Interview* How do I plan a new bread roll production line?

How soon should bakeries enter the planning phase for a new bread roll line, and which are the milestones that need to be considered on the way to commissioning?

Ulrich Sontheimer: Due to the increasing complexity and diverse demands placed on bread roll lines, a high level of customization is required. It easily takes nine to twelve months from planning to commissioning. We recommend starting the project at least one year before the expected commissioning. The first milestone is a needs analysis of the products that will be produced with the new line. Following needs analysis, we recommend running tests on the planned line at the WP Baking Center with your own recipes, flours, and ingredients. It must also be verified beforehand that the intended installation location meets all the requirements in terms of load capacity and footprint. It is important that all supply lines for the required media have been laid and are ready for connection. The installation and commissioning of a bread roll line is usually very quick, because it is delivered fully assembled from the factory.
 

Which mistakes in the overall project structure do you see most often in practice? How can those be avoided?

Ulrich Sontheimer: The benefit of a bread roll line is the high hourly output of precisely defined products with consistent quality. To this end, we need the precise definition of the product composition and quality from the customer. This is the key factor that helps avoid mistakes. It is our task to configure the lines accordingly. We not only modify the technical parameters, but, in case of very sensitive products, also test them under real conditions in the WP Baking Center. Configuration of the line is only approved when the customer is 100 % happy with the result.
 

Many bakeries want to produce different types of bread rolls on a single line. At which point does modularity become economically viable?

Ulrich Sontheimer: Flexibility is becoming increasingly important. It does become economically viable when less employees are required for production or a higher hourly output would be possible with the same number of employees. Another point in favor of modularity of bread roll lines is future needs that are as yet unknown. It is therefore feasible to look into the possibilities of extending a line so as not to jeopardize future opportunities.
 

How precise should bakers define beforehand whether processes such as depositing, proofing, or tray logistics need to be integrated in the line?

Ulrich Sontheimer: Precise product definition is elementary for line configuration. At WP, product definition is an integral part of order confirmation, and is reviewed by the design and application engineering departments.

On what footing should a baker choose the optimal bread roll line? In your opinion, which are the key criteria for a future-proof investment?

Line configuration should primarily be guided by current needs and production volumes, but should allow for change. Therefore, it is important to analyze all processes in production beforehand and to determine where a new bread roll line would provide relief. Many artisan small-scale businesses are surprised at how many manual steps can be transferred to the bread roll line without compromising on quality.