VIDEO: Making Rye Bread on an Automated Line

Consumers are increasingly looking for healthier products. Likewise, the craze for traditional and authentic products is growing. Rye bread, which is rich in fiber and very nutritious, responds to these two consumer trends. Indeed, rye flour is an excellent alternative to wheat flour and a very attractive solution for developing new varieties of crusty bread.

Discover how MECATHERM supports manufacturers by helping them overcome product quality and performance optimization challenges in this video of rye bread production.

This line, which was installed in 2020, is capable of producing up to 4,000 loaves of rye bread per day. That’s equal to three tons of dough.

From dosing, proofing, and seeding to baking, cooling, and depanning, let's discover the key stages of an optimal bread manufacturing process.

Due to the liquid consistency that results from a very hydrated dough, rye breads are made in molds. After dosing the dough into the molds,  it’s fermented in a proofer equipped with the M-UB mechanization system. The precise adjustment of steaming conditions and identical circuit of each mold  combined with the fluid and regular circular movement of the dough products allows smooth and optimal fermentation.

The fermented products then go through a high-precision automated seeder, which gives them the authentic appearance and taste consumers seek.

Next comes the important stage of baking the products. The M-TA Oven provides precise heating curve settings  and the ability to select one of six heat transfer mode combinations. It also makes it easy to adjust the intensity in each of the independent modules. The oven transmits a very high heat to the hearth when baking begins to achieve a homogeneous product density. This precise oven setting also supports the formation of a crispy crust and reveals the very characteristic aromas of rye bread.

At this stage, the tin of rye bread goes through a cooler equipped with the M-UB mechanization system, which guarantees a shock-free path. Cooling the products in their molds absorbs the condensation. The rye loaves of bread are then removed from the molds by suction or by needles. Finally, they are placed on the conveyor belt and fed into a spiral freezer before being packaged.

Interested in learning more about the production of rye bread or other products?

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