Efficiency and sustainability: The new recipe for success in baking

By Jack Helm, Account Manager – Beverage, Bakery & Functional Foods, at ACI Group

 

Efficiency has always been the cornerstone of a thriving bakery. From precise ingredient management to optimized baking times, every decision on the bakery floor has traditionally aimed at reducing waste, cutting costs, and maintaining top product quality. But the baking industry is evolving, and with it, the very meaning of efficiency is shifting. Today, efficiency isn't just about maximizing output or streamlining processes; it's about making thoughtful, sustainable choices that positively impact operations, the environment, and supply chains.

 

The financial tightrope of running a bakery

Running a bakery involves much more than balancing flour, sugar, and rent. Ingredient prices can fluctuate unexpectedly, equipment breakdowns incur costly repairs, and overproduction means wasted goods and lost revenue. Packaging and labelling expenses steadily erode profit margins, while staff training, soaring energy bills for refrigeration and ovens, and strict food safety regulations demand continuous investment. These hidden and growing costs make running a bakery a constant financial challenge.

 

In this complex landscape, efficiency must go beyond simple cost-cutting; it requires innovative approaches that balance profitability with sustainability and safety.

 

Advanced seed adhesives prevent loose seeds from becoming slip hazards, minimizing cleanup efforts and saving time and resources

 

The energy efficiency revolution

One of the clearest examples of efficiency's transformation is how bakeries manage energy consumption. In the face of global energy supply uncertainties and rising costs, bakers are more mindful of usage than ever.

 

Many bakeries have improved energy efficiency by targeting Scope 1 (direct emissions from their operations). However, the focus is now shifting to Scope 2 emissions arising from purchased electricity, steam, heat, or cooling. Addressing these demands, a holistic strategy that incorporates smarter ingredient choices and process optimizations.

 

For example, selecting low-dust dusting flours improves air quality and reduces health risks for workers. This reduces the burden on ventilation systems, cutting the need for energy-intensive filtration. Similarly, using high-efficiency release agents means equipment requires less frequent cleaning, lowering water and energy consumption. Advanced seed adhesives prevent loose seeds from becoming slip hazards, minimizing cleanup efforts and saving time and resources.

 

Sustainability and profitability: The perfect pairing

Ingredient innovations are more than just operational improvements; they're key to meeting ambitious Environmental, Social, and Governance (ESG) goals. By reducing waste and energy use, bakeries can appeal to environmentally conscious consumers and regulators, simultaneously boosting brand reputation and profitability.

 

Sustainability doesn't stand apart from safety and efficiency; they reinforce each other. Lower airborne flour means healthier air for employees, reducing respiratory risks. Less greasy residue on equipment cuts fire hazards and smooths production flow. These seemingly minor issues can cause major inefficiencies and safety concerns, but they become opportunities for progress with the right solutions.

 

ACI's innovative ingredient technologies help bakeries tackle these challenges head-on. ACI's solutions enhance every production stage, from low-dust dusting flours to high-efficiency release agents and advanced seed adhesives. This proves sustainability and profitability are not mutually exclusive but mutually reinforcing drivers of positive industry change.

 

The unique granulation of low-dust release flours reduces adhering dough residues in large-scale production or hand-processing.

 

Flour power: Protecting workers, saving costs

Occupational asthma is one of the most significant health risks bakery workers face. Flour dust, enzymes, and sensitizing agents contribute to respiratory diseases, making bakers far more vulnerable than workers in many other sectors.

 

A 2013 UK Parliament motion revealed that bakers are approximately 40 times more likely to develop occupational asthma due to flour and bakery dust exposure, a risk that research now suggests maybe even higher. Despite this, many bakeries continue to rely on suboptimal prevention methods.

 

ACI's TIP-TOP range of low-dust release flours, based on wheat and rye, offers a healthier, more economical, and hygienic alternative. Their unique granulation dramatically reduces adhering dough residues in large-scale production or hand-processing.

 

TIP-TOP flours cut flour usage by up to 70 per cent compared to conventional flour or flour-starch mixes. Lower dust levels significantly reduce the risk of baker's asthma, protecting employees' health. Hydrothermal treatment of raw materials prevents mould growth on trays, belts, and proofing linens (a hygiene boost that improves product safety).

 

This low-dust flour also reduces deposits and residues on equipment, lowering wear and maintenance costs. Its clean-label formulation meets rising consumer demand for ingredient transparency while improved air quality fosters a healthier workplace.

 

One industrial bakery customer reduced standard flour use by 330 metric tonnes annually after switching to TIP-TOP, slashing over 50 kilograms of personal protective equipment waste and cutting CO2 emissions through decreased cleaning and ventilation needs.

 

Seeding success: Tackling waste and safety

Loose seeds scattered on bakery floors cause slip hazards, increase allergen exposure, and demand frequent, costly cleanups. Traditional water or gum-based adhesion methods often fail, leading to seed loss, waste, and inefficiencies.

 

GECKO Ultra, a breakthrough adhesive, combines strong bonding with operational versatility. It secures seeds, kernels, and toppings on baked goods without the downsides of water or gum-based alternatives. The wheat flour-based, additive-free, clean-label formula meets consumer demands for transparency.

 

Applied as a jelly-like suspension by spraying, rolling, brushing, or immersion - without heating or clogging - GECKO Ultra is easy to integrate into existing production lines. It is neutral in flavour and odour, preserving the natural profile of toppings like sesame, poppy, or grain.

 

Trials show bakeries halving seed usage while improving surface coverage and achieving ROI in just six months using automated spray systems. Beyond aesthetics and savings, GECKO Ultra supports sustainability by minimizing raw material waste, water consumption, and airborne allergens during transport and display.

 

Spraying a release agent

 

The speciality bread market, particularly seeded varieties, is expected to grow from £7.8 billion to £9 billion by 2026. With 50 per cent of UK consumers shifting towards seeded bread and taste a priority for 41 per cent, demand for these products presents a major opportunity and challenge for bakeries.

 

As production scales up, seed wastage and operational efficiency become critical. GECKO Ultra offers a smart solution that reduces industrial waste, cuts water use, improves product consistency, and drives sustainability and consumer appeal.

 

 

 

Greasing the wheels: The role of release agents

Beyond flour dust and loose seeds, release agents are vital to bakery efficiency and safety. Traditional greasing methods often use excessive oil to ensure clean product release from tins, trays, and hotplates. This overuse creates greasy surfaces, elevating fire risks near ovens.

 

ACI Group's DÜBÖR Release Oil is a high-performance solution that reduces waste, improves safety, and boosts efficiency.

 

Conventional release agents require heavy application, leading to costly waste, carbon buildup, and fire hazards. DÜBÖR's advanced formulation enables up to 80 per cent less product use while ensuring consistent release of baked goods. This reduces operational costs and enhances product quality.

 

Switching to DÜBÖR eliminates baking paper use, cutting material waste and expenses. Its residue-free formula prevents carbonisation of baking surfaces, extending machinery lifespan, lowering fire risks, and reducing deep-cleaning frequency - a more sustainable and cost-effective choice.

 

DÜBÖR's lower water content relative to oil means a cleaner solution with less buildup on tins and trays, improving hygiene and cutting reliance on harsh chemicals.

 

Sustainability drives the bakery industry forward, and DÜBÖR aligns perfectly. The vegan, allergen-free release agents, some with plant-based wax, offer sustainable alternatives to traditional products. Reduced ingredient use, transport emissions, and waste help bakeries meet ESG goals and improve environmental footprints while enhancing operational efficiency.

 

Many bakeries underestimate the inefficiency of outdated release agents, making DÜBÖR a vital tool in the modern bakery's arsenal.

 

Bake smarter, not harder

The future bakery isn't just about faster production or lower costs; it's about building a smarter, more sustainable ecosystem where every ingredient, process, and decision drives business success and environmental responsibility.

 

By seeing efficiency, sustainability, and safety as interconnected priorities, bakeries can stay ahead of trends, foster innovation, and secure long-term growth in a changing market.

 

ACI helps bakeries uncover hidden inefficiencies and implement solutions that cut waste, lower carbon footprints, and optimize operations. Testing ACI's advanced ingredients and systems lets bakeries experience improved efficiency, hygiene, and sustainability firsthand.

 

Smarter sourcing boosts product quality and delivers lasting cost savings, making balancing profitability with responsible production easier.

 

With ACI's expertise, bakeries can reduce costs, improve efficiency, and embrace sustainability, eliminating hidden inefficiencies that eat into profits. Let ACI help you calculate your waste reduction and carbon savings potential, implement high-performance solutions, and future-proof your bakery for a sustainable, successful tomorrow.