wastage of expensive seeds, they started to look for a more efficient seed adhesive solution capable of effectively applying Gecko®—a groundbreaking adhesive liquid that’s notoriously challenging to spray.  

Solution

With over 80 years of expertise in spray technology and a dedicated food system development facility, we were uniquely positioned to provide assistance.

The application of a high-viscosity slurry - like Gecko® - presents a big challenge when striving for precise and uniform spray patterns. We conducted several lab tests and production trials at our state-of-the-art Spraying Systems lab in Poland. The primary objective of these trials was to optimize spray performance during testing and tailor the system for seamless integration into the existing bakery production line. Every aspect and technical detail of the spray process was refined before being presented to the bakery, allowing them to assess the quality of our solution prior to making a purchase.

Ultimately, we decided on a top-tier AutoJet® E2850+ system mounted on a hygienic mobile frame, equipped with an industry-standard Siemens PLC. This advanced system allows individual control over the 25 PulsaJet® nozzles in the spray header. The adhesive liquid is supplied from a 50-liter pressure tank featuring an automatic refilling valve, seamlessly connected to a 200-liter mixing tank integrated within the system. This setup not only ensures liquid dilution but also facilitates pressure tank refills without any production downtime.

In addition to this setup, we incorporated automatic cleaning functionality to limit maintenance to an absolute minimum.

Result

The bakery was impressed with the performance of the initial trials. The ability to exercise precise control over 25 individual PulsaJet® nozzles proved to be a game-changer in achieving an accurate and uniformly distributed spray pattern. Turned on by these promising outcomes, they gave the green light to the project, and we seamlessly integrated the AutoJet® E2850+ system into their existing production line.

With some tweaking we finally installed a solution that greatly outperformed their old seed adhesive system.

The ultimate results are truly impressive: The seed dispenser’s capacity has been reduced by 50%, resulting in a more generous distribution of grains on the loaf’s surface compared to water application. This, in turn, translated into a significant enhancement in product quality and visual appeal.

Thanks to the substantial reduction in grain consumption, the customer estimated a return on investment (ROI) timeframe of approximately 6 months under full production load. Beyond the financial savings, minimizing seed loss also aligns with the bakery’s commitment to reducing food waste, harmonizing seamlessly with their “Zero Waste” approach.

These results not only signify a substantial cost reduction for the customer but also contribute to a more sustainable and efficient production process.