The Importance of Smart Quality Control

For generations, the bakery was governed by the “feel” of the dough. Master bakers, with years of experience, could instinctively adjust for a temperamental batch of flour. However, the industry is evolving. As master bakers retire and automation increases throughput, that invaluable hands-on expertise is gradually disappearing from the plant floor. This presents a modern paradox: we demand absolute consistency but have fewer seasoned experts to manage flour’s inherent variability. Join us as we share insights from our recent Smart Quality Control for Modern Bakery BAKERview.

The Data Dilemma: When “In-Spec” Flour Fails

The quality control tools we’ve inherited, like the Farinograph, Alveograph, and Falling Number apparatus, are industry staples, essentially invented decades ago for millers. They provide data but don’t always predict flour’s performance on your line, for your specific product. 

Consider two flours with nearly identical Farinograph results:

• Flour A: WA 60.4%, Stability 34.7 min, Volume 1606 ml, Total Score 250/300
• Flour B: WA 59.9%, Stability 34.2 min, Volume 1245 ml, Total Score 216/300

On a standard spec sheet, both might be approved. Yet, Flour B shows a significant dip in gas production after 2 hours, resulting in a denser loaf. Standard tests offer a narrow snapshot, missing the bigger picture of flour’s true baking character. This is at the core: 96% of manufacturers report issues with “in-spec” flours. The old metrics are no longer sufficient.

Stop Guessing, Start Knowing

The future of quality control isn’t about discarding our tools; it’s about using them more intelligently. It means combining information for a clearer picture and moving from prediction to precise measurement. Here’s how:

1. Objectively Measure Your Final Product and Process: Don’t just test the flour; test the dough. New technologies enable rapid analysis of dough rheology on the production floor, delivering results in as little as 2 minutes and being compatible with high-speed lines.
2. Characterize the “Good Dough”: Use tools to provide objective data on historical expertise. Define the specific torque profile of perfect doughs, measure them, and set these as your gold standards.
3. Build Your Own Specifications: A “good” flour for a baguette differs from that for a whole wheat loaf or cake. Stop relying on generic advice. Build specifications based on what suits your product and unique process.

Embrace Innovation

Sometimes, innovation lies not in a new device but a new method. There are two ways to use lab equipment:

• The Standard Method: Essential for communication and comparison, though its rigid conditions may limit R&D potential.
• The Customized Method: By adapting protocols and tool settings, you unlock insights into non-standard products like sourdough, high-egg cake batters, or novel grains like Tritordeum, leading to true innovation and competitive advantage.

Want to learn more? Watch the BAKERview:

Modern Quality Control

KPM Analytics advocates a smarter approach to quality assurance, understanding the complexities of baking. They offer solutions tailored to your needs, helping bakers:

• Recognize Complexity: Measure and observe rather than merely predict.
• Define Objectives: Choose the right tool for the specific problem.
• Look Beyond Protein: Remember that 70% of flour is starch, crucial in functionality during proofing.
• Partner for Success: Beyond devices, they offer application support and services to maximize your investment.

Don’t settle for flour that merely meets the spec sheet. Demand flour that performs optimally in your plant. Ready to elevate your quality assurance from guessing to a precise, data-driven success? Contact KPM Analytics to learn more and transform your approach to quality control.

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