LONG

SHELF LIFE
BAKED
GOODS
 Packaged
Baked Goods
and Long Shelf
Life Trends
 APAC
Indonesia
 8
FOODSTEPS
 Baked goods
market is
growing in
volume
0,3%
0,9% 0,0% +1,7%
Eastern
North- Western Europe
America Europe

3,9%
Asia-
4,4% Pacific
Middle East 1,9%
& Africa
1,7% Austral-
+1,7% Asia
South-
Worldwide America
Source: Euromonitor, Total Volume, CAGR % 2019-2023
 Baked Goods Market 2023-2027
Baked goods
consumption
Volume Growth Value Growth will continue
CAGR: +3,43% CAGR: +6,3%
to grow
1,79 64,9
1,51 Bio T Trillion IDR
Bio T
47.9
Trillion IDR

All the Markets are Growing

in Volume and Value
Source: Euromonitor, baked good market 2023-2027
 Sweet baked
goods market
grows fast
VALUE GROWTH
CAGR: +6.3 %

40,1
Trillion IDR

29,5
Trillion IDR

VOLUME GROWTH
Source: Euromonitor, Sweet baked goods (Pastry excl. Patisserie)market 2023-2027 CAGR: +3%
 Packaged Bread Market 2021-2025
Baked goods
consumption
Volume Growth Value Growth will continue
CAGR: +3,0% CAGR: +6,6%
to grow
441 6,8
380 Mio T Trillion IDR
Mio T
5,0
Trillion IDR

All the Markets are Growing

in Volume and Value
Source: Euromonitor, Packaged Leavened Bread Market 2021-2025
DRIVERS OF
CHOICE
APAC

BREAD PASTRY, CAKE & CHOCOLATE

FINE PATISSERIE
Taste remains a
key driver of 1 Taste Taste Taste
choice, while
consumers are 2 Price Price Price
also being more 3 Healthiness Freshness Healthiness
mindful about
their budget
APAC
Consumers choose to
pay more for specific benefits…

Naturalness or Use of health

Freshness ‘clean’ ingredient list boosting ingredients

45% 28% 26%

 T ste
& Texture
85% China 77%
85% Philippines
APAC

85% India

83% Indonesia
likes to have a familiar
element when trying new
66% South Korea types of food

65% Australia
72%
2021
47% Japan
 79% 73%
Within these APAC APAC
classics,
consumers are
curious to
try new formats &
experience
different textures.
82% 84%
Likes to try food with Likes to try food in new
different textures formats

72% 69%
 73% 71%
APAC APAC
Consumers are
more open to
experiment with
new flavours,…
80% 79%
Would like to try Wants to try new or a
exotic tastes from combination of tastes
other parts of the which are unusual at
world first

66% 67%
2021 2021
Consumers look
for flavour
combinations
that bring unique
flavours and
textures, Carrefour Sensation
translating to a Black Sesame Mochi Global Grub Make It Yourself
Pc Presidents Choice Ube Boba
distinctive eating Ice Cream Cream Pie
Mochi Donut Kit
experience France, Aug 2023 United States, Aug 2023 Canada, May 2023
Black sesame ice Kit includes sweet rice flour,
cream coated “A vibrant, Filipino-inspired dessert
matcha and strawberry. Taste
with a rice paste and made with luscious, silky-smooth
of Japan. purple yam filling with chewy
sprinkled black sesame A special collaboration with tapioca pearls.”
seeds. legendary Chef Morimoto.
.

Source: Taste Tomorrow

Always-On Trend Radar 2023
 Brands revive classics by adding a fresh SPOTTED
twist to traditional products NEW
CLASSICS

Thomas' breakfast bread innovates with Bauli revives their traditional

seasonal (Pumpkin Spice) and new flavors Panettone with a Baileys
(Apple Strudel – apple & cinnamon) to collaboration.
stay interesting. (Bauli, Italy)
(Bimbo, Canada)

Source: Innova Market Insights

 Emergent ingredients are cheese, spices, SPOTTED
beans, veggies, … EMERGENT
INGREDIENTS

Vegetable bread (Bell Cinnamon Raisin Low carb bread with Potato bread with
pepper, Cauliflower, Bagels Einkorn, Soy, Chia, cheese
Spinach) Linseed, Pumpkin seed &
(Canada, Apr 2023) (Argentina, May 2023)
Sesame
(The Netherlands, Feb 2019)
(Bulgaria, Oct 2022)

Source: Innova Market Insights

Mixing up textures and/or combining two SPOTTED
classics TEXTURES

Bread on the outside, Brioche Brioche

croissant on the
Croissant Roll Pretzel
inside
(Bimbo, Spain) (Europastry, US) (St. Pierre, UK)
 From taste & texture…. SPOTTED
to piece of mind and beauty TEXTURES

“Extreme beauty” “natural” bread “Extreme raw” “milk butter” bread

• Chewy yet crispy texture • Super soft & melting
• Gentle flavor and subtle sweetness • Butter and honey
of wheat • Hokkaido milk and creal

@shokupan-sakimoto, Japan
Fruits and flavors
that either bring
the sourness or
accompany it
nicely emerge
strongly in this The sourness of citrus Berries are well suited to a Sourness is refreshing
trend. Often, fruits is versatile and range of different baking
berry flavoring is popular recipes
paired with a
Citrus fruits such as lemon and lime The tart flavors and sourness of berries such Finally, sourness creates a light and
lemon or lime to are very popular, and consumers as raspberries, blueberries and refreshing sensation. This makes it
achieve pleasing use them in a wide range of recipes
adding their flavor and sourness for
blackberries mean that consumers have a
wide array of fruits at their disposal to
popular for desserts often, because
consumers enjoy how they feel
flavors an elevated and enjoyable taste. incorporate into their cakes, bakes and afterward almost as much as they do
more. These types of fruits are mentioned
while they were eating
thousands of times in online conversations.

Source: Taste Tomorrow

Always-On Trend Radar 2023
Freshness
 The key drivers of freshness are...

Smell Crunchiness Expiry Date

and aroma

62% 48% 46%

68% 45% 55%
 FRESH
79%
FOOD
Fresh food is still seen as
most qualitative; quality
perception of packaged
PACKAGED
GOODS
60% food has increased slightly

PREBAKED 51% 45% 33%

2021 2018

FROZEN
31%
FOOD
 FRESH
81%
FOOD Fresh food is still seen as
most qualitative; quality
perception of packaged
PACKAGED 70%
GOODS food has increased

PREBAKED 70% 45% 33%

2021 2018

FROZEN
61%
FOOD
Emphasizing freshness on packaging SPOTTED
FRESHNESS

“Due to clever combination of

pasteurisation and packaging our
products come with up to a 10
month shelf life… which can be
prolonged even further if you
freeze them.”
“Long Life Freshness” “Everfresh”
Claim min. 35-day Claim up to 10
shelf life months of shelf life
(UK, Oct 2023) (UK, Dec 2020)
AMBIENT PRESERVATION
OF BAKED GOODS

5-7th December 2023

Challenges AGENDA
Food Safety
Freshness

Puratos Solutions
Bread
Patisserie
Fillings and others
How to There are 2 main challenges…
extend SL in
baked goods
FOOD SAFETY

Safe product

PRODUCT FRESHNESS
AND TASTE

Sensorial property

33
Microbiological spoilage of baked goods
FOOD
SAFETY
MOULD SPOILAGE
(Penicillium sp., Aspergillus sp.)

BACTERIAL SPOILAGE
(Bacillus mesentericus)

YEAST SPOILAGE
(Chalk moulds)

34
How to control microbiological spoilage?
FOOD
SAFETY
• Prevent contamination

• Reduce growth

35
 FOOD
 Recipe SAFETY

Control of pH
Addition of preservatives
Control of water activity

36
Control
pH

Lower product pH  slower μOrg growth

Lower product pH  more undissociated

form of organic acids
(eg. Propionic acid more functional)

37
Preservatives To destroy the microorganisms

Acids Effective pH Range Action

E210 Benzoic acid 2.5 – 4.0 Effective against yeast & molds

E200 Broad spectrum against yeast &

Sorbic acid 3.0 – 6.5
molds.

E282 Effective against molds, not

Propionic acid 2.5 – 5.0
yeast.

E260 Acetic acid

3.0 – 5.0 Good against yeasts & bacteria
(vinegar)

Yeast & molds inhibition +

No acid Alcohol (ethanol) /
softness increase

Natural preservatives (herbs & spices - rosemary, cinnamon, citrus…)

Optimal μOrg Bread pH ~ 5.5 Sourdough Bread

38 growth: pH 6-7 Cake pH 5.5-6.5 pH ~ 4,2- 4.5
Preservatives Mechanism

Outside the cell

Ca-propionate + H2O  Propionic acid (lipophilic)

(salt) (undissociated acid)

Inside the mould cell

pH 7.0

H+ + Propionate ion  Propionic acid

(dissociated acid) (undissociated acid)

decreased pH  enzyme inhibition

39
Preservatives Organic acids : undissociated form = anti-microbial effect

Percentage undissociated acid (pKa) at different pH-values

Preservative pKa 2.5 3.5 4.5 5.0 5.5 6.0 7.0
Acetic acid (E260) 4.74 99 95 63 35 14 5.2 0.55
Citric acid (E330) 3.13 81 30 4.1 1.3 0.4 0.13 0.01
Lactic acid (E270) 2.74 64 15 1.7 0.5 0.2 0.06 0.01
Malic acid (E296) 3.40 89 44 7.4 2.5 0.8 0.25 0.03
CH3COOH  CH3COO- + H+ Tataric acid (E334) 2.98 75 23 2.9 0.9 0.3 0.10 0.01
(undissociated AA) (dissociatedacetic acid) Benzoic acid (E210) 4.19 98 83 33 13 4.7 1.5 0.15
Propionic acid (E280) 4.87 100 96 70 43 19 6.9 0.74
pH ↓  % undissociated acid ↑ Sorbic acid (E200) 4.76 99 95 65 37 15 5.4 0.57
pH < pKa : active form ↑ Sulphur dioxide (E220) 1.81 17 2 0.2 0.06 0.02 0.01 0.00
pKa = pH at which 50% of the acid is in the undissociated form => Active!

Bakery products :
40
- pH 3.8 – 7.5
- most bread ~ 5,5
Preservatives Molderator 1-3% (Clean label alternative)

Molderator
Fermented wheat sourdough

lactic / acetic acid

Ca-Propionate
CP by chemical process ~ additive (E-282)
CP by natural fermentation
pH 
Ca-Propionate more active.
Less required & less off-flavor Slow down mould

Labelling: Wheat flour – fermented

41 wheat flour, sourdough
1-3%
 Labelling: Wheat flour - preservative:

Preservatives Intens Mould Control (1-3%) calcium propionate (E282), sorbic acid
(E200) - dried wheat sourdough

Challenge Tested and approved

Prevention of microbiological Pan bread – 1% Vinegar
spoilage of bread First appearance of mould (days)
But conventional preservatives: 100 90
90
80 NO impact
• give a strong off-flavour 70 on yeast
60
• slow down the fermentation as 50 activity
40
they inhibit the yeast activity 30
20 12 15
10 6
0
Reference 0.3% 0.2% 1.6% Intens
calpro sorbic acid Mould
Control

42
Control
Aw
W W

W W

W W

W W

W The bound water = chemically bound water to components

+ W The free water = available for microbial reaction = Water activity (Aw)

Total Water Content = Total Moisture

43
 Aw Approximate shelf-life

Control Ideal water activity 0.75 6 weeks ≤ SL < 3 months

0.80 2 ≤ SL < 6 weeks

Aw 0.85 1 ≤ SL < 2 weeks

0.90 Up to 1 week

Bakery applications

Finished goods Water activity Microorganisms

aw
1
Short shelf-life - Soft FG
0,9 Normal
bacteria
Aw 0.7
0,8
– 0.8
0,7

0,6
Medium/long shelf-life – Soft FG Normal yeasts /
0,5 molds
0,4

0,3
Crispy, hard Cookies
0,2
Chocolate
Xerophilic molds /
44 Osmophilic yeasts
0,1
0
Control
Aw
• Less water in recipe
– Attention: Water is the best softening agent!

• Addition of solutes (sugar, salt) or fat

• Addition of humectants/polyols
– Propylene Glycol / Glycerol / Sorbitol / Maltitol
– Glycerol 1-4%
– Sorbitol 2%
– Bad taste!

45
 FOOD
SAFETY
 Process
Preventive: Cleaning, Disinfection, Hygiene

46
Personnel Hygiene Best Practices (GMP)
PROCESS

47
Cake is “Sterile” after Baking…
Critical Points
CLEAN AREA

Filtered Air at Over Pressure

Proper cleaning, disinfection, and cleaning validation

48
What is the right temperature/time to pack…

Temp

END OF
BAKING PACKING
28 – 30°C Time
30’ to 2h (size)

Cake packed too early Cake packed too late

 CONDENSATION &  CONTAMINATION
49
CONTAMINATION  DRYING OUT
 FOOD
SAFETY
 Packaging

50
Role of Packaging PACKAGING

Extend SHELF-LIFE
PHYSICAL protection
Sensorial –
Mechanical - logistics
microbiological

HYGIENE & ATTRACTIVENESS

FOOD SAFETY
Microbiology Communication &
Contamination Convenience
Different Layers can be combined PACKAGING

O2 H2O Light
Polymer Flexible Rigid Sealable
barrier barrier barrier
Polyamide PA  
Polyethylene PE   
Polypropylene PP    
Oriented polypropylene OPP  
Ethylene-vinyl alcohol EVOH 
Aluminium ALOx   
…

An example of Sealable / Flexible / Water & Oxygen barrier packaging

PE-EVOH-PA-EVOH-PE
Modified Atmosphere Packaging PACKAGING

• Microorganisms need O2
• Substitution of air by a mixture of gas

• Gas : N2 - CO2
• Nitrogen: no antimicrobial effect (filler gas)
• Carbon dioxide: bacteriostatic and
fungistatic
Packaging Options & Shelf-Life PACKAGING

Functionality

ALU Protect against Light oxidation

Thermoresistant for Pasteurisation

Multi with O2 barrier + Modified Gas Protect against moulds

+ O2 absorbers / + Alcohol
Multi layer Printing, Flexibility, Moisture, Strength

Simple OPP Keep moisture

paper Hygiene

Shelf-life
 PASTEURIZED BREAD (RF) PACKAGING

Traditional pasteurization methods

use hot air circulation, dripping hot
water or direct steam injection with
long heating time, consequently
the product loses its quality in
terms of sensorial (color, flavor,
texture, etc.) and nutritional
characteristics.
That can be avoided thanks to the
ability of radio frequency to rapidly
generate heat volumetrically within
the product. The heating process is
fast, uniform and controlled,
therefore product deterioration is
minimized.
 FRESHNESS
& TASTE

 Recipe

56
PLACE
PURATOS FRESHNESS AND TASTE SOLUTIONS
FOR YOUR
TEXT

BAKERY PATISSERIE INTERACTION with

FILLINGS &
CHOCOLATE

57
Why does bread become hard & dry? BAKERY
Drying out & exchange with the environment

Water to filling / inclusions

Water to air

Alteration  staling

Starch crystallisation + interactions

 Hardness
 minimized with Improvers

58
Application scope BAKERY
LEAN breads Soft’r Cotton

New generation of multipurpose bakery

improver in powder format providing a
better softness, moistness and resilience to
soft lean baked goods such as toast bread
& hamburger buns.

Usage Rate
0,7% on flour weight
Labelling
Wheat flour – emulsifiers - ascorbic acid -
enzymes

59
Application scope BAKERY
MEDIUM to SWEET rich breads Intens X Fresh

Unique freshness technology that

allows to produce soft and sweet
bakery items with as supreme melting
Softness Moistness
texture. For bakery applications with
10% sugar and 5% of fat.

Usage Rate Resilience Short bite

1% on flour weight
Labelling
Wheat flour – emulsifier - enzymes

60
An intermediate thermostable protease that is
increasing the short bite but that has no
negative impact on volume or resilience

• Improved Short bite

• Melting sensation
• Premium texture
• Fat reduction
Single solutions
to industry Speed of
rather than Innovation
Development
single
ingredients

Ease of
Flexibility
Implementing
Working on a single
functionality of the dough or
the final bread.
Can be used in all bakery
applications and processes.
INTENS Product Range BAKERY

Dough Rheology Shelf Life

Intens Extensibility Intens Mould control
Intens Strength (CL)

Texture
Visual & Shape Intens Freshness
Intens Oven Spring Croissant Intens Freshness Cool
Intens Sliceability Intens X Fresh

Intens Resilience
Cost reduction Intens Short Bite

Intens Gluten replacement 1% Intens Best

Intens Egg replacement

Intens Fat Reduction

 PATISSERIE

64
Acti is a range of enzyme-based cake solutions PATISSERIE
Improve texture
(softness, cohesiveness, resiliency, moistness, melting and
chewiness)

Contribute to clean(er) labels

Enzymes are naturally present in our environment and
their usage does not bring additives

Reduce cost
Egg reduction, fat/emulsifier reduction, simplification of recipes,
less waste,… are some of the features that the Acti Range can bring
to your products
65
Acti is available as PATISSERIE

Acti cake improvers Easy Acti

= =
A concentrated mix containing Acti technology and
A functional ingredient to be used in customers’
other key functional ingredients, to be used as a
recipes in order to tackle several challenges faced in
base in order to produce cakes with innovative
cake production
textures, optimal taste and long-lasting freshness
(food waste, costs, H&WB…)

66
Acti range enables to tackle key challenges PATISSERIE
faced in cake production

Fighting food waste Reducing ingredient cost Improving H&W

67
Acti Fresh works in many applications (aerated
and non aerated)
Successful implementation at customers:

Crispy waffle Swiss roll

Layer cake

Dense loaf cake Brownie Cupcake Cake Donuts

…
 FILLING
Impact of filling* and water activity INTERACTIONS
Water migration from High Aw  Low Aw

Aw Aw
Rule
filling crumb

• Aw filling > aw crumb • Aw filling < aw crumb

 Water migrates from filling to crumb  Water migrates from crumb to filling
 Filling’s color migrates too!  Crumb hardening and drying
 Moistening of crumb  Alteration filling’s texture
RISK OF MOLD
GROWTH

69
Which filling to choose?
Finished goods Water activity Puratos Solutions
Short shelflife - Soft aw
FG
1
COLDFIL Custard Cream SMOOBEES
0,9 0,85 CREMYVIT
VIVAFIL CREMFIL
0,8 SMOOBEES
low Aw
Medium/long shelflife VIVAFIL CREMFIL
0,7 CREMFIL Ultim
– Soft FG TM TM
0,6

0,5

0,4

0,3
CARAT
Crispy, hard Cookies 0,2

Chocolate 0,1

70
Puratos solution: Use the right fillings
SMOOBEES
VIVAFIL CREMFIL CREMFIL ULTIM
(Aw 0.8)

Controlled water activity (aw)
Excellent bake & freeze/thaw stability
Minimum 20% fruit with natural fruit
markers
No artificial colours, no artificial flavours
Excellent Bake stability Chocolate & nut filling
Soft and smooth texture for a moist and
Stable in your process Preserving freshness creamy-like mouthfeel
Stable in ambient finished Soft centre in soft sweet goods Fruity & non-fruity flavors
products TM Aw Clean Label and plant based
For Fresh, frozen and packed.

71
 Aw Approximate shelf-life
Improved shelf-life (bread/cakes) 0.75 6 weeks ≤ SL < 3 months
0.80 2 ≤ SL < 6 weeks
SMOOBEES (Aw 0.9-0.8) 0.85 1 ≤ SL < 2 weeks

CREMFIL ULTIM 0.90 Up to 1 week

Bakery applications
SUPERCREM
VIVAFIL MONTHS
CREMFIL WEEKS

SHELF-LIFE
DAYS
Controlled Aw filling

Medium Aw filling
High Aw filling

MAP
Sealed bag
Clamshell
Puratos Product Summary

Molderator Intens Mould Control

Bread Cakes Fillings

Soft’r Range ACTI Range Vivafil

Lean Cremfil
Rich (Melting) Acti Cake improver
Cremfil Ultim
Easy Acti
Intens Range Smoobees
 Packaging 101
Extend Freshness, Seal Flavor
 Since
Established in 1981, Supernova today is the largest integrated flexible packaging
1981 manufacturer in Indonesia.

4
PLANTS Ancol JB 2 JB 6 MM2100

Equipped with various advanced machineries ranging from cylinder making, printing,
extrusion machines, dry lamination and bag making facilities.

1981
>70% MULTI-NATIONAL Our
MAJOR LOCAL COMPANIES certification
Customers

76
OUR FACILITY
Blowing Machine
Lamination

Rotogravure

77
 Bag Making
OUR FACILITY
Cylinder Making

Slitting

Metalizing

78
OUR PRODUCT

79
Kemasan Fleksibel
Kemasan dari bahan plastik fleksibel, yang dapat dipadukan dengan aluminium foil, kertas, atau
plastik lain serta dicetak dan dapat direkatkan sehingga tertutup rapat

Fungsi Kemasan

Perlindungan Marketing Nilai Tambah

Melindungi dari bahaya fisik, Membantu mempromosikan & Memberikan nilai tambah
biologis, sinar, & kelembapan memberikan informasi produk pada produk
Kemasan Melindungi Produk

Mencegah udara luar masuk ke dalam Komposisi Umum Kemasan

Mencegah aroma keluar dari kemasan

Lapisan Dalam
Luar Dalam ● Lapisan segel (seal) → segel kemasan
● Bahan: Polietilen film (LLDPE)

Lapisan Barrier
● Melindungi produk dari sinar, oksigen,
dan kelembapan
● Bahan: Metalize film, Alu Foil

Lapisan Luar
● Lapisan cetak → desain kemasan
dicetak
● Bahan: Poliester film (PET), Nylon,
Polipropilen film (OPP)
Kemasan
Mengapa perlu barrier yang baik?
Fungsi Contoh produk

Menjaga kesegaran dan - Cookies dan snack

→
rasa produk - Produk powder (minuman, garam, gula)

Menjaga aroma produk → - Kopi dan teh

- Daging
Mencegah kontaminasi
→ - Nugget, Sosis, dan Ham
bakteri
- Seafood

Lapisan barrier yang umum digunakan Shelf Life

Metalize Tahan kelembapan dan oksigen 6 bulan – 1 tahun
Alu Foil Sangat tahan kelembapan dan oksigen 1 Tahun
Menentukan kemasan yang tepat

Produk apa yang akan dikemas?

Berapa umur produk yang diinginkan?

Bagaimana produk akan didistribusikan?

Faktor yang memengaruhi shelf Life
Faktor

- Apakah produk segar (fresh)?

Karakteristik Produk →
- Apakah produk sensitif pada zat atau kondisi tertentu (udara, suhu, dll)?

- Bagaimana produk diproses (dipanggang, ditambah pengawet, dll)?

Pemrosesan produk →
- Bagaimana proses filling dan segel kemasan produk?

Lingkungan → - Bagaimana kondisi lingkungan saat distribusi, penyimpanan, dan display?

Contoh: Roti

Ketahanan produk roti bergantung pada 3 faktor yaitu karakter produk,

pemrosesan, dan lingkungan. Shelf life produk dipengaruhi oleh potensi
pertumbuhan jamur. Modified Atmosphere Packaging (MAP) dengan komposisi
CO2 dan Nitrogen dapat mencegah pertumbuhan jamur.

Contoh kompoisisi gas dalam MAP

Karbon dioksida
Produk Oksigen Nitrogen
(CO2)
Crispy Bread 0 50-100 0-50
Kue, Biskuit 0 50 50
Buah, Sayur 3-10 3-10 80-90
Kopi 0 0 100
* Sumber:White Paper – How Modified Atmosphere Packaging extends the shelf life of food pproducts
 Produk Struktur Distribusi Shelf Life

Roti → CPP → Retail Fast Moving 4-5 hari

OPP/LLDPE
Frozen Pao → Ny/LLDPE (Vacuum) → Frozen 1 Tahun
OPP Anti Fog / LLDPE Anti Fog

Kue Kering → PET/VMPET/LLDPE → Retail ≤ 1 Tahun

Retail Baked Goods → PET/Alu/LLDPE → Retail ≤ 1 Tahun

Ready-to-eat → PET/Alu/Ny/CPP (Retort) → Retail 1 Tahun

* Shelf life bergantung pada produk dan pemrosesan (filling, sealing, dll)
Kemasan Anti-fog, Breathable, dan MAP
Kemasan Definisi Tujuan Barrier Contoh Produk
Penggunaan antifogging agent
untuk menghindari embun Mempertahankan
Anti-fog Barrier tetap Frozen Food
(fog) pada plastik ketika terjadi visibilitas produk
penurunan suhu
Popok (untuk
Memungkinkan aliran udara Untuk mengatur Barrier menghindari
Breathable
untuk mengatur kelembapan kelembapan berkurang iritasi dari uap
air)
Kemasan dengan komposisi
gas tertentu untuk Barrier
Memperpanjang umur
menghambat potensi bergantung
Modified simpan dengan Roti, kue,
MAP kerusakan produk pada produk
Atmosphere memodifikasi komposisi daging, sayur,
Packaging (MAP) Contoh: Crispy Bread gas tertentu pada buah
Contoh: Nylon
(Komposisi: O2=0%, CO2=50- kemasan
untuk Roti
100%, N2=0-50%)

Sumber:White Paper – How Modified Atmosphere Packaging extends the shelf life of food pproducts, Modified Atmosphere Packaging, Modified Atmosphere Packaging &
Controlled Atmosphere Packaging
DIGITAL PRINTING Personalized

Digital printing in Supernova is to provides better flexibility

in design development and suitable for short run order

Design Flexibility

Regular QR Micro QR

HP INDIGO 20000
Security Printing

88
DIGITAL PRINTING

Small MOQ

89
Unique Design for Standing Pouch with Zipper

*Price may vary based on the quantity order

90
DIGITAL PRINTING

91
Sustainability
 Circular Economy

1. Recyclable Packaging
Mono-material structures to enable recycling of products after use (All PP/PE, High Barrier All
PP/PE, All PET, or All Paper)
2. Recycled Material
2.1. Use of PIR (Post-Industrial Recycled) resin that comply with ISCC (International
Sustainability and Carbon Certificate), a mature technology and already implemented in industry
2.2. Use of PCR (Post-Consumer Recycled) resin in film production, a developing technology
3. De-inking and De-lamination
Sustainable De-inking agent and de-lamination adhesive in combination with alkaline treatment to release the
Packaging ink and adhesive layers from the substrate

Bio-based

1. Bio-based Polymers
Use of polymer resins made of renewable feedstock
2. Biodegradable or Compostable Products
Enabling of biodegradation and/or composting of products after use

93
We develop sustainable structure for several items

Cereal Condensed Sweet soy Seasoning Body wash

milk sauce
Thank you
Frozen
Bakery
Solutions
Frozen solutions AGENDA
BREAD
Overview & Challenges
Frozen dough
Fully baked frozen
PATISSERIE
Challenges in:
Prepare/Assemble/Pack
Freeze&Store/Transport/Thaw
Freshness is the n°1 How do consumers
criterium for buying bread define freshness?

When Expiry
baked/
prepared
date
43%
56% Overall
Smell appearance/ Crunchiness
56% colour 32%
52%
 Challenges
in the point of sales
Offer fresh quality all day long
Consistency across stores
Waste versus out of stock

Low baking skills and tools

Flexibility
 Advantages of the Frozen process
at the point of sales

Scratch baking Frozen bake off

 Sharing our passion
and expertise for
every frozen
process
MANUFACTURER POINT OF SALES

READY TO
PROOF

READY TO
BAKE

READY TO
BAKE-OFF

READY TO
SERVE
 Sharing our passion
and expertise for
every frozen
process

KIMO

QUICK STEP

DOUBLE BAKE

S500 – SOFT’R
 UNFERMENTED
FROZEN

KIMO
 UNFERMENTED
FROZEN

ADVANTAGES DISADVANTAGES

• Small size and cost frozen • Loss of fermentation power during

logistics freezer storage
• Low cost • Need for proof-box & space
• Provides more feeling of • Strong bakery skills needed
authentic bakery to the • Long time to consumer
store • Low quality consistency
• High ‘left-over’ = waste
 UNFERMENTED
FROZEN

THIS IS THE ONLY FROZEN TECHNOLOGY

WHERE WE NEED TO KEEP, AS MUCH AS
POSSIBLE, BOTH OUR YEAST ALIVE AND OUR
GLUTEN INTACT. THIS IS KEY FOR SUCCESS
 UNFERMENTED
FROZEN
Volume loss – yeast survival

0’
• Yeast is sensitive to low temperatures
30’ (osmotic pressure and ice crystals)
• If the yeast starts to proof before freezing is
even more sensitive.
60’ • Dough is to be mixed at very low
temperatures (16 – 18ºC)
90’
• Increase the yeast dosage
 UNFERMENTED
FROZEN
Yeast survival – osmotic pressure

Tº > 0ºC Tº < 0ºC

More concentrated
solution

Pure ice Crystals

 UNFERMENTED
FROZEN
Ice crystal formation

Slow freezing Fast freezing

H. J. Aufm Kampe et al.,
 UNFERMENTED
FROZEN
VOLUME LOSS – GLUTEN NETWORK

Puratos - Oniris
 UNFERMENTED
FROZEN
Volume loss over shelf-life

-/-10%

-/-12,5%

-/-20%
 UNFERMENTED
FROZEN
UFF – ideal freezing conditions

optimal: 2-3 m/s

-8°C to -10°C

-25°C to -30°C

± 20°C
Kimo • Helps to keep the volume during freezing shelf
improver life

• Reduce cost by optimized logistics with

extending freezer shelf-life

• Provides minimal quality loss for freezing

periods up to 6 months (KIMO LONG) and up
to 2-3 months (KIMO SHORT)
FOR
UNFERMENTED
FROZEN
BAKED GOODS
 A unique type of family 8 xylanases
Intens with optimal enzymatic activity at
lower dough temperatures.
Strength
 UNFERMENTED
FROZEN TIPS

• Use strong Flours (Protein >12)

• Add gluten for very long SL (1-3%) or intens gluten replacement as
cost effective solution.
• Use the right improver (Kimo Range)
• Keep dough cold (18-20C)
• ↑ yeast depending on the frozen SL (50-100%)
• Go as fast as possible before freezing
• Respect the freezing, transport and storage conditions
• @ Point of Sales:
• Let it thaw and then proof, avoid thermal shock
• Develop clear instructions for bakers
 FULLY BAKED
FROZEN

MANUFACTURER POINT OF SALES

READY TO
SERVE
 FULLY BAKED
FROZEN

ADVANTAGES DISADVANTAGES

• No make-off • Full size piece for frozen

• Very fast response to demand
• Very low ‘left-over’ /waste
• No need for any equipment
• Quality consistency
• Long freezer shelf-life
logistics
• Not possible for crusty items
• Less freshness than directly
baked product
FULLY BAKED
FROZEN
 FULLY BAKED
FROZEN

optimal: 2-3 m/s

-8°C to -10°C

-30°C - 40°C

± 25- 30°C
S500 & • For soft applications

Soft’r • Helps to develop the gluten network at

low temperatures resulting in increased
improvers tolerance thanks to Intens Strength
from the Antarctic

• Outstanding freshness thanks to the

best combination of freshness enzymes
FOR and Short Bite technology
FULLY BAKED (thermostable proteases)
FROZEN
BAKED GOODS
 Be/Fr – Frozen Brioche à la cannelle

• Finished good : Fully baked frozen cinnamon Brioche

• Shelf Life and storage condition: 9 months, frozen
• How it is used: Thaw and serve (even microwave)

• Thaw and serve concept

• Suggested to thaw in the fridge (3h). Also can be
used microwave oven 30sec. Oven reheated 5min
• Full clean label brioche
 Be/Fr – Sliced frozen Brioche

• Finished good : Sliced fully baked frozen Brioche

• Shelf Life and storage condition: 9 Months, frozen
• How it is used: Thaw and serve or even toasted

• Thaw and serve concept

• Suggested to toast, bake it or even thaw in the
fridge (5h) for different results and eating
experiences.
• Full clean label brioche (even acerola is used)
 Be/Fr – Frozen Brioche Parisienne

• Finished good : Fully baked frozen Brioche

• Shelf Life and storage condition: 9 Months, frozen
• How it is used: Thaw and serve (even microwave)

• Thaw and serve concept

• Suggested to thaw in the fridge (2h) for use
microwave oven 10sec.
• Full clean label brioche (with acerola instead of Vit
C)
 Spain– Burger Cristal

• Finished good : Fully baked frozen hamburger

• Shelf Life and storage condition: 9 Months, frozen
• How it is used: Thaw, bake1min and serve

• Bake (1min) and serve.

• Very crispy crust (crystal), achieved through long
cold fermentation and sourdough process.
• Lean recipe
• Open crumb
• CL, Vegan, with olive oil, sourdough.
Sharing our expertise in
Frozen Patisserie
Why Freezing?

Freshness Reduce Waste

Convenience Optimize Storage

Flexibility Improve Profitability

Reduce Water Mobility Control Starch Retrogradation

Purpose is to keep products

FRESH → reduce water
mobility
Frozen General comments
Patisserie

• Process has a huge impact on your product but the right ingredients can minimize
this impact.
• Pay a lot of attention to the SELECTION of your ingredients
• Base
• Fillings
• Fruits
• Inclusions
• Puratos can help you with a full range of Freeze/Thaw stable products
Frozen Puratos Solutions
Patisserie

SATIN RANGE, Vivafil is a RTU fruit Smoobees, Soft and

adapted to Freeze filling, with different % smooth inclusions also
and Thaw, even with fruits and freeze/thaw freeze and thow
Actifresh inside stable stable

Cremyvit, delicious
AMBIANTE works with
and smooth custard
blast & direct freezing
cream mix prepared
as well as continuos
with only cold water.
and planetary mixers
Freeze/Thaw stable
Frozen Equipments
Patisserie
Two different types of freezers

Cryogenic refrigeration system Mechanical refrigeration system

With liquid N2 or CO2 With system containing a compressor, a condenser,
an expansion valve and an evaporator

Rule of thumb: -10°C (core)

Freezing
Which freezing process?

• Cost-in-use?
• Product
• Size & shape
• Composition
• Process (blast freezing)
• T°
• Air flow & orientation
• Humidity & delta-T°
• Product load Cryogenic: lower up-front capital costs and investment. But uses
relative large amounts of expensive refrigerant: more suitable
when you have low production volume.
Mechanical: higher capital costs and investment. But they are
more efficient and cost-effective in their use. Is most often used
for high-volume production.
Freezing
Freezing speed defines the size of ice crystals

Small crystals Big crystals

Slow freezing:
T  formation of large ice crystals
 more mechanical structural damage

-4°C t Ice crystal formation

slow
CRITICAL ZONE (big ice crystals)
fast
-18°C Stable crystal

Go as fast as possible below

Fast freezing: the limit of stable ice crystal
 formation of smaller ice crystals formation, which is below -18
 less mechanical structure damaging degree Celsius.
Freeze
Freeze/Storage/Transport: Golden rules to stabilize water crystals
Storage
Freezing: avoid
– Excessive air circulation
• freeze burn, freeze drying
– Too long freezing
• freeze drying
– Too slow, recrystallization,
big ice crystals
• Texture modification:
ice cream, vegetable cream
Storage: avoid
– Unpacked goods
• freeze burn, freeze drying
– Excessive storage times
• quality decrease
– Temperature fluctuations
• freeze drying, crystal growth
Thawing: avoid
– Fast thawing (water migration & drying):
• generates cracking and holes
 Conclusion

Prepare Assemble & Pack Freeze/Store Transport Thaw

Ingredient: Puratos
Process / Blast freezer
adapted Fillings
Ingredients: TSCC, (mechanical or Control! Control!
(Topfil, Cremfil,…) &
Ambiante,… cryo)
Decors (Miroirs…)
 Spain/Fr/Be/Jp Variety of Frozen Choux pastry

• Finished good : Thaw and serve Choux, eclairs,…

• Shelf Life and storage condition: 9 Months, frozen
• How it is used: Thaw and serve

• Thaw and serve choux pastry in different formats

and fillings.
• Very convenient, trendy.
• Fillings must be adapted as well as the toppings.
 Spain – Frozen Churros

• Finished good : Ready to fry Churros

• Shelf Life and storage condition: 9 Months, frozen
• How it is used: frozen batter to be fried

• Frozen Churro dough, shaped, ready to be fried in

a pan or fryer.
• Available in different sizes (XXL porras, bites,
mini,…)
• Can be filled with stable fillings like Cremfil
Caramel, fruitfil strawberry and apple, cremfil
classic Vanilla.
 Spain – Frozen Churros and xuxo

• Finished good : Xuxo, fried and filled laminated croissant,

ready to thaw and serve
• Shelf Life and storage condition: 9 Months, frozen
• How it is used: Thaw and serve
• Cremfil vanilla and Chocolate
 Japan – Frozen Allergy care celebration cake

• Finished good : Frozen Allergen free cakes

• Shelf Life and storage condition: 9 Months, frozen
• How it is used: Thaw and eat

• Frozen celebration cake made without allergens.

• Target: Children with allergies for birthday parties
and other celebration occasions.
• No eggs, no milk, no gluten
 Sharing our passion
In frozen, process and technical support and expertise for
are key for succes every frozen
process

Process & technical Solutions Recipes

support
THANK
YOU