Digital tools have helped improve operations from the beginning through the entire process. Dan Alper, product marketing manager, AMF Bakery Systems, said the most positive impact has been in the middle of the bakery where precise control over key parameters directly influences product quality and efficiency.

“By integrating digital tools and real-time monitoring, bakeries can analyze production performance, identifying strengths and areas for improvement to maximize pan bread efficiency, reduce waste and minimize production disruptions,” he said.

Alper cited AMF’s Sustainable Oven Service, which provides real-time monitoring and adjustments for ovens; Chain Guardian System that monitors chain conditions in proofers, coolers and conveyors; and Mixer Guardian, which automates dough quality control, reducing reliance on skilled labor. He also mentioned the value of digital tools at the end of the line.

“As the final step in the production process, packaging lines provide valuable data that helps calculate profit and loss by accurately tracking the number of sliced and bagged loaves,” Alper explained. “Newer technologies enhance packaging operations by reacting to incoming products/selected recipes to prepare the packaging line in advance in addition to alerting maintenance teams to perform preventative maintenance, reducing unexpected downtime.”

Bakers can improve operations using a variety of digital tools in several areas, said Jerry Murphy, vice president of sales, Gemini Bakery Solutions. This includes radio frequency identification tags (RFID) that can be added to pans to notify bakers of coating cycles as well as optimizing pan inspection and maintenance, fault monitoring and recovery through onscreen guidance, and drive faceplates that provide speed, voltage, current and temperature for each motor. A remote access gateway supports customers with fault recovery or operation monitoring.

“Onboard HMI-based maintenance and troubleshooting manuals and instructions, in addition to preventive maintenance (PM) cycle counts, can help the technical personnel isolate and solve issues more efficiently and provide more timely PM tasks,” he said.

Improving changeovers is the aim of Mecatherm’s M-Plan simulation software that enables bakers to determine the most efficient methodology.

“It plays out different production scenarios on the 3D model of the customer’s production line,” explained Franck Ellenbogen, sales director, North America, Mecatherm. “It prevents issues from arising during real production changeovers. This reduces consequent product damage and losses. As a result, it helps manufacturers achieve the best availability rate and the lowest changeover times.”

A comprehensive look at recurring problems and alarms can help operators identify issues and take preventive steps to avoid them moving forward.

“Operators can be warned in advance with predictive failure alerts in case of a critical problem that could lead to an equipment shutdown within the next few hours, allowing them to intervene proactively,” Ellenbogen said.

He cited Mecatherm’s Hygro Control System as a digital tool that simplifies humidity monitoring in an oven by minimizing steam and heating consumption and improving products.

“This solution analyses the hygrometry parameter inside and outside the oven to adjust automatically the hygrometry level in the oven,” Ellenbogen said. 

Stewart Systems, a Middleby company, has a Utility Monitoring System, which gathers data for oven gas and power consumption. 

“Data is collected for each product and time of the day,” said Joakim Nordell, global category sales manager, bread and bun, Middleby Bakery. “The information is used to alert of any wasteful consumption from either poor setting of the oven, operator problems or any other equipment issues.”

Cameras along the line are being used not just for product rejection but also to detect line problems, he added.

“This information can be used to detect products left in the pan, pockets without dough, misaligned pans, damaged pans, verification of printed labels and confirmation the package has the correct number of products,” Nordell pointed out.

Jeff Zeak, national development manager, bakery, Reiser, said that digital tools can help automated mixers, conveyors, proofers and ovens by maintaining consistent speeds and quality.

“Smart scales for accurately scaling ingredients and verification, servo-driven dough dividers and process check weighers ensure exact measurements and consistent results,” he said.

Digital tools can undoubtedly assist bakers to improve operations, but using insights uncovered by these tools effectively can be challenging. Manufacturers are doing what they can to make tasks easier for bakers and their operators.

To make the most of digital tools, producers need training in data analysis and interpretation, operating advanced machinery and software, understanding AI-driven insights and implementing data-driven decision-making processes, Zeak said.

“Companies are helping bakers by offering integrated digital solutions, providing ongoing support and developing user-friendly interfaces that simplify the adoption of new technologies,” he said. 

 PLC controls of recipe management enable flexibility for bakers producing varied products, Murphy said. 

“Very precise time sequences can be programmed and controlled, which in the end creates the ability to make very consistent products over longer periods of time,” he added.

Mecatherm aims to provide intuitive and user-friendly equipment that simplifies daily operations.

“Each of our customers benefits from tailored individual training sessions during the deployment of our solutions on their production lines,” Ellenbogen said. “These sessions are adapted to their specific needs, ensuring that operators, maintenance teams and production managers can efficiently integrate digital insights into their daily workflows.”

Yan Morin, director of engineering, Rexfab, said his company customizes control programming tailored to the bakery’s processes to ensure it integrates well with other equipment.

“On-site and remote training sessions cover best practices for equipment operation, troubleshooting techniques and leveraging data insights to make informed decisions,” he said.

Bakerywide connectivity is a priority for AMF Bakery Systems along with operator efficiency and ease of use, Alper said. The company’s AMFMethod platform delivers a structured learning management and customer training program that includes step-by-step guides, articles, troubleshooting, and on-site and virtual operator training.

“This multi-tiered support platform ensures bakeries maximize the value of their digital tools while keeping production running smoothly,” he said.

Royal Kaak provides remote support that monitors processes and equipment along with an app that provides insights on equipment and products.

“It follows a ‘manage by exception’ philosophy by leading the user’s attention to exceptional situations using signals,” said Johan Laros, managing director, Royal Kaak. “The app is able to aggregate big data into the most important insights.”

Bakeries with pan bread processing lines need to keep product losses at a minimum and run the most efficient operation possible. Digital tools can be a big help as long as bakers learn to use them to their full advantage.

This article is an excerpt from the April 2025 issue of Baking & Snack. To read the entire feature on Pan Bread Processing, click here.