Bakers will have two big opportunities this year to learn about the latest technology available at baking conferences: iba in Germany in May and the International Baking Industry Exposition in Las Vegas in September. That’s good news as optimizing production is critical these days because ingredient and labor costs are soaring, which makes inefficiency and product loss even more expensive.

Manufacturers operating pan bread lines are relying on digital tools to help them head off problems and make the most of their operations.

“By measuring overall equipment effectiveness (OEE) and analyzing downtime, speed losses and quality issues, bakeries can pinpoint problematic areas and take targeted actions,” said Yan Morin, director of engineering, Rexfab. “A good software solution compares the input and output of production to identify at which stage of the process waste occurs. By knowing where waste is generated, you can focus on the issues in order of importance.”

Cloud-based data integration allows bakeries to monitor multiple production lines across different locations in real time, improving standardization and performance benchmarking, he added.

With digital tools, bakeries can quickly identify where they’re having problems, including where inefficiencies lie, where equipment needs attention to improve performance, and minimize waste and downtime.

“The latest developments in bakery automation revolve around advanced sensors and intelligent connectivity,” said Dan Alper, product marketing manager, AMF Bakery Systems. “Today’s sensors don’t just collect data — they communicate with each other, transmitting real-time performance insights to the HMI. These technologies, such as those within AMF’s Bakery Intelligence portfolio like the Sustainable Oven Service (SOS), analyze critical parameters such as energy consumption, temperature fluctuations and production trends, empowering bakers to optimize energy usage, detect anomalies early and prevent costly production stoppages.”

Bakers are collecting not only high-level data, which helps evaluate the overall general health of production lines, but also precise operational data that refines machine settings and detects changes in product quality, said Franck Ellenbogen, sales director, North America, Mecatherm. 

“Manufacturers require powerful tools to measure their production line efficiency and identify areas for improvement,” he explained. “First, to limit product losses by detecting anomalies early in the production process. Then they seek to optimize production costs, particularly by better managing raw materials and minimizing unplanned downtime.”

He added that the new MyMecatherm platform addresses key challenges in pan bread lines by combining performance indicators like energy consumption and production rates with detailed insights from the equipment.

A wide range of data can be collected on lines, including ingredient verification and scaling, mixing times, dough temperatures during and after mixing, divider scaling weight control, proofing conditions and more.

“Digital and visual systems provide immediate information on dough performance, machine efficiency and quality assurance checks,” said Jeff Zeak, national development manager, bakery, Reiser. “Internally created artificial intelligence (AI) systems offer real-time insights into production performance, process control troubleshooting and prescriptive maintenance that enable quick action at early stages of operation.”

He added that Reiser’s Vemag dividers are designed with data extraction in mind, and Vemag HPR machines can pinpoint failing parts problems while HMI monitors can guide operators through issues.

Onboard system self-monitoring, run time and maintenance intervals are some of the most recent developments in digital tools, said Jerry Murphy, vice president of sales, Gemini Bakery Solutions.

“Onboard, HMI-based maintenance and troubleshooting manuals and instructions help the technical personnel isolate and solve issues more efficiently,” he added.

Vision systems, which have been around for decades to reject subpar products, can collect data for all products, giving bakeries a clear picture about what is working well and what needs attention, said Joakim Nordell, global category sales manager, bread and bun, Middleby Bakery. 

“For instance, dark spots — air pockets under the skin — on the product could indicate the mixing process needs attention. If the shape is not uniform, that could point us to the makeup area, and general color issues could be from the oven,” he pointed out. “So this type of data collection of the finished product will aid the baker to optimize his process, minimize scrap and drive productivity.”

Monitoring the entire pan bread production line with cameras is one of the most effective ways to improve operations.

“Since the whole process lasts for two to three hours, relating causes to events is the key to understanding the problems’ roots, helping to reduce waste and be more profitable,” Morin said.

Automated calibration and adjustments ensure equipment stays within optimal parameters, minimizing variation and improving overall process control, he added.

“Remote diagnostics and troubleshooting allow maintenance teams to react quickly to performance fluctuations without requiring physical intervention,” Morin said.

Digital tools like augmented reality instructions and remote support systems can make installation of equipment run more smoothly, said Johan Laros, managing director, Royal Kaak.

“During and after commissioning, Royal Kaak and the bakery benefit from having all necessary data available to get a production line running up to desired performance as soon as possible,” he 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.

Morin said Rexfab 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.

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.