Case Histories
British Bakels, UK Bakery Ingredients Manufacturer Increases Production Volume with CRYOVAC® Fluid Packaging
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British Bakels Limited, part of the Bakels Group of companies, manufacture
and distribute a wide range of bakery ingredients both to the industrial
and craft sectors worldwide.
Their extensive product range includes bread
improvers, dough conditioners, shelf-life extenders, pre-mixes for bread,
pastry and confectionery products; bakery fats; release agents; cake and
bread emulsifiers; baking powders, instant yeasts; cake coverings, icings
and filling creams; fruit fillings, glazes and flavouring pastes; chocolate
and truffle mixes.
These materials are used for the manufacture of bread,
cakes and confectionery. According to their company philosophy, linking
together such a broad offer, Bakels products must all be safe, of high
quality and affordable.
Located in Bicester near Oxford with 100 employees, British Bakels achieved a turnover of UK£ 15 million (24.67 million EURO) in 2000. In the past two years, the company experienced a 25% increase in output, reaching 270 tonnes per week. Overall production output reached 12,500 tonnes in 2000.
British Bakels are one of the leading UK and European suppliers of ingredients to the bakery industry and globally, 27 different companies and 1’500 employees ensure that Bakels products are available in more than 120 countries. Their strategy is based on a high-value product range coupled with professional customer support. This is provided by well-established sales and technical teams strongly supported by local R&D. The company views this synergy between a high value-added product range and professional technical support as a key offer in this industry.
The Bakels Group will be celebrating their centenary in 2004.
Expansion and growth through value-added products
Looking at future expansion to support ongoing growth, the company anticipates a move from basic powders to more value-added pre-mixed pumpable ingredients, a move which should lead to significant growth in the wet plant production. The convenience ingredients pack business is expected to grow significantly over the next 5 years, so British Bakels are making sure they will reap the benefits of this positive trend.
Within their wide range of products, British Bakels produce and distribute prepared icings, toppings, glazes and custards. Until recently, these products were packed in pails and polyethylene-lined boxes of limited sizes (10.5 and 12.5 kg). Looking for more added-value products and processes, the company was quickly convinced by the food packaging specialist Cryovac to adopt innovative and more convenient packaging.
Cryovac’s unique fluid packaging technology
In August 1998, British Bakels introduced Cryovac’s high performance fluid packaging technology in its plants. More specifically, they adopted the CRYOVAC® FS 5250B blue laminate for vertical-form-fill-seal (VFFS) applications. This film is used to create resistant pouches on the CRYOVAC® 2000B and 2050 models of vertical form-fill-seal machines. The film is a high-performance rollstock material which is automatically formed into a pouch, filled, heat-sealed and cut to its programmed package size.
Cryovac’s fluid packaging system features a patented squeeze roller assembly which eliminates contamination between the laminate surfaces and ensures tight and secure seals. In addition, high barrier materials guarantee a very long shelf life. This unique system produces high-integrity, flexible and hermetically sealed pouches with no headspace. Flexible pouches have greater shipping and storage efficiencies, virtually 100% product yield; no dangerous jagged edges, and less solid waste volume.
Increased customer convenience
The Cryovac fluid packs chosen by British Bakels have significantly improved customer convenience. Firstly, they come in smaller unit sizes (1 kg) than the current industry standard. This prevents having to break down larger 12.5 kg packs and hygienically storing the remainder, thus reducing significantly the level of bulky waste disposal. Secondly, thanks to the angled seal bar on the Cryovac 2050 machine, the product can now be provided ready for piping or filling with easy disposal of the empty container.
The packs bring numerous other advantages, including improved storage logistics, improved safety and security of the packs because of no headspace, increased mechanical resistance and easier transport than with pails and boxes.
Worldwide market trend for increased convenience in use
In the segment of retail in-store bakery ingredients there is an important move toward value-added, ready-to-use ingredients. This means a steady transition from pail and lined carton pre-prepared bulk containers and powders requiring preparation to the more convenient ready-to-use CRYOVAC® fluid pouches. For example, the latest ready-to-use piping bag concept used for strawberry tart jelly is already being exported to Ireland, Chile and Finland.
Thanks to the new Cryovac pouches, British Bakels achieved an increase in wet plant volume of 10-15% over the last two years. "The use of the Cryovac Fluids System has been a key step in our move to provide our customers with convenient, value-added bakery ingredients", commented Geoff Nixon, Wet Plant Production Manager at Bicester.
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