Analysis: how artisan bread production is being transformed at scale
As consumer demand for transparency, natural ingredients, and free-from options continues to reshape the baking industry, food manufacturers are navigating a complex technical landscape.
Modern bread doughs — particularly those formulated for gluten-free or high-hydration artisan recipes — behave fundamentally differently than traditional mixtures. These delicate doughs often fail when subjected to conventional high-pressure dividing and handling systems, which can compromise the integrity of the crumb and the final product quality.
To address these challenges, European Process Plant Ltd (EPP) is highlighting the necessity of gentler handling solutions that bridge the gap between old-world craftsmanship and industrial efficiency.
Since 2009, EPP has partnered with Minipan to bring specialised Italian engineering to the UK market. Minipan, a company with roots stretching back to 1957, has focused its research on creating systems that respect the biological requirements of the dough. This collaboration has become a cornerstone for large-scale artisan bakeries that need to maintain “clean label” standards while increasing throughput. By minimising mechanical stress during processing, these systems allow bakers to produce large volumes of bread that retain the hand-crafted aesthetic and flavour profile sought by health-conscious consumers.
The core of this transformation lies in the ability to manage high-hydration levels, with some doughs containing up to 85% water. Traditional industrial extruders often strip these doughs of their natural gases and structure. In contrast, the Minipan approach utilises a gentle sheeting method. Instead of aggressive dividing, the dough is allowed to rest and move through the system with minimal tension, mimicking the patience and care of a manual artisan process.
Steve Merritt, managing director of EPP, notes that this preservation of the dough’s natural structure is what ultimately results in a more authentic product with superior texture and flavour.
The versatility of these systems is already being proven across a wide range of popular product lines, including sourdough, ciabatta, baguettes, and focaccia.
The technology has even gained a foothold in high-volume retail environments, with a major UK high street retailer currently utilising Minipan systems for its commercial pizza lines. This demonstrates that the “gentle” approach is not just for boutique batches but is a robust, reliable solution for the most demanding high-volume environments.
For the modern bakery, the path forward involves a commitment to dough integrity and operational efficiency. By prioritising equipment that honors traditional methods through innovative engineering, manufacturers can meet the surging demand for premium, natural bread. EPP and Minipan continue to empower bakers to scale their operations without sacrificing the quality that defines the artisan category, ensuring that the clean label promise is kept from the mixing bowl to the supermarket shelf.
