IBIE 2004 proves a buyer's market IBIE 2004 proves a buyer's market

All nervous feelings of another terrorist attack or poor attendance at International Baking Industry Exposition (IBIE) 2004 were eliminated when the first-day crowd flooded the exhibition floor. Not only did bakers fly from all over the world to check out the latest in ingredient and equipment technology, but they also brought their checkbooks.

"We are extremely pleased with the buzz we've heard on the exhibit floor," Robert Kirkpatrick, IBIE 2004 chairman, said. "Attendees were very interested in the products focused on nutritional foods in addition to a wide range of new equipment technologies. IBIE definitely delivered as the source for solutions in response to changing market needs."

The trends dominating the baking industry were on display at IBIE 2004. On the ingredient side, low-carbohydrate ingredients were showcased, but not with the same intensity as seen at previous tradeshows, such as Institute of Food Technologists' Food Expo and American Society of Baking's tabletop showcase. In lieu of low-carbohydrate domination, ingredient suppliers marched out new products designed to improve the health properties of bakery foods.

On the equipment side, suppliers focused on launching new manufacturing systems designed to completely automate bakery functions and eliminate human labor. These automated systems drew huge crowds to various booths and caused many equipment suppliers to leave the show with orders in hand.

Robotic systems
Several equipment suppliers showcased robots at IBIE 2004, signifying the increased usage of these systems to reduce labor expenses.

Precision Automated Technology Inc. showcased its Motorman six-axis robot that can be used in various production operations. "The show was very positive, and we generated a lot of leads," Ryan Park, Precision Automated Technology Inc.'s vice president of engineering and technology, said. "Booth attendees had real projects they were looking at. Not a lot of tire kicking."

Colborne Corp., Lake Forest, Ill., exhibited various robotic systems at its booth. The company's BBL Series places wrapped breads, buns, rolls and English muffins into baskets, trays and boxes. The robotic system incorporates a Pattern Optimization Program that identifies the size of the bread package and determines the best way to package the products in a basket or tray.

AMF Bakery Systems, Richmond, Va., also exhibited a range of robotic systems used in the packaging department. The company's VersaPak Product Orienter Loader also places bagged bread in baskets. According to the company, the VersaPak is unique because it features a pressure-activated vacuum head. As a result, the unit's end affecter is only activated after the vacuum cups sense the pressure of the bread bags, eliminating any product mishandling or damage.

Raque Food Systems LLC featured variable speed placement robotic technology at IBIE 2004. Using long spider-like arms, the Robotic Pick and Place system grabbed plastic donuts and placed them into black containers. The system operates at speeds as fast as 150 containers per minute.

Lematic Inc., Jackson, Mich., is focusing its efforts on robotics through its partnership with French-based De La Ballina Industrie. According to Lematic's D.J. Lecrone, "With the current state of the industry, you have to replace people and we're focusing on robotic solutions to do this." The company manufactures a wide range of robotic packaging and vision systems.

Packaging Progressions Inc. (PPI), Collegeville, Pa., and JLS Automation exhibited a unique pick and place robot that resides before PPI's interleaving system. The Flexpicker robot makes 150 picks per minute using a vision system that can orient randomly spaced objects. The PickMaster^ô vision system is a PC-based application software developed for high-speed picking of random objects from moving conveyors.

Besides robotics, many exhibitors also showcased innovative bagging and slicing systems for breads and buns. The Henry Group Inc., Greenville, Texas, displayed its innovative bun slicing system that uses dual vacuums to hold buns on a conveyor while they are being sliced. This process eliminates the need for a top conveyor and provides a better cut, the company says.

Formost Packaging Machines Inc., Woodinville, Wash., exhibited its premium bread bagging system that provides an alternative to traditional wrapped bread products. Instead of being wrapped, Formost's GT-4 Bread Bagger bags the loaf, then conveys them through a shrink tunnel to create a tight, tamper-evident, easily-opened inner package, the company says.

Bettendorf Stanford Inc. showcased its slicing and bagging system designs that help production line operators repair breakdowns. These systems featured open designs and PLC controls to automatically select packaging set up for changes in bread production, which eliminates manual adjustment.

Mixing to baking
Although packaging systems attracted significant attention at IBIE 2004, the front end of a production line also was covered with various new mixing and makeup systems. Shaffer Manufacturing Corp., Lemont, Ill., showcased its Dough Reclamation Slurry System that allows bakers to use 100% of their scrap in fresh dough for sheeted dough products. Besides eliminating waste, the system also increases fermentation flavor because the slurry reacts in fresh dough as a flavor enhancer.

The system operates by taking scrap dough, water and a proprietary DRS Activator and mixing them into slurry that is then pumped through a heat exchanger, which prohibits yeast activity. The activator accelerates the natural dough fermentation process while eliminating the adverse effects of glutathione. Next, the slurry is pumped into an agitated holding tank, where it sits until it is metered into the mixer.

Kaak Group North America Inc., Lithia Springs, Ga., also exhibited an innovative mixer at IBIE 2004. The company's Diosna mixer features a bottom discharge that allows high-volume bakers to transfer mixed dough through the bottom of the mixer directly onto a conveyor or into a trough.

New and innovative makeup systems also were exhibited at IBIE 2004. Rheon U.S.A., Irvine, Calif., displayed its V4-Twin Divider, which uses a Gravimetric cutting system that can operate with one or two lanes. According to the company, this option allows a wider portioning range with larger products by one-lane cutting and smaller products by two-lane cutting.

Rollequip/Konig also demonstrated a makeup line designed for artisan bread products. The company's Artisan SFR makeup line can round a dough ball that has 75% hydration and three hours of fermentation time. The system processes square, rectangular and round dough pieces.

Burford Corp., Maysville, Okla., showcased its seeding/topping system that reduces seed and topping waste by using electronic nozzles that spray buns with water. This system prevents seeds or toppings from sliding off bakery foods and reduces waste by 20%.

APV found success at IBIE 2004 exhibiting its Jet Circ Oven. The oven uses technology that combines traditional baking with modern convection baking. The oven bakes cookies, cereal bars and other soft dough products, and reduces baking time by 50%.

Ingredient innovations
Equipment manufacturers were not the only suppliers to offer innovative new products at IBIE 2004. Ingredient manufacturers launched a variety of new products aimed at making baking easier and more healthful. ADM, Decatur, Ill., introduced two new ingredients: a line of wheat protein isolates and a fluid bread shortening system. The company's Prolite wheat protein isolates can be used in a variety of bakery foods to enhance taste and texture. The ingredient also stimulates dough relaxation without the use of enzymes, improves sheeting tolerance in weak flours, and increases protein values in reduced-carbohydrate products.

MGP Ingredients Inc., Atchison, Kan., also showcased a wheat protein isolate to exhibitors at IBIE 2004. The company touted its Arise 5000's functions of reducing mix time and increasing water absorption. The company also states that the product improves moisture control at the molecular level in frozen and par-baked bakery foods

Caravan Products Co. Inc., Totowa, N.J., exhibited an ingredient with applications in low-carbohydrate bakery foods. The company's Trim-Carb line of high-fiber, reduced-sugar bases and mixes creates low-carb and reduced-calorie breads, rolls, bagels, tortillas, flat breads and pizza.

ConAgra Food Ingredients, Omaha, Neb., made a big splash at IBIE 2004 by launching its Ultragrain white whole wheat flour. The ingredient already has received considerable national press, but IBIE 2004 offered the company immediate exposure with a large amount of bakeries.

According to ConAgra, Ultragrain combines the nutritional benefits of whole grains with the taste, texture and finished bake qualities of refined flour. The company processes the grain using a patented milling technique and special flour milling equipment to retain the nutrients found in whole grains. The company says the product has a light flour color, a soft and smooth texture, and a reduced visibility of bran specks.

Orlando getaway
IBIE 2004 proved successful for almost everyone in attendance. According to many exhibitors, bakers were placing orders on the scene.

Instead of sitting back and focusing on the success of IBIE 2004, the IBIE committee already has started promoting IBIE 2007, which takes place in Orlando from October 7 to 10. This will represent a significant shift for the show that has made Las Vegas its home, but bakers can rest assured that suppliers are already preparing new launches for 2007.

Foundation meeting generates excitement In a who's who of the baking industry, American Bakers Association and North American Millers' Association conducted a meeting to launch the Foundation for the Advancement of Grain Based Foods' campaign to promote bread. The meeting featured various speakers that enlightened the crowd on research about the bread industry and the initial nuts and bolts of the Foundation's campaign. Signifying the importance of the meeting, some of the baking industry's major players attended the presentation, including George Deese and Gene Lord of Flowers Foods; Pat Callaghan of Pepperidge Farm; Gary Prince of Weston Foods U.S.; Bohn Popp of Perfection Bakeries; and Reynaldo Reyna of Bimbo Bakeries. These bakers, as well as countless other bakery executives and suppliers, listened to various presentations about the operations of the Foundation. In discussing the approach of the campaign, the presenters kept mentioning the importance of using the word "grains" when describing bread products. According to research conducted for the campaign, "grains" connote a positive message with consumers and should be used when describing bread products. After the research was presented and the campaign outlined, Gary Prince of Weston Foods U.S. gave an impassioned speech about the importance of the baking industry to support the Foundation. "I for one believe that we can make a difference, and I believe we must," Prince said while challenging bakers to financially support the Foundation's efforts. Putting his money where his mouth is, Prince also announced that Weston Foods U.S. was doubling its contribution because "we believe we have to." After a rousing ovation, Bimbo Bakeries announced that it also was doubling its contribution, signifying the momentous occasion of this meeting.

AIB educates IBIE 2004 attendees American Institute of Baking brought an educational slant to International Baking Industry Exposition 2004 by conducting a series of educational sessions to attendees at the show. According to Kirk O'Donnell, AIB's vice president of education, the sessions, held from August 15 to August 17, were very successful. The sessions averaged 150 people per day. "These numbers are close to what we had hoped for," O'Donnell says. "In terms of attendance, we met our expectations. The most important thing is reaction and we had very focused questions relating to the topics."