Reading Bakery Systems - Via Oliveto - 3

The manual production process
To produce the flatbread, the family evolved
a unique, labor-intensive process involving
convection baking in rack ovens. Their 24 " wide
system included a bowl mixer, a three-roll sheeter,
three gauge rolls and 18 " by 26 " pans. Semiautomatic
equipment sprayed the cut triangular
pieces of dough with water, salt, seeds and herbs
before the trays were manually placed into the rack
ovens to bake, then manually removed to cool. This
process included four double rack ovens with 32
aluminum racks and 2,500 baking pans, all of it
handled by four people.
Production on this system peaked at about 100
kg per hour, and it made growing the bakery a
challenge. In 2015, Patrick's wife, Rachel, began
managing the business and relieved much of the
administrative pressure, but the production pain
points remained. The Zappias knew they wanted
to upgrade to a more automated, labor-saving
solution, they just didn't know how.
The family began reaching out to tunnel oven
manufacturers in 2019 to explore their options.
Their efforts included a trip to the International
Baking Industry Exposition (IBIE) in Las Vegas,
where they met more oven manufacturers and got
system quotes. Some of those OEMs didn't quite
understand what the Zappias needed, and others
proposed oven systems that were either too big,
or too expensive. The family found the process
overwhelming, but luckily, found their way to the
RBS booth.
Meeting RBS at IBIE
The Zappias were struck by how confident RBS
was that they could help Via Oliveto move from
rack ovens to a tunnel oven system. " We thought,
how could this be so easy for them? " recalls
Patrick Zappia. " We thought it was going to be
such a challenge - but, RBS made it sound like
the opposite. " The family was impressed by the
company's willingness to work with such a small
bakery. They also liked that RBS, unlike some of
Topping dispensers distribute salt,
seeds or herbs as each recipe requires.
their competitors, was proposing a one-stop-shop
solution that featured an integrated sheeting
line and oven, and the flexibility to produce new
products in the future.
Eager to take the next step, the Zappias invited RBS
to Via Oliveto to observe their production process
and further assess their requirements. After seeing
the family's flatbread line in action, RBS technical
sales reps proposed a configuration of the modular,
fully automated Multi-Crisp Baked Snack System.
The Zappias were impressed with the RBS visit and
proposal but remained wary of making such a big
move. To help allay their concerns, RBS invited the
Zappias to the company's Science & Innovation
Center for a flatbread trial run.
R&D product trials at RBS
In January 2020, Pasquale, Patrick and Adriano
made the eight-hour drive to the RBS Science
& Innovation Center to see how the Multi-Crisp
System would handle their five flatbread varieties.
The pieces of the system were all available for
demonstration in smaller, pilot-sized equipment.
The Zappias wanted to be sure that the final
products would be similar enough to what they were
already producing that their customers wouldn't
notice any difference.
Via Oliveto takes leap from racks to tunnel oven * 3

Reading Bakery Systems - Via Oliveto

Table of Contents for the Digital Edition of Reading Bakery Systems - Via Oliveto

Reading Bakery Systems - Via Oliveto - 1
Reading Bakery Systems - Via Oliveto - 2
Reading Bakery Systems - Via Oliveto - 3
Reading Bakery Systems - Via Oliveto - 4
Reading Bakery Systems - Via Oliveto - 5
https://www.nxtbook.com/sosland/rbs/reading-bakery-systems-via-oliveto
https://www.nxtbookmedia.com