Pan Releases – Get unstuck!

Pan releases remain prevalent to facilitate efficient release of baked goods.

 

 

 

Even as pan glazers with state-of-the-art permanent pan glazes and bakery equipment manufacturers throw massive resources behind the elimination of sticking points in the baking process, the use of pan releases remain prevalent to facilitate efficient release of baked goods.

The loaf of bread that sticks to the pan never gets sold. Neither does the bun or the cake that is stuck. High speed production of huge volumes of pan bread, soft buns and cakes would be impossible without some release treatment to ease depanning, especially where the depanning is automated.

Many doughs and batters require side support during baking, while other products take their shape from the pan. And where dough and pans come together, the moisture and heat that are part and parcel of the baking process will ensure that the dough sticks to any untreated pan sides and bottoms.

For this reason, commercial bakers use silicone-blazed and other glazed baking pans, but even these pans often require some release agent to protect the coating itself, to extend the life of the coating and to prevent frequent de-carbonning and re-glazing.

After the dough is divided, the dough balls are placed in pans that have been pre-treated with a uniformly applied release agent commonly referred to as depanning oil or pan oil, which facilitate the smooth release of the baked product from the pan. Since the release is subjected to the same high temperature as the baked goods, its properties when heated dictate the right choice. For this reason, release oil formulations are more highly developed and researched than, for example, divider oil or trough grease.

Release agents are applied in thin layers on the baking pans, and although only small amounts are used, the proper selection and performance of a release agent is critical to ensure that baked goods are released effortlessly and in a saleable condition.

When selecting a pan release or reviewing a previous selection, two main issues need careful consideration – the pan release itself and its application.

A number of pertinent questions must be answered about the pan release itself before a decision can be made. The selection of the right release agent is not only driven by technical performance, but also by a host of regulatory, allergen and health and safety concerns.

Is the release safe and suitable for human consumption as per the legal requirements? Since the release agent is in direct contact with the baked goods, this is possibly the most crucial question of all. Also look for certification of quality from, for example, the SABS. In addition, consider if the release is Kosher and/or Halaal certified.

Should mineral oil be preferred over vegetable oil as a base, or vice versa, given your specific requirements? Mineral oils are generally colourless, odourless and tasteless, and are also stable against polymerisation and staining of the product.

However, mineral oils may have smoke points that could result in smoke in ovens. Vegetable oils with their higher smoke points are more resistant to oven smoking, but are more prone to polymerisation during heating, which could result in gumming on the pans.

Vegetable oil can carbon the pan surface at temperatures of 180°C to the extent that the effect of the silicone glaze is negated. When the cost of bread sticking becomes prohibitive, the pans have to be de-carbonned and re-coated. In addition, vegetable oils can become rancid over time.

If selecting an oil-based release, also take care to understand what oil it is based on. Soy oil is often used due to its abundance and low cost. If soy – which is an allergen – is present, this may have to be declared on the label. The same goes for oils that are GMO.

A compromise between mineral oils that could smoke and vegetable oils that can polymerise is a blend of mineral and vegetable oils with stabilisers such as antioxidants added. By varying the ratio of mineral to vegetable oil, the right balance of properties can be achieved.

A more recent alternative is silicone emulsions which are water-soluble, non-gumming and carbon-free. Because the silicone emulsions can withstand temperatures of up to 305°C, it produces no carbon build up. Previously, silicone was not used because of the high cost of silicone oil and the difficulty in creating an emulsion from it. Now that technology has created solutions to these challenges, silicone emulsions offer a truly comprehensive pan release solution worth investigating.

Further questions must also be answered regarding the application of the release agent, since a consistent, thin, oily film is all that prevents the sticking that results in product defects that increase waste and eats into profits as defective baked goods are disposed of.

How will the release agent be delivered, stored and prepared for use within the bakery? Releases are commonly sprayed under pressure – whether by handheld or conveyor systems – but these systems must produce minimal airborne spray. An alternative is an airless system, which has been proven to reduce overspray, saving money and reducing cleaning costs.

What is the optimal amount of release to be used? This will depend not only on the product being released but also on the type of release agent. Obviously, the objective is to use the minimum amount of release that will still yield an efficient release of an undamaged product.

One release agent may be more expensive than another on a litre-per-litre comparison, but if less of the more expensive release is required to produce the same results, the release that appears more expensive initially may be the more cost-effective option. Cheap is often more expensive in the long run.

How will the release be applied to ensure a thin, uniform, full coverage and a slick release surface that allows the product to slide out without sticking? Over-application of a release agent is not the solution to problems in achieving uniform coverage – this merely wastes the release agent and can result in puddles of release agent, which, once broken down chemically, can result in gumming of the pans which will require time-consuming and costly cleaning.

Over-application may well also result in equipment surfaces being sprayed, which will require further cleaning.
Speak to the equipment supplier for specific advice pertinent to your unique equipment and equipment settings requirements.

In general, the supplier will provide a recommended initial setting for each product line and these would then have to be fine-tuned through trail-and-error by, for example, nozzle adjustment, air pressure adjustment and storage temperature adjustment to ensure the release is used at the right viscosity for maximum coverage. Those who have implemented an airless spray system seem to agree that its efficiency is impressive.

There are also speciality release agents that are used for special baking processes, such as band oven baking and high-temperature baking. All these options and considerations highlight one important fact: choose a reputable supplier that can provide solid advice based on extensive experience and expertise and make sure that all the relevant questions are thoroughly considered and answered before making this important decision – the wrong choice can truly leave your bakery in a sticky situation!

Suppliers in South Africa –

 

Chemplus – CHEMPLUS was established in 1989 by Mr. P. Ligeris, who identified a need for specialized lubrication products that were not readily available in the South African market. Since the company’s inception, we have become globally renowned for our unparalleled service and technologically superior chemical products.

Ongoing R&D and dynamic innovation in the fields of surface chemistry, food science and process engineering allow us to consistently develop high quality products and automated systems.

Bakery Release Oils –

All products have been Halaal and Kosher accredited by the relevant governing bodies of South Africa and is manufactured under FSSC-22000 food safety standards.

Pangrease is a fat emulsion that is suitable for use in pan release applications. Typically encountered in the bakery industry, for the rapid and clean release of baked flour or flour-based products. E.g. bread, rolls etc.

Our pan release oils are suitable for use in the bakery industry for the rapid and clean release of yeast-based baked products for the Pangrease range and high sugar content baked confectionary for Panglide.
Packaged in 5L, 25L, 210L, 1000L IBC flow bins

Pangrease HV –

A low-cost viscous emulsion consisting of vegetable edible oil, emulsifiers, preservatives and water. Suitable for use in pan release applications, typically encountered in the bakery industry, for the rapid and clean release of baked flour or flour-based products, e.g., bread, rolls etc.

It is eminently suitable for use where baking pans are coated manually; dispensing via a spray system is not recommended. Apply by brushing or sponging onto the pan and/or dough product, prior to baking. Expected usage is 5 – 8 g/loaf depending on pan condition.

Pangrease HVS –

An entry level, semi-viscous emulsion consisting of vegetable edible oil, emulsifiers, preservatives and water. Suitable for use in pan release applications, typically encountered in the bakery industry, for the rapid and clean release of baked flour or flour-based products, e.g., bread, rolls etc.

It is suitable for use, where automated spray guns are utilised to coat the pans, since it allows optimum amount of oil to be dispensed, while ensuring complete coverage. Expected usage is 0.6 – 2.1 g/loaf depending on pan condition.

Pangrease HP –

A high-grade semi-viscous emulsion consisting of food grade silicone oil, vegetable oil, emulsifiers, preservatives and water. Suitable for use in pan release applications, typically encountered in the bakery industry, for the rapid and clean release of baked flour or flour-based products, e.g. bread, rolls etc.

It is exceedingly suitable for use, where automated spray guns are utilised to coat the pans, since it allows optimum amount of oil to be dispensed, while ensuring complete coverage. Expected usage is 0.4 – 1.6 g/loaf depending on pan condition.

The thermal degradability of the product is decreased at the normal baking temperatures, a property that allows the pans to remain clean over a considerably longer period of time while allowing better heat-transfer during baking and thereby effecting energy reduction via minimal carbon build-up.

Pangrease CF –

A premium grade semi-viscous emulsion consisting of food grade silicone oil, vegetable oil, emulsifiers, preservatives and water. Suitable for use in pan release applications, typically encountered in the bakery industry, for the rapid and clean release of baked flour or flour-based products, e.g., bread, rolls etc.

It is eminently suitable for use, where automated spray guns are utilised to coat the pans, since it allows an optimum amount of oil to be dispensed, whilst ensuring complete coverage. Expected usage is 0.2 – 1.4 g/loaf depending on pan condition.

This product has been engineered to reduce carbonization by two synergistic mechanisms:

The thermal degradability of the product is minimal at normal baking temperatures.

The product provides a cleaning action on soiled pans whereby adhered matter is dislodged from the pan-alloy surface.

This allows the pans to remain clean over a considerably longer period of time with a concomitant reduction in energy consumption during baking.

Panglide VAG –

A release agent, which is suitable for use in release applications, as typically encountered in the confectionery industry, for the rapid and clean release of sugar-based or similar products. It is suitable for use with automated spray systems and for manual application.

Bakery Divider Oils –

Food safe, pharmaceutical grade white mineral oils that consist of a blend of processed base oils with premium lubricity and anti-wear additives. It is intended for use in and around food processing areas as a lubricant with direct food contact. Halaal and Kosher accredited by the relevant governing bodies of South Africa and manufactured under FSSC 22000 food safety standards.

Divoil 30 –

Primarily used to ensure good transfer of product through the dough hopper in bread bakeries and to lubricate the blades on the divider. This ensures consistent dough weights into the tins. Designed for tight tolerance divider blades that require oil of low viscosity, and other food application requiring a mineral oil with a low viscosity. Divoil 30 is extremely stable and completely inert. It provides both lubrication and product release in the baking and candy industry as well as in meat and food processing.
Kinematic viscosity @ 40°C = 11 – 15 cSt

Divoil 70 –

Primarily used to ensure good transfer of product through the dough hopper in bread bakeries and to lubricate the blades on the divider. This ensures consistent dough weights into the tins. Designed for moderate tolerance divider blades that require oil of intermediate viscosity, and other food application requiring a mineral oil with an intermediate viscosity. Divoil 70 is extremely stable and completely inert. It provides both lubrication and product release in the baking and candy industry as well as in meat and food processing.
Kinematic viscosity @ 40°C = 18 – 23 cSt

Divoil 240 –

Primarily used to ensure good transfer of product through the dough hopper in bread bakeries and to lubricate the blades on the divider. This ensures consistent dough weights into the tins. Designed for high tolerance divider blades that need an extra heavy white mineral oil, and other food application requiring a mineral oil with a higher viscosity. Divoil 240 is extremely stable and completely inert. It provides both lubrication and product release in the baking and candy industry as well as in meat and food processing.
Kinematic viscosity @ 40°C = 61 – 75 cSt

Automated Process Systems –

Chemplus has developed highly sophisticated, automated process systems for use in plant bakeries. We offer our clients effective, user-friendly solutions, ensuring efficient application of our high-quality range of pan release oils, divider oils and crate washing detergents.

Pan Release Oil Systems –

The new generation A1 spray control panels offer exceptional spray control and consistency for lubricating and release applications, whilst ensuring the bread pan lining is protected from adverse chemical activity, thus achieving maximum bake cycles.

A culmination of 3 years rigorous R&D in fluid dynamics and control systems, the tamper-free A1 panels have been designed to maintain a fixed spray rate, despite variations in process input variables. A custom built PLC controller, programmable with a tablet/laptop via a mini-USB port, together with cutting edge algorithms provide a solution to archaic and inconsistent spray systems.

A multitude of system faults, both electrical and mechanical, can be detected via an array of signals decoded by the PLC’s alarm algorithm. In this event, an alarm code is shown on the PLC face with troubleshooting details of each code made available on a label. This allows for minimum downtime by virtue of rapid fault detection.

Divider Oil Delivery and Lubrication Systems –

Sophisticated, bespoke systems which automatically deliver divider oil from the storage area to the location of the dough dividers in the bakery. Automated spray lubrication systems can be installed on the divider hoppers, delivery chutes or hi-tip buckets, significantly reducing divider oil consumption, as well as waste and spillage in the vicinity.

South Bakels – South Bakels manufacture and distribute a wide range of premixes and specialised ingredients, some of which are tailor made for industrial and in-store bakeries while others are specifically developed for the Craft and Foodservice sectors.

Products are formulated to suit each market sector and South Bakels has well-established sales and technical teams focusing on serving the particular needs of every customer.

Serving specific customer needs does not stop at product development and technical support. Packaging (from small packs to tanks) and equipment to support product application are also tailored to ensure that whatever size our customers are, whatever products they are producing, South Bakels can supply appropriate products and support.

South Bakels also provides a range of Release Agents suitable for all baking processes:

Bakels Sprink Non-stick Spray

A Canola Oil based non-stick aerosol spray. This is a non-stick spray that is specially formulated to aid the release of baked goods from pans and moulds. To use, shake the can well. Hold upright about 15-20 cm away from cold surface. Spray evenly to ensure that the entire surface is covered well.
Available in a case of 12 x 500ml cans with a 24-month shelf life.

Sprink: https://www.sbakels.co.za/products/bakels-sprink-non-stick-spray/

Release 30

Release 30 is a white semi-viscous water in oil emulsion. It is a vegetable-based greasing emulsion suitable for all yeast raised goods and types of baking tins, sheets, trays etc. Creates no smoke or carbon during the baking process.
Release 30 is designed for application by hand.
Available in a 25lt Drum with a 6-month shelf life.

Release: https://www.sbakels.co.za/products/release-30/

Tincol

Tincol is a white semi-viscous vegetable-based water in oil emulsion and is a superb, high viscosity pan greasing emulsion suitable for all yeast-raised goods and all types of baking tins, sheets, trays, etc. The viscosity of Tincol allows application with a greasing unit or by hand.

Tincol forms a very fine film, that adheres to the metal surface of the baking tins and is not absorbed by the dough. It creates no smoke or carbon during the baking process.
Available in a 25lt Drum with a 6-month shelf life.

Tincol: https://www.sbakels.co.za/products/tincol/

Tinglide

A pan release emulsion specially formulated for the release of cakes, sponges and similar confectionery rich in sugar. Applied with a brush. Available in a 5kg and 25kg Carton with a 9 Month shelf life.

Tinglide: https://www.sbakels.co.za/products/tinglide/

 

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