The correlation of CO2 and mold growth for hygiene control in bakeries is not sufficiently recognized globally. CO2 monitoring for hygiene, baked goods quality and also for air-related occupational safety is new worldwide.
The AMG MasterKonzept 4.0 (MK4.0) is based on the knowledge that CO2 has so far received little attention as a fermentation product, especially alcoholic fermentation in dough and as a combustion product of fuel in ovens (natural gas, oil, wood). One kilogram of dough produces around 3 liters of CO2 through yeast fermentation. About 1/3 of the CO2 produced in a piece of dough is released into the ripening atmosphere. The remaining 2 liters initially remain bound in the dough, float it up and leave it during the baking process. With knowledge of hygiene and quality control, the concept of the controlled system regulates CO2, temperature, humidity and fresh air independently of one another.
The special climatic conditions in baking companies are addressed, which are characterized, among other things, by cold and warm, dry and humid zones and whose atmosphere is very often characterized by critically high CO2 pollution of up to over 10,000 ppm. High CO2 values are now weighted as unacceptable parameters in relation to the process and product and must be regulated.
CO2 is a booster for the mold and causes its growth to explode in the typical bakery conditions of high temperatures, condensate and organic substances (e.g. flour dust). Molds themselves breathe out CO2 and contribute to its accumulation. This is associated with an increased synthesis of numerous mycotoxins or inhaled proteins as metabolic products of the mold. These allergens cause allergies and numerous other illnesses in humans. The controlled limitation of the CO2 concentration primarily helps to stop the growth of mold.
The dough also needs oxygen to breathe
The baker often looks for the cause of irregular baking results in the oven. The solution lies in correcting the ripening climate during the fermentation (storage) process, usually before baking.
The air in production rooms with a lack of oxygen often reaches critical levels of CO2, fine dust as a carrier of mold spores, VOCs, viruses or NOx. The residence time of dough pieces in rooms is often several hours to days, so the CO2 concentration is particularly high and can interact with dough pieces for a particularly long time. Air masses containing CO2 are specifically heavier and dilute the oxygen concentration vertically, a circumstance that has negative effects on dough and pastries.
The MK4.0 ensures that the O2 concentration and the absolute humidity in rooms are kept at a stable level and that the maximum CO2 concentration is not exceeded. Among other things, CO2 displaces oxygen, which is essential for the formation of glue and dough, and hinders overall dough stability. High CO2 and lower O2 values lead, among other things, to moist, sticky doughs that spread, poor machine accessibility, increased baking agent requirements, reduced baking volume, weakened browning, unfavorable aroma-flavor profiles and reduced freshness.
The technical innovation primarily provides for important contributions to air-related occupational safety in production and fermentation rooms, which for the first time enable more manageable hygiene with the MK4.0.
The MK4.0 makes an important contribution to avoiding reclamations and food waste, as well as the responsible use of raw materials through increased product yield and a relevant reduction in energy requirements.
Benefit for the user
The benefit of the innovation is that, for the first time, operational and system-related hygiene can be controlled automatically with significantly increased safety. This means that cleaning measures can be significantly reduced and production downtimes can be avoided. The requirements of the Food Hygiene Ordinance (LMHV) and other comparable regulations (ISO standard, HACCP) are thereby underpinned and their effects can be measured.
