By Jack Helm, Account Manager – Beverage, Bakery & Functional Foods at ACI Group
In modern baking, efficiency often hides in plain sight. Behind every successful loaf or pastry is a series of calculated decisions, small tweaks in formulation, ingredient choice, or process design that quietly improve quality, reduce waste, and drive down costs. To many, a recipe may appear fixed and finite. But to those focused on continuous improvement, it is a blueprint open to refinement.
Efficiency in baking isn’t always about large-scale changes. Often, it comes from small, precise adjustments: a more balanced hydration ratio, a refined fat-emulsifier combination, or a more effective release or adhesion agent. Each refinement might seem minor in isolation, yet together, they can reshape the economics and consistency of bakery production.
Trays, tins and release agents
In a busy bakery, efficiency is built from small, reliable actions, many of which happen behind the scenes. One such process is the release of baked goods from trays, tins, and moulds. It’s a short step in the production line, but when handled poorly, it can lead to sticking, damage, waste, and unnecessary delays. This step becomes consistent, efficient, and cost-effective with the right release agent.
Food-grade release agents are formulated for safe use in food environments and to meet the unique demands of different baked goods. Each type is tailored to suit specific processes, whether applied as a spray, oil, or emulsion. A well-selected release agent reduces product loss, shortens cleaning time, and helps extend the life of baking equipment by preventing buildup and wear. ACI Group offers a portfolio of high-performance solutions designed to support cleaner, more consistent production. Among these, DÜBÖR’s release agents stand out for their ability to combine efficiency with sustainability.
Many standard release oils require a generous application to be effective, leading to higher usage rates and increased operational costs. DÜBÖR’s advanced formulas offer a more efficient alternative. Their high-performance carnauba wax-based release oil can reduce oil usage by up to 80%, helping bakeries lower energy use, minimise waste, and maintain a cleaner working environment.
Accurate application is just as important as the product itself. Too little release agent leads to sticking and waste, while too much results in pooling, burning, and uneven finishes. DÜBÖR’s concentrated, 100% vegetable oil solutions are free from allergens, hardened oils, and mineral content, delivering precise release with minimal waste—ensuring consistency and a more sustainable production line.
Release agents also contribute to equipment longevity. Continuous exposure to heat, fat, and residue takes a toll on trays and moulds, but the right formulation helps minimise this wear. DÜBÖR’s advanced coatings reduce buildup and extend the usable life of equipment, reducing cleaning effort and the need for frequent recoating or replacement.
Far from being just a functional necessity, release agents are a practical tool for cost control, quality assurance, and process improvement. With ACI Group’s ingredient expertise and DÜBÖR’s leading formulations, bakeries can reduce waste, extend equipment life, and maintain a cleaner, more efficient production environment.
Low dust, high performance
Release flour is key to maintaining efficiency, hygiene, and worker health, but its impact may not always be front of mind. TIP-TOP® Ultra Clean release flours, part of ACI Group’s portfolio, offer a comprehensive solution to these challenges. With these low-dust, hydrothermally treated flours, bakeries can source all their needs from one trusted partner, simplifying supply chains and optimising processes. By significantly reducing airborne particles, TIP-TOP® Ultra Clean helps mitigate respiratory issues like baker’s asthma, ensuring a safer, cleaner workplace.
Unlike standard flours, which generate excessive airborne dust, TIP-TOP® Ultra Clean reduces dust by 70–80%, significantly cutting fire hazards and energy costs associated with ventilation systems. An industrial bakery using 480MT of standard flour per year switched to this low-dust solution and saved 330MT annually, reduced PPE waste by 50+ kg, and cut CO2 emissions from decreased cleaning and ventilation.
The unique hydrothermal treatment process of TIP-TOP® Ultra Clean results in a highly effective low-dust flour that settles quickly, creating a more controlled environment in bakeries. It reduces up to 80% of respirable dust compared to traditional wheat flour, improving air quality and promoting healthier working conditions. This benefits employee health and fosters a more productive atmosphere, contributing to overall efficiency.
In addition to its health benefits, TIP-TOP® Ultra Clean enhances bakery hygiene and product quality. The flour’s water-repellent surface prevents mould growth on trays, proofing baskets, and other equipment, reducing the risk of contamination. This leads to cleaner work surfaces, higher-quality products, and less downtime for cleaning, resulting in significant operational savings.
TIP-TOP® Ultra Clean’s high-density granulation also ensures cost savings, with up to 70% less flour needed compared to conventional flour mixes. This reduces waste, extends equipment lifespan by preventing buildup, and decreases the need for frequent maintenance. Available in conventional and organic varieties, TIP-TOP® Ultra Clean is a versatile, high-performance solution for bakeries of all sizes, making it an essential part of our carefully selected ingredient portfolio.
Stick with success
GECKO® Ultra is a cutting-edge solution that combines exceptional adhesive properties with operational versatility, ensuring secure attachment of seeds, kernels, and toppings to a wide range of baked goods. Unlike water-based methods or gums, which often lead to seed loss and higher water usage, GECKO® Ultra significantly improves retention, reduces waste, and enhances product appearance without altering taste or aroma.
Its formulation, based solely on wheat flour, is additive-free and clean-label, responding directly to consumer demands for transparency. The jelly-like suspension applies cleanly via spraying, rolling, brushing or immersion, without heating or clogging, making it simple to integrate into existing bakery setups. Neutral in odour and flavour, it preserves the natural profile of toppings, whether sesame, poppy or grain.
In trials, one industrial bakery cut seed usage by 50%, improving surface coverage and achieving ROI in six months using an AutoJet® E2850+ spray system. Beyond aesthetics and savings, GECKO® Ultra supports sustainability goals by minimising raw material waste, water usage, and airborne allergens from loose seeds during transport and display.
Through ACI Group, bakeries gain access to GECKO® Ultra and benefit from our technical expertise and support. Whether integrating the product into existing lines or rethinking ingredient strategies, ACI helps bakeries streamline processes and stick to higher standards, literally and strategically.
Rethink your ingredient strategy
In today’s highly competitive bakery industry, efficiency, quality, and sustainability are more important than ever. Assessing your current operations and considering a streamlined approach to sourcing your ingredients can significantly reduce costs, improve product consistency, and elevate the overall effectiveness of your production processes.
Hidden inefficiencies in standard ingredients – excessive dust, high oil usage, or poor seed adhesion – add to significant costs over time. All of these solutions help bakeries reclaim those losses by reducing waste, improving safety, and optimising operations.
By consolidating your sourcing, you gain access to a hand-picked portfolio of high-performance ingredients designed to optimise bakery efficiency. From release agents to low-dust flours and high-adhesion solutions, ACI Group’s products work seamlessly together to create a smarter, cleaner, and more cost-effective operation.