Industrial sourdough plants
23/01/2025
Systems
Efficiency and quality for craft production on a large scale
INOXPA is specialised in designing innovative plants for sourdough production, optimising both quality and efficiency when producing bakery products on a large scale.
These plants are designed to meet the needs of an industry that aims to maintain the authenticity of traditional methods without compromising on production capacity, as such providing a balance between craft and automated methods.
The importance of sourdough in breadmaking
There has been a resurgence in using sourdough for making bread given its numerous benefits. This traditional process gives bread a coarser texture and a more complex flavour, along with a crunchier crust and a crumb with large alveoli.
In addition to its aesthetic and aromatic appeal, bread made with sourdough has a lower glycaemic index and it also lasts longer, maintaining its organoleptic qualities for longer compared to breads produced with commercial yeast.
Despite being a craft process, INOXPA have adapted the technique to industrial production, ensuring that even larger bakeries can offer high quality products without sacrificing efficiency.
How INOXPA sourdough plants work
INOXPA’s proprietary production system is based on an automated process that ensures controlled and efficient fermentation. The plant comprises several key stages:
1. Preparation tank: The initial mix of flour and water with the yeasts takes place in a preparation tank fitted with an agitator. This is an automated process governed by the selected recipe.
2. Controlled fermentation: The mix is transferred to fermentation tanks once homogenised, where controlled sourdough fermentation occurs over a set period. These tanks are designed to maintain optional temperature conditions in which the micro-organisms that give the bread its organoleptic characteristics can develop.
3. Automatic dosing: Once fermented, the sourdough is dosed automatically into the mixers. The system retains 10% of the fermented sourdough to guarantee the continuity of the process, given it will form the basis for the next fermentation cycle. This enables a continuous regeneration process without requiring manual intervention.
4. Automatic cleaning system: The entire plant can come equipped with a CIP (Clean-in-place) cleaning system, ensuring safety and preventing cross contamination between batches. A PIG system (product recovery system) can also be fitted, which minimises the amount of waste product. It also means less water and chemical solutions are used for CIP cleaning.
INOXPA offer a range of industrial plants adapted to customers’ different needs.
- Small plants: Ideal for smaller productions, these plants can auto-regenerate sourdough for precise manual dosing while the phases still run automatically. Critical process parameters such as pH and temperature are still controlled precisely despite their size.
- Medium and large plants: Conceived for larger-scale industrial operations, these plants enable non-stop continuous production. The automatic dosing system feeds the production line directly without the need to stop for cleaning. These plants are also fitted with advanced pH and temperature control systems, essential for end product quality.
Every plant is designed with single-walled preparation tanks and agitators to ensure flour and water are mixed homogeneously. The fermentation tanks have heating chambers to keep the fermentation temperature stable. In addition, the integrated automation monitors all stages of the process, allowing operators to focus on production without the need for constant manual adjustments.
Benefits of INOXPA industrial sourdough plants
Efficiency: INOXPA solutions enable non-stop sourdough production, maximising time and resource efficiency.
Constant quality: Precise control over temperature, pH and other parameters ensures that each sourdough batch fulfils the highest quality standards.
Sustainability: PIG and CIP systems significantly reduce water use and keep product waste to a minimum, contributing to more sustainable production.
Adaptability: From small bakeries to large industrial production, INOXPA plants adapt to different scales of production, making customised solutions available to each client.
INOXPA industrial sourdough plants are a comprehensive solution for producing craft bread on a large scale. Combining the tradition of sourdough with the advantages of automation, these plants enable the bakery industry to offer high quality products using an efficient, controlled and sustainable approach. With a focus on innovation and keeping traditional methods in mind, INOXPA continue to position themselves as a benchmark in the food industry.
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